W. R. Grace Co.-Conn.

Engelhard Corporation

Rasto Brezny

Awdhoot V Kerkar

Semyon D Friedman

Manoj M Koranne

Jacob Block

John W Lau

Frederick J Parker

Ernest W Hughes

Poovatholil F Francis

Martin B Sherwin

William B Retallick

James Neil Pryor

Roy W Rice

David Monroe Chapman

Robert M Spotnitz

James George Miller

Takeshi Egami

James W Patten, Jr

Eugene Mamontov

Paul John Westgate

Manoj Mukund Koranne

The present invention is directed to an improved catalyst support and to the resultant catalyst suitable for treating exhaust products from internal combustion engines, especially diesel engines. The support of the present invention is a structure comprising alumina core particulate having high porosity and surface area, wherein the structure has from about 1 to about 40 weight percent silica in the form of cladding on the surface area of said alumina core. The resultant support has a normalized sulfur uptake (NSU) of up to 15 &#x3bc;g/m.

Sulfur tolerant alumina catalyst support

Mixed oxides of cerium oxide and zirconium oxides having a high oxygen storage and high oxygen release rate are disclosed. The mixed oxides are made of polycrystalline particles of cerium oxide and zirconium oxide having a controlled domain structure on the subcrystalline level wherein adjacent domains within a single crystallite have a different ratio of zirconium and cerium. The mixed oxides are prepared by a co-precipitation technique using mixed salt solutions of cerium and zirconium having a solid content of at least 23%, based on an oxide basis.

Catalyst support material having high oxygen storage capacity and method of preparation thereof

A process for the preparation of mixed oxide compositions of cerium oxide and at least one non-noble metal oxide is disclosed. The process involves contacting a salt solution containing a cerium (IV) salt with hydrogen peroxide and thereafter, treating the resulting solution with excess base to precipitate a mixed oxides. Mixed oxide compositions produced by the process maintain a high specific surface area after prolonged exposure to high temperatures.

Thermally stable support material and method for making the same

A method for producing by electrophoretic deposition multi-layer, polyfunctional, catalyst members for use in catalytic converters having a plurality of suitably porous and adherent catalyst support coatings of substantially uniform thickness, a plurality of non-identical catalytic agents imbued therein/on, and a flexible metal substrate, are disclosed. Such process involves maintaining electrical interaction between a metal substrate previously coated with catalyst-catalyst support material, the power source, and the electrodes disposed in the electrophoretic deposition ('EPD') cell containing a slurry of a second catalyst support material and a second catalyst composition non-identical to that found in the first catalytically-active layer.

Multi-layer non-identical catalyst on metal substrate by electrophoretic

A powder composition of ceric oxide and a stabilizing non-noble metal oxide, such as zirconium oxide, mixed at the atomic level in complete solid solution. The powder is used to form washcoats for catalytic converters. The composition has high oxygen storage capacity and maintains an ultrafine crystallite size at high temperatures. The powder is formed by a spray pyrolysis process that includes atomizing a clear solution of cerium ions and ions of the non-noble metal into a fine mist that is passed rapidly through a furnace to form powder particles.

Ceric oxide washcoat

A barrier is formed on a metal substrate by coating the substrate with a metal oxide, calcining the substrate, impregnating the coated substrate with an acid, and calcining the impregnated coating at a temperature high enough to cause the metal oxide to form the barrier. The resulting barrier acts as an excellent electrical insulator, and also provides improved resistance to abrasion, and improved adhesion to the substrate. The particles forming the barrier also have improved cohesion. The metal substrate having the barrier of the present invention can be used in electrically heated catalytic converters, where it is necessary to provide closely spaced layers of metal foil that must be electrically insulated from each other. The invention can also be used in other metal structures intended to be placed in the exhaust stream of a chemical or manufacturing process or an engine.

Barrier for a metal substrate

Flexible metal foil catalyst members suitable for use in catalytic devices for combustion engine emission control are prepared by electrophoretic deposition using an aqueous slurry of catalyst support particles. The deposited support layer is of uniform thickness and stable surface area. The catalyst support may then be impregnated with catalytic species and assembled into a catalytic device. The catalyst members from the invention are especially suitable for use in automotive applications, and more especially in electrically heated catalytic devices.

Metal foil catalyst members by aqueous electrophoretic deposition

A bioremediation support for the support of microorganisms used in the biotreatment of an aqueous waste stream or contaminated vapor is made of a low-density siliceous glassy material. This material has a cellular or frothy texture, large pores of greater than 1,000 Anstrom units in diameter dispersed throughout the material, a high macropore volume in pores of greater than 1,000 .ANG. of more than 0.3 cc/cc and a BET surface area of greater than 10 m.sup.2 /g. A preferred material is pumice.

Low density glassy materials for bioremediation supports

Porous monolithic ceramic bodies containing reticulated macropores are produced by:

Method of making microcellular ceramic bodies

Ceramic beads having a bimodal pore distribution are prepared by a process involving a) formation of a ceramic particle slurry, b) adding a foamable prepolymer to the slurry to form a mixture, c) dispersing the mixture as beads in a second liquid, d) polymerizing and foaming the prepolymer, e) recovering the beads and firing them to remove the polymer and bond the ceramic particles. The beads can optionally be joined by sintering. Beads with a monodal pore distribution can be made by using a non-foaming prepolymer.

Porous ceramic beads

Ceramic beads having a bimodal pore distribution are prepared by a process involving a) formation of a ceramic particle slurry, b) adding a foamable prepolymer to the slurry to form a mixture, c) dispersing the mixture as beads in a second liquid, d) polymerizing and foaming the prepolymer, e) recovering the beads and firing them to remove the polymer and bond the ceramic particles. The beads can optionally be joined by sintering. Beads with a monodal pore distribution can be made by using a nonfoaming prepolymer.

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Catonsville, MD, United States of America

Rasto Brezny