Plural Layers On A Support, Each Layer Having A Distinct Function Patents (Class 502/527.12)
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Patent number: 7922988Abstract: A layered three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Engine exhaust treatment system and methods of using the same are also provided. The catalytic material can be provided in layers such that a larger amount of oxygen storage component is provided in a downstream zone as compared to an upstream zone. For example, the upstream zone can be configured to have one, two, or three layers, and the downstream zone can be independently configured to have one, two, or three layers. In one or more embodiments, the catalyst supported on a carrier has three layers, where at least two of the layers are zoned to have an oxygen storage component being present in an upstream zone in an amount that is less than the oxygen storage component present in the downstream zone.Type: GrantFiled: October 30, 2009Date of Patent: April 12, 2011Inventors: Michel Deeba, Stephan Siemund, Xinyi Wei, Stefan Kotrel, Knut Wassermann, Glenn Svoboda, Harold Rabinowitz
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Patent number: 7906449Abstract: The present invention is a selective catalytic reduction type catalyst for purifying nitrogen oxides in exhaust gas exhausted from lean combustion engines using ammonia or urea as a reducing agent, it is provided with a selective catalytic reduction type catalyst The catalyst comprises a lower-layer catalyst layer (A) having an oxidative function for nitrogen monoxide (NO) in exhaust gas and an upper-layer catalyst layer (B) having an adsorbing function for ammonia on the surface of a monolithic structure type carrier (C), and that the lower-layer catalyst layer (A) comprises a noble metal component (i), an inorganic base material constituent (ii) and zeolite (iii), and the upper-layer catalyst layer (B) comprises substantially none of component (i) but the component (iii).Type: GrantFiled: May 5, 2008Date of Patent: March 15, 2011Assignee: N.E. Chemcat CorporationInventors: Ryuji Ando, Takashi Hihara, Yasuharu Kanno, Makoto Nagata
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Patent number: 7879758Abstract: A catalytically active porous element for promoting catalytic gas phase reactions is proposed, said element comprising a porous structural element of sintered ceramic or metallic primary particles, which are selected from fibrous and/or granular particles, a secondary structure of titania nano particles deposited on the surface of said sintered primary particles and a catalytic component deposited on the surface of the titania nano particles. Thereby porous catalytic elements for catalytic gas phase reactions which are useful not only in NOX reduction reactions but also for other catalytic gas phase reactions are provided.Type: GrantFiled: July 5, 2005Date of Patent: February 1, 2011Assignee: Pall CorporationInventors: Steffen Heidenreich, Manfred Nacken
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Patent number: 7875573Abstract: The present invention is directed to a diesel oxidation catalyst for the treatment of exhaust gas emissions, such as the oxidation of unburned hydrocarbons (HC), and carbon monoxide (CO) and the reduction of nitrogen oxides (NOx). More particularly, the present invention is directed to a novel washcoat composition comprising two distinct washcoat layers containing two distinctly different ratios of Pt:Pd.Type: GrantFiled: June 24, 2009Date of Patent: January 25, 2011Assignee: BASF CorporationInventors: Tilman W. Beutel, Joseph C. Dettling, Dustin O. Hollobaugh, Torsten W. Mueler-Stach
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Patent number: 7862643Abstract: A method of manufacturing a hydrogen separation membrane comprises the steps of forming an intermediate layer suitable for controlling oxidation of a hydrogen permeable metal layer on the surface of the hydrogen permeable metal layer on the surface of the hydrogen permeable metal used as a substrate; and attaching a catalytic metal in a granular form on the surface of the intermediate layer. This method can be used to manufacture a hydrogen separation membrane in which the quantity of catalytic metal used is controlled.Type: GrantFiled: April 7, 2005Date of Patent: January 4, 2011Assignee: Toyota Jidosha Kabushiki KaishaInventor: Satoshi Aoyama
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Patent number: 7851403Abstract: A honeycomb structure includes adhesive layers and plural honeycomb units bonded to each other by interposing the adhesive layers between the plural honeycomb units. Each of the honeycomb units has partition walls extending along a longitudinal direction of the honeycomb units to define plural through holes. The plural honeycomb units include a SOx absorbent, inorganic particles, and an inorganic binder. An expression Y??0.3X+1.55 (about 1.0?X?about 2.5) is satisfied, in which X represents a content (mol/L) of the SOx absorbent in the partition walls and Y represents a ratio B/A in which A represents a Young's modulus of the honeycomb units and B represents a Young's modulus of the adhesive layers.Type: GrantFiled: October 7, 2008Date of Patent: December 14, 2010Assignee: Ibiden Co., Ltd.Inventors: Masafumi Kunieda, Mari Kitajima
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Patent number: 7816300Abstract: The present invention provides an exhaust gas purification catalyst comprising a base material, and a two or more layered catalyst coating layer, formed on the base material, wherein the two or more layers have upper and lower layers, and wherein the upper layer contains a large amount of noble metal per liter of the base material more than that of the lower layer, and the lower layer contains a large amount of an oxygen storage/release material per liter of the base material more than that of the upper layer. This exhaust gas purification catalyst has more excellent H2S purifying performance than conventional catalysts while maintaining purifying performance against NOx and the other exhaust gas components.Type: GrantFiled: June 5, 2007Date of Patent: October 19, 2010Assignees: Cataler Corporation, Toyota Jidosha Kabushiki KaishaInventors: Michihiko Takeuchi, Hirotaka Ori, Takeru Yoshida, Kazunobu Ishibashi, Ichiro Hachisuka
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Patent number: 7816299Abstract: A stacked bed catalyst system comprising at least one first catalyst selected from conventional hydrotreating catalyst having an average pore diameter of greater than about 10 nm and at least one second catalyst comprising a bulk metal hydrotreating catalyst comprised of at least one Group VIII non-noble metal and at least one Group VIB metal and optionally a binder material.Type: GrantFiled: March 31, 2009Date of Patent: October 19, 2010Assignee: ExxonMobil Research and Engineering CompanyInventors: Gary P. Schleicher, Kenneth L. Riley
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Patent number: 7811966Abstract: A catalyst, catalyst precursor, or catalyst carrier formed as an elongated shaped particle having a cross section comprising three protrusions each extending from and attached to a central position. The central position is aligned along the longitudinal axis of the particle. The cross-section of the particle occupies the space encompassed by the outer edges of six outer circles around a central circle, each of the six outer circles contacting two neighbouring outer circles, the particle occupying three alternating outer circles equidistant to the central circle and the six interstitial regions, the particle not occupying the three remaining outer circles which are between the alternating occupied outer circles. The ratio of the diameter of the central circle to the diameter of the outer occupied circle is more than 1, and the ratio of the diameter of the outer unoccupied circle to the diameter of the outer occupied circle is more than 1.Type: GrantFiled: January 18, 2008Date of Patent: October 12, 2010Assignee: Shell Oil CompanyInventors: Hans Peter Alexander Calis, Guy Lode Magda Maria Verbist
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Patent number: 7811963Abstract: An elongated-shaped particle having two protrusions; each extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross-section of the particle occupying the space encompassed by the outer edges of six circles around a central circle, in which each of the six circles touches two neighboring circles and two alternating circles are equidistant to the central circle and may be attached to the central circle, and the two circles adjacent to the two alternating circles (but not the common circle) touching the central circle, minus the space occupied by the four remaining outer circles and including four remaining interstitial regions.Type: GrantFiled: November 3, 2003Date of Patent: October 12, 2010Assignee: Shell Oil CompanyInventors: Hilbrand Klaver, Carolus Matthias Anna Maria Mesters, Gerardus Petrus Lambertus Niesen, Guy Lode Magda Maria Verbist
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Patent number: 7799727Abstract: A layered composition which can be used in various processes has been developed. The composition comprises an inner core such as a cordierite core and an outer layer comprising a refractory inorganic oxide, a fibrous component and an inorganic binder. The refractory inorganic oxide layer can be alumina, zirconia, titania, etc. while the fibrous component can be titania fibers, silica fibers, carbon fibers, etc. The inorganic oxide binder can be alumina, silica, zirconia, etc. The layer can also contain catalytic metals such as gold and platinum plus other modifiers. The layered composition is prepared by coating the inner core with a slurry comprising the refractory inorganic oxide, fibrous component, an inorganic binder precursor and an organic binding agent such as polyvinyl alcohol. The composition can be used in various hydrocarbon conversion processes.Type: GrantFiled: December 15, 2009Date of Patent: September 21, 2010Assignee: UOP LLCInventors: Dean E. Rende, James E. Rekoske, Jeffery C. Bricker, Jeffrey L. Boike, Masao Takayama, Kouji Hara, Nobuyuki Aoi
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Patent number: 7785551Abstract: A catalyst and a method for selectively reducing nitrogen oxides with ammonia are provided. The catalyst includes a first component of copper, chromium, cobalt, nickel, manganese, iron, niobium, or mixtures thereof, a second component of cerium, a lanthanide, a mixture of lanthanides, or mixtures thereof, and a zeolite. The catalyst may also include strontium as an additional second component. The catalyst selectively reduces nitrogen oxides to nitrogen with ammonia at low temperatures. The catalyst has high hydrothermal stability. The catalyst has high activity for conversion of nitrogen oxides in exhaust streams, and are not significantly influenced by the NO/NO2 ratio. The catalyst and the method may have special application to selective reduction of nitrogen oxides in exhaust gas from diesel vehicles, although the catalyst and the method have broad application to a wide range of gas streams that contain nitrogen oxides.Type: GrantFiled: November 20, 2008Date of Patent: August 31, 2010Assignee: Catalytic Solutions, Inc.Inventors: Stephen J. Golden, Svetlana Iretskaya
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Patent number: 7759283Abstract: To improve a CO conversion in stoichiometry-lean atmosphere, and additionally to prevent the rise of pressure loss. A catalytic coating layer 2 is constituted of a lower layer 20 including an oxygen storage capacity material and an upper layer 21 being formed on a surface of the lower layer 20 and including a catalytic noble metal, and a thickness of the upper layer is adapted so as to be 5 ?m-40 ?m. The upper layer 21 is good in terms of gas diffusibility, and thereby OSC resulting from the oxygen storage capacity material being included in the lower layer 20 is demonstrated maximally.Type: GrantFiled: July 24, 2007Date of Patent: July 20, 2010Assignees: Toyota Jidosha Kabushiki Kaisha, Denso CorporationInventors: Masanori Yamato, Takatoshi Shinyoshi, Takumi Suzawa, Keiji Ito
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Patent number: 7758834Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.Type: GrantFiled: April 23, 2009Date of Patent: July 20, 2010Assignee: BASF CorporationInventors: Shau-Lin F. Chen, Harold Rabinowitz, Jin Sakakibara, Tian Luo, Michel Deeba
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Patent number: 7754171Abstract: A multilayered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Provided is a catalytic material of at least four layers in conjunction with a carrier, where each of the layers includes a support, at least three layers comprise a precious metal component, and at least one layer comprises an oxygen storage component (OSC). The catalytic material can further comprise a fifth layer, where at least four layers comprise a precious metal component, at least one layer comprises an oxygen storage component, and at least one layer is substantially free of an oxygen storage component.Type: GrantFiled: January 9, 2008Date of Patent: July 13, 2010Assignee: BASF CorporationInventors: Shau-Lin F. Chen, Knut Wassermann, Stephan Siemund, Tian Luo, Torsten Neubauer, Jin Sakakibara, Harold Rabinowitz
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Patent number: 7749472Abstract: The present invention provides for novel poisoning-resistant catalysts used for automobile exhaust gas treatment systems. To alleviate the detrimental affects of engine oil and/or fuel additive poisoning the present invention provides for an overcoat layer comprising a porous refractory oxide and one or more base metal oxides, which is coated over one or more precious metal containing washcoat layers. The overcoat of the present invention prevents phosphorous as well as other poisoning deposits, from fouling and/or negatively interacting with the underlying precious metal containing washcoats. In an alternative embodiment, the present invention provides for the coating of the upstream end of a catalytic member by the overcoat layer, thereby creating an upstream poison capture zone.Type: GrantFiled: August 14, 2006Date of Patent: July 6, 2010Assignee: BASF CorporationInventors: Shau-Lin Franklin Chen, Knut Wassermann, Jin Sakakibara
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Patent number: 7741243Abstract: Provided is a production method of a catalyst layer which is improved in catalyst activity and catalyst utilization efficiency. The method of producing a catalyst layer includes the steps of forming a first layer including a catalyst precursor on a substrate by a vapor phase process; forming cracks in the first layer; and reducing the first layer having the cracks formed therein.Type: GrantFiled: October 2, 2008Date of Patent: June 22, 2010Assignee: Canon Kabushiki KaishaInventor: Atsuhito Yoshizawa
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Patent number: 7737077Abstract: This is to provide a catalyst for purifying exhaust gases, catalyst which are good in terms of the purifying performance.Type: GrantFiled: November 25, 2004Date of Patent: June 15, 2010Assignee: Cataler CorporationInventors: Ichiro Kitamura, Akimasa Hirai, Kenichi Taki
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Patent number: 7737080Abstract: The invention relates to a structure, comprising a substrate supporting a layer with a photocatalytic and anti-soiling property on at least part of the surface thereof, said layer being based on titanium dioxide (TiO2) which is at least partially crystallized in the anatase form thereof. Said structure is characterised in comprising a sublayer (SC) directly under at least one TiO2 layer, said sublayer having a crystallographic structure which provides assistance to crystallization by heteroepitaxial growth in the anatase form of the TiO2-based upper layer, the photocatalytic property being obtained without any heating step.Type: GrantFiled: October 22, 2004Date of Patent: June 15, 2010Assignee: Saint-Gobain Glass FranceInventors: Laurent Labrousse, Nicolas Nadaud
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Patent number: 7736717Abstract: A honeycomb body includes a honeycomb structure through which a fluid can flow and which is disposed in a tubular casing that is substantially gas-impermeable in a radial direction. The tubular casing includes at least one inner tubular casing part and at least one outer tubular casing part, in which at least the outer tubular casing part has cutouts at least in a subregion. The tubular casing has a reduced weight as compared to standard tubular casings, yet nevertheless has the same mechanical stability and gas-tightness. It is also possible to form the tubular casing with thermal expansion properties which are adapted to a subsequent use.Type: GrantFiled: April 17, 2006Date of Patent: June 15, 2010Assignee: Emitec Gesellschaft fuer Emissionstechnologie mbHInventor: Hermann Josef Müller
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Patent number: 7704464Abstract: Hydrocarbon processing devices and systems are constructed to modify the combustion characteristics of hydrocarbon fuels and emissions for the purpose of emissions reduction and to increase the overall performance characteristics of the engine. According to one exemplary embodiment, a catalytic device for processing a fluid containing hydrocarbons includes a reactive body formed of a plurality of metallic materials arranged in a layered structure. The plurality of metallic materials is formed of at least two different materials. The body has an inner core member having a first density and another region, that is formed along a longitudinal length of the rolled layered structure, has a second density which is less than the first density.Type: GrantFiled: September 19, 2005Date of Patent: April 27, 2010Assignee: 0783963 BC Ltd.Inventor: Jeffrey A. Stephenson
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Patent number: 7674743Abstract: This catalyst system simultaneously removes ammonia and enhances net NOx conversion by placing an NH3—SCR catalyst formulation downstream of a lean NOx trap. By doing so, the NH3—SCR catalyst adsorbs the ammonia from the upstream lean NOx trap generated during the rich pulses. The stored ammonia then reacts with the NOx emitted from the upstream lean NOx trap-enhancing the net NOx conversion rate significantly, while depleting the stored ammonia. By combining the lean NOx trap with the NH3—SCR catalyst, the system allows for the reduction or elimination of NH3 and NOx slip, reduction in NOx spikes and thus an improved net NOx conversion during lean and rich operation.Type: GrantFiled: December 1, 2008Date of Patent: March 9, 2010Assignee: Ford Global Technologies, LLCInventors: Haren Sakarai Gandhi, John Vito Cavataio, Robert Henry Hammerle, Yisun Cheng
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Patent number: 7662743Abstract: The present invention provides an NOx purifying catalyst that removes NOx with sufficient efficiency even under low temperature operation such as diesel engine automobiles. An NOx purifying catalyst for processing NOx in exhaust gas by rich/lean control of the air-fuel ratio of the exhaust gas, includes a first catalytic layer containing ?-zeolite having iron and/or cerium elements, and a second catalytic layer including a noble metal and cerium oxide-based material; in which the second and the first catalytic layers are coated on a support in that order so that the first catalytic layer is the uppermost layer. The NOx purifying catalyst purifies NOx as showed in Reaction Formulations (1) to (4). Lean condition 1: NO+½O2?NO2??(1) Rich condition: CO+H2O?CO2??(2) NOx+H2?NH3??(3) Lean condition 2: NOx+NH3+O2?N2+H2O??(4).Type: GrantFiled: July 12, 2007Date of Patent: February 16, 2010Assignee: Honda Motor Co., Ltd.Inventors: Naohiro Satoh, Osami Yamamoto, Koichi Inaba
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Patent number: 7641875Abstract: A multi-phase catalyst for the simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons is provided. A catalyst composition comprising the multi-phase catalyst and methods of making the catalyst composition are also provided. The multi-phase catalyst may be represented by the general formula of CeyLn1-xAx+sMOZ, wherein Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of lanthanides; A is an element selected from a group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, or any combination thereof; and M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, or any combination thereof; x is a number defined by 0?x<1.0; y is a number defined by 0?y<10; s is a number defined by 0?s<10; where s=0 only when y>0 and y=0 only when s>0.Type: GrantFiled: November 3, 2008Date of Patent: January 5, 2010Assignee: Catalytic Solutions, Inc.Inventor: Stephen J. Golden
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Patent number: 7638459Abstract: A layered composition which can be used in various processes has been developed. The composition comprises an inner core such as a cordierite core and an outer layer comprising a refractory inorganic oxide, a fibrous component and an inorganic binder. The refractory inorganic oxide layer can be alumina, zirconia, titania, etc. while the fibrous component can be titania fibers, silica fibers, carbon fibers, etc. The inorganic oxide binder can be alumina, silica, zirconia, etc. The layer can also contain catalytic metals such as gold and platinum plus other modifiers. The layered composition is prepared by coating the inner core with a slurry comprising the refractory inorganic oxide, fibrous component, an inorganic binder precursor and an organic binding agent such as polyvinyl alcohol. The composition can be used in various hydrocarbon conversion processes.Type: GrantFiled: May 25, 2005Date of Patent: December 29, 2009Assignee: UOP LLCInventors: Dean E. Rende, James E. Rekoske, Jeffery C. Bricker, Jeffrey L. Boike, Masao Takayama, Kouji Hara, Nobuyuki Aoi
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Patent number: 7622096Abstract: A layered three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Engine exhaust treatment system and methods of using the same are also provided. In one or more embodiments, the catalyst supported on a carrier has three layers, where at least two of the layers are zoned to have an oxygen storage component being present in an upstream zone in an amount that is less than the oxygen storage component present in the downstream zone.Type: GrantFiled: August 9, 2007Date of Patent: November 24, 2009Assignee: BASF Catalysts LLCInventors: Michel Deeba, Knut Wassermann, Glenn Svoboda, Harold Rabinowitz, Stephan Slemund, Xinyi Wei
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Patent number: 7611680Abstract: An engine exhaust catalyst containing precious metal nanoparticles is promoted with bismuth. The bismuth promotion improves the catalyst's CO oxidation performance. Also, by varying the amount of bismuth that is added, the NO conversion rate that can be realized with the catalyst can be controlled. The control over the NO conversion rate is important because the passive regenerative performance of a particulate filter used in engine exhaust systems is based on the amount NO2 that is present in the exhaust stream that reaches the particulate filter. The amount of NO2 being produced needs to be optimized (not necessarily maximized) so that adequate particulate filter regeneration performance can be maintained while avoiding unused, toxic NO2 from being exhausted into the atmosphere.Type: GrantFiled: January 9, 2007Date of Patent: November 3, 2009Assignee: Nanostellar, Inc.Inventors: Jifei Jia, Kyle L. Fujdala, Timothy J. Truex
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Patent number: 7601671Abstract: A method for preparing an exhaust gas catalyst includes preparing a washcoat comprising a catalytically effective amount of at least one catalytically active metal disposed upon an oxide support; disposing the catalytically active metal-oxide support washcoat upon a catalyst substrate; drying the washcoated catalyst substrate using microwave energy to affix the precious metals to the oxide support; and conventionally calcining the dried washcoated catalyst substrate. The catalysts comprising a substrate having dispersed thereon an inorganic oxide washcoat, the washcoat having been affixed to the substrate by microwave drying, exhibit high exhaust gas purifying performance and long durability. The catalysts thus produced further provide a long in-service lifetime for reforming organic fuel species into hydrogen, carbon monoxide and light hydrocarbons used in the nitrogen oxides reduction process.Type: GrantFiled: October 28, 2004Date of Patent: October 13, 2009Assignee: Umicore AG & Co. KGInventor: William J. LaBarge
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Patent number: 7585477Abstract: The invention provides a catalyst for catalytic reduction of nitrogen oxides contained in exhaust gases wherein fuel is supplied and subjected to combustion under periodic rich/lean conditions and the resulting exhaust gases are brought into contact therewith, which catalyst comprises: (A) a catalyst component A comprising (c) ceria or (d) praseodymium oxide or (e) an oxide and/or a composite oxide of at least two elements selected from the group consisting of cerium, zirconium, praseodymium, neodymium, terbium, samarium, gadolinium and lanthanum; (B) a catalyst component B comprising (d) a noble metal catalyst component selected from the group consisting of platinum, rhodium, palladium and oxides thereof and (e) a carrier; and (C) a catalyst component C comprising (f) a solid acid, and (g) a solid acid supporting an oxide of at least one element selected from the group consisting of vanadium, tungsten, molybdenum, copper, iron, cobalt, nickel and manganese.Type: GrantFiled: November 8, 2004Date of Patent: September 8, 2009Assignee: Honda Motor Co., Ltd.Inventors: Tadao Nakatsuji, Norio Suzuki, Hiroshi Ohno, Naohiro Sato, Tomoko Morita, Katsuji Wada
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Patent number: 7576031Abstract: The present invention is directed to a diesel oxidation catalyst for the treatment of exhaust gas emissions, such as the oxidation of unburned hydrocarbons (HC), and carbon monoxide (CO) and the reduction of nitrogen oxides (NOx). More particularly, the present invention is directed to a novel washcoat composition comprising two distinct washcoat layers containing two distinctly different ratios of Pt:Pd.Type: GrantFiled: June 9, 2006Date of Patent: August 18, 2009Assignee: BASF Catalysts LLCInventors: Tilman Wolfram Beutel, Joseph Charles Dettling, Dustin Owen Hollobaugh, Torsten Wolfgang Mueller
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Patent number: 7563744Abstract: The present invention relates to a catalyst for the purification of exhaust gases from an internal combustion engine, which comprises a catalytically active coating on an inert ceramic or metal honeycomb body, said coating comprising at least one platinum group metal selected from the group consisting of platinum, palladium, rhodium and iridium on a fine, oxidic support material. As an oxidic support material, the catalyst comprises a low-porosity material on the basis of silicon dioxide that comprises aggregates of essentially spherical primary particles having an average particle diameter of between 7 and 60 nm.Type: GrantFiled: August 8, 2002Date of Patent: July 21, 2009Assignee: Umicore AG & Co. KGInventors: Harald Klein, Ulrich Neuhausen, Egbert Lox, Jürgen Gieshoff, Thomas Kreuzer
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Patent number: 7563745Abstract: The invention relates to a shaped catalyst or catalyst precursor containing a catalytically active component or a precursor therefore, the component selected from elements of Group VIII of the Periodic Table of the Elements, supported on a carrier, which catalyst or catalyst precursor is an elongated shaped particle having three protrusions each extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross-section of the particle occupying the space encompassed by the outer edges of six circles around a central circle, each of the six circles touching two neighboring circles while three alternating circles are equidistant to the central circle and may be attached to the central circle, minus the space occupied by the three remaining outer circles and including the six interstitial regions.Type: GrantFiled: June 6, 2003Date of Patent: July 21, 2009Assignee: Shell Oil CompanyInventors: Arend Hoek, Hans Michiel Huisman, Carolus Matthias Anna Maria Mesters
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Patent number: 7550124Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.Type: GrantFiled: August 17, 2007Date of Patent: June 23, 2009Assignee: BASF Catalysts LLCInventors: Shau-Lin F. Chen, Harold Rabinowitz, Jin Sakakibara, Tian Luo
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Patent number: 7547656Abstract: An exhaust gas cleaning catalyst comprising: a carrier substrate; a catalyst carrying layer formed on the carrier substrate; and a noble metal catalyst carried by the catalyst carrying layer; wherein said catalyst carrying layer comprises at least two layers, and of the at least two layers, lower layer on the side of the carrier substrate is a metal oxide layer with porosity of 40˜75% and upper layer on the side of the top surface is a metal oxide layer having thermal conductivity of 5 W/mK or less.Type: GrantFiled: July 13, 2004Date of Patent: June 16, 2009Assignee: Toyota Jidosha Kabushiki KaishaInventor: Masahide Miura
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Patent number: 7547659Abstract: The present invention relates to a structured catalyst for reforming of gasoline and a method of preparing the same, more particularly to a structured catalyst for reforming of gasoline for fuel-cell powered vehicles prepared by wash-coating the transition metal based reforming catalyst on the surface of the ceramic honeycomb support wash-coated with sub-micron sized alumina or its precursor to sufficiently increase the effective surface area and the performance of the catalyst and a method of preparing the same.Type: GrantFiled: October 30, 2006Date of Patent: June 16, 2009Assignee: Korea Institute of Science and TechnologyInventors: Dong Ju Moon, Jong Woo Ryu, Dong Min Kang, Byung Gwon Lee, Byoung Sung Ahn, Sang Deuk Lee
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Patent number: 7531479Abstract: A method of depositing a catalytically reactive coating to a substrate including selecting a target light off temperature for a predetermined catalytic combustion environment, selecting a thermal barrier coating composition, selecting a catalytic material and codepositing the thermal barrier coating composition and the catalytic material onto the substrate in proportions selected to produce the target light off temperature when exposed to the combustion environment. The method may include controlling the codepositing step to cause the thermal barrier coating composition to interact with the catalytic material to produce a phase having a light off temperature different from the respective light off temperatures of the thermal barrier coating composition and the catalytic material. A catalyst element may include a substrate and a first layer comprising a thermal barrier coating composition and a catalytic material throughout its depth disposed over a first portion of the substrate.Type: GrantFiled: May 5, 2004Date of Patent: May 12, 2009Assignee: Siemens Energy, Inc.Inventors: Andrew Jeremiah Burns, Ramesh Subramanian, Vasudevan Srinivasan
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Patent number: 7527776Abstract: A catalyst and a method for selectively reducing nitrogen oxides with ammonia are provided. The catalyst includes a first component of copper, chromium, cobalt, nickel, manganese, iron, niobium, or mixtures thereof, a second component of cerium, a lanthanide, a mixture of lanthanides, or mixtures thereof, and a zeolite. The catalyst may also include strontium as an additional second component. The catalyst and the method may have special application to selective reduction of nitrogen oxides in exhaust gas from diesel vehicles, although the catalyst and the method have broad application to a wide range of gas streams that contain nitrogen oxides.Type: GrantFiled: January 9, 2007Date of Patent: May 5, 2009Assignee: Catalytic Solutions, Inc.Inventors: Stephen J. Golden, Svetlana Iretskaya
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Patent number: 7517510Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.Type: GrantFiled: June 7, 2007Date of Patent: April 14, 2009Assignee: Basf Catalysts LLCInventors: Shau-Lin F. Chen, Harold Rabinowitz, Jin Sakakibara, Tian Luo
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Patent number: 7449427Abstract: The honeycomb structured body of the present invention is a honeycomb structured body in which a plurality of porous ceramic members are combined with one another through an adhesive layer, each of the porous ceramic members having a plurality of cells which are allowed to penetrate in a longitudinal direction with a wall portion therebetween and either one end of which is sealed, with a catalyst supporting layer being adhered to the wall portion, wherein an average pore diameter of the porous ceramic member is larger than an average particle diameter of particles constituting the catalyst supporting layer, and when a pore diameter distribution of the porous ceramic member and a particle diameter distribution of particles constituting the catalyst supporting layer are drawn with the pore diameter and the particle diameter being on the same axis, a pore volume in an overlapped area of both the distributions is about 10% or less to the entire pore volume of the porous ceramic member.Type: GrantFiled: September 12, 2006Date of Patent: November 11, 2008Assignee: Ibiden Co., LtdInventors: Kazushige Ohno, Hiroki Sato, Masayuki Hayashi, Kazutake Ogyu
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Patent number: 7446070Abstract: An exhaust gas-purifying catalyst includes a zeolite and a perovskite composite oxide containing palladium placed at its B site.Type: GrantFiled: September 27, 2006Date of Patent: November 4, 2008Assignees: Cataler Corporation, Daihatsu Motor Co., Ltd.Inventors: Asuka Hori, Keiichi Narita, Yasunori Sato, Hirohisa Tanaka, Ichiro Takahashi, Nobuhiko Kajita
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Patent number: 7435274Abstract: There is disclosed a metal particle-dispersed composite oxide comprising a matrix material containing a composite oxide comprising a non-reducible metal oxide and an easily reducible metal oxide, the composite oxide containing 0.01 to 0.25 mol % of at least one additive metal selected from Al, Sc, Cr, B, Fe, Ga, In, Lu, Nb and Si, surface metal particles precipitated on an outer surface of the matrix material containing the composite oxide, and inner metal particles precipitated on an inner surface of the matrix material containing the composite oxide.Type: GrantFiled: February 26, 2004Date of Patent: October 14, 2008Assignee: Kabushiki Kaisha ToshibaInventors: Seiichi Suenaga, Tomohiro Suetsuna, Takayuki Fukasawa, Yasuhiro Goto, Koichi Harada
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Patent number: 7384888Abstract: A cerium-zirconium composite metal oxide having improved durability at high temperature and a stable oxygen storage capacity is provided. The cerium-zirconium composite metal oxide is characterized in that the total mole number of Ce and Zr is at least 85% based on the total mole number of metal in the composite metal oxide, a molar ratio Ce/Zr is within a range from 1/9 to 9/1, and an isoelectric point of the composite metal oxide is more than 3.5. Preferably, the molar ratio Ce/Zr is within a range from 3/7 to 7/3 and the isoelectric point is within a range from 3.8 to 5.0, and the cerium-zirconium composite metal oxide contains a rare earth metal (excluding Ce) in a concentration of less than 15% by mole based on the total mole number of metal in the composite metal oxide. Also the present invention provides a cerium-zirconium composite metal oxide, characterized in that CeO2 forms a core surrounded by ZrO2.Type: GrantFiled: September 15, 2003Date of Patent: June 10, 2008Assignee: Toyota Jidosha Kabushiki KaishaInventor: Oji Kuno
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Patent number: 7361625Abstract: A carrier supporting titania thereon is further caused to carry a metal compound thereon. This metal compound is hydrogen reduced in a heating atmosphere at a first treatment temperature, then oxidized in a heating atmosphere at a second treatment temperature not higher than the first treatment temperature to thereby obtain a photocatalyst. In this event, metal is released from an extremely strong reduction state and thus highly dispersed on the catalyst in the form of fine particles so that high activity of the catalyst can be obtained. Then, by purifying gas while feeding light and heat to the photocatalyst by, for example, blacklights, a volatile organic compound such as acetaldehyde can be decomposed at a high decomposition rate through cooperation between photocatalytic activity and thermal catalytic activity of the photocatalyst.Type: GrantFiled: February 23, 2004Date of Patent: April 22, 2008Assignee: Sundecor Co., LtdInventors: Katsuyuki Nakano, Eiko Higashi, Masanori Nanri
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Patent number: 7323432Abstract: A catalyst assembly comprising a substrate, nanofilaments which have a nanometer-size diameter and are formed on the substrate, and particles which have a nanometer-size diameter, at least one of the nanofilaments and the particles having a catalytic function, is provided to use a catalyst more efficiently and to provide a catalytic function more efficiently. Interstices between the nanofilaments serve as distribution channels of a reactive gas, and the reactive gas spreads sufficiently not only around the ends of nanofilaments but also inside a catalyst assembly. A combination of nanofilaments and particles enables dispersion of a catalyst at a distance of not more than about 100 nanometers.Type: GrantFiled: August 21, 2003Date of Patent: January 29, 2008Assignees: DENSO Corporation, Koichi Niihara, Tadachika NakayamaInventors: Koichi Niihara, Tadachika Nakayama, Jun Hasegawa, Miho Ito
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Patent number: 7316806Abstract: A reforming catalyst for partial oxidation to reform hydrocarbon compound including a sulfur-containing compound includes platinum and rhodium. Even in reforming a hydrocarbon compound including a sulfur-containing compound such as, for example, a town gas, the catalyst effectively prevents poisoning and elongates catalyst life.Type: GrantFiled: October 22, 2004Date of Patent: January 8, 2008Assignee: Nippon Shokubai Co., Ltd.Inventors: Masaaki Okuno, Akiyoshi Nakajima
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Patent number: 7306771Abstract: A filter catalyst for purifying exhaust gases having a catalytic layer comprising the first catalyst support 2 having an average particle diameter of 1 ?m or less, the second catalyst support 3 having an average particle diameter from 1/20 to ½ of the average pore diameter of the filter cellular walls 12 and catalytic ingredients, on the filter cellular walls 12 having an average pore diameter of from 20 to 40 ?m, and the catalytic layer having uneven surfaces is used. Since the second catalyst support hardly enters into the pore with a diameter of 20 ?m or less, it exists partly on the filter cellular walls and the inside surface of the wall. Therefore, since particles collide with the convex part of the catalytic layer, it becomes possible to collect them easily and the collecting rate for particles and the ability of the particles purification are improved.Type: GrantFiled: September 12, 2003Date of Patent: December 11, 2007Assignee: Toyota Jidosha Kabushiki KaishaInventor: Seiji Okawara
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Patent number: 7238640Abstract: The present invention provides a catalyst for use in a NOx trap that has reduced NOx release during rich purges, increased NO conversion efficiency under stoichiometric conditions, and improved sulfur tolerance. The catalyst of this embodiment includes a precious metal, an oxygen storage component in contact with the precious metal, and a NOx storage material. The oxygen storage component in contact with the precious metal is present in an amount that provides sufficient oxygen storage capacity to reduce the NOx release from the NOx trap during rich purges to less than 20% of the NOx that is stored in the NOx trap across the operating temperature window of the NOx trap, increase the NOx conversion efficiency under stoichiometric conditions to a value greater than 70%, and increase the sulfur tolerance of the NOx trap.Type: GrantFiled: December 30, 2003Date of Patent: July 3, 2007Assignee: Ford Global Technologies, LLCInventors: Hungwen Jen, Gopichandra Surnilla, Christian Goralski, Jr., Joseph Theis, Justin Ura
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Patent number: 7220699Abstract: A method and device for loading a catalyst into a chamber. The catalyst loading is well suited for production of hydrogen producing microreactors. The catalyst is coated onto a strip which is mountable within the chamber.Type: GrantFiled: March 31, 2003Date of Patent: May 22, 2007Assignee: Intelligent Energy, Inc.Inventor: Anand Chellappa
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Patent number: 7220702Abstract: A noble metal and an NOx sorption member are loaded on a support which includes composite particles having a structure including a core portion in which ZrO2 is a major component and a superficial portion formed on a surface of the core portion and including an oxide, whose basicity is lower than ZrO2, more than the core portion. The composite particles exhibit a high basicity at the inside and a low basicity on the surface by Al2O3 or TiO2 which exists more in the surface. Accordingly, the sulfur-poisoning resistance is improved, and, at the same time, the post-durability NOx purifying ability is improved.Type: GrantFiled: February 4, 2002Date of Patent: May 22, 2007Assignee: Toyota Jidosha Kabushiki KaishaInventors: Naoyuki Hara, Ichiro Hachisuka
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Patent number: 7214829Abstract: The present invention relates to an improvement in a process for preparing primary amines by hydrogenating nitriles. The improvement in the hydrogenation process is that a hydrogenation catalyst modified ex situ with preadsorbed alkali metal carbonate or hydrogencarbonate such as K2CO3 or KHCO3 is used.Type: GrantFiled: February 13, 2003Date of Patent: May 8, 2007Assignee: Clariant Produkte (Deutschland) GmbHInventors: Sandor Goeboeloes, Andras Fasi, Jozsef Margitfalvi, Laszlone Millian