Catalytic and sorptive articles comprising metal fiber felt substrates

A metal fiber felt and metal fiber technology, which can be applied in the directions of alkali metal compounds, metal/metal oxide/metal hydroxide catalysts, alkali metal oxides/hydroxides, etc., and can solve the problems of low effectiveness and the like

Inactive Publication Date: 2019-08-09
BASF CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0006] Catalysts used to treat the exhaust of internal combustion engines are less effective during relatively low temperature operation, such as the initial cold start period of engine operation, because the engine exhaust temperature is not high enough to effectively catalytically convert harmful components of the exhaust

Method used

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  • Catalytic and sorptive articles comprising metal fiber felt substrates
  • Catalytic and sorptive articles comprising metal fiber felt substrates
  • Catalytic and sorptive articles comprising metal fiber felt substrates

Examples

Experimental program
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preparation example Construction

[0064] The method of preparation of the metal fiber mat is not critical. Metal fiber mats are produced, for example, by a process involving sintering metal fibers under compression. Such methods are taught, for example, in Published US Patent Application No. 2011 / 0209451 by Kotthoff et al., which is incorporated herein by reference.

[0065]Metal fiber mats are highly porous and therefore exhibit a high degree of void volume (voids) or "true spaces" throughout their thickness. For example, prior to treating / supporting the catalyst and / or sorbent composition with the catalyst and / or sorbent composition, the metal fiber felt has a void volume of an average of about 20%, about 25%, about 30% of the total volume of the metal felt, About 35%, about 40%, about 45%, about 50% or about 55% to about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90% or about 95% %. In some embodiments, the void volume may average from about 20% to about 95% or about 50% of the tot...

Embodiment 1

[0136] Example 1: DOC comprising comparative cordierite matrix 1

[0137] The catalytic coating was applied to a 1" diameter x 3" long cordierite monolithic core at 400 cpsi by washcoat technique to provide 3.5 g / in 3 coating concentration and 120g / ft 3 A 1:1 weight ratio of Pt:Pd. In the catalytic powder used to prepare the coating slurry, Pt and Pd were supported on commercially available gamma alumina. Catalytic powders were prepared by incipient wetness impregnation of support materials with PGM precursors, followed by drying and calcination at about 500 °C. After coating the catalytic slurry, the core was dried and calcined at about 500°C.

Embodiment 2

[0138] Example 2: DOC comprising a corrugated metal fiber mat matrix 1

[0139] The same coating as Comparative Example 1 was applied to a 1 inch diameter by 2 inch long corrugated fiber at 400 cpsi On the core, the same catalyst composition was applied in the same amount, then dried and calcined. Fiber metal felt is spongy and allows for easy application of washcoat slurries. Figure 5 is a photograph of a coated metal fiber felt of the present invention. Catalyst composition in the article of the present invention is with 5.2g / in 3 level application. Under this load, the voids in the metal felt are filled with the catalytic composition such that no gas flows through the channel walls except by diffusion.

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Abstract

Catalytic and / or sorptive articles comprising a metal fiber felt, the metal felt having an array of metal fibers and voids and a catalyst composition and / or a sorbent composition disposed on the metalfibers and within the voids are described. Such articles can be highly effective towards the abatement of pollutants in exhaust gas streams from internal combustion engines.

Description

[0001] field of invention [0002] The present invention relates to functional articles, such as catalytic and / or sorbent articles, for the treatment of exhaust gases from internal combustion engines. The invention also relates to methods of making and using such functional articles and exhaust gas treatment systems using such articles. Background technique [0003] Lean burn engines, such as diesel engines, provide users with excellent fuel economy due to their operation at high air / fuel ratios under lean fuel conditions. However, diesel engines result in exhaust emissions containing particulate matter (PM), unburned hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NO x ), where NO x Various chemicals describing nitrogen oxides, including nitric oxide and nitrogen dioxide, among others. The two main components of waste particulate matter are soluble organic fraction (SOF) and soot fraction. The SOF layer condenses on the soot and usually comes from unburned di...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B01J35/06B01J23/86B01J20/28B01J20/02F01N3/20
CPCB01J20/02B01J35/06F01N3/2807F01N3/2835F01N2330/10B01J23/40B01J35/04B01D53/02B01D53/88B01D53/9431B01D53/944B01D2255/1021B01D2255/1023B01D2255/2092B01J20/041B01J20/043B01J20/06B01J20/186B01J20/28038B01J20/3204B01J20/3236B01J20/3238B01J20/2804B01J19/249B01J2219/2454B01J2219/2458B01J2219/2459B01J2219/2479B01J2219/2482B01J2219/2485B01J2219/2487B01J2219/2498Y02T10/12B01J23/862B01J20/28023B01J20/0229F01N3/20B01J23/42B01J23/44F01N3/0814
Inventor O·伊利尼奇S·A·罗斯J·霍克
Owner BASF CORP
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