Abstract: An engine exhaust system is disclosed which in operation is capable of substantially reducing the quantities of hydrocarbons emitted to the atmosphere during engine start-up. The system utilizes molecular sieve means, such as a high-silica zeolite, which function to adsorb hydrocarbons emitted during engine start-up, before the catalytic converter has attained its effective operating temperature. The system is designed so that, once the catalytic converter has attained an effective operating temperature, the hydrocarbons can be desorbed from the molecular sieve means and conveyed to the converter for conversion to non-toxic by-products.

Abstract: An apparatus and method for converting exhaust gases to innocuous products is disclosed. Exhaust gas is conveyed by a first conduit to, and passed through a first multicellular unit in which a portion of the cells are catalyzed with a first catalyst for reacting at least a portion of the NO.sub.x to ammonia, and thereafter the resulting modified mixture only is conveyed by a second conduit from the first unit and to a second multicellular unit to react the ammonia and the remaining NO.sub.x to produce innocuous products. The second conduit is connected only to the first and second units. The passage of the exhaust gas through the units results in conversion of NO.sub.x, CO, and hydrocarbons to innocuous products.

Abstract: Low expansion molecular sieves bodies and method of making them which involves forming a mixture of up to about 40 weight parts of a thermal expansion control component which can be at least one of zircon, feldspar, calcium silicate, talc, steatite, forsterite, kyanite sillimanite, nepheline syenite, glasses, about 10 to 30 weight parts of permanent binder, at least 50 weight parts of molecular sieve, and temporary binder which can be cellulose ethers, cellulose ether derivatives, and combinations thereof, in a vehicle. The mixture is shaped into a green body which is then dried and fired to produce the product body. Among the preferred bodies are zeolites which find use in hydrocarbon adsorption, denox, and three-way catalyst applications.

Abstract: Secondary discharge slots are cut into the face of newly made or used extrusion dies such that the secondary discharge slots communicate transversely and longitudinally with primary discharge slots but do not communicate with the feed holes. The novel extrusion die arrangement is set forth for the production of ceramic honeycomb structures which produce a greater number of cells per square inch, protrusions on the cell walls, or a combination of both dependent upon the Primary Slots' Volume to Secondary Slots' volume ratio. The secondary discharge slots can produce honeycomb substrates with much greater surface areas, using an extrusion die with a significantly reduced number of feed holes and a greater number of discharge slots.

Abstract: A method and system for removing low molecular weight olefins from gases generated during the first five minutes of start-up of an internal combustion engine. The mixture is contacted with hydrophilic material to remove at least some of the water therefrom. The hydrophilic material can be molecular sieve having pores large enough for adsorption of water molecules and small enough to prevent molecules larger than water from being adsorbed, high surface area aluminas, precursors for high surface area aluminas, high surface area silicas, and combinations thereof. The mixture is then contacted with a downstream hydrocarbon-removing agent for removing the olefins. The hydrocarbon-removing agent can be at least one molecular sieve which can be pentasil zeolites, faujasite zeolites, mordenite, beta zeolites, carbon molecular sieve, metallophosphates, aluminophosphates, silicoaluminophosphates, and combinations thereof.

Abstract: Thin-walled honeycomb structures of activated carbon, useful for the adsorption of hydrocarbon vapors are prepared without the need for firing or sintering at elevated temperatures. The structures are prepared by forming a substantially homogeneous batch from an admixture of thermally gellable cellulose ether and/or derivative thereof such as methylcellulose, an additional organic binder such as a polyvinyl alcohol resin, and particles of activated carbon; plasticizing the batch with liquid, extruding the batch into a honeycomb shape; and drying the extruded shape at a temperature up to about 225.degree. C.

Abstract: A method for producing a thermally shock resistant washcoated substrate involves introducing a buffer solution into the microcracks, and optionally the micropores of a porous sintered body, the pH of the buffer solution being at a predetermined value to result in the formation of a gel on contact of the buffer solution with the slurry which is to be subsequently applied, contacting the body with a washcoating slurry to form a gel at the interface of the buffer solution and slurry. Formation of the gel prevents the slurry from entering the microcracks. The body is then calcined at a temperature and for a time sufficient to form the washcoated substrate.

Abstract: A porous catalyst support which may be used in a catalytic converter for treating automotive exhaust gases. The support comprises a substrate having a multichannel structure of generally thin walls and washcoat particles of colloidal particle size mainly or wholly within the pores of the walls so as to increase open frontal area and reduce back pressure. Substrate is either ceramic or metal. In a ceramic substrate with microcracks in the walls, the washcoat colloidal dispersion is free of soluble inorganic constituents and the particles do not fill the microcracks so as to prevent undesirable increase in thermal expansion and corresponding decrease in thermal shock resistance.

Abstract: A process of using a catalyst system for the oxidation of hydrocarbons, carbon monoxide, and the reduction of nitrogen oxides is provided. The unique synergy of the catalyst system, a combination of molecular sieves and noble metals, provides a system that partially or entirely replaces the need for rhodium as a catalyst in three way catalyst systems.

Abstract: A system and method are disclosed for removing hydrocarbons from a gaseous mixture, which comprises selecting a plurality of agents which are effective for adsorbing hydrocarbons at predetermined temperatures, wherein for at least two of the adsorbing agents, the temperatures at which the maximum adsorption rates for the hydrocarbons occur, are different from one another, and contacting the adsorbing agents with the gaseous mixture at the predetermined temperatures to cause adsorption of the hydrocarbons. A multistage catalyst system for converting NO.sub.x, CO, and hydrocarbons from a gaseous mixture to innocuous products is disclosed, which comprises the above described system for removing hydrocarbons as one stage, and a main body catalyst stage for converting NO.sub.x, CO, and hydrocarbons to innocuous products, wherein the gaseous mixture passes from one stage to the other.

Abstract: A phosphate-Al.sub.2 O.sub.3 material is disclosed wherein the phosphate is homogeneously dispersed throughout, the specific surface area as measured by N.sub.2 BET method is at least about 50 m.sup.2 /g, and the average pore radius is no greater than about 200.ANG.. A method is disclosed for producing the material which comprises forming a precursor material by wet-mixing a phosphate yielding species and an aluminum oxide yielding species which can be aluminum oxide, aluminum hydroxylated oxides, aluminum hydroxide, aluminum alkoxides, and combinations thereof, in amounts sufficient to result in an AlPO.sub.4 content of about 3 to 12 percent by weight in the phosphate-Al.sub.2 O.sub.3, drying and heat-treating the precursor material at a temperature and for a time sufficient to form the phosphate- Al.sub.2 O.sub.3. The material is used as a support for catalyst metals.

Abstract: An apparatus, system and method are disclosed for modifying a gaseous mixture. The apparatus comprises a unitary body having an inlet end, an outlet end, and a multiplicity of cells extending from inlet end to outlet end, the cells being separated from one another by porous walls, and filler material comprising electrically non-conducting active powder material, loaded into at least part of the volume of the cells, with some of the cells being unloaded and open, wherein a gaseous mixture enters the body at the inlet end through the open cells, and at least some of the gaseous mixture passes through the porous walls and is compositionally modified by the active material, and thereafter the resultant modified mixture passes through the open cells and exits the body at the outlet end. The apparatus can be used in conjunction with other apparatuses which are catalyzed to form a gas modifying system. The apparatus and system are especially suited for conversion of hydrocarbons, NO.sub.

Abstract: A catalyst system for the oxidation of hydrocarbons, carbon monoxide, and the reduction of nitrogen oxides is provided. The unique synergy of the catalyst system, a combination of molecular sieves and noble metals, provides a system that partially or entirely replaces the need for rhodium as a catalyst in three way catalyst systems.

Abstract: A method of forming an activated carbon or graphite structure is provided by (1) forming, such as extrusion, of a plasticized mixture of: binder selected from cellulose ether and derivative thereof, starch, and mixture thereof; furfuryl alcohol and/or polyfurfuryl alcohol; and carbon, graphite, or a carbon-containing material; and (2) subjecting the formed mixture to a carbon-forming pyrolysis step. The use of furfuryl alcohol allows extrusion at ambient temperatures and provides a "reactive" solvent that provides carbon upon pyrolysis.

Abstract: A washcoated substrate and method for producing the washcoat on the substrate are disclosed which comprises forming a slurry comprising at least one ionizable compound of A, where A is selected from barium, strontium, and combinations thereof, and A is in an amount sufficient to yield AO in an amount of about 0.2-20% by weight of the washcoat, an aluminum oxide yielding species, and a medium wherein at least a portion of the ionizable compound ionizes to form ions of A, contacting the slurry with a substrate to form a green coating containing A and the aluminum oxide yielding species thereon, and heat treating the resulting green-coated substrate at a temperature and for a time sufficient to form a washcoat consisting essentially of AO-Al.sub.2 O.sub.3 on the substrate, wherein A is homogeneously distributed throughout the Al.sub.2 O.sub.3, the washcoat having a specific surface area, as measured by the N.sub.2 BET method, of at least about 50 m.sup.

Abstract: The present invention features a process, and a product formed by the process, wherein a catalyst device is fabricated in situ. Metal powders, metal alloy powders and mixtures thereof are introduced to a substrate, by means of a washcoat suspension. After the suspension is applied, the metals are transformed into active catalyst and catalyst support materials. The process comprises the steps of: (a) introducing to a substrate, metal powders, metal alloy powders and mixtures thereof, having particles in average diameter sizes of approximately between 5 and 50 microns; and (b) transforming in situ the particles of the metals and metal alloys and mixtures thereof, whereby the metals, metal alloys and mixtures thereof are converted into active catalyst and catalyst support materials having sub-micron average diameter sizes.

Abstract: An engine exhaust system and method of controlling hydrocarbon emissions are provided. The system and method are based on the use of two catalytic converter chambers, a first chamber containing a catalytic material and a second chamber containing catalyst as well as molecular sieves capable of adsorbing hydrocarbons during engine start-up and of having hydrocarbons desorbed therefrom when the catalysts reach an effective converting temperature. According to the invention, engine exhaust is selectively conveyed to each of the two converters in a manner such that initially produced hydrocarbon is withheld in the system by the molecular sieves in order to be recycled through the converters and brought into contact with the catalyst after an effective converting temperature has been attained.

Abstract: A monolithic ceramic structure, useful as a support for catalytic material or as a fluid filter, has a high surface area phase which consists essentially of a porous metal oxide material, at least 50% by weight of which is alumina, titania, and/or zirconia, and phosphate dispersed substantially throughout the porous metal oxide material. The presence of the phosphate stabilizes the porous metal oxide material against thermal degradation during sintering or exposure to elevated temperatures encountered in catalytic service and thereby aids in the retention of higher overall surface area in the monolithic structure.

Abstract: A catalyst support having both substantial high strength and high surface area can be produced by heating a shaped mixture of a porous oxide having a surface area of at least 20 m.sup.2 /g and the precursor of an inorganic binder for the porous oxide. The binders are precursors of alumina, silica, or .[.titania,.]. .Iadd.zirconia .Iaddend.and are capable of imparting substantial strength to the support at relatively low firing temperatures.

Abstract: A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.