WO2022173921A1

WO2022173921A1 - Exhaust treatment apparatus with cellular disc

Info

Publication number: WO2022173921A1
Application number: PCT/US2022/015940
Authority: WO
Inventors: Sam George; Achim Karl Erich HEIBEL; Sandeep VISWANATHAN
Original assignee: Corning Incorporated
Priority date: 2021-02-12
Filing date: 2022-02-10
Publication date: 2022-08-18

Abstract

An exhaust treatment apparatus for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising: a first exhaust component comprising a honeycomb structure comprised of a matrix of intersecting porous walls of a first porosity, a reducing agent injector junction disposed on the exhaust line housing, and a cellular disc disposed within the exhaust line housing and between the first exhaust component and the reducing agent injector junction, the cellular disc comprising a honeycomb body comprised of a matrix of intersecting porous walls of a second porosity, the second porosity being lower than the first porosity.

Description

EXHAUST TREATMENT APPARATUS WITH CELLULAR DISC

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S.

Provisional Application Serial No. 63/149069 filed on February 12, 2021, the content of which is relied upon and incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] Embodiments of the present disclosure generally relate to engine exhaust treatment apparatus, in particular exhaust treatment apparatus that accommodates injection of a reducing agent.

BACKGROUND

[0003] Particulate filters, for example, diesel particulate filters (DPFs), filter particulates from the exhaust stream from engines such as engines burning diesel fuel, respectively. In various engine exhaust configurations, a catalytically active particulate filter may provide a reduced space requirement and/or increased catalytic performance for exhaust flows. Many exhaust treatment systems use a selective catalytic reduction (SCR) component which utilize injection of a reducing agent such as ammonia or urea.

SUMMARY

[0004] In a first aspect, exhaust treatment apparatus is disclosed herein for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising: a first exhaust component comprising a honeycomb structure comprised of a matrix of intersecting porous walls of a first porosity, a reducing agent injector junction disposed on the exhaust line housing, and a cellular disc disposed within the exhaust line housing and between the first exhaust component and the reducing agent injector junction, the cellular disc comprising a honeycomb body comprised of a matrix of intersecting porous walls of a second porosity, the second porosity being lower than the first porosity.

[0005] Additional embodiments of the disclosure are disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0007] FIG. 1 schematically illustrates an apparatus or an exhaust system comprising an exhaust line comprising a DOC+DPF+SCR architecture with an injector and mixer system upstream of the SCR, representative of a horizontal configuration or orientation.

[0008] FIG. 2 schematically illustrates an apparatus or an exhaust system comprising an exhaust line comprising a DOC+DPF+SCR architecture with an injector and mixer system upstream of the SCR, representative of a vertical configuration or orientation.

[0009] FIG. 3 schematically illustrates an embodiment of a protective cellular disc as disclosed herein.

[0010] FIG. 4 schematically illustrates an exhaust treatment system or apparatus apparatus as disclosed herein which comprises exhaust line comprising a cellular disc, such as the cellular disc of FIG. 3.

[0011] FIG. 5 schematically illustrates a test set up used to evaluate or replicate potential damage to a filter wherein a reducing agent injector is disposed downstream of a diesel particulate filter (DPF).

[0012] FIG. 6 is a photographic image of a cross-section of a diesel particulate filter, with one end having plugs being cut off, which illustrates the damage that was sustained as a result of contact with DEF fluid and/or byproducts thereof. [0013] FIG. 7 shows photographic image of an example of a plugged end face of a filter with deposits after 2 hours of DEF exposure.

[0014] FIGS. 8 A, 8B, and 8C graphically show a summary of comparisons of thermal strain, E-Mod and MOR, respectively, for the sample with deposits from DEF present in the matrix of walls/cells vs. reference (baseline) samples (i.e. samples without deposits from DEF).

[0015] FIG. 9 schematically illustrates a test set up that was used to evaluate the effectiveness of the protective cellular disc interposed between a DPF (porosity about 50%) and a reduction agent (DEF) injection, as disclosed herein.

[0016] FIG. 10 shows a photographic image of a DPF exposed to DEF without a protective disc in place.

[0017] FIG. 11 shows a photographic image of the substantially similar location of a substantially similar DPF exposed to twice the duration as the DPF of FIG. 10, but with a protective disc in place.

DETAILED DESCRIPTION

[0018] Before describing several exemplary embodiments of the disclosure, it is to be understood that the disclosure is not limited to the details of construction or process steps set forth in the following description. The disclosure is capable of other embodiments and of being practiced or being carried out in various ways.

[0019] For exhaust treatment systems that use a selective catalytic reduction (SCR) component which utilize injection of a reducing agent such as ammonia or urea, under non-ideal conditions there is potential that a reducing agent or byproducts thereof come into contact and/or get deposited on a susceptible exhaust component such as the particulate filter and accumulate, contaminate, and/or damage the exhaust component. For example, as schematically illustrated in FIG. 1, an exhaust system may comprise an exhaust line comprising a DOC+DPF+SCR architecture with an injector and mixer system upstream of the SCR which delivers a reducing agent like ammonia or urea or mixtures containing ammonia or urea, like Diesel Exhaust Fluid (“DEF”) or “AdBlue™” which is an aqueous solution of 32.5% urea and 67.5% DI water. Although the reducing agent (such as DEF solution) is expected to decompose in the exhaust gas stream beyond 200°C, in vertically oriented systems as schematically illustrated in FIG. 2, the agent might condensate and drop down onto the DPF, and in horizontally oriented systems as illustrated in FIG. 1, the agent might pool up and accumulate over time, eventually coming into contact with the DPF. Systems oriented at an inclined angle may also experience one or both of these non-ideal conditions. We have surprisingly found that a cellular disc interposed between a DPF and the reducing agent injection site can mitigate, and even greatly reduce, and even eliminate, contact between the DPF and the reducing agent, thereby reducing or even eliminating the formation of deposits on the DPF due to the reducing agent, thereby protecting the structure and/or functionality of the DPF. The cellular disc can also protect exhaust components other than a DPF, such as another exhaust component that comprises a porous ceramic honeycomb structure or other porous ceramic structure. Preferably the cellular disc is comprised of a porous material which has a porosity that is lower than the porosity of the exhaust component that the cellular disc is provided to protect. FIG. 3 schematically illustrates an example embodiment of a cellular disc 10 as disclosed herein which in this embodiment comprises a plurality of generally parallel cell channels 11 formed by and at least partially defined by intersecting cell walls 14 (which may also be referred to as “webs”) that extend from a first end 12 to a second end 13. The channels 11 in the illustrated embodiment are all unplugged and flow can pass straight down the channel from the first end 12 to second end 13. Preferably, the honeycomb article 10 also comprises an outer peripheral wall or skin 15 around the matrix of cell walls 14. FIG. 4 schematically illustrates an apparatus as disclosed herein which comprises a cellular disc, such as the cellular disc of FIG. 3.

[0020] By “cellular”, we mean a body having a structure comprised of walls that form a plurality of cells that define channels or cavities that extend through the structure and which are capable of allowing a fluid, such as a gas, to enter the body and flow through the channels. Such structure may be a honeycomb structure comprised of intersecting walls that define cells defining channels or cell channels that extend in an axial direction from an inlet to an outlet.

[0021] In one set of embodiments, an exhaust treatment apparatus is disclosed herein for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising: a first exhaust component disposed within the exhaust line housing, the exhaust component comprising a body comprising an inlet end and an outlet end and an axial length from the inlet end to the outlet end, the body comprising a honeycomb structure comprised of a matrix of intersecting porous walls defining a plurality of cells which extend axially from the inlet end to the outlet end, the walls defining a plurality of axial channels extending axially from the inlet end to the outlet end, wherein the porous walls of the exhaust component comprise a first porosity; a reducing agent injector junction disposed on the exhaust line housing; and a cellular disc disposed within the exhaust line housing and between the first exhaust component and the reducing agent injector junction, the cellular disc comprising a honeycomb body comprising an inlet end and an outlet end and an axial length from the inlet end to the outlet end, the honeycomb body comprising a honeycomb structure comprised of a matrix of intersecting porous walls defining a plurality of cells which extend axially from the inlet end to the outlet end, the walls defining a plurality of axial channels extending axially from the inlet end to the outlet end, wherein the porous walls of the cellular disc comprise a second porosity, wherein the second porosity is lower than the first porosity. The reducing agent injector junction can be disposed downstream of the first exhaust component in an exhaust treatment line, or the reducing agent injector junction can be disposed upstream of the first exhaust component. In some embodiments, the first exhaust component is a particulate filter; in other embodiments the first exhaust component is a non-filter exhaust component. In some embodiments, the particulate filter comprises plugs fixed within at least some of the channels, such that the axial channels comprise inlet channels and outlet channels, wherein the inlet channels are open at the inlet end, and the outlet channels are open at the outlet end, to allow flow into the inlet channels and out of the outlet channels in the downstream direction. In some embodiments, the particulate filter is a diesel particulate filter; in other embodiments the particulate filter is a gasoline particulate filter. [0022] In some embodiments, the reducing agent injector junction is disposed upstream of the particulate filter, and the cellular disc is disposed downstream of the reducing agent injector junction and upstream of the particulate filter. In other embodiments, the reducing agent injector junction is disposed downstream of the particulate filter, and the cellular disc is disposed upstream of the reducing agent injector junction and downstream of the particulate filter. In some embodiments, the cellular disc is disposed downstream of the particulate filter. In some embodiments, the reducing agent injector junction is disposed downstream of the particulate filter.

[0023] In some embodiments, the reducing agent injection portion is coupled to an SCR unit; and some of these embodiments the reducing agent doser is disposed upstream of an SCR unit; in other of these embodiments the reducing agent doser is incorporated into the SCR unit.

[0024] In some embodiments the reducing agent comprises ammonia, urea, or a combination thereof, or a mixture of ammonia or urea with another fluid, such as deionized (DI) water.

[0025] In some environments, the exhaust apparatus further comprises a diesel oxidation catalyst (DOC) unit disposed upstream of the particulate filter in the exhaust line.

[0026] In some embodiments, the cellular disc is disposed adjacent to the particulate filter. [0027] In some embodiments, the plurality of axial channels of the cellular disc are flow through channels.

[0028] In some embodiments, none of the channels in the cellular disc are plugged.

[0029] In some embodiments, the porous material of the cellular disc is comprised of one or more selected from the group of a ceramic material, a metal material, a glass material, and combinations thereof.

[0030] In some embodiments, the porous material of the cellular disc is comprised of one or more selected from the group of cordierite, aluminum titanate, magnesium titanate, silica carbide, mullite, alumina, spinel, and combinations thereof.

[0031] In some embodiments, the first exhaust component is a flow-through substrate wherein the plurality of axial channels are non-plugged flow-through channels.

[0032] In some embodiments, the exhaust treatment apparatus further comprises one or more catalytic exhaust components disposed within the exhaust line housing. In some of these embodiments, one or more of the catalytic exhaust components is selected from the group consisting of a DOC component, an SCR component, and an LNT component.

[0033] In some embodiments, the exhaust treatment apparatus further comprises an SCR component disposed within the exhaust line housing and downstream of the first exhaust component. In some of these embodiments, the first exhaust component is a particulate filter. [0034] In some embodiments, the exhaust treatment apparatus further comprises a DOC component and an SCR component disposed within the exhaust line housing, wherein the DOC component is disposed upstream of the first exhaust component and the SCR component is disposed downstream of the first exhaust component. In some of these embodiments, the reducing agent injector junction is disposed between the first exhaust component and the SCR component.

[0035] In some embodiments, the exhaust treatment apparatus further comprises a reducing agent injector coupled to the reducing agent injector junction. In some embodiments the exhaust treatment apparatus further comprises a reducing agent doser.

[0036] In some embodiments, the cellular disc is disposed adjacent to the particulate filter.

[0037] In some embodiments, the cellular disc comprises an inlet end, an outlet end, an axial length from the inlet and to the outlet end, an inlet face at the inlet end, an outlet face at the outlet end, wherein the cellular disc has a cross-sectional area and a perimeter, wherein the inlet face has an effective diameter equal to 4 times the cross-sectional area divided by the perimeter, and wherein the cellular disc has an aspect ratio equal to the axial length divided by the effective diameter of the cellular disc which is less than 0.5. in some of these embodiments, the aspect ratio of the cellular disc is between 0.1 and 0.5.

[0038] In some embodiments, the difference in porosity between the first porosity and the second porosity is more than 5%. In some embodiments, the difference in porosity between the first porosity and the second porosity is more than 10%. In some embodiments, the difference in porosity between the first porosity and the second porosity is more than 15%. In some embodiments, the second porosity is between 5% and 20% less than the first porosity.

[0039] In some embodiments, the first porosity is greater than 40%. In some embodiments, the first porosity is between 40% and 70%.

[0040] In some embodiments, the second porosity is less than 50%. In some embodiments, the second porosity is less than 45%. In some embodiments, the second porosity is less than 40%. In some embodiments, the second porosity is less than 35%. In some embodiments, the second porosity is between 30% and 35%. In some embodiments, the second porosity is between 10% and 35%. [0041] In some embodiments, the matrix of intersecting walls of the filter body comprises cells present in a pattern of 100 to 600 cells per square inch.

[0042] In some embodiments, the matrix of intersecting walls of the filter body comprises cells present in a pattern of substantially similarly shaped cells.

[0043] In some embodiments, the matrix of intersecting walls of the filter body comprises cells present in a pattern of substantially similarly sized cells.

[0044] In some embodiments, the outlet channels of the filter body are larger in area than the inlet channels of the filter body.

[0045] In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 600 cells per square inch. In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 500 cells per square inch. In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 400 cells per square inch. In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 200 to 400 cells per square inch. In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 600 cells per square inch.

[0046] In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of substantially similarly shaped cells.

[0047] In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of substantially similarly sized cells.

[0048] In some embodiments, the outlet channels of the cellular disc are of substantially similar area as the inlet channels of the cellular disc.

[0049] In some embodiments, the outlet channels of the cellular disc are larger in area than the inlet channels of the cellular disc.

[0050] In some embodiments, the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of less than 8 mils. In some embodiments, the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 2 to 8 mils. In some embodiments, the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 2 to 7 mils. In some embodiments, the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 3 to 7 mils. In some embodiments, the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 4 to 6 mils.

[0051] In some embodiments, the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 200/6, 300/5, or 400/4 (in cells per square inch, and wall thickness in mils).

[0052] In some embodiments, the cellular disc further comprises the catalyst material disposed on, in, or both on and in at least a portion of the intersecting walls of the cellular disc. In some of these embodiments, the catalyst material comprises a HC oxidation catalyst material or a NO oxidation catalyst material.

[0053] FIG. 5 schematically illustrates a test set up used to evaluate or replicate potential damage to a filter wherein a reducing agent injector is disposed downstream of a diesel particulate filter (DPF) such that DEF fluid is sprayed onto the outlet face of the DPF against the exhaust flow that is exiting the DPF. Such a test set up can be used to simulate a vertical SCR system where DEF condensate may fall onto a DPF face against exhaust flow and form deposits thereon.

[0054] FIG. 6 is a photograph of a cross-section of a diesel particulate filter, with one end having plugs being cut off, which illustrates the damage that was sustained as a result of contact with DEF fluid and/or byproducts thereof. Through various testing of different types of filters in the test set up of FIG. 5, we found that the level of damage had a strong correlation with the porosity of the intersecting walls of the filter, wherein higher porosity results in worse damage. We found after exposure to DEF that the filter sustained urea based deposits which needed to be burned out at >600°C to clear away the deposits. FIG. 7 shows a photographic image of an example of a plugged end face of a filter with deposits after 2 hours of DEF exposure. Physical properties (CTE, E-Mod, MOR) were measured on a filter with urea based deposits from DEF exposure. These measurements were performed on samples from an area with deposits and a second area without DEF exposure. FIGS. 8A, 8B, and 8C graphically show a summary of comparisons of thermal strain, E-Mod and MOR, respectively, for the sample with deposits from DEF present in the matrix of walls/cells vs. reference (baseline) samples (i.e. samples without deposits from DEF). The tests were performed at an exhaust temperature of 400°C. The damage zone shown in FIG. 6 was mapped with thermocouples and was found to be in the 150-400°C range. From FIGS. 8A-8C it can be inferred that the significant increase in CTE and E-Mod with the presence of deposits (DEF byproducts formed as a result of poor decomposition of urea in the 200-400°C temperature range) created stresses high enough to damage the filter. The samples with deposits have greater MOR as a result of added material and is quite variable from sample to sample in FIGS. 8A-8C because of non-uniformity in distribution of deposits, but the increase in MOR is not sufficient to withstand the high stresses generated as a result of the ~ lOx increase in CTE and ~2-3x increase in E-Mod. Various testing appeared to point to thermo mechanical property changes due to composite resulting from DEF/urea decomposition by products depositing in the filter matrix was the primary driver for the damage.

[0055] FIG. 9 schematically illustrates a test set up that was used to evaluate the effectiveness of the protective cellular disc interposed between a DPF (porosity about 50%) and a reduction agent (DEF) injection, as disclosed herein. FIG. 10 shows a photographic image of a DPF exposed to DEF without a protective disc in place, whereas FIG. 11 shows a photographic image of the substantially similar location of a substantially similar DPF exposed to twice the duration as the DPF of FIG. 10, but with a protective disc in place. The exemplary protective cellular discs used in a series of tests was a porous ceramic body with an outside diameter the same as the outside diameter of the DPF, an axial length of about 2.5 inches, and with a honeycomb structure having 200 cells per square inch and a wall thickness (average wall thickness) of 6 mils, the walls being primarily comprised of cordierite having porosity of 30 to 35% as measured by mercury porosimetry. In the case of not having a protective disc damage to the the DPF was observed after 6 hours of exposure; on the other hand, when a protective disc was in place, there was no damage observed even after 12 hours of exposure. Furthermore, the disc itself also did not exhibit any damage, on either face. Thus the low porosity (or, lower porosity) cellular disc appeared to substantially prevent, and even completely prevent, reduction agent byproduct penetration into the channel walls of the filter, which kept that exhaust component undamaged and intact.

[0056] Reference throughout this specification to "one embodiment," "certain embodiments," "one or more embodiments" or "an embodiment" means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, the appearances of the phrases such as "in one or more embodiments," "in certain embodiments," "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

[0057] Although the disclosure herein has been described with reference to particular embodiments, those skilled in the art will understand that the embodiments described are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the method and apparatus of the present disclosure without departing from the spirit and scope of the disclosure. Thus, the present disclosure can include modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. An exhaust treatment apparatus for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising: a first exhaust component disposed within the exhaust line housing, the exhaust component comprising a body comprising an inlet end and an outlet end and an axial length from the inlet end to the outlet end, the body comprising a honeycomb structure comprised of a matrix of intersecting porous walls defining a plurality of cells which extend axially from the inlet end to the outlet end, the walls defining a plurality of axial channels extending axially from the inlet end to the outlet end, wherein the porous walls of the exhaust component comprise a first porosity, a reducing agent injector junction disposed on the exhaust line housing; and a cellular disc disposed within the exhaust line housing and between the particulate filter and the reducing agent injector junction, the cellular disc comprising a honeycomb body comprising an inlet end and an outlet end and an axial length from the inlet end to the outlet end, the honeycomb body comprising a honeycomb structure comprised of a matrix of intersecting porous walls defining a plurality of cells which extend axially from the inlet end to the outlet end, the walls defining a plurality of axial channels extending axially from the inlet end to the outlet end, wherein the porous walls of the cellular disc comprise a second porosity, wherein the second porosity is lower than the first porosity.

2. The exhaust treatment apparatus of claim 1 wherein the reducing agent injector junction is disposed downstream of the first exhaust component.

3. The exhaust treatment apparatus of claim 1 wherein the reducing agent injector junction is disposed upstream of the first exhaust component.

4. The exhaust treatment apparatus of claim 1 wherein the first exhaust component is a particulate filter.

5. The exhaust treatment apparatus of claim 4 wherein the particulate filter comprises plugs fixed within at least some of the channels, such that the axial channels comprise inlet channels and outlet channels, wherein the inlet channels are open at the inlet end, and the outlet channels are open at the outlet end, to allow flow into the inlet channels and out of the outlet channels in the downstream direction.

6. The exhaust treatment apparatus of claim 5 wherein the particulate filter is a diesel particulate filter.

7. The exhaust treatment apparatus of claim 1 wherein the reducing agent injector junction is disposed upstream of the particulate filter, and the cellular disc is disposed downstream of the reducing agent injector junction and upstream of the particulate filter.

8. The exhaust treatment apparatus of claim 1 wherein the reducing agent injector junction is disposed downstream of the particulate filter, and the cellular disc is disposed upstream of the reducing agent injector junction and downstream of the particulate filter.

9. The exhaust treatment apparatus of claim 1 wherein the cellular disc is disposed downstream of the particulate filter.

10. The exhaust treatment apparatus of claim 1 wherein wherein the reducing agent injector junction is disposed downstream of the particulate filter.

11. The exhaust treatment apparatus of claim 1 wherein the reducing agent injection portion is coupled to an SCR unit.

12. The exhaust treatment apparatus of claim 11 wherein the reducing agent injection portion is disposed upstream of the SCR unit.

13. The exhaust treatment apparatus of claim 11 wherein the reducing agent injection portion is incorporated into the SCR unit.

14. The exhaust treatment apparatus of claim 1 wherein the reducing agent comprises ammonia, urea, or a mixture comprising ammonia or urea.

15. The exhaust treatment apparatus of claim 1 wherein the exhaust apparatus further comprises a diesel oxidation catalyst (DOC) unit disposed upstream of the particulate filter.

16. The exhaust treatment apparatus of claim 1 wherein the cellular disc is disposed adjacent to the particulate filter.

17. The exhaust treatment apparatus of claim 1 wherein the plurality of axial channels of the cellular disc are flow-through channels.

18. The exhaust treatment apparatus of claim 1 wherein none of the channels in the cellular disc are plugged.

19. The exhaust treatment apparatus of claim 1 wherein the porous material is comprised of one or more selected from the group of a ceramic material, a metal material, a glass material, and combinations thereof.

20. The exhaust treatment apparatus of claim 1 wherein the porous material is comprised of one or more selected from the group of cordierite, aluminum titanate, magnesium titanate, silica carbide, mullite, alumina, spinel, and combinations thereof.

21. The exhaust treatment apparatus of claim 1 wherein the first exhaust component is a flow through substrate wherein the plurality of axial channels are non-plugged flow-through channels.

22. The exhaust treatment apparatus of claim 1 further comprising one or more catalytic exhaust components disposed within the exhaust line housing.

23. The exhaust treatment apparatus of claim 22 wherein one or more of the catalytic exhaust components is selected from the group consisting of a DOC component, an SCR component, and an LNT component.

24. The exhaust treatment apparatus of claim 1 further comprising an SCR component disposed within the exhaust line housing and downstream of the first exhaust component.

25. The exhaust treatment apparatus of claim 24 wherein the first exhaust component is a particulate filter.

26. The exhaust treatment apparatus of claim 1 further comprising a DOC component and an SCR component disposed within the exhaust line housing, wherein the DOC component is disposed upstream of the first exhaust component and the SCR component is disposed downstream of the first exhaust component.

27. The exhaust treatment apparatus of claim 26 wherein the reducing agent injector junction is disposed between the first exhaust component and the SCR component.

28. The exhaust treatment apparatus of claim 1 further comprising a reducing agent injector coupled to the reducing agent injector junction.

29. The exhaust treatment apparatus of claim 1 wherein the cellular disc comprises an inlet end, an outlet end, an axial length from the inlet and to the outlet end, an inlet face at the inlet end, an outlet face at the outlet end, wherein the cellular disc has a cross-sectional area and a perimeter, wherein the inlet face has an effective diameter equal to 4 times the cross-sectional area divided by the perimeter, and wherein the cellular disc has an aspect ratio equal to the effective diameter divided by the axial length of the cellular disc which is less than 0.5.

30. The exhaust treatment apparatus of claim 1 wherein the aspect ratio of the cellular disc is between 0.1 and 0.5.

31. The exhaust treatment apparatus of claim 1 wherein the plurality of axial channels of the cellular disc are flow-through channels.

32. The exhaust treatment apparatus of claim 1 wherein none of the channels are plugged.

Wherein the intersecting walls of the cellular disc are comprised of a porous material having a second porosity, wherein the second porosity is lower than the first porosity.

33. The exhaust treatment apparatus of claim 1 wherein at least some of the intersecting walls are comprised of a porous material having a second porosity, wherein the second porosity is lower than the first porosity.

34. The exhaust treatment apparatus of claim 1 wherein the difference in porosity between the first porosity and the second porosity is more than 5%.

35. The exhaust treatment apparatus of claim 1 wherein the difference in porosity between the first porosity and the second porosity is more than 10%.

36. The exhaust treatment apparatus of claim 1 wherein the difference in porosity between the first porosity and the second porosity is more than 15%.

37. The exhaust treatment apparatus of claim 1 wherein the second porosity is between 5% and 20% less than the first porosity.

38. The exhaust treatment apparatus of claim 1 wherein the first porosity is greater than 40%.

39. The exhaust treatment apparatus of claim 1 wherein the first porosity is between 40% and 70%.

40. The exhaust treatment apparatus of claim 1 wherein the second porosity is less than 50%.

41. The exhaust treatment apparatus of claim 1 wherein the second porosity is less than 45%.

42. The exhaust treatment apparatus of claim 1 wherein the second porosity is less than 40%.

43. The exhaust treatment apparatus of claim 1 wherein the second porosity is less than 35%.

44. The exhaust treatment apparatus of claim 1 wherein the second porosity is between 30% and 35%.

45. The exhaust treatment apparatus of claim 1 wherein the second porosity is between 10% and 35%.

46. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the filter body comprises cells present in a pattern of 100 to 600 cells per square inch.

47. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the filter body comprises cells present in a pattern of substantially similarly shaped cells.

48. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the filter body comprises cells present in a pattern of substantially similarly sized cells.

49. The exhaust treatment apparatus of claim 1 wherein the outlet channels of the filter body are larger in area than the inlet channels of the filter body.

50. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 600 cells per square inch.

51. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 500 cells per square inch.

52. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 400 cells per square inch.

53. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 200 to 400 cells per square inch.

54. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 100 to 600 cells per square inch.

55. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of substantially similarly shaped cells.

56. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of substantially similarly sized cells.

57. The exhaust treatment apparatus of claim 1 wherein the outlet channels of the cellular disc are of substantially similar area as the inlet channels of the cellular disc.

58. The exhaust treatment apparatus of claim 1 wherein the outlet channels of the cellular disc are larger in area than the inlet channels of the cellular disc.

59. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of less than 8 mils.

60. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 2 to 8 mils.

61. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 2 to 7 mils.

62. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 3 to 7 mils.

63. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises intersecting wall thickness of 4 to 6 mils.

64. The exhaust treatment apparatus of claim 1 wherein the matrix of intersecting walls of the cellular disc comprises cells present in a pattern of 200/6, 300/5, or 400/4 (in cells per square inch, and wall thickness in mils).

65. The exhaust treatment apparatus of claim 1 wherein the cellular disc further comprises the catalyst material disposed on, in, or both on and in at least a portion of the intersecting walls of the cellular disc.

66. The exhaust treatment apparatus of claim 65 wherein the catalyst material comprises a HC oxidation catalyst material or a NO oxidation catalyst material.