Abstract: The present disclosure features a high metal cation content zeolite-based binary catalyst (e.g., a high copper and/or iron content zeolite-based binary catalyst, where the zeolite can be a chabazite) for NOx reduction, having relatively low N2O make, and having low corresponding metal oxide content; where the metal in the metal oxide corresponds to the metal of the metal cation. The present disclosure also describes the synthesis of the zeolite-based binary catalyst having high metal cation content.

Abstract: The present disclosure describes a catalytic aftertreatment system that includes a dosing compartment including a doser configured to introduce a diesel exhaust fluid (DEF) including urea into a diesel exhaust; a mixing chamber subsequent to the doser configured to mix the DEF with the diesel exhaust, the mixing chamber including an optional static metallic mixer, and a catalyst substrate including a combined urea hydrolysis-selective catalytic reduction binary catalyst coated thereon; and a SCR unit subsequent to the mixing chamber unit, including an SCR catalyst configured to facilitate reduction of nitrogen oxide (NOx) in the diesel exhaust with NH3.

Abstract: The present disclosure describes, inter alia, binary catalyst compositions including a (metal) zeolite having a crystal lattice that incorporates a metal oxide, wherein the metal oxide is covalently bound to elements within the crystal lattice. The metal oxide forms an integral part of the (metal) zeolite crystal lattice, forming covalent bonds with at least the Si or Al atoms within the crystal lattice of the (metal) zeolite, and is dispersed throughout the (metal) zeolite crystal lattice. The metal oxide can substitute atoms within the crystal lattice of the (metal) zeolite.

Abstract: The present disclosure describes hybrid binary catalysts (HBCs) that can be used as engine aftertreatment catalyst compositions, specifically 4-way catalyst compositions. The HBCs provide solutions to the challenges facing emissions control. In general, the HBCs include a porous primary catalyst and a secondary catalyst. The secondary catalyst partial coats the surfaces (e.g., the internal porous surface and/or the external surface) of the primary catalyst resulting in a hybridized composition. The synthesis of the HBCs can provide a primary catalyst whose entire surface, or portions thereof, can be coated with the secondary catalyst.

Abstract: The present disclosure features a high metal cation content zeolite-based binary catalyst (e.g., a high copper and/or iron content zeolite-based binary catalyst, where the zeolite can be a chabazite) for NOx reduction, having relatively low N2O make, and having low corresponding metal oxide content; where the metal in the metal oxide corresponds to the metal of the metal cation. The present disclosure also describes the synthesis of the zeolite-based binary catalyst having high metal cation content.

Abstract: The present disclosure describes, inter alia, binary catalyst compositions including a (metal) zeolite having a crystal lattice that incorporates a metal oxide, wherein the metal oxide is covalently bound to elements within the crystal lattice. The metal oxide forms an integral part of the (metal) zeolite crystal lattice, forming covalent bonds with at least the Si or Al atoms within the crystal lattice of the (metal) zeolite, and is dispersed throughout the (metal) zeolite crystal lattice. The metal oxide can substitute atoms within the crystal lattice of the (metal) zeolite.

Abstract: A thermally integrated catalyst aftertreatment exhaust system includes a flow channel that directs diesel exhaust through a diesel oxidation catalyst unit that includes a diesel oxidation catalyst, by a doser that introduces DEF into the diesel exhaust, through a mixing chamber that includes a static metallic mixer coated with a DEF hydrolysis catalyst, and through an SCR unit that includes an SCR catalyst. The diesel oxidation catalyst converts a portion of diesel exhaust into water, carbon dioxide, or nitrogen dioxide. The DEF hydrolysis catalyst facilitates hydrolysis of the mixed DEF and diesel exhaust. The SCR catalyst facilitates reduction of NOx in the diesel exhaust. A first portion of the flow channel is in direct thermal contact with a second portion of the flow channel that houses the SCR unit such that heat from the diesel exhaust before the diesel exhaust reaches the doser is passed to the SCR unit.

Abstract: The present disclosure describes hybrid binary catalysts (HBCs) that can be used as engine aftertreatment catalyst compositions. The HBCs provide solutions to the challenges facing emissions control. In general, the HBCs include a porous primary catalyst and a secondary catalyst. The secondary catalyst partial coats the surfaces (e.g., the internal porous surface and/or the external surface) of the primary catalyst resulting in a hybridized composition. The synthesis of the HBCs can provide a primary catalyst whose entire surface, or portions thereof, can be coated with the secondary catalyst.

Abstract: A thermally integrated catalyst aftertreatment exhaust system includes a flow channel that directs diesel exhaust through a diesel oxidation catalyst unit that includes a diesel oxidation catalyst, by a doser that introduces DEF into the diesel exhaust, through a mixing chamber that includes a static metallic mixer coated with a DEF hydrolysis catalyst, and through an SCR unit that includes an SCR catalyst. The diesel oxidation catalyst converts a portion of diesel exhaust into water, carbon dioxide, or nitrogen dioxide. The DEF hydrolysis catalyst facilitates hydrolysis of the mixed DEF and diesel exhaust. The SCR catalyst facilitates reduction of NOx in the diesel exhaust. A first portion of the flow channel is in direct thermal contact with a second portion of the flow channel that houses the SCR unit such that heat from the diesel exhaust before the diesel exhaust reaches the doser is passed to the SCR unit.

Abstract: A diesel exhaust fluid (DEF) doser includes a DEF inlet configured to receive DEF, a DEF outlet configured to spray DEF out of the DEF doser, and an electrochemical cell. The electrochemical cell is located between the DEF inlet and the DEF outlet and couplable to a power source. The electrochemical cell is configured such that, when DEF is flowing from the DEF inlet to the DEF outlet and when the electrochemical cell is coupled to the power source, the electrochemical cell causes an electrolytic reaction in the DEF flowing from the DEF inlet to the DEF outlet to produce gaseous products in the DEF flowing from the DEF inlet to the DEF outlet, and wherein the gaseous products comprise one or more of H2 or NH3.

Abstract: The present disclosure describes hybrid binary catalysts (HBCs) that can be used as engine aftertreatment catalyst compositions, specifically 4-way catalyst compositions. The HBCs provide solutions to the challenges facing emissions control. In general, the HBCs include a porous primary catalyst and a secondary catalyst. The secondary catalyst partial coats the surfaces (e.g., the internal porous surface and/or the external surface) of the primary catalyst resulting in a hybridized composition. The synthesis of the HBCs can provide a primary catalyst whose entire surface, or portions thereof, can be coated with the secondary catalyst.

Abstract: The present disclosure describes hybrid binary catalysts (HBCs) that can be used as engine aftertreatment catalyst compositions. The HBCs provide solutions to the challenges facing emissions control. In general, the HBCs include a porous primary catalyst and a secondary catalyst. The secondary catalyst partial coats the surfaces (e.g., the internal porous surface and/or the external surface) of the primary catalyst resulting in a hybridized composition. The synthesis of the HBCs can provide a primary catalyst whose entire surface, or portions thereof, can be coated with the secondary catalyst.

Abstract: A thermally integrated catalyst aftertreatment exhaust system includes a flow channel that directs diesel exhaust through a diesel oxidation catalyst unit that includes a diesel oxidation catalyst, by a doser that introduces DEF into the diesel exhaust, through a mixing chamber that includes a static metallic mixer coated with a DEF hydrolysis catalyst, and through an SCR unit that includes an SCR catalyst. The diesel oxidation catalyst converts a portion of diesel exhaust into water, carbon dioxide, or nitrogen dioxide. The DEF hydrolysis catalyst facilitates hydrolysis of the mixed DEF and diesel exhaust. The SCR catalyst facilitates reduction of NOx in the diesel exhaust. A first portion of the flow channel is in direct thermal contact with a second portion of the flow channel that houses the SCR unit such that heat from the diesel exhaust before the diesel exhaust reaches the doser is passed to the SCR unit.

Abstract: This disclosure features a urea conversion catalyst located within a urea decomposition reactor (e.g., a urea decomposition pipe) of a diesel exhaust aftertreatment system. The urea conversion catalyst includes a refractory metal oxide and a cationic dopant. The urea conversion catalyst can decrease the temperature at which urea converts to ammonia, can increase the urea conversion yield, and can decrease the likelihood of incomplete urea conversion.

Abstract: Catalytic cores for a wall-flow filter include juxtaposed channels extending longitudinally between an inlet side and an outlet side of the core, wherein the inlet channels are plugged at the outlet side and outlet channels are plugged at the inlet side. Longitudinal walls forming the inlet and outlet channels separate the inlet channels from the outlet channels. The walls include pores that create passages extending across a width of the walls from the inlet channels to the outlet channels. Catalysts are distributed across the width and length of the walls within internal surfaces of the pores in a manner such that the loading of each catalyst across the width varies by less than 50% from an average loading across the width.

Abstract: This disclosure features an exhaust aftertreatment system that includes a selective catalytic reduction catalyst that includes (1) a metal oxide catalyst and a metal zeolite catalyst, (2) a metal oxide catalyst that is other than a vanadium oxide catalyst and a vanadium oxide catalyst, or (3) a metal oxide catalyst that is other than a vanadium oxide catalyst together with a metal zeolite catalyst and a vanadium oxide catalyst. When used in a selective catalytic reduction system in a diesel engine, the catalyst composition can increase a conversion efficiency of nitrogen oxides (NOx) to nitrogen and water by a minimum of 2 percent compared to the metal zeolite catalyst alone, the metal oxide catalyst alone, or the vanadium oxide catalyst alone, when present.

Abstract: The present disclosure features a method of making an engine aftertreatment catalyst, where the engine aftertreatment catalyst includes a metal oxide, a metal zeolite, and/or vanadium oxide when the metal oxide is different from vanadium oxide, each of which can be independently surface-modified with a surface modifier. The method includes providing a solution including an organic solvent and an organometallic compound; mixing the solution with a metal oxide, a metal zeolite, and/or a vanadium oxide to provide a mixture; drying the mixture; and calcining the mixture to provide a surface-modified metal oxide catalyst, a surface-modified metal zeolite catalyst, and/or a surface-modified vanadium oxide catalyst. The organometallic compound can be, for example, a metal alkoxide, a metal carboxylate, a metal acetylacetonate, and/or a metal organic acid ester.

Abstract: A diesel exhaust fluid (DEF) doser includes a DEF inlet configured to receive DEF, a DEF outlet configured to spray DEF out of the DEF doser, and an electrochemical cell. The electrochemical cell is located between the DEF inlet and the DEF outlet and couplable to a power source. The electrochemical cell is configured such that, when DEF is flowing from the DEF inlet to the DEF outlet and when the electrochemical cell is coupled to the power source, the electrochemical cell causes an electrolytic reaction in the DEF flowing from the DEF inlet to the DEF outlet to produce gaseous products in the DEF flowing from the DEF inlet to the DEF outlet, and wherein the gaseous products comprise one or more of H2 or NH3.

Abstract: A thermally integrated catalyst aftertreatment exhaust system includes a flow channel that directs diesel exhaust through a diesel oxidation catalyst unit that includes a diesel oxidation catalyst, by a doser that introduces DEF into the diesel exhaust, through a mixing chamber that includes a static metallic mixer coated with a DEF hydrolysis catalyst, and through an SCR unit that includes an SCR catalyst. The diesel oxidation catalyst converts a portion of diesel exhaust into water, carbon dioxide, or nitrogen dioxide. The DEF hydrolysis catalyst facilitates hydrolysis of the mixed DEF and diesel exhaust. The SCR catalyst facilitates reduction of NOx in the diesel exhaust. A first portion of the flow channel is in direct thermal contact with a second portion of the flow channel that houses the SCR unit such that heat from the diesel exhaust before the diesel exhaust reaches the doser is passed to the SCR unit.

Abstract: This disclosure features an exhaust aftertreatment system that includes a selective catalytic reduction catalyst that includes a metal oxide catalyst and a metal zeolite catalyst, a metal oxide catalyst that is other than a vanadium oxide catalyst and a vanadium oxide catalyst, or a metal oxide catalyst that is other than a vanadium oxide catalyst together with a metal zeolite catalyst and a vanadium oxide catalyst. When used in a selective catalytic reduction system in a diesel engine, the catalyst composition can increase a conversion efficiency of nitrogen oxides (NOx) to nitrogen and water by a minimum of 2 percent compared to the metal zeolite catalyst alone, the metal oxide catalyst alone, or the vanadium oxide catalyst alone, when present.