Basf Corporation

Engelhard Corporation

Basf Catalysts LLC

Honda Motor Co., Ltd.

Michael P Galligan

Pascaline Tran

Ye Liu

Xinsheng Liu

Joseph Charles Dettling

Young Gin Kim

Keshavaraja Alive

Robert J Farrauto

Kenneth Edwin Voss

Bulent O Yavuz

Qinglin Zhang

Milena Kudziela

Xinzhu Liu

Shiang Sung

Hiroyuki Horimura

Patrick L Burk

Xiaolin Yang

Shau-Lin Franklin Chen

John J Mooney

Matthew P Larkin

Wenyong Lin

H Shinn Hwang

Shau-Lin Frank Chen

Qingyuan Hu

John R Adomaitis

Doan Lieu

Akiko Iwasa

Rudolph H Lechelt

Ronald J Brown

Michelle Casper

Weiliang Feng

Xin Zhu Liu

Pascaline Harrison Tran

Alive Keshavaraja

Catalytic articles comprising a substrate having a catalytic coating thereon, the catalytic coating comprising a catalytic layer having a thickness and an inner surface proximate to the substrate and an outer surface distal to the substrate; where the catalytic layer comprises a noble metal component on support particles and where the concentration of the noble metal component towards the outer surface is greater than the concentration towards the inner surface are highly effective towards treating exhaust gas streams of internal combustion engines. The articles are prepared via a method comprising providing a first mixture comprising micron-scaled support particles and applying the first mixture to a substrate to form a micro-particle layer; providing a second mixture comprising nano-scaled support particles and a noble metal component having an initial pH and applying the second mixture to the micro-particle layer and calcining the substrate.

Catalytic articles

Catalyst articles comprising palladium and related methods of preparation and use are disclosed. Disclosed is a catalyst article comprising a first catalytic layer formed on a substrate, wherein the first catalytic layer comprises palladium impregnated on a ceria-free oxygen storage component and platinum impregnated on a refractory metal oxide, and a second catalytic layer formed on the first catalytic layer comprising platinum impregnated on an oxygen storage component and rhodium impregnated on a zirconia-coated or yttria-coated alumina. The palladium component of the catalyst article is present in a higher proportion relative to the other platinum group metal components. The catalyst articles provide improved reductions in NOx in exhaust gases, particularly after lean-rich aging.

Aging-resistant catalyst article for internal combustion engines

Aspects of the invention pertain to catalytic articles and methods of making catalytic articles comprising a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn; a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of any platinum group metal; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating, optionally with a barrier layer.

Catalytic articles containing platinum group metals and non-platinum group metals and methods of making and using same

Hollow porous metal oxide microspheres are provided. The microspheres may be used as a support for a catalyst, particularly an exhaust treatment catalyst for an internal combustion engine. Also provided are methods of making the microspheres, methods of using the microspheres as catalyst supports, and methods of exhaust treatment using catalyst articles comprising the microspheres.

Hollow microsphere catalyst support and methods of making same

Provided herein are catalytic articles and methods of making same using a single coat process. The catalytic article comprises an elongated substrate monolith having a plurality of longitudinally extending passages, each passage having at least a first surface and a second surface opposite the first surface, the first and second surfaces coated with at least a first coating and a second coating, wherein the first coating comprises a first catalyst composition and overlies the second coating on the first surface, the second coating comprises a second catalyst composition and overlies the first coating on the second surface, and wherein the first catalyst composition and second catalyst composition have a difference in surface charge. The washcoat may be applied as one slurry, which then self-segregates into two coatings.

Catalytic article with segregated washcoat and methods of making same

Catalyst articles comprising substantially only a palladium precious metal component in a first catalytic layer and a rhodium component in a second catalytic layer and related methods of preparation and use are disclosed. Also disclosed is a catalyst article comprising a first layer formed on a carrier substrate, wherein the first layer comprises a refractory metal oxide and has a surface that is substantially uniform; a second layer formed on the first layer, wherein the second layer comprises i) an oxygen storage component that is about 50-90% by weight of the second layer and ii) a palladium component in an amount of about 2-5% by weight of the second layer, wherein the palladium component is substantially the only platinum group metal component, and a palladium-free third layer comprising a rhodium component supported on a thermostable oxygen storage component which is about 80-99% by weight of the second layer. One or more improved properties are exhibited by the catalyst article.

Small engine layered catalyst article and method of making

Catalyst articles comprising palladium and related methods of preparation and use are disclosed. Disclosed is a catalyst article comprising a first catalytic layer formed on a substrate, wherein the first catalytic layer comprises palladium impregnated on a ceria-free oxygen storage component and platinum impregnated on a refractory metal oxide, and a second catalytic layer formed on the first catalytic layer comprising platinum and rhodium impregnated on a ceria-containing oxygen storage component. The palladium component of the catalyst article is present in a higher proportion relative to the other platinum group metal components. The catalyst articles provide improved conversion of carbon monoxide in exhaust gases, particularly under rich engine operating conditions.

Carbon monoxide conversion catalyst

Aspects of the invention relate to a base metal catalyst composition effective to catalyze the abatement of hydrocarbons, carbon monoxide and nitrogen oxides under both rich and lean engine operating conditions comprising a support including at least 10% by weight of reducible ceria doped with up to about 60% by weight of one or more of oxides selected from the group Al, Pr, Sm, Zr, Y, Si, Ti and La; and a base metal oxide on the reducible ceria support, the base metal selected from one or more of Ni, Fe, Mn, Cu, Co, Ba, Mg, Ga, Ca, Sr, V, W, Bi and Mo, the base metal catalyst composition effective to promote a steam reforming reaction of hydrocarbons and a water gas shift reaction to provide Has a reductant to abate NOx. Other aspects of the invention relate to methods of using and making such catalysts.

Base metal catalyst and method of using same

Aspects of the invention relate to a method of treating a gas stream generated by a motorcycle, the method comprising: contacting a gas stream containing hydrocarbons, carbon monoxide and nitrogen oxides and generated by a motorcycle under both rich and lean engine operating conditions with a base metal catalyst composition, thereby removing at least a part of the hydrocarbons, carbon monoxide and nitrogen oxides in gas stream. The base metal catalyst composition comprises a support including at least 10% by weight of reducible ceria, and about 3 to about 7 wt % MnO and about 8 to about 22 wt % CuO on the reducible ceria support. The base metal catalyst composition is effective to promote a steam reforming reaction of hydrocarbons and a water gas shift reaction to provide Has a reductant to abate NOx.

Base metal catalyst composition and methods of treating exhaust from a motorcycle

A pliable refractory metal carrier () may have coated thereon an anchor layer () to improve adherence to the carrier () of a catalytic coating (). The conformable catalyst member () may be bent to conform to a curved or bent exhaust pipe () within which it is mounted. The pliable metal carrier may be in the form of a tube such as carrier () having perforations () formed therein, or it may be a metal strip () which is folded into accordion pleats () and has perforations () formed therein. The perforations () serve to permit the passage of exhaust gas therethrough. A series of interior closures () and annular baffles () may be provided to import a serpentine flow path to gases flowed through an exhaust pipe () containing a conformable catalyst member () therein. A mounting member () may be supplied to fasten one end of the conformable catalyst member () to the discharge end of an exhaust pipe ().

Metal catalyst carriers and catalyst members made therefrom

Catalyst articles comprising substantially only a palladium precious metal component and related methods of preparation and use are disclosed. Disclosed is a catalyst article comprising a first layer formed on a carrier substrate, wherein the first layer comprises a refractory metal oxide and has a surface that is substantially uniform; and a second layer formed on the first layer, wherein the second layer comprises i) an oxygen storage component that is about 50-90% by weight of the second layer and ii) a palladium component in an amount of about 10-150 g/ftof palladium, wherein the palladium component is substantially the only platinum group metal component. One or more improved properties are exhibited by the catalyst article.

Small engine palladium catalyst article and method of making

A coated metal substrate useful for carrying an exhaust emission treatment catalyst such as a three-way conversion catalyst for use with small engine platforms. The coated metal substrate comprises a metal such as a stainless steel, a carbon steel, a FeCr alloy, HASTELLOY&#xae; and the like. The coating on the metal substrate comprises an alumina silicate having alumina particles impregnated therein. The coating is applied using a liquid dispersion containing an aluminum silicate and the alumina particles are dispersed into the aluminum silicate coating while the coating is still wet. The coated metal substrate is then calcined. Thereafter, a washcoat containing an engine exhaust treatment catalyst may be applied to the surface of the coated metal substrate.

Methods for preparing coated metal substrates

A low-cost catalytic article is provided for treating gaseous fluid streams such as exhaust streams from gasoline-powered engines. The articles contain residence chambers defined by chamber walls and foraminous catalytic elements that contain a catalyst composition for converting a reactant contained in the fluid stream, and deflectors, which increase the residence time of the fluid stream in the residence chamber and the contact time of the fluid stream with the catalytic element.

Deflector plate to enhance fluid stream contact with a catalyst

The present invention is directed to an improved dual phase muffler for the abatement of reduction of sound and emission pollutants such as hydrocarbons, carbon monoxide, and nitrogen oxides. More specifically, the muffler comprises a muffler casing, an inner chamber formed in the muffler, and a catalytically coated supported material contained within the inner chamber. The present invention is also directed to a catalytically coated metallic foam catalyst support, which optionally can be pre-coat with a metallic thermal arc sprayed layer.

Growing community of inventors

Clark, NJ, United States of America

Michael P Galligan