Abstract: Provided is an emissions treatment system for an exhaust stream, having a NOx storage reduction (NSR) catalyst with a NOx sorbent at a concentration of at least 0.1 g/in3 and a platinum group metal component dispersed on a refractory metal oxide support; and, an SCR catalyst disposed downstream of the NSR catalyst. The emissions treatment system is advantageously used for the treatment of exhaust streams from diesel engines and lean burn gasoline engines.

Abstract: The present invention is directed to an improved apparatus and method of minimizing catalyst poisoning from exhaust gas streams containing inorganic deposits and particulate matter. More specifically, the present invention is directed to an upstream metallic foam trap and a downstream monolithic precious metal catalyst, wherein the trap physically blocks inorganic deposits and particulate matter from poisoning the downstream catalyst. The present invention is also directed to a metallic foam trap containing a coat comprising a first metallic thermal arc sprayed layer and optionally a second refractory metal oxide.

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: The present invention is directed to 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.

Abstract: The present invention is directed to an exhaust gas treatment system and method for removing particulate matter and nitrogen oxides from diesel engine exhaust streams. More specifically, the present invention relates to an emission treatment system that effectively provides simultaneous treatment of the particulate matter, as well as the NOx and other gaseous components of diesel engine exhaust. The emission treatment system uses an integrated soot filter coated with a catalyst washcoat composition comprising sub-micron particles, thereby providing an ultra-thin sub-micron washcoat layer showing improved catalyst performance without causing excessive backpressure.

Abstract: A filter for removing soot particles from the exhaust gas of a diesel engine comprises a plurality of hollow channels which contain therein a metal mesh. The metal mesh can be coated with an oxidation catalyst to promote ignition of the soot particles and regeneration of the metal mesh for filtering the soot particles. The metal mesh can optionally be removed from the hollow channels and replaced with regenerated or new metal mesh if desired.

Abstract: Provided is an emissions treatment system and method for reducing NOx emissions in the exhaust stream produced from an internal combustion engine. The system has an injector for periodically metering ammonia or an ammonia precursor into an exhaust stream; and a first substrate with a first SCR catalyst composition, downstream of the injector. The first substrate has an inlet end, an outlet end, a length extending between the inlet end to the outlet end, wall elements and a plurality of passages defined by the wall elements. The first SCR catalyst composition is disposed on the wall elements from the inlet end toward the outlet end to a length that is less than the substrate's axial length to form an inlet zone. The first substrate also has an NH3 destruction catalyst composition with a platinum group metal component dispersed on a refractory 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: Provided is an emissions treatment system for an exhaust stream, having a NOx storage reduction (NSR) catalyst with a NOx sorbent at a concentration of at least 0.1 g/in3 and a platinum group metal component dispersed on a refractory metal oxide support; and, an SCR catalyst disposed downstream of the NSR catalyst. The emissions treatment system is advantageously used for the treatment of exhaust streams from diesel engines and lean burn gasoline engines.

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.