Abstract: Apparatus and a method for controlling gas flow into a combustion engine exhaust gas filter e.g., to control filter temperatures during filter regeneration, comprising providing a fluidic exhaust stream diverter proximate to and centrally of the inlet face of the filter and activating the fluidic diverter to divert exhaust gas flow away from central filter portions toward peripheral filter portions.

Abstract: An improved method and apparatus is set forth for packaging substrates in a monolith reactor, wherein the substrates are positioned in a stacked relationship along a longitudinal axis of the reactor housing. The stack of substrates is supported in a fixed position at the bottom of the stack, and the upper end of the stack is provided with a predetermined constant compression to not only compensate for different expansions between the stacked substrates and the reactor housing, but also to hold the stacked assemblies together in a tight relationship so as to prevent deleterious vibration of the substrates. The compression is preferably applied by spring-loaded means, which may be adjusted by threading a nut against the loading spring.

Abstract: A multi-channel modular device (10) processes between two fluid streams of different compositions. The device (10) includes a porous body (150) having a first plurality of feed-flow pathways (110) disposed in the body (150) for transporting a first stream (180). A pathway wall (114) surrounds each of the first plurality of feed-flow pathways (110) for processing the first stream (180) into a first composition (1852) and a second composition (1802). At least one feed-flow inlet (1101) is disposed in the body (150) for introducing the first stream (180) into the first plurality of feed-flow pathways (110). At least one feed-flow outlet (1102) is disposed in the body (150) for discharging the remaining first stream containing the second composition (1802). At least one second pathway (210) is disposed in the body (150) for transporting a second stream (280) having a second inlet (2101) and a second outlet (2102).

Abstract: An improved method and apparatus is set forth for packaging substrates in a monolith reactor, wherein the substrates are positioned in a stacked relationship along a longitudinal axis of the reactor housing. The stack of substrates is supported in a fixed position at the bottom of the stack, and the upper end of the stack is provided with a predetermined constant compression to not only compensate for different expansions between the stacked substrates and the reactor housing, but also to hold the stacked assemblies together in a tight relationship so as to prevent deleterious vibration of the substrates. The compression is preferably applied by spring-loaded means, which may be adjusted by threading a nut against the loading spring.

Abstract: A method of making activated carbon of various pore size distributions involves an providing oxidized pitch, carbonizing the pitch when the softening point of the pitch is less than about 250° C., and activating the pitch to produce activated carbon. A catalyst metal can be included with the pitch to produce mesoporosity in the activated carbon.

Abstract: A method of making mesoporous carbon involves combining a carbon precursor and a pore former. At least a portion of the pore former dissolves molecularly in the carbon precursor. The pore former has a decomposition or volatilization temperature above the curing temperature and below the carbonization temperature of the carbon precursor. The carbon precursor is cured, carbonized, and optionally activated, and at the same time the pore former is removed.

Abstract: A modified in-line adsorber system capable of meeting the California ultra-low emission vehicle (ULEV) standard using a combination of burn-off catalyst and a modified adsorber constructed with an open flow region of substantially unobstructed flow having a hole or a region of larger cell openings to increase the amount and rate of contact between the exhaust gas and the burn-off catalyst, and thereby reduce the light-off time of the burn-off catalyst. For best effect, the open flow region of the adsorber is positioned along the exhaust stream between the engine and the burn-off catalyst as defined by the exhaust flow path of least resistance.

Abstract: An improved system for the control of combustion engine exhaust from a motor vehicle includes an adsorber for the adsorption of hydrocarbons concentrated in the exhaust stream at engine startup, the adsorber being of honeycomb shape which includes a peripheral channeled portion and a central channeled portion, the latter including an exhaust gas by-pass port parallel with the channels, with the through-channels in the central portion of the honeycomb having a relatively high resistance to exhaust gas flow compared to the channels traversing the peripheral portion. Systems with reduced secondary air requirements and providing more efficient burn-off of the adsorbed hydrocarbons are also disclosed.

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: A modified in-line adsorber system capable of meeting the California ultra-low emission vehicle (REV) standard using a combination of burn-off catalyst and a modified adsorber constructed with an open flow region of substantially unobstructed flow having a hole or a region of larger cell openings to increase the amount and rate of contact between the exhaust gas and the burn-off catalyst, and thereby reduce the light-off time of the burn-off catalyst. For best effect, the open flow region of the adsorber is positioned along the exhaust stream between the engine and the burn-off catalyst as defined by the exhaust flow path of least resistance.

Abstract: Flow diverter methods and apparatus useful, for example, in adsorber systems capable of meeting the California ultra-low emission vehicle (ULEV) standard, are described, the adsorber systems incorporating a combination of a burn-off catalyst and a modified adsorber constructed with an open flow region of substantially unobstructed flow having a hole or a region of larger cell openings, the flow diverter acting to control exhaust flow through the adsorber to both increase adsorption and reduce the light-off time of the burn-off catalyst.

Abstract: A body made up of substantially continuous high strength multicellular support having porous cell walls, and pores in the cell walls having an average pore diameter of which have active material embedded therein, and an outer surface. The body is made of material which can be ceramics, glass, glass-ceramic, cermet, metal, oxides, and combinations of these. The active material can be molecular sieve, activated carbon, and combinations these. A method for producing a pore-impregnated body which involves providing the substrate having a wall porosity greater than about 45% by volume, and an average pore diameter of about 15 to 30 micrometers, providing a slurry of active material dispersed in a medium, contacting the support with the slurry at subatmospheric pressure to substantially fill the open pores of the substrate with the active material, removing excess slurry from the outer surface and the non-pore surfaces of the cell walls, followed by drying.

Abstract: A engine exhaust system is disclosed for reducing the amount of hydrocarbons emitted during engine start-up (cold-start), before the catalytic converter has attained its effective operating temperature. The system includes a flow control device, in particular a bi-metallic flap, occupying a first position at the first temperature to direct substantially all of the engine exhaust through a molecular sieve structure to adsorb the hydrocarbons, and a second position at the second temperature, to direct the engine exhaust stream directly from the light-off catalyst to the burnoff catalyst, bypassing the molecular sieve structure.

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: Mixed zeolites embedded in and strongly bound to a substrate and method for producing same are disclosed. The method comprises providing a plurality of seed zeolites, raw material for forming zeolites, the raw material comprising a source of silica, and a substrate, and combining the above, heat-treating the combination at a temperature and for a time sufficient to insure the formation of stable SiO.sub.2, and hydrothermally treating the heat-treated combination with alkali hydroxide, and optionally, a source of alumina as additional raw material at least when the combination is absent a source of alumina, to produce the mixed zeolites. The substrate can either enter into the reaction to form the zeolites, or they can be non-reactive.

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: Multi-stage catalytic systems and methods are provided for converting NO.sub.x, CO, and hydrocarbons in a mixture, to innocuous products. The systems include first and second stages, each with substrate and catalyst. The mixture is contacted with the first stage for conversion of the major portion of the NO.sub.x and a portion of the CO and hydrocarbons. The output is contacted with the second stage to for conversion of CO and hydrocarbons. In one system, the first stage catalyst consists essentially of rhodium and a zeolite; the second stage catalyst comprises a noble metal including platinum and/or palladium, and a support. The mixture has a mole ratio of reducing to oxidizing agents of at least 0.8. Low ammonia is generated. In another system, the first stage substrate is made of material capable of being heated to at least 150.degree. C. in no more than about 20 seconds, has heating means for doing same, and is at this temperature at least part of the time of contact with the mixture.

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 structure comprising a mixture of metals and metal alloys which are sintered into a hard porous body is presented. The structure can be useful for many different chemical and physical purposes, such as for catalysis, desorption and absorption, and selective leaching of the structure components into solutions.