GB2275624A - Exhaust converter structure - Google Patents

Exhaust converter structure Download PDF

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Publication number
GB2275624A
GB2275624A GB9304586A GB9304586A GB2275624A GB 2275624 A GB2275624 A GB 2275624A GB 9304586 A GB9304586 A GB 9304586A GB 9304586 A GB9304586 A GB 9304586A GB 2275624 A GB2275624 A GB 2275624A
Authority
GB
United Kingdom
Prior art keywords
support structure
catalyst
metal
concentration
channels
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB9304586A
Other versions
GB9304586D0 (en
Inventor
John Lenard Arthur Barnes
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jaguar Land Rover Ltd
Original Assignee
Jaguar Cars Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jaguar Cars Ltd filed Critical Jaguar Cars Ltd
Priority to GB9304586A priority Critical patent/GB2275624A/en
Publication of GB9304586D0 publication Critical patent/GB9304586D0/en
Publication of GB2275624A publication Critical patent/GB2275624A/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/19Catalysts containing parts with different compositions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/50Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807Metal other than sintered metal
    • F01N3/281Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2814Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates all sheets, plates or foils being corrugated
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825Ceramics
    • F01N3/2828Ceramic multi-channel monoliths, e.g. honeycombs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/02Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • F01N2330/04Methods of manufacturing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/06Ceramic, e.g. monoliths

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

An exhaust catalyst includes a support structure defining a plurality of channels extending from one end to the other, an inlet 13 for exhaust gas being provided adjacent one end, the area of the inlet 13 being substantially smaller than the cross-sectional area of the support structure 11, a metal catalyst being deposited at high concentrations in an axially extending portion A of the support structure in direct flow path from the inlet 13 and at low concentrations in axially extending portions of the support structure 11 more remote from the direct flow path of the inlet 13. <IMAGE>

Description

EXHAUST CATALYSTS The present invention relates to exhaust catalysts and in particular to exhaust catalysts based on a support structure.
Catalysts for the exhaust systems of motor vehicles may be based on a support structure. The support structure defines a plurality of channels extending axially through the structure from one end to the other, the channels forming paths for the flow of exhaust gasses.
The support structure may be of monolithic form made from ceramic materials such as cordierite, cordierite-aalumina, silicone nitride, zircon mullite, spodumene, alumina-silica-magnesia, zirconium silicate, sillimanite, magnesium silicates, zircon, petalite, a-alumina and alumino silicates. Preferably these materials are in crystaline form so that the walls defining the channels of the support structure are porous.
Alternatively, the support structure may be made of metals of monolithic form similar to the ceramic structures described above or formed from corrugated metal sheets.
Conventionally, the support structure is coated with a carrier layer of catalytically active metal oxide, for example y-alumina with relatively high porosity. A metal catalyst, for example platinum and/or rhodium is then deposited in the pores of the carrier layer.
Conventionally the distribution of these metal catalysts are substantially uniform throughout the catalyst structure.
Catalytic structures of the form described above are located in the exhaust system of the motor vehicle. In order to effectively remove all noxious pollutants from the exhaust gases, the catalytic structure will typically be of the order of 100 mm long. In order to achieve an acceptable back pressure, the cross-sectional area of the catalytic structure must be considerably increased in relation to the cross-sectional area of the exhaust pipe.
For example, for an exhaust system having an exhaust pipe of 50 mm diameter, the catalyst structure will typically be of elliptical cross-section having a major diameter of 185 mm and a minor diameter of 90 mm. Because of this significant difference in cross-sectional areas of the exhaust pipe and catalytic structure, flow of exhaust gases through the catalytic structure are concentrated through the portion thereof in the direct flow path from the exhaust pipe while areas of the catalytic structure more remote from the direct flow path have low flow rates. In order to accommodate the high flow rates through the central portion of the catalytic structure, the gas passing through the channels in this portion of the catalytic structure will be moving faster than the gas flowing through the channels in the outer portions of the catalytic structure and consequently will have less time to react with the catalyst. Furthermore, due to the high flow rates through the central portions of the catalytic structure, the catalyst in this region will be deactivated at a faster rate than the catalyst in the outer regions.
According to the present invention an exhaust catalyst comprises a support structure, said support structure being mounted within a catalyst-container, the container having an inlet and an outlet, the support structure being mounted within the container between the inlet and outlet so that exhaust gases entering the container by the inlet must flow through the support structure to reach the outlet, the cross-sectional area of the inlet being substantially smaller than the cross-sectional area of the support structure, said support structure defining a plurality of channels extending axially from one end of the support structure to the other, a carrier coating being applied to the walls of the channels and a metal catalyst being deposited on the carrier coat, the metal catalyst being deposited at higher concentrations in the axially extending portion of the support structure in the direct flow path from the inlet and at lower concentrations in axially extending portions of the support structure more remote from the direct flow path from the inlet.
In this manner, the amount of catalytic metal available to treat the faster flowing exhaust gases is increased thereby overcoming the problems of reduced reaction time and increased deactivation in those areas, without increasing the overall amount of catalytic metal used and hence the cost of the exhaust catalyst.
According to a preferred embodiment of the present invention the ratio of the concentration of metal catalyst in portions of higher concentration to that in portions of lower concentration is from 6:5 to 6:1. The concentration of metal catalyst in the regions of higher concentration may be from 0.00175 gm/cc (50gm/ft3) to 0.0035 gm/cc (lOOgm/ft3) and the concentration of metal catalyst in the regions of lower concentration may be from 0.0007 gm/cc (20gm/ft3) to 0.00175 gm/cc (50 gm/ft3).
According to a further aspect of the present invention a method of forming an exhaust catalyst as hereinbefore defined includes depositing a metal catalyst on a support structure, the support structure defining a plurality of channels extending axially from one end of the support structure to the other, the metal catalyst being deposited so that in selected axially extending portions of the support structure the concentration of metal catalyst is higher than in other axially extending regions of the support structure.
The carrier coating may be applied to the support structure in any suitable manner. Hitherto, this has been achieved by dipping the support structure into a slurry of the coating material. Alternatively, a slurry of the coating material may be poured over one end of the support structure, so that it washes through the channels, depositing the coating material on the walls of the channels. The support structure is then dried and the coating layer calcined by heating to a temperature between 1500 and 8000C.
The metal catalyst may also be applied to the support structure, by pouring a solution of salts of the metal catalyst over the end of the support structure and allowing it to wash through the channels and subsequently reducing the salts by heating. In order to obtain the differential dispersion of the metal catalyst throughout the support structure, this operation may be carried out in several passes, the regions of low metal catalyst concentration being masked off for some passes, so that lower concentrations of the metal catalyst will be deposited. Alternatively, the solution of salts of the metal catalyst may be sprayed onto the end face of the catalyst the concentration of the solution or the rate or duration at which the solution is sprayed onto different areas of the end face may be varied to vary the deposition of the metal catalyst in different regions of the catalyst.
An embodiment of the invention is now described, by way of example only, with reference to the accompanying drawings which illustrate in cross-section, an exhaust catalyst in accordance with the present invention.
As illustrated, an exhaust catalyst 10 comprises a monolithic catalyst support structure 11 formed from cordierite. The support structure 11 is 101.6 mm long and of elliptical cross-section having a major diameter of 185 mm and a minor diameter of 90 mm. The support structure 11 is located in a container 12 of similar internal cross-sectional dimensions. The container 12 has an inlet 13 on one side of the catalyst 10 and an outlet on the side of the catalyst 10 axially remote from the inlet 13. The support structure 11 is located adjacent the inlet 10. The container 12 may be longer than the support structure 11 and may contain silencing baffles through which the exhaust gases must travel after passing through the catalyst 10 and before exiting the container 12 through the outlet. The inlet 13 is 57.15 mm in diameter and enters the container 12 coaxially of the container 12 and the support structure 11 located therein.
Because of the difference in cross-sectional areas of the inlet 13 and support structure 11, the flow of exhaust gases is concentrated through the cross-sectional area A of the support structure 11.
The support structure 11 defines a matrix of channels or cells which extend longitudinally from one end face of the support structure 11 to the other. The support structure 11 defines of the order of 60 channels per square centimetre of the end face, each channel being separated from adjacent channels by walls of a thickness of the order of 0.165 mm.
The walls of the channels are coated with a porous layer of calcined y-alumina. This coating is produced by pouring a slurry of alumina over the end face of the catalyst structure and allowing it to wash down through the channels. This is done in a controlled manner, so as to ensure a uniform coating, by passing the support structure standing on end, through a waterfall of the yalumina slurry.
After depositing the y-alumina on the support structure, the support structure is dried and the layer of y-alumina calcined by heating.
A catalytic layer containing five parts platinum to one part rhodium is then deposited on the porous layer of yalumina. This is done by pouring a solution of platinum and rhodium salts over the end face of the support structure 10 in similar manner to that in which the coating of y-alumina was formed. The metal catalyst is however deposited in several passes. For the initial passes, the metal catalyst solution is passed over the whole area of the end face of the support structure 11.
When the concentration of metal catalyst in the support structure 11 reaches 0.0007 gm/cc (20 gm/ft3) the end face of the support structure outside the area A, is masked. Further passes are then made depositing further metal catalyst on only the channels open to the area A of the end face of the support structure 11, until concentration of the metal catalyst in this area A is 0.0021 gm/cc (60 gm/ft3). The catalyst structure is subsequently baked in an oven to reduce the salts to the metals.
An exhaust catalyst 10 is thereby built up in which the concentration of metal catalyst in the regions of the catalyst subjected to high exhaust gas flow are substantially higher than those in regions of low gas flow. In this manner, the exhaust catalyst 10 can accommodate the different flow rates in the different regions and also the life of the catalyst may be prolonged without increasing the amount of metal catalyst used and hence the cost of the catalyst.
Various modifications may be made without departing from the invention. For example, it will be appreciated that the regions of high and low catalyst concentrations may be varied to accommodate the gas flows through a particular exhaust system. Furthermore, rather than having just two regions of varying metal catalyst concentration, the metal catalyst concentration may be varied in several graduations or even continuously, between the high concentration and low concentration regions.

Claims (10)

CLAINS
1. An exhaust catalyst comprising a support structure, said support structure being mounted within a catalyst container, the container having an inlet and an outlet, the support structure being mounted within the container between the inlet and outlet so that exhaust gases entering the container by the inlet must flow through the support structure to reach the outlet, the crosssectional area of the inlet being substantially smaller than the cross-sectional area of the support structure, said support structure defining a plurality of channels extending axially from one end of the support structure to the other, a carrier coating being applied to the walls of the channels and a metal catalyst being deposited on the carrier coat, the metal catalyst being deposited at higher concentrations in the axially extending portion of the support structure in the direct flow path from the inlet and at lower concentrations in axially extending portions of the support structure more remote from the direct flow path from the inlet.
2. An exhaust catalyst according to Claim 1 in which the support structure is of monolithic form made of metal or ceramic material.
3. An exhaust catalyst according to Claim 1 in which the support structure is formed from corrugated metal sheet.
4. An exhaust catalyst according to any one of the preceding claims in which the ratio of the concentration of metal catalyst in portions of higher concentration to that in portions of lower concentration is from 6:5 to 6:1.
5. An exhaust catalyst according to any one of the preceding claims in which the concentration of metal catalyst in the regions of higher concentration is from 0.00175 gm/cc (50 gm/ft3) to 0.0035 gm/cc (100 gm/ft3) and the concentration of metal catalyst in the regions of lower concentration is from 0.0007 gm/cc (20 gm/ft3) to 0.00175 gm/cc (50 gm/ft3).
6. An exhaust catalyst substantially as described herein with reference to, and as shown in, the accompanying drawing.
7. A method of forming an exhaust catalyst as claimed in any one of Claims 1 to 6 including depositing a metal catalyst in a support structure, the support structure defining a plurality of channels extending axially from one end of the support structure to the other, the metal catalyst being deposited so that in selected axially extending portions of the support structure, the concentration of metal catalyst is higher than in other axially extending regions of the support structure.
8. A method according to Claim 7 in which the metal catalyst is deposited from a solution of the metal salts, the solution being poured over an end face of the support structure so that it will wash through the channels depositing the metal salts on the walls of the channels, the deposition of the metal salts being carried out in several passes, the end face of the catalyst corresponding-to the areas of lower concentration being masked off to prevent entry of the solution into the channels in that area, during at least one pass the metal salts being subsequently reduced to the metals.
9. A method of producing an exhaust catalyst according to Claim 7 in which a solution of salts of the metal catalyst is sprayed onto an end face of the support structure, so that the solution will wash through the channels, depositing the metal salts on the walls of the channels, the concentration of the solution or the rate or duration at which the solution is sprayed onto different areas of the end face being varied to vary the deposition of metal catalyst in different regions of the support structure the metal salts being subsequently reduced to the metals.
10. A method substantially as described herein with reference to the accompanying drawing.
GB9304586A 1993-03-05 1993-03-05 Exhaust converter structure Withdrawn GB2275624A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9304586A GB2275624A (en) 1993-03-05 1993-03-05 Exhaust converter structure

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9304586A GB2275624A (en) 1993-03-05 1993-03-05 Exhaust converter structure

Publications (2)

Publication Number Publication Date
GB9304586D0 GB9304586D0 (en) 1993-04-21
GB2275624A true GB2275624A (en) 1994-09-07

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008113801A1 (en) * 2007-03-19 2008-09-25 Umicore Ag & Co. Kg Method for introducing a catalytic coating into the pores of a ceramic honeycomb flow body
DE102010053603A1 (en) * 2010-11-12 2012-05-16 Bayerische Motoren Werke Aktiengesellschaft Catalyzer e.g. particulate filter, for cleaning exhaust gas in self-ignition engine, has carrier structure with total passage area that is divided into partial cross sections, where one of sections is radially enclosed by other section
WO2012021556A3 (en) * 2010-08-09 2012-06-21 Cormetech, Inc. Catalyst compositions and applications thereof
FR3104037A1 (en) * 2019-12-05 2021-06-11 Renault S.A.S Impregnated monolith for a treatment device for a motor vehicle engine exhaust system and associated manufacturing process

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5043311A (en) * 1989-04-20 1991-08-27 Degussa Aktiengesellschaft Monolithic or honeycomb-type catalyst
US5087430A (en) * 1989-03-28 1992-02-11 Mitsubishi Petrochemical Co., Ltd. Process for purifying exhaust gas

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5087430A (en) * 1989-03-28 1992-02-11 Mitsubishi Petrochemical Co., Ltd. Process for purifying exhaust gas
US5043311A (en) * 1989-04-20 1991-08-27 Degussa Aktiengesellschaft Monolithic or honeycomb-type catalyst

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
WPI Abstract Acc. No. 86-146221/23 and JP610004536 A *
WPI Abstract Acc. No.86-073847/11 and JP610025644 A *

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008113801A1 (en) * 2007-03-19 2008-09-25 Umicore Ag & Co. Kg Method for introducing a catalytic coating into the pores of a ceramic honeycomb flow body
US8491966B2 (en) 2007-03-19 2013-07-23 Umicore Ag & Co. Kg Method for introducing a catalytic coating into the pores of a ceramic honeycomb flow body
CN101674877B (en) * 2007-03-19 2013-08-14 尤米科尔股份公司及两合公司 Method for introducing catalytic coating into the pores of ceramic honeycomb flow body
KR101513004B1 (en) 2007-03-19 2015-04-17 우미코레 아게 운트 코 카게 - Method for introducing a catalytic coating into the pores of a ceramic honeycomb flow body
WO2012021556A3 (en) * 2010-08-09 2012-06-21 Cormetech, Inc. Catalyst compositions and applications thereof
US8901033B2 (en) 2010-08-09 2014-12-02 Cormetech, Inc. Catalyst compositions and applications thereof
DE102010053603A1 (en) * 2010-11-12 2012-05-16 Bayerische Motoren Werke Aktiengesellschaft Catalyzer e.g. particulate filter, for cleaning exhaust gas in self-ignition engine, has carrier structure with total passage area that is divided into partial cross sections, where one of sections is radially enclosed by other section
FR3104037A1 (en) * 2019-12-05 2021-06-11 Renault S.A.S Impregnated monolith for a treatment device for a motor vehicle engine exhaust system and associated manufacturing process

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Publication number Publication date
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