Abstract: This disclosure is directed to catalyst compositions, catalytic articles for purifying exhaust gas emissions and methods of making and using the same. In particular, the disclosure relates to a catalytic article including a catalytic material on a substrate, wherein the catalytic material has a first layer and a second layer. The first layer provides effective lean NOx trap functionality and the second layer provides effective three-way conversion of carbon monoxide, hydrocarbons, and nitrogen oxides (NOx).

Abstract: The present invention provides a tri-metallic layered catalytic article comprising a first layer comprising palladium supported on at least one of an oxygen storage component, and an alumina component; a second layer comprising platinum and rhodium, each supported on at least one of an oxygen storage component and a zirconia component; and a substrate, wherein the weight ratio of palladium to platinum is in the range of 1.0:0.4 to 1:2. The present invention also provides a process for preparing the tri-metallic layered catalytic article, an exhaust system for internal combustion engine and use of the tri-metallic layered catalytic article for purifying a gaseous exhaust stream.

Abstract: The presently claimed invention provides a tri-metallic layered catalytic article comprising: a) a top layer comprising platinum supported on at least one of an oxygen storage component, zirconia component and an alumina component, and rhodium supported on an oxygen storage component; b) a bottom layer comprising a front zone and a rear zone, said front zone comprising palladium supported on an oxygen storage component and an alumina component, and the rear zone comprises platinum supported on at least one of an alumina component, a ceria component, and an oxygen storage component; and c) a substrate, wherein the weight ratio of palladium to platinum is in the range of 1.0:0.4 to 1.0:2.0.

Abstract: This disclosure is directed to catalyst compositions, catalytic articles for purifying exhaust gas emissions and methods of making and using the same. In particular, the disclosure relates to a catalytic article including a catalytic material on a substrate, wherein the catalytic material has a first layer and a second layer. The first layer provides effective lean NOx trap functionality and the second layer provides effective three-way conversion of carbon monoxide, hydrocarbons, and nitrogen oxides (NOx).

Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: Provided is a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, and at least one catalytic layer. Also provided are methods for preparing the catalyst and methods for monitoring the oxygen storage capacity of an exhaust article containing the catalyst.

Abstract: A support for a catalyst for controlling vehicular exhaust emissions comprising a high surface area refractory metal oxide, e.g., gamma-alumina, having a monomolecular layer of a second oxide selected from the group consisting of titanium dioxide, cerium dioxide and zirconium dioxide. Typically, the monomolecular layer will have a thickness of less than about 10 angstroms. The support may be converted into a vehicular exhaust emission control catalyst by depositing the support on a substrate such as cordierite depositing a precious metal component such as platinum on at least part of the monomolecular layer. Preferably, the catalyst will also contain at least one NOx storage component deposited on at least part of the monomolecular layer. Catalysts prepared using the catalyst supports of the invention exhibit outstanding thermal stability and resistance to sulfur poisoning.

Abstract: A support for a catalyst for controlling vehicular exhaust emissions comprising a high surface area refractory metal oxide, e.g., gamma-alumina, having a monomolecular layer of a second oxide selected from the group consisting of titanium dioxide, cerium dioxide and zirconium dioxide. Typically, the monomolecular layer will have a thickness of less than about 10 angstroms. The support may be converted into a vehicular exhaust emission control catalyst by depositing the support on a substrate such as cordierite depositing a precious metal component such as platinum on at least part of the monomolecular layer. Preferably, the catalyst will also contain at least one NOx storage component deposited on at least part of the monomolecular layer. Catalysts prepared using the catalyst supports of the invention exhibit outstanding thermal stability and resistance to sulfur poisoning.

Abstract: A catalytic trap disposed in an exhaust passage of an internal combustion engine which is operated with periodic alternations between lean and stoichiometric or rich conditions, for abatement of NOx in an exhaust gas stream which is generated by the engine. The trap comprises a catalytic trap material and a refractory carrier member on which the catalytic trap material is disposed. The catalytic trap material comprises: (i) a refractory metal oxide support; (ii) a catalytic component effective for promoting the reduction of NOx under stoichiometric or rich conditions; and (iii) a NOx sorbent effective for adsorbing the NOx under lean conditions and desorbing and reducing the NOx to nitrogen under stoichiometric or rich conditions. The NOx sorbent comprises a metal oxide selected from the group consisting of one or alkali metal oxides, alkaline earth metal oxides and mixtures of one or more alkali metal oxides and alkaline earth metal oxides.

Abstract: The present invention relates to a method and a catalyst composite useful for reducing contaminants in exhaust gas streams containing sulfur oxide contaminants. The method for removing NOx and SOx contaminants from a gaseous stream comprises providing a catalyst composite having a downstream section and an upstream section. The downstream section comprises a first support, a first platinum component, and a NOx sorbent component. The upstream section comprises a second support, a second platinum component, and a SOx sorbent component selected from the group consisting of oxides of Mg, Sr, and Ba. In a sorbing period, a lean gaseous stream comprising NOx and SOx is passed through the upstream section to sorb at least some of the SOx contaminants. The downstream section sorbs and abates the NOx in the gaseous stream.

Abstract: An article, apparatus and method for simulating poisoning and deactivating catalysts with catalyst poison compounds at least one catalyst poison compound selected from the group consisting of a compound comprising phosphorous, a compound comprising zinc compound and a compound comprising phosphorous and zinc.

Abstract: Provided is a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, and at least one catalytic layer. Also provided are methods for preparing the catalyst and methods for monitoring the oxygen storage capacity of an exhaust article containing the catalyst.

Abstract: A catalytic trap disposed in an exhaust passage of an internal combustion engine which is operated with periodic alternations between lean and stoichiometric or rich conditions, for abatement of NOx in an exhaust gas stream which is generated by the engine. The trap comprises a catalytic trap material and a refractory carrier member on which the catalytic trap material is disposed. The catalytic trap material comprises: (i) a refractory metal oxide support; (ii) a catalytic component effective for promoting the reduction of NOx under stoichiometric or rich conditions; and (iii) a NOx sorbent effective for adsorbing the NOx under lean conditions and desorbing and reducing the NOx to nitrogen under stoichiometric or rich conditions. The NOx sorbent comprises a metal oxide selected from the group consisting of one or alkali metal oxides, alkaline earth metal oxides and mixtures of one or more alkali metal oxides and alkaline earth metal oxides.

Abstract: The present invention relates to a method and a catalyst composite useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with a method for removing NOX and SOX contaminants from a gaseous stream comprising providing a catalyst composite having a downstream section and an upstream section. The downstream section comprises a first support, a first platinum component, and a NOx sorbent component. The upstream section comprises a second support, a second platinum component, and a SOx sorbent component selected from the group consisting of oxides of Mg, Zn, Mn, Fe, and Ni. In a sorbing period, a lean gaseous stream comprising NOX and SOX is passed within a sorbing temperature range through the upstream section to sorb at least some of the SOX contaminants and thereby provide a SOX depleted gaseous stream exiting the upstream section and entering the downstream section.

Abstract: A catalytic trap (10) for the treatment of exhaust generated by lean-burn or partial lean-burn engines is resistant to deactivation by high temperature, lean operating conditions aging. The catalytic trap (10 or 10′) comprises a carrier member (12 or 12/12′) on which is coated a catalytic trap material (20), optionally in discrete layers (20a, 20b) comprising a NOx sorbent and a refractory metal oxide support on which is dispersed a palladium catalytic component in an amount of at least 25 g/ft3 Pd up to about 300 g/ft3 Pd. A platinum and/or a rhodium catalytic component may also be present. The NOx sorbent may be one or more basic oxygenated compounds of an alkali metal and/or an alkaline earth metal, e.g., of cesium and/or barium. A method of making includes applying the NOx sorbent by a post-dipping technique.

Abstract: A method for applying a coating of catalytic material onto a metallic substrate involves thermal spray deposition of refractory oxide particles directly onto the substrate, preferably to attain an undercoat having a surface roughness of Ra 3 or greater. The catalytic material may then be applied to the undercoated substrate in any convenient manner. In a particular embodiment, the metallic substrate is treated by grit blasting prior to the application of an undercoat principally containing alumina. The coated substrate can be used in the assembly of a catalyst member for the treatment of exhaust gases.

Abstract: In a system for treating an exhaust stream, such as the exhaust of an internal combustion engine (10), the exhaust is initially treated by a first catalytic converter (14) and its effluent is cooled in an indirect heat exchanger (18) with an extraneous coolant fluid, i.e., one other than recycled engine exhaust, before introducing the exhaust into a hydrocarbon trap (30) to adsorb hydrocarbons therefrom at least during a cold-start period of engine operation. Such cooling enables utilization of highly efficient adsorbent materials such as activated carbon which otherwise could not be used. Adsorbed hydrocarbons are desorbed from the hydrocarbon trap (30) as the engine exhaust heats up. The exhaust is passed from hydrocarbon trap (30) to a second catalytic converter (34) for oxidation of the hydrocarbons.

Abstract: A method of improving the performance of a pollutant abatement means, e.g., catalytic converter (16), used to purify engine exhaust gas streams and the like includes combusting a combustion mixture of air and a low ignition temperature fuel in the exhaust gas stream upstream of the catalytic converter (16) to oxidize carbon monoxide and unburned hydrocarbons, and/or to rapidly heat the catalytic converter to its operating temperature. Reaction conditions are maintained so as to cause the combustion mixture to ignite spontaneously. A control system may be used to regulate the supply of the combustion mixture in response to time lapse or temperature of the catalyst or both. The apparatus includes a fuel supply (18) and a fuel line (20) controlled by a valve (22) to deliver a low ignition temperature fuel into the exhaust gas discharge line (14) associated with the engine (12). An air pump (26) provides combustion air through an air line (28) into the exhaust gas discharge line (14).

Abstract: A method for controlling exhaust gas emissions from an engine (16) includes extracting a light distillate fuel (Fd) from conventional gasoline or other liquid hydrocarbon fuel and supplying the engine with the light distillate fuel during an initial operation period of the engine. This reduces the oxidizable pollutants in the engine exhaust during a cold-start period before a catalytic converter (22) used to abate pollutants in the engine exhaust gases has not yet attained its operating temperature. After the catalytic converter (22) has been sufficiently heated, the fuel supply to the engine (16) is switched to gasoline or other liquid hydrocarbon fuel. Both the distillate fuel (Fd) and the liquid hydrocarbon fuel may be passed through a heated cracking catalyst bed (30) to crack the fuel fed to the engine.