Abstract: Provided is an emission treatment system and method for simultaneously remediating the nitrogen oxides (NOx), particulate matter, and gaseous hydrocarbons present in diesel engine exhaust streams. The emission treatment system has an oxidation catalyst upstream of a soot filter coated with a material effective in the Selective Catalytic Reduction (SCR) of NOx by a reductant, e.g., ammonia. Also provided is a method for disposing an SCR catalyst composition on a wall flow monolith that provides adequate catalyst loading, but does not result in unsuitable back pressures in the exhaust.

Abstract: Zeolite catalysts and systems and methods for preparing and using zeolite catalysts having the CHA crystal structure are disclosed. The catalysts can be used to remove nitrogen oxides from a gaseous medium across a broad temperature range and exhibit hydrothermal stable at high reaction temperatures. The zeolite catalysts include a zeolite carrier having a silica to alumina ratio from about 15:1 to about 256:1 and a copper to alumina ratio from about 0.25:1 to about 1:1.

Abstract: The present invention is directed to a method of coating a substrate, such as a honeycomb having a plurality of parallel channels defined by the honeycomb walls. The honeycomb has different zones along the length of the channels. The zones are defined by their coating (or lack of coating) and extend for a length of the channel in which there is the same coating and architecture. Soluble components in coating compositions are fixed in their respective zones by forcing a heated gas stream through the channels.

Abstract: Zeolite catalysts and systems and methods for preparing and using zeolite catalysts having the CHA crystal structure are disclosed. The catalysts can be used to remove nitrogen oxides from a gaseous medium across a broad temperature range and exhibit hydrothermal stable at high reaction temperatures. The zeolite catalysts include a zeolite carrier having a silica to alumina ratio from about 15:1 to about 256:1 and a copper to alumina ratio from about 0.25:1 to about 1:1.

Abstract: Provided are selective catalytic reduction (SCR) filters that effectively provide simultaneous treatment of particulate matter and NOx. Provided also are methods for reducing NOx concentration and particulate matter in a diesel engine exhaust by using the SCR filters. The SCR filter can include a fiber matrix wall flow filter comprising a plurality of non-woven inorganic fibers and a chabazite molecular sieve SCR catalyst on the fiber matrix wall flow filter. By combining a fiber matrix wall flow filter with a chabazite molecular sieve SCR catalyst, high catalyst loading can be achieved without causing excessive back pressure across the filter when implemented in emission treatment systems.

Abstract: The present invention relates to a method and article for treating a diesel engine exhaust stream. The stream is contacted with an upstream catalytic composition having a cerium component and/or a zeolite component to reduce the quantity and amount of the particulate matter in the exhaust stream. The stream passes from the upstream catalytic composition to a particulate filter located downstream from the upstream catalytic composition.

Abstract: The present invention is directed to a catalyzed metallic substrate, such as a metal plate. There is a catalyst layer supported on the substrate surface. The article is useful as part of exhaust systems which can be used with small engines for applications such as motorcycles, lawn mowers, chain saws, weed trimmers and the like. The present invention includes methods to prepare the catalyzed metal substrate and methods of use of the catalyzed substrate.

Abstract: An apparatus useful to treat exhaust gas stream, including diesel engine exhaust. The exhaust stream passes form and exhaust outlet to a catalyzed filter in communication with the exhaust outlet. The catalyzed filter comprises a first catalyst which comprises a first platinum group metal; a first cerium component; and preferably a zirconium component. There can be a second catalyst in communication with the first catalyst, the second catalyst comprises a second cerium component.

Abstract: Composite of at least two metal oxides in the form of Primary Particles and a support having a particle size greater than the Primary Particles used in the formation of a catalyst composition for the treatment of a pollutant containing gas.

Abstract: The present invention is directed to a catalyzed metallic substrate, such as a metal plate. There is a catalyst layer supported on the substrate surface. The article is useful as part of exhaust systems which can be used with small engines for applications such as motorcycles, lawn mowers, chain saws, weed trimmers and the like. The present invention includes methods to prepare the catalyzed metal substrate and methods of use of the catalyzed substrate.

Abstract: The present invention relates to sulfur tolerant catalyst composites useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with improved NOx trap catalysts for use in diesel engines as well as lean burn gasoline engines. The sulfur tolerant NOx trap catalyst composites comprise a platinum component, a support, and a NOx sorbent component prepared by hydrothermal synthesis. The NOx sorbent component comprises a first metal oxide and a second metal oxide. The metal in the first metal oxide is selected from the group consisting of aluminum, titanium, zirconium, silicon, and composites thereof, and the metal in the second metal oxide is selected from the group consisting of Group IIA metals, Group II metals, Group IV metals, rare earth metals, and transition metals. The metal in the first metal oxide is different from the metal in the second metal oxide.

Abstract: A pliable refractory metal carrier (46) may have coated thereon an anchor layer (47) to improve adherence to the carrier (46) of a catalytic coating (48). The conformable catalyst member (26, 82, 82′, 126, 226, 326) may be bent to conform to a curved or bent exhaust pipe (20, 220, 320) within which it is mounted. The pliable metal carrier may be in the form of a tube such as carrier (46) having perforations (54) formed therein, or it may be a metal strip (76) which is folded into accordion pleats (80) and has perforations (78) formed therein. The perforations (54, 78) serve to permit the passage of exhaust gas therethrough. A series of interior closures (58) and annular baffles (60) may be provided to import a serpentine flow path to gases flowed through an exhaust pipe (22) containing a conformable catalyst member (226) therein. A mounting member (68) may be supplied to fasten one end of the conformable catalyst member (226) to the discharge end of an exhaust pipe (220).

Abstract: Electric arc spraying a metal onto a substrate produces an anchor layer on the substrate that serves as a surprisingly superior intermediate layer for a catalytic material deposited thereon. Spalling of catalytic material is resisted even when subjected to the harsh conditions imposed by small engines or in a close-coupled position for a larger engine.

Abstract: The present invention relates to sulfur tolerant catalyst composites useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with improved NOx trap catalysts for use in diesel engines as well as lean burn gasoline engines. The sulfur tolerant NOx trap catalyst composites comprise a platinum component, a support, and a NOx sorbent component prepared by hydrothermal synthesis. The NOx sorbent component comprises a first metal oxide and a second metal oxide. The metal in the first metal oxide is selected from the group consisting of aluminum, titanium, zirconium, silicon, and composites thereof, and the metal in the second metal oxide is selected from the group consisting of Group IIA metals, Group III metals, Group IV metals, rare earth metals, and transition metals. The metal in the first metal oxide is different from the metal in the second metal oxide.

Abstract: Electric arc spraying a metal onto a substrate produces an anchor layer on the substrate that serves as a surprisingly superior intermediate layer for a catalytic material deposited thereon. Spalling of catalytic material is resisted even when subjected to the harsh conditions imposed by small engines or in a close-coupled position for a larger engine.

Abstract: An apparatus useful to treat exhaust gas stream, including diesel engine exhaust. The exhaust stream passes form and exhaust outlet to a catalyzed filter in communication with the exhaust outlet. The catalyzed filter comprises a first catalyst which comprises a first platinum group metal; a first cerium component; and preferably a zirconium component. There can be a second catalyst in communication with the first catalyst, the second catalyst comprises a second cerium component.

Abstract: The present invention relates to sulfur tolerant catalyst composites useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with improved NOx trap catalysts for use in diesel engines as well as lean burn gasoline engines. The sulfur tolerant NOx trap catalyst composites comprise a platinum component, a support, and a NOx sorbent component prepared by hydrothermal synthesis. The NOx sorbent component comprises a first metal oxide and a second metal oxide. The metal in the first metal oxide is selected from the group consisting of aluminum, titanium, zirconium, silicon, and composites thereof, and the metal in the second metal oxide is selected from the group consisting of Group IIA metals, Group III metals, Group IV metals, rare earth metals, and transition metals. The metal in the first metal oxide is different from the metal in the second metal oxide.

Abstract: The present invention relates to a method and article for treating a diesel engine exhaust stream. The stream is contacted with an upstream catalytic composition having a cerium component and/or a zeolite component to reduce the quantity and amount of the particulate matter in the exhaust stream. The stream passes from the upstream catalytic composition to a particulate filter located downstream from the upstream catalytic composition.

Abstract: Composite of at least two metal oxides in the form of Primary Particles and a support having a particle size greater than the Primary Particles used in the formation of a catalyst composition for the treatment of a pollutant containing gas.

Abstract: Composite of at least two metal oxides in the form of Primary Particles and a support having a particle size greater than the Primary Particles used in the formation of a catalyst composition for the treatment of a pollutant containing gas.