Abstract: Processes are provided for making partially coated monolith catalysts that are useful, for example, as pre-combustor catalysts for diesel exhaust aftertreatment. Monolith substrates are provided with interconnectivity and/or temporary barriers that allow from about 10 to about 90% of the monolith channels to be coated after the monolith substrate is assembled without having to carefully pick out among a large number of openings which ones to inject into or which ones to plug. The invention includes options of injecting into a multipath monolith substrate and of emplacing blocking material during monolith construction. Either catalyst coating material or coat-blocking material can be injected. Blocking materials allow the use of machinery for ordinarily non-selective processes, such as machinery for dip coating. Both multipath injections and pre-placed barriers can be used in a single partial coating process.

Abstract: An exhaust aftertreatment system is provided with a large channel combustor, a fuel reformer, and a lean NOX trap. The lean NOX trap is denitrated by steps comprising: heating the fuel reformer to steam reforming temperatures by introducing vaporized fuel to the large channel combustor and combusting a portion of the vaporized fuel under lean conditions, then making the exhaust-injected fuel mixture overall rich, whereby the fuel reformer produces syn gas that denitrates the lean NOX trap. The fuel reformer has a low thermal mass, whereby it is designed to heat to at least about 500° C. and catalyze steam reforming reaction with each denitration. The large channel combustor is a monolith having an average channel size larger than the fuel reformer and a thermal mass no more than about 20% that of the fuel reformer, whereby the large channel combustor facilitates low temperature startup of the fuel reformer.

Abstract: A power generation system and method of operating a power generation system which comprises a diesel engine which produces lean exhaust which passed to an exhaust after treatment system comprising an exhaust line which is in communication with a controller, reformer, lean NOx trap and SCR has been taught wherein the reformer comprises oxidation and reforming catalyst is a composition which comprises a catalyst wash coat comprising a ZrO2 refractory metal oxide support, a LnxOy distributed on the surface of the refractory metal oxide in an amount to form a monolayer over the refractory metal oxide support wherein Ln is selected from the group consisting of La, Nd and mixtures thereof and Rh distributed over the catalyst surface in an effective amount to catalyze steam reforming at 650° C.

Abstract: Processes are provided for making partially coated monolith catalysts that are useful, for example, as pre-combustor catalysts for diesel exhaust aftertreatment. Monolith substrates are provided with interconnectivity and/or temporary barriers that allow from about 10 to about 90% of the monolith channels to be coated after the monolith substrate is assembled without having to carefully pick out among a large number of openings which ones to inject into or which ones to plug. The invention includes options of injecting into a multipath monolith substrate and of emplacing blocking material during monolith construction. Either catalyst coating material or coat-blocking material can be injected. Blocking materials allow the use of machinery for ordinarily non-selective processes, such as machinery for dip coating. Both multipath injections and pre-placed barriers can be used in a single partial coating process.

Abstract: The invention provides devices and methods for generating H2 and CO in an O2 containing gas stream. The invention also provides devices and methods for removal of NOX from an O2 containing gas stream, particularly the oxygen-rich exhaust stream from a lean-burning engine, such as a diesel engine. The invention includes a fuel processor that efficiently converts added hydrocarbon fuel to a reducing mixture of H2 and CO. The added fuel may be a portion of the onboard fuel on a vehicle. The H2 and CO are incorporated into the exhaust stream and reacted over a selective lean NOX catalyst to convert NOX to N2. thereby providing an efficient means of NOX emission control.

Abstract: The present invention provides systems and methods to improve the performance and emission control of internal combustion engines equipped with nitrogen oxides storage-reduction (“NSR”) emission control systems. The system generally includes a NSR catalyst, a fuel processor located upstream of the NSR catalyst, and at least one fuel injection port. The fuel processor converts a fuel into a reducing gas mixture comprising CO and H2. The reducing gas mixture is then fed into the NSR catalyst, where it regenerates the NSR adsorbent, reduces the NOx to nitrogen, and optionally periodically desulfates the NSR catalyst. The fuel processor generally includes one or more catalysts, which facilitate reactions such as combustion, partial oxidation, and/or reforming and help consume excess oxygen present in an engine exhaust stream. The methods of the present invention provide for NSR catalyst adsorbent regeneration using pulsed fuel flow. Control strategies are also provided.

Abstract: An exhaust aftertreatment system is provided with a large channel combustor, a fuel reformer, and a lean NOX trap. The lean NOX trap is denitrated by steps comprising: heating the fuel reformer to steam reforming temperatures by introducing vaporized fuel to the large channel combustor and combusting a portion of the vaporized fuel under lean conditions, then making the exhaust-injected fuel mixture overall rich, whereby the fuel reformer produces syn gas that denitrates the lean NOX trap. The fuel reformer has a low thermal mass, whereby it is designed to heat to at least about 500° C. and catalyze steam reforming reaction with each denitration. The large channel combustor is a monolith having an average channel size larger than the fuel reformer and a thermal mass no more than about 20% that of the fuel reformer, whereby the large channel combustor facilitates low temperature startup of the fuel reformer.

Abstract: The inventions relates to catalysts comprising precious metals supported on La stabilized refractory metal oxides. The La is provided on the surface of the refractory metal oxide in an amount to form at least about a monolayer, preferably about 1-2 mono-layers. Preferably, the La has no crystalline structure shown by X-ray diffraction. Nd and mixtures of La and Nd can be used in place of La. In one embodiment, the catalyst is a reforming catalyst comprising an effective amount of Rh on a ZrO2 support. Preferably, the Rh is provided in a relatively low concentration, typically about 0.5% or less based on the weight of the ZrO2 support. The inventors have found that if the Rh loading is kept sufficiently low, the Rh can be maintained in the form of small particles (less than 5 nm, typically about 2 nm or less) through lean rich cycling as a consequence of an effect involving the La.