Apparatus and method for coating radially zoned catalysts

Abstract

The present disclosure relates to apparatus and methods for coating portions of catalyst supports, such as radially segmented catalyst supports, such as those used in catalytic converters for treating exhaust gas streams of internal combustion engines.

Description

[0001] The present disclosure relates to apparatus and methods for coating catalyst supports, such as radially partitioned catalyst supports. The catalyst supports are used, for example, to treat the exhaust gas stream of an internal combustion engine, such as a diesel engine.

[0002] Typically, the technique for introducing the catalyst material into the monolithic catalyst support includes introducing the first open end of the support into the slurry and pumping the slurry through the channels of the catalyst support. However, since one of the open ends of the support must contact the slurry, a portion of the outer surface of the support is wetted or coated by the slurry.

[0003] Typically, the catalyst material comprises precious metals which do not participate in the catalytic reaction, since the outer surface of the catalyst carrier does not come into contact with the exhaust gases during operation due to the potting surrounding the catalyst carrier. Therefore, not all of the catalyst material is used in an effective manner. In order to recover the unused catalyst material, the outer surface of the carrier is cleaned, brushed or sandblasted. In this way, some material can be recovered and the outer surface can be provided in a clean manner, which is important, for example, if the potting involves welding. At the same time, however, the manufacturing costs of such catalyst carriers are relatively high due to the additional cleaning and recovery steps. Furthermore, not all unused material on the outside of the carrier can be recovered.

[0004] Thus, the present disclosure provides apparatus and methods for coating a catalyst support having an outer surface free of catalyst material.

[0005] In one aspect, a method for coating a catalyst carrier is provided, comprising the steps of: (a) providing a catalyst slurry through a disk, wherein the disk includes a reservoir configured to receive the slurry, a sealing cover configured to receive the catalyst carrier, and a plurality of spring-loaded rods configured to connect the cover to the disk; (b) introducing the catalyst carrier into the sealing cover; (c) introducing an open input end of the catalyst carrier into the catalyst slurry; (d) directing a certain amount of catalyst slurry into the interior of the catalyst carrier through the input end; (e) removing the catalyst carrier from the catalyst slurry; (f) rotating the catalyst carrier relative to the disk; and (g) directing the catalyst slurry within the catalyst carrier to the open output end of the catalyst carrier.

[0006] On the other hand, a method for coating a catalyst carrier is provided, comprising the following steps: (a) providing a catalyst slurry through a slurry disk; (b) connecting a sealing cover to the slurry disk through a plurality of spring-loaded rods, wherein the sealing cover is configured to receive the catalyst carrier and seal at least a portion thereof; (c) introducing the catalyst carrier into the sealing cover; (d) introducing an open input end of the catalyst carrier into the catalyst slurry; (e) directing a certain amount of catalyst slurry through the input end into the interior of the catalyst carrier; (f) removing the catalyst carrier from the catalyst slurry; (g) rotating the catalyst carrier relative to the disk; and (h) directing the catalyst slurry within the catalyst carrier to the open output end of the catalyst carrier.

[0007] In another aspect, a method for coating a catalyst carrier is provided. The method comprises the following steps: (a) coupling a sealing cover to a clamping mechanism configured to engage a catalyst carrier, wherein the sealing cover is configured to receive the catalyst carrier and seal at least a portion thereof and comprises a plurality of spring-loaded rods configured to engage a slurry disk; (b) introducing the catalyst carrier into the sealing cover; (c) introducing an open input end of the catalyst carrier into a catalyst slurry in the slurry disk; (d) directing a quantity of catalyst slurry through the input end into an interior of the catalyst carrier; (e) removing the catalyst carrier from the catalyst slurry; (f) rotating the catalyst carrier relative to the disk; and (g) directing catalyst slurry in the catalyst carrier to an open output end of the catalyst carrier.

[0008] In some embodiments of the aforementioned aspects, the catalyst carrier can rotate about 180 degrees relative to the disk, for example 180 degrees + / - 30 degrees, + / - 15 degrees, + / - 5 degrees or substantially + / - 0 degrees. In some embodiments, the cover includes an impermeable sealing surface, which is configured to seal at least one of the front or circumferential edges of the input end of the catalyst carrier to prevent the contact between the outer surface of the catalyst carrier and the catalyst slurry. The cover can also be configured to prevent the slurry from flowing axially through the radial portion of the front and / or prevent the catalyst slurry from flowing axially through the outer ring area of ​​the front. The direction of the cover can be adjusted relative to the disk.

[0009] In some embodiments, the step of introducing the catalyst carrier into the cover includes transporting the catalyst carrier by a clamping mechanism, and the clamping mechanism is configured to press the catalyst carrier into the cover to form a seal between them. In some embodiments, the step of introducing the open input end of the catalyst carrier into the catalyst slurry includes compressing the spring-loaded rod to provide a sealing force against the catalyst carrier. In some embodiments, the step of guiding a certain amount of catalyst slurry through the input end includes applying a pressure difference between the input end of the catalyst carrier and the output end of the catalyst carrier. In some embodiments, the step of removing the catalyst carrier from the catalyst slurry includes separating the catalyst carrier from the cover. In some embodiments, the step of rotating the catalyst carrier is carried out by a clamping mechanism, and the clamping mechanism is fixed to the catalyst carrier by a rotating mechanism. In some embodiments, the step of directing the catalyst slurry in the catalyst carrier to the open output end of the catalyst carrier includes directing air flow to the open input end of the catalyst carrier.

[0010] In some embodiments, the method further comprises the steps of: introducing the catalyst carrier into a second sealing cover, the second sealing cover being configured to seal different parts of the catalyst carrier, introducing the open output end or the open input end of the catalyst carrier into the second catalyst slurry, directing a certain amount of the second catalyst slurry into the second inner part of the catalyst carrier, removing the catalyst carrier from the second catalyst slurry, rotating the catalyst carrier relative to the disk, and directing the catalyst slurry in the catalyst carrier toward the open end of the catalyst carrier. In some embodiments, the second catalyst slurry can be provided in the same disk as the first catalyst slurry. In some embodiments, the second catalyst slurry can be provided in a second disk.

[0011] On the other hand, a device for enabling radial coating of a catalyst carrier is provided, the device having a coating station including a slurry disk and a clamping mechanism. In some embodiments, the device includes a sealing cover configured to releasably hold the catalyst carrier and seal the front or circumference of the input end of the catalyst carrier to prevent contact between the outer surface of the catalyst carrier and the catalyst slurry. In some embodiments, the device includes a plurality of spring-loaded rods configured to couple the sealing cover to the slurry disk. In some embodiments, the coating station is a conventional coating station.

[0012] On the other hand, a device for enabling radial coating of a catalyst carrier is provided, the device having a coating station including a slurry disk and a clamping mechanism. In some embodiments, the device includes a sealing cover configured to seal the front or circumference of the input end of the catalyst carrier to prevent contact between the outer surface of the catalyst carrier and the catalyst slurry. In some embodiments, the device includes a plurality of spring-loaded rods configured to engage with the slurry disk, wherein the sealing cover is configured to be coupled to a clamping mechanism configured to releasably hold the catalyst carrier. In some embodiments, the coating station is a conventional coating station.

[0013] In some embodiments of the aforementioned aspects, the sealing cover may be configured to prevent the slurry from flowing axially through the radial portion of the front side of the catalyst carrier and / or to prevent the catalyst slurry from flowing axially through the outer ring area of ​​the front side. In some embodiments, the device may also include a rotating mechanism that is coupled to the clamping mechanism and is configured to rotate the catalyst carrier about 180 degrees, such as 180 degrees + / - 30 degrees, + / - 15 degrees, + / - 5 degrees or substantially + / - 0 degrees. In some embodiments, the device includes an actuator that is coupled to the rotating mechanism and is configured to drive the rotation of the catalyst carrier.

[0014] In another aspect, a coating station for applying a catalyst to at least a portion of an inner surface area of ​​a catalyst carrier is provided. In some embodiments, the station includes a platform having a slurry tray in which the catalyst slurry can be located; a clamping mechanism configured to releasably clamp the catalyst carrier and provide relative movement thereof relative to the slurry tray; a sealing cover configured to seal the front face or circumference of the input end of the catalyst carrier to prevent contact between the outer surface of the catalyst carrier and the catalyst slurry; and a plurality of spring-loaded rods configured to engage the slurry tray.

[0015] In some embodiments, the sealing cover is also configured to prevent contact with a portion of the front of the catalyst carrier and any axial channel extending therefrom. In some embodiments, the sealing cover can also be configured to be releasably connected to the clamping mechanism. In some embodiments, the coating station includes a second sealing cover, which is also configured to be releasably connected to the clamping mechanism, wherein the sealing cover is interchangeable to provide different sealing configurations to the front of the catalyst carrier. In some embodiments, a plurality of spring-loaded rods can be configured to couple the sealing cover to the slurry disk. In some embodiments, the clamping mechanism can be further configured to provide vertical motion to the catalyst carrier, thereby immersing the open end of the catalyst carrier in the slurry disk and also removing it therefrom.

[0016] In some embodiments, the coating station includes a rotating mechanism that is coupled to a clamping mechanism and configured to rotate the catalyst carrier about 180 degrees, such as 180 degrees + / - 30 degrees, + / - 15 degrees, + / - 5 degrees or substantially + / - 0 degrees. In some embodiments, the coating station includes an actuator that is coupled to a rotating mechanism and configured to drive the rotation of the catalyst carrier. In some embodiments, the coating station includes a removable cover that is configured to seal one or more of the upper open end of the catalyst carrier, the upper surface of the clamping mechanism, and the upper surface of the platform to apply pressure to the volume closed by the cover. In some embodiments, the coating station includes a second platform with a second slurry disk, in which the second catalyst slurry can be located; and a second sealing cover that is configured to seal different parts of the front of the input end of the catalyst carrier to prevent the second catalyst slurry from contacting the outer surface of the catalyst carrier and different parts of the front and any axial passage extending therefrom.

[0017] In order to provide an understanding of the embodiments of the present disclosure, reference is made to the accompanying drawings, in which the figure numerals refer to components of exemplary embodiments of the present disclosure. The accompanying drawings are exemplary only and should not be construed as limited disclosures. The disclosure described herein is shown in the accompanying drawings by way of example and not limitation. For simplicity and clarity of illustration, the features shown in the drawings do not have to be drawn to scale. For example, for clarity, the size of some features may be enlarged relative to other features. Further, where deemed appropriate, reference numerals have been repeated in the accompanying drawings to indicate corresponding or similar elements.

[0018] Figure 1A is a perspective view of a honeycomb-type substrate that may be coated with an apparatus according to one or more embodiments of the present disclosure.

[0019] Figure 1B yes Figure 1A A partial enlarged cross-sectional view of a substrate, taken along a plane parallel to an end surface of the substrate, to show multiple gas flow channels according to one or more embodiments of the present disclosure.

[0020] Figure 2 NO2:NO from conventional and radially coated diesel oxidation catalysts x Graphic representation of the ratio.

[0021] Figure 3 is a schematic diagram of an exemplary coating station according to one or more embodiments of the present disclosure.

[0022] Figures 4A-4D Describes the use of one or more embodiments of the present disclosure Figure 3 Method of coating station.

[0023] Figures 5A-5Dis a schematic diagram of an apparatus for coating a catalyst support during various stages of a process according to one or more embodiments of the present disclosure.

[0024] Figures 6A-6D is a schematic diagram of an apparatus for coating a catalyst support during various stages of a process according to one or more embodiments of the present disclosure.

[0025] Figures 7A-7D is a schematic diagram of an apparatus for coating a catalyst support during various stages of a process according to one or more embodiments of the present disclosure.

[0026] Figures 8A-8D is a schematic diagram of an apparatus for coating a catalyst support during various stages of a process according to one or more embodiments of the present disclosure.

[0027] Figures 9A-9D is a schematic diagram of an apparatus for coating a catalyst support during various stages of a process according to one or more embodiments of the present disclosure.

[0028] Fig.10 is a perspective view of an exemplary catalyst support coated according to one or more embodiments of the present disclosure.

[0029] Figure 1A and 1B An exemplary substrate 2, i.e., a catalyst carrier, coated with a catalyst composition as described herein is illustrated. In some embodiments, the catalyst carrier 2 is a flow-through substrate, such as a flow-through honeycomb monolithic substrate. Typically, the flow-through substrate has thin parallel gas flow channels extending from the inlet end of the substrate to the outlet end, so that the channels are open to fluid flow. The channel, which is a substantially straight path from its fluid inlet to its fluid outlet, is defined by a wall on which a catalytic coating is deposited so that the gas flowing through the channel contacts the catalytic material. The flow passage of the flow-through substrate can be a thin-walled channel, which can have any suitable cross-sectional shape and size, such as a trapezoidal, rectangular, square, sinusoidal, hexagonal, elliptical, circular, and the like. As described herein, the flow-through substrate can be ceramic or metallic. The flow-through substrate can, for example, have a cross-sectional shape of about 50 in. 3 About 1200in 3 The catalytic composition may be applied to a substrate to produce a catalytic article.

[0030] In some embodiments, any suitable substrate for catalytic articles may be used, such as, for example, a type having a plurality of thin, substantially parallel gas flow channels extending along the longitudinal axis of the substrate, wherein, for example, each channel is plugged at one end of the substrate body and alternate channels are plugged at the opposite end face (a "wall flow filter"). Flow-through and wall flow substrates are also taught, for example, in International Application Publication No. WO2016 / 070090, which is incorporated herein by reference in its entirety.

[0031] Such monolithic wall-flow filter substrates may contain up to about 900 or more flow channels (or "cells") per square inch of cross-section, although far fewer flow channels may be used. For example, the substrate may have about 7 to about 600, such as, for example, about 100 to about 400 cells per square inch ("cpsi"). The cells may have a cross-section that is rectangular, square, circular, oval, triangular, hexagonal, or other polygonal in shape. Blocked or plugged ends may alternate with open channels, each of which has an open and blocked end, respectively. The wall-flow substrate also includes an inlet end, an outlet end, and porous cell walls configured for diffusion of exhaust gases therethrough. The plugged ends prevent gas flow and promote diffusion through the cell walls.

[0032] The wall flow filter substrate typically has a wall thickness of about 50 microns to about 2000 microns, such as, for example, about 50 microns to about 450 microns or about 150 microns to about 400 microns. The wall of the wall flow filter is porous and the wall porosity is typically at least about 50% or at least about 60% before the functional coating is placed, with an average pore size of at least about 5 microns. For example, the wall flow filter article substrate will have a porosity of ≥50%, ≥60%, ≥65% or ≥70% in some embodiments. For example, in some embodiments, before the catalytic coating is placed thereon, the wall porosity of the wall flow filter article substrate will be about 50%, about 60%, about 65% or about 70% to about 75%, about 80%, or about 85%, with an average pore size of about 5 microns, about 10, about 20, about 30, about 40 or about 50 microns to about 60 microns, about 70, about 80, about 90 or about 100 microns. The terms "wall porosity" and "substrate porosity" are synonymous and interchangeable. Porosity is the ratio of the void volume divided by the total volume of the substrate. The pore size can be determined according to the ISO 15901-2 (static volume) procedure for nitrogen pore size analysis. Nitrogen pore size can be determined on a Micromeritics TRISTAR 3000 series instrument. Nitrogen pore size can be determined using the BJH (Barrett-Joyner-Halenda) calculation and 33 desorption points. Useful wall flow filters have high porosity, allowing high loadings of catalyst compositions to be operated without excessive back pressure.

[0033] refer to Figure 1A , the exemplary catalyst carrier 2 shown has a cylindrical shape and a cylindrical outer surface 4; however, other shapes are expected and considered within the scope of the present disclosure and will be determined to be suitable for a particular application. In some embodiments, the catalyst carrier may have a cross-sectional shape corresponding to an ellipse, rectangle, trapezoid, hexagon, etc. The catalyst carrier 2 also includes an upstream (or inlet) end face 6 and a corresponding downstream (or outlet) end face 8, which may be the same as the end face 6. The catalyst carrier 2 may have a plurality of thin, parallel gas flow channels 10 formed therein. As shown Figure 1B As shown in the exemplary embodiment of FIG. 1 , the flow channel 10 is formed by a wall 12 and extends through the catalyst carrier 2 from the upstream end face 6 to the downstream end face 8, and the channel 10 is unobstructed to allow a fluid (e.g., airflow) to pass longitudinally through the catalyst carrier 2 via its airflow channel 10. As shown in FIG. Figure 1B As can be more easily seen in the figure, the wall 12 can be sized and configured so that the gas flow channel 10 has a substantially regular polygonal shape. As shown in this exemplary embodiment, if desired, the catalyst composition can be applied in multiple different layers. In the embodiment shown, the catalyst composition consists of a discrete bottom layer 14 adhered to the wall 12 of the support member and a second discrete top layer 16 coated on the bottom layer 14. The present disclosure can be practiced with one or more (e.g., one, two, three, or four or more) catalyst composition layers and is not limited to Figure 1B Two layer embodiment shown. Additional coating configurations are disclosed herein below.

[0034] In order to produce a catalytic article, a substrate or catalyst support as described above is coated with a catalytic composition. The coating is a "catalytic coating composition" or a "catalytic coating". The terms "catalyst composition" and "catalytic coating composition" are synonyms. The catalytic coating may include one or more thin adhesion coatings that are disposed on at least a portion of the substrate and adhere to at least a portion of the substrate. In some embodiments, the catalytic article of the present invention may include the use of one or more catalyst layers and a combination of one or more catalyst layers. The catalytic material may be present only on the inlet side of the substrate wall, only on the outlet side, on both the inlet side and the outlet side, or the wall itself may be composed of catalytic material in whole or in part. The catalytic coating may be on the surface of the substrate wall and / or in the pores of the substrate wall, i.e., in the substrate wall and / or on the substrate wall. Therefore, the phrase "catalytic coating disposed on the substrate" refers to any surface, such as on the wall surface and / or on the pore surface. The catalytic coating may include separate functional components, such as a first catalyst composition and a second catalyst composition, as described in more detail below.

[0035] The catalyst composition can be applied generally in the form of a washcoat containing a support material having a catalytically active substance thereon. The catalyst composition can be mixed with water (if in dry form) to form a slurry for coating the catalyst substrate. In addition to the catalyst particles, the slurry can optionally contain alumina as a binder, an associative thickener, and / or a surfactant (including anionic, cationic, nonionic, or amphoteric surfactants). In some embodiments, the pH of the slurry can be adjusted to an acidic pH of, for example, about 3 to about 5. When present, the alumina binder is typically present at about 0.02 g / in 3 To about 0.5g / in 3 The alumina binder may be, for example, boehmite, gamma-alumina or delta / theta alumina.

[0036] The slurry can be ground to enhance the mixing of particles and the formation of a homogeneous material. Grinding can be done in a ball mill, a continuous grinder or other similar equipment, and the solid content of the slurry can be, for example, about 20-60wt%, more specifically about 30-40wt%. In one embodiment, the slurry is characterized by a D90 particle size of about 10 to about 50 microns (e.g., about 10 to about 20 microns) after grinding. D90 is defined as the particle size at which about 90% of the particles have a finer particle size than it. Exemplary coating compositions are disclosed below.

[0037] The slurry can be coated on the catalyst substrate using washcoat techniques known in the art. As used herein, the term "wash-coat" has its usual meaning in the art, i.e., a thin adherent coating of a material applied to a substrate (such as a honeycomb flow-through monolith substrate or a wall-flow filter substrate) that is porous enough to allow the treated gas flow to pass therethrough. As used herein and as described in Heck, Ronald and Robert Farrauto in Catalytic Air Pollution Control (New York: Wiley-Interscience, 2002, pages 18-19), a washcoat layer includes a compositionally different material layer disposed on the surface of the monolithic substrate or an underlying washcoat layer. The substrate may contain one or more washcoat layers, and each washcoat layer may have a unique chemical catalytic function.

[0038] In one embodiment, the substrate is dipped one or more times in the slurry or otherwise coated with the slurry. Thereafter, the coated substrate is dried at an elevated temperature (e.g., 100-150° C.) for a period of time (e.g., 1-3 hours), and then calcined by heating, for example, at 400-600° C., typically for about 10 minutes to about 3 hours. After drying and calcining, the final washcoat coating can be considered to be substantially free of solvent.

[0039] After calcination, the catalyst loading can be determined by calculating the difference between the coated weight and the uncoated weight of the substrate. It will be apparent to those skilled in the art that the catalyst loading can be varied by changing the slurry rheology. Additionally, the coating / drying / calcining process can be repeated as needed to build up the coating to a desired loading level or thickness.

[0040] The catalyst composition can be applied as a single layer or in multiple layers. Catalyst layers produced by repeated support coating of the same catalyst material to increase the loading level are generally considered to be single layer catalysts. In another embodiment, the catalyst composition is applied in multiple layers, wherein each layer has a different composition. In some embodiments, the catalyst composition can be zone coated, which means that a single substrate can be coated with different catalyst compositions in different regions along the gas effluent flow path as described below.

[0041] The washcoat may be applied so that the different coatings are in direct contact with the substrate. Alternatively, there may be one or more "undercoats" so that at least a portion of the catalytic or adsorbent coating or coatings is not in direct contact with the substrate (but is in contact with the undercoat). There may also be one or more "overcoats" so that at least a portion of the coating or coatings is not directly exposed to the gas stream or atmosphere (but is in contact with the overcoat).

[0042] Different coatings may be in direct contact with each other without an "intermediate" overlap zone. Alternatively, different coatings may not be in direct contact with a "gap" between two zones. In the case of a "primer" or "topcoat", the gap between different layers is called an "intermediate layer". A primer is a layer "below" a coating, a topcoat is a layer "above" a coating, and an intermediate layer is a layer between two coatings. Intermediate layers, primers, and topcoats may contain one or more functional compositions or may not contain a functional composition.

[0043] The catalytic coating can include more than one thin adhesion layer, which adheres to each other and the coating adheres to the substrate. The entire coating includes a separate "coating". The catalytic coating can be advantageously "partitioned", which includes a partitioned catalytic layer. This can also be described as "lateral partitioning". For example, one layer can extend from the inlet end to the outlet end, extending about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80% or about 90% of the length of the substrate. Another layer can extend from the outlet end to the inlet end, and extend about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80% or about 90% of the length of the substrate. Different coatings can be adjacent to each other and do not cover each other. Alternatively, different layers can cover a portion of each other, thereby providing a third "middle" zone. The intermediate region can extend, for example, from about 5% to about 80% of the length of the substrate, such as about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, or about 70% of the length of the substrate. The different layers can each extend the entire length of the substrate, or can each extend a portion of the length of the substrate and can partially or completely cover or cushion each other. Each different layer can extend from the inlet end or the outlet end.

[0044] As used herein, the phrase "radially partitioned oxidation zones" refers to applying different catalyst compositions to at least two different regions of a catalytic article substrate such that the two or more oxidation zones each provide a different level of oxidation activity. As described above, the catalyst carrier may include an inlet side and an outlet side, and a plurality of passages extending from the inlet side to the outlet side. The first region may include a first subset of the plurality of channels, and the second region may include a second subset of the plurality of channels. For example, when a cylindrical catalyst carrier is viewed from the gas inlet side, one region may be an outer annular portion of a radial face that extends axially from the face along at least a portion of the length of the body, and the second region may be an inner circular region of the radial face that also extends some of the length of the body. Note that embodiments of the present disclosure are not limited to two regions. For example, a catalyst carrier according to the present disclosure may include 3, 4 or more regions, each region including a subset of the plurality of passages of the substrate (see, e.g., Fig.10 ). However, for ease of discussion, only two regions are illustrated in the drawings and referred to in the following description of exemplary embodiments.

[0045] In some embodiments, a coating system according to the present disclosure may include a clamping mechanism for holding a catalyst carrier, a reservoir for holding a catalyst slurry, and a sealing device for preventing contact between the outer surface of the catalyst carrier and the slurry. An example of such a system is disclosed in U.S. Patent Publication No. 2012 / 0114853, the entire disclosure of which is incorporated herein by reference.

[0046] Figure 3 An exemplary coating station according to one or more embodiments of the present disclosure is shown. The coating station includes a loading platform 320 that accommodates a catalyst carrier 310. A sealing element 330 is supported by a sealing bracket 332, and a sealing retainer is connected to a lifting mechanism 336. In some embodiments, the sealing bracket 332 can be connected to the lifting mechanism 336 by a quick release fastener. In some embodiments, the lifting mechanism includes an actuator portion 336a, which includes a spindle rod. Figure 3 The exemplary coating station may further include a pan 340 , and a receiving pan 344 may be located below the pan 340 , and the receiving pan may receive the residual slurry through an overflow port 346 .

[0047] In some embodiments, the coating station further comprises a movable cover 350, which can be raised / lowered from / onto the loading platform 320. In some embodiments, the cover is movable and connected to a lifting mechanism 354 held by the support 322. In some embodiments, the coating station comprises a pivot device 356, which can be connected to the cover 350 via the lifting mechanism 354 for pivoting the cover eccentrically relative to the longitudinal axis of the loading platform 320 and the tray 340.

[0048] Figure 3 The exemplary coating station shown in FIG. 3 includes another lifting mechanism for raising and lowering the tray 340. As shown, in some embodiments, the tray lifting mechanism 348 and the sealing element lifting mechanism 336 can be connected to the same support. Thus, in some embodiments, Figure 3 An exemplary coating station includes three lifting mechanisms: a first lifting mechanism 336a, 336 for lifting and lowering a sealing bracket connected to a sealing element; a second lifting mechanism 348 for lifting and lowering a disk 340; and a third lifting mechanism 354 for lifting and lowering a cover 350. In some embodiments, a first lifting mechanism 336 for moving a sealing element and a second lifting mechanism 348 for moving a disk are attached to the same support member by individually controllable actuators. In some embodiments, another separate support member is used to hold a third lifting mechanism that lifts and lowers the cover 350. In some embodiments, the third lifting mechanism 354 is combined with a pivoting device 356, which is arranged to pivot the cover 350, and its rotation axis is eccentrically arranged with respect to the longitudinal axis of the vacuum cover, the disk, the loading platform, and the sealing element. In some embodiments, the third lifting mechanism 354 is connected to the support member 322.

[0049] In some embodiments, the housing 350 includes an opening 350a for applying positive or negative pressure (ie, vacuum) to the interior of the housing 350. In some embodiments, the opening 350a is adapted to be connected to a pump (not shown).

[0050] In some embodiments, the lifting mechanism can include guide rods and actuator elements, such as pneumatic or hydraulic pistons or electromagnetic actuators. In some embodiments, the support for the cover lifting mechanism is connected to the support of the lifting device for the loading platform 322 and the sealing bracket 336. In some embodiments, an electric servo drive can be used to drive the lifting mechanism, wherein each lifting mechanism is driven by an associated individual servo drive. In some embodiments, a gear mechanism can be used to connect the lifting mechanism to the corresponding servo drive, such as a worm gear or a spindle gear assembly.

[0051] Figures 4A-4D An exemplary catalyst carrier 110 is shown housed in a loading platform 120. The exemplary carrier has a cylindrical shape with two end faces. Figures 4A-4D The outer surface of the loading platform 120 extending between the two ends holds the carrier. Figures 4A-4D In FIG. 1 , only the contact elements of the loading platform 120 are shown symbolically. Figures 4A-4D The exemplary embodiment shown in further includes a sealing element 130 below the open input end 110a of the catalyst carrier 110. In addition, a tray 140 is located below the carrier 110 and the sealing element 130, wherein a slurry 142 is located within the tray 140.

[0052] exist Figure 4A In the first step of the exemplary embodiment shown, the carrier 110 is held by the loading platform 120 at a distance above the sealing element 130 and above the slurry 142. Then, the sealing element 130 is lifted to reach a position as shown in FIG. Figure 4B In this position, the sealing element covers the entire circumference of the input end 110a. This can be achieved by lifting the sealing element or a sealing bracket that holds the sealing element. Figures 4A-4D In the embodiment, only the sealing element 130 is shown in a symbolic manner, and other parts of the cover mechanism including the sealing bracket will be described with reference to the exemplary embodiments shown in Figures 5-9.

[0053] After the periphery of the input end 110a is covered by the sealing member 130, as shown in FIG. Figure 4B As shown, the disc 140 including the slurry 142 is lifted toward the carrier 110 so that the surface provided by the slurry and the slurry itself contacts the input end 110a (and a portion of the sealing element 130). Figure 4C It can be seen that the outer surface surrounding the catalyst carrier 110 is not in contact with the slurry 142, especially the portion above the circumference of the input end 110a is not in contact with the slurry 142. However, at the same time, the entire input end 110a of the carrier 110 is immersed in the slurry. Figure 4DIn the subsequent step shown, vacuum is applied to the open end 110b of the carrier 110 opposite to the input end 110a. The end 110b of the carrier 110 opposite to the input end 110a is open and connected to the open input end 110a through the internal passage of the carrier 110. The movable cover 150 is lowered onto the catalyst carrier 110, partially surrounding the carrier 110 and temporarily surrounding the output end 110b. The cover 150 is in contact with the loading platform 120 so that the volume above the output end 110b is surrounded by the cover 150. The sealed connection of the cover 150 to the loading platform 120 and the sealed connection of the loading platform 120 to the outer peripheral surface of the carrier 110 allow vacuum to be applied to the output end 110b through the cover 150 connected to the vacuum pump 152. By pressure balance and due to the connection via the internal passage of the carrier 110, the slurry 142 is sucked into the carrier 110 via the open input end 110a. For example, in some embodiments, the slurry 142 is sucked through the inner opening of the annular sealing element 130 and through the complete cross section of the input end 110a of the catalyst carrier. In this way, a certain amount of slurry 142 located in the disk 140 is sucked into the carrier, thereby coating the inner surface (e.g., the inner channel) of the catalyst carrier 110. However, during this step of guiding a certain amount of slurry 142 to the inside of the catalyst carrier 110, no slurry is transferred to the circumferential outer surface of the carrier 110 because the sealing element 130 blocks the slurry 142 on the circumference of the input end 110a. In this way, a certain amount of slurry is guided to the inside of the catalyst carrier without dirtying the outer circumferential surface of the catalyst carrier 110. For example, in some embodiments, even the portion of the circumferential outer surface of the carrier 110 located below the slurry surface in the disk 140, that is, the lower part of the catalyst carrier 110 immersed in the slurry, does not contact the slurry, because the sealing element 130 provides a covering protection for the outer circumferential surface during the immersion of the input end 110a in the slurry.

[0054] In some embodiments, after the step of directing a quantity of slurry 142 into carrier 110 is completed, the vacuum provided by pump 152 is terminated and hood 150 is released by lifting the hood from loading platform 120, similar to Figure 4C Then, the tray 140 is lowered, as shown in FIG. Figure 4B As shown. Subsequently, the sealing element 130 is removed from the periphery of the input end 110a by lowering the sealing element 130. Figures 4A-4D As can be seen in FIG. 1 , in some embodiments, the distance that the disc 140 is raised and lowered is greater than the distance that the sealing element 130 is raised and lowered. This ensures that the sealing element 130 is only in contact with the slurry when necessary, i.e., when the input end 110a is immersed in the slurry 142, such as Figure 4DFurthermore, this ensures that lowering the sealing element 130 does not result in contact between the sealing element 130 and the slurry 142. If the input end 110a contacts only the slurry and the sealing element 130 covers the circumference of the input end 110a, the translational movement (lowering and lifting) of the sealing element 130 can be performed overlappingly or during the movement (lowering or lifting) of the disc 140.

[0055] In some embodiments, the tray 140 may be fixed in position and the loading platform 120 lowers and raises the carrier 110, such as Figures 4A-4D In such an embodiment, the lifting mechanism of the sealing element 130 can be active or passive.

[0056] For example, in some embodiments, the lifting mechanism that moves the sealing element can be a passive mechanism including a spring that pushes the sealing element 130 toward the carrier 110. In some embodiments, the carrier is lowered toward the disk 140 and contacts the sealing element 130. After contacting the sealing element 130, the circumference of the input end 110a, that is, the circumferential edge of the input end of the carrier, remains in contact with the sealing element 130, while the force that pushes the sealing element toward the carrier 110 maintains the contact between the sealing element 130 and the circumference of the input end 110a. As the lowering process continues, the sealing element 130 is immersed in the slurry 142 together with the input end 110a, and the spring force applied to the sealing element 130 ensures that the sealing element covers the circumference of the input end of the carrier during the entire immersion process.

[0057] Figures 5A-5D An exemplary manufacturing apparatus 400 for radial coating is depicted, which uses a cover and sealing mechanism (cover assembly) 460 configured to enable radial coating. The exemplary arrangement shown is configured for coating the inside of a carrier 410 (e.g., coating the inside of a radial face such as a circle extending axially along the length of the carrier 410). The exemplary apparatus 400 includes a cover 462 and a plurality of spring-mounted rods 464 (springs 464a, rods 464b). In some embodiments, two spring-mounted rods 464 are provided; however, the number and position of rods 464 can vary to suit a particular application. The cover 462 includes a sealing surface 466, which is configured to prevent contact between the slurry 442 and a portion of the catalyst carrier 410, such as the outer surface 410c and the outer ring 410d of the radial face of the carrier 410. The spring-mounted rod 464 is connected to the cover 462 and the slurry disk 440. In some embodiments, the spring-mounted rod 464 is releasably coupled to the disk 440 or an adjacent support structure or platform to interchangeably couple various cover assemblies to the coating station. Spring 464 a provides a force to sealing surface 466 to seal the surface to carrier 410 .

[0058] Figure 5ADepicts an exemplary device 400 of a slurry pan 440 mounted on a conventional coating machine (e.g., an MCC4 type coating machine); however, this arrangement can be incorporated into the novel coating station disclosed herein. As shown, one end of a rod 464b is attached to the slurry pan 440 (e.g., by threaded engagement or other mechanical fasteners), and the other end is attached to a cover 462, with a spring 464a sandwiched between them. Rod 464b can be releasably or permanently attached to cover 462 to suit a particular application. In some embodiments, the rod is slidably coupled to the cover so that it can move between them. The cover 462 shown has a recessed portion that defines an opening located in the center and provides a sealing surface 466 for the carrier 410. In the exemplary embodiment shown, the recess and the sealing surface 466 are configured to seal around the circumference of the carrier 410 and a portion of its face 410a. However, the exact size and shape of the cover, recess, and sealing surface will vary to suit a particular application (e.g., the cross-sectional shape of the carrier, the carrier portion to be coated, etc.).

[0059] In some embodiments, the sealing surface 466 includes a first portion (e.g., a lip portion) that can be in the form of a truncated cone, such as a truncated cone or similar conical structure having a wall thickness that decreases in a direction corresponding to the taper direction of the truncated cone. In some embodiments, the sealing surface 466 also includes a second portion that includes an outer portion that extends along the plane from which the truncated cone emerges and corresponds to a portion of the radial face of the catalyst carrier. In some embodiments, the first portion is suitable for receiving the circumference of the input end of the catalyst carrier, i.e., the circumferential edge, and the second portion is suitable for attachment to the cover 462 and for contacting a specific portion of the radial face of the catalyst carrier (e.g., its outer ring).

[0060] Figure 5B The catalyst carrier 410 is depicted being transported to the device by a holding fixture (or other type of loading platform) 470 and inserted into the cover assembly 460 and in contact with the sealing surface 466. In some embodiments, the fixture / platform 470 is movable in three dimensions (x, y, z) so that the carrier 410 can be introduced into the coating station, the carrier is lowered and raised relative to the slurry, and the carrier is removed to another station. In some embodiments, the loading platform 470 includes a cover 450, which can be configured to seal one end of the carrier 410 so that a pressure differential can be applied across the carrier 410. In some embodiments, the cover 450 can be a separate component that contacts the platform 470, the carrier 410, and / or the cover assembly 460.

[0061] Figure 5CThe catalyst carrier 410 is depicted being pushed downward by the movement of the cover 450 to press the carrier 410 against the sealing surface 466 of the cap assembly 460. Alternatively, in some embodiments, the slurry pan 440 may be raised to contact the slurry with the carrier 410, or a combination of the two. The physical covering and pressure seal between the catalyst carrier 410 and the sealing surface 466 prevent any contact between the slurry 442 and a designated portion (e.g., the outer surface 410c) of the catalyst carrier 410. Once sealed, the slurry 442 can be filled into the desired portion of the catalyst carrier 410 by, for example, applying a vacuum 453 to the cover 450 and extending to the interior area of ​​the carrier 410.

[0062] Figure 5D Depicted has been flipped about 180 ° and then transferred to another coating station containing slurry catalyst carrier 410, where excess slurry 442 can be pushed into another disk 480. As shown, inlet face 410a is now at the top, and outlet face 410b is now at the bottom. In some embodiments, then can be applied to the cover positive pressure 455 (e.g., a blast of air) to push slurry 452 along the catalyst carrier 410. In some embodiments, radial coating with a given area length or full length can be achieved by controlling various coating parameters, such as the composition of the catalyst slurry and / or the configuration of the sealing surface 466. Typically, if the sealing surface 466 is unintentionally contaminated by slurry 452, there is little effect on the catalyst function, because this will only affect the first millimeter or so of the entire channel length. This will represent a small amount of material that affects the overall catalyst function.

[0063] In the exemplary embodiment shown, the fixture or loading platform 470 includes a rotating mechanism 472, such as an electric motor or pneumatically controlled actuator and any necessary couplings, bearings, gears, etc., to rotate the carrier 410 about 180 degrees. In some embodiments, the cover is removed before rotation and then reattached to allow the introduction of air blast 453. In some embodiments, the coating station described herein can be provided according to the processing station described in U.S. Patent 9,186,662 or in combination with it, and its entire disclosure is incorporated herein by reference. In some embodiments, the loading platform 470 is supported by a rotating or pivoting mechanism 472 for inverting the carrier (and optionally, the loading platform). In some embodiments, the mechanism 472 can be synchronized with another pivoting mechanism for pivoting the cover 450. In this way, when the carrier is inverted and the cover has not completely disengaged from the carrier, the cover can follow the pivoting motion. An example of such a mechanism is described in U.S. Patent 9,186,662.

[0064] Figures 6A-6DAn exemplary apparatus 500 is depicted in which a cap assembly 560 is configured to enable an outer ring of a radial face of a catalyst support to be coated (ie, overcoat) according to one or more embodiments of the present disclosure. Figures 6A-6C The use of the exemplary apparatus 500 will be similar to that described with respect to Figures 5A-5D The exemplary apparatus 400 is described. Fig. 6A As can be seen, the cover 462 has a different configuration in which a portion of the sealing surface 566 is located Figure 5A Another portion of the sealing surface 466 is located at the outer periphery of the recess 568 so as to engage the carrier 510 at the central opening.

[0065] It can be seen that the fixture / platform 570 introduces the carrier 510 into the cover assembly 560 ( Figure 6B ) and pushes the carrier 510 against the sealing surface 566 and into the slurry 542, where it can be filled ( Figure 6C The carrier 510 can then be flipped 180 degrees and transferred to another coating station where excess slurry can be recovered ( Fig.6D ). In some embodiments, the exemplary apparatus 400 , 500 may be interchangeably coupled to the same disk 442 (having the same or different slurry compositions) to coat different radial regions of the carrier 410 , 510 .

[0066] Figures 7A-7D Another exemplary device 600 according to one or more embodiments of the present disclosure is depicted. In this exemplary embodiment, the cover assembly has been reconfigured so that the cover 662 includes two pieces: a base 662a for attachment to the slurry disk 642 and a spring-mounted and slidably engaged carrier 662b that provides a sealing surface 666. Rod 664b connects the cover 662 to the disk 642, while the spring 664a is now located around the bearing portion of the cover 662b and provides a sealing force to the carrier 610 once it is introduced into the device 600. The cover 662 is shown for an intermediate coating process; however, the cover 662 can be reconfigured to achieve an outer coating process. The remaining operation is substantially similar to that described above.

[0067] Figures 8A-8D 9A-9D (inner coating) depict other exemplary embodiments of apparatus 400, 500 in which cover assembly 760, 860 is configured to attach to loading platform 770, 870 instead of slurry pan 740, 840. In general, use of apparatus 700, 800 will be similar to use of the other apparatus described above.

[0068] like Figures 8A-8DAs shown, the cover assembly 760 is now connected to the loading platform 770 via a spring mounted rod 764, which can, for example, be threadedly engaged with the platform 770. In some embodiments, the slurry pan 740 may include a clearance hole disposed in its top surface for alignment with the rod 764b. In some embodiments, the spring 764a can be coupled to the rod or platform to maintain the integrity of the spring mounted rod assembly 764.

[0069] like Figures 9A-9D As shown, the cover assembly 860 is similar to Figures 7A-7D As described above, and now coupled to the loading platform 870 via rod 864b. In some embodiments, the cover base 862a is slidably coupled to the rod 864b fixedly coupled to the platform 870, and the cover carrier 862b is slidably coupled to the cover base 862a, as described above. Figures 7A-7D As described.

[0070] The materials selected for the different components of the exemplary devices 400, 500, 600, 700, and 800 will vary to suit the particular application. For example, in some embodiments, the cover can be made of stainless steel, aluminum, or other material compatible with the slurry, whether metallic or polymeric. In some embodiments, the seal can be made of rubber or other elastomeric material compatible with the slurry. In some embodiments, the seal or sealing surface can be coupled to the cover by an adhesive, a mechanical fastener, or an interference or similar fit.

[0071] According to one or more embodiments of the present disclosure, the catalyst support may be composed of any material commonly used to prepare automotive catalysts, and may include, for example, a metal or ceramic honeycomb structure. The substrate generally provides a plurality of wall surfaces on which the carrier coating composition is applied and adhered, thereby serving as a substrate for the catalyst composition.

[0072] The ceramic catalyst carrier can be made of any suitable refractory material, such as cordierite, cordierite-α-alumina, aluminum titanate, silicon titanate, silicon carbide, silicon nitride, zircon mullite, spodumene, alumina-silica-magnesia, zirconium silicate, sillimanite, magnesium silicate, zircon, petalite, α-alumina, aluminosilicate, etc.

[0073] The metal catalyst carrier may be made of one or more metals or metal alloys. The metal catalyst carrier may include any metal substrate, such as those with openings or "punching holes" in the channel wall. Examples of metal substrates include heat-resistant base metal alloys, such as those alloys in which iron is the basic or main component. This alloy may contain one or more of nickel, chromium and aluminum, and in each case, the total amount of these metals may include at least about 15% by weight (weight percentage) of the alloy, such as about 10% by weight to about 25% by weight of chromium, about 1% by weight to about 8% by weight of aluminum, and about 0% by weight to about 20% by weight of nickel, based on the weight of the substrate. Examples of metal catalyst carriers include substrates with straight channels; substrates with protruding blades along axial channels to interrupt gas flow and open channels for gas flow; and substrates with blades and holes to enhance gas transmission between channels and allow radial gas transmission throughout the monolith. In certain embodiments, for example, a metal catalyst carrier is advantageously used in a close-coupled position, thereby allowing rapid heating of the carrier and correspondingly rapid heating of the catalyst composition coated therein.

[0074] In describing the amount of washcoat or catalytic metal component or other components of a composition, it is convenient to use units of weight of the component per unit volume of the catalyst substrate. Thus, the units used herein are grams per cubic inch ("g / in 3 ”) and grams per cubic foot (“g / ft 3 ”) refers to the weight of the component per volume of the substrate (including the volume of the void spaces of the substrate). Other weight per volume units, such as g / L, are also sometimes used. In some embodiments, the total loading of the catalyst composition (including the catalytic metal and the support material) on the catalyst substrate (such as a monolithic flow-through substrate) is from about 0.5 to about 6 g / in 3 , such as, for example, from about 1 to about 5 g / in 3 In some embodiments, the total loading of the PGM or base metal components without support material is between about 0.5 and about 200 g / ft 3 (e.g., about 10 to about 100 g / ft 3 ). Note that these weights per unit volume are typically calculated by weighing the catalyst substrate before and after treatment with the catalyst washcoat composition, and because the treatment process involves drying and calcining the catalyst substrate at high temperatures, these weights represent a substantially solvent-free catalyst coating since substantially all of the water of the washcoat slurry has been removed.

[0075] Catalyst and / or sorbent compositions as described herein may include one or more supports or carriers, such as refractory inorganic solid oxide porous powders including functionally active materials.

[0076] The catalyst and / or adsorbent composition may be prepared using a binder, such as a ZrO2 binder derived from a suitable precursor such as zirconyl acetate or any other suitable zirconium precursor such as zirconyl nitrate. Zirconyl acetate binders provide a coating that remains uniform and intact after thermal aging, such as when the catalyst is exposed to high temperatures of at least about 600°C, such as, for example, about 800°C and higher and a high water vapor environment of about 5% or more. Other suitable binders include, but are not limited to, alumina and / or silica. Alumina binders include alumina, aluminum hydroxide, and aluminum oxyhydroxide. Colloidal forms of aluminum salts and alumina may also be used. Silica binders include various forms of SiO2, including silicates and colloidal silica. The binder composition may include any combination of zirconium oxide, alumina, and silica. Other exemplary binders include boehmite, γ-alumina or δ / θ alumina, and silica sols. When present, the binder is typically used in an amount of about 1-5 wt% of the total carrier coating loading. Alternatively, the binder may be zirconia-based or silica-based, such as zirconium acetate, zirconia sol or silica sol. When present, the alumina binder is typically present in an amount of about 0.05 g / in 3 About 1g / in 3 Amount used.

[0077] In some embodiments, the catalytic articles described herein include at least a first oxidation catalyst composition and a second oxidation catalyst composition. Typically, the oxidation catalyst composition (also referred to as a "diesel oxidation catalyst (DOC) composition") includes a platinum group metal (PGM) component dispersed on a support, such as a refractory metal support. The oxidation catalyst composition can be used to treat the exhaust gas of a diesel engine to convert hydrocarbon (HC) and carbon monoxide (CO) gaseous pollutants into carbon dioxide and water by catalyzing the oxidation of these pollutants.

[0078] In some embodiments, the oxidation catalyst composition comprises a catalytically active PGM component and a metal selected from alkali metals, alkaline earth metals, and combinations thereof. The PGM component that can be used in the disclosed DOC composition includes any component comprising a PGM. In some embodiments, the PGM component comprises one or more platinum group metals selected from platinum, palladium, ruthenium, rhodium, osmium, iridium, gold, and combinations thereof (i.e., Pt, Pd, Ru, Rh, Os, Ir, Au, and combinations thereof). In some embodiments, the PGM may be in the form of a zero-valent metal, or the PGM may be in the form of an oxide. The PGM component may include one or more PGMs in any valence state. Therefore, the terms "platinum (Pt) component", "rhodium (Rh) component", "palladium (Pd) component", "iridium (Ir) component", "ruthenium (Ru) component", etc. refer to corresponding platinum group metal compounds, complexes, etc., which decompose or otherwise convert into a catalytically active form when calcining or using the catalyst, such as, for example, a metal or a metal oxide. In some embodiments, the PGM component is a metal or an oxide thereof (e.g., including but not limited to platinum or an oxide thereof).

[0079] In some embodiments, the oxidation catalyst composition includes a PGM component in an amount ranging from about 0.1 wt % (weight percent), about 0.5 wt %, about 1.0 wt %, about 1.5 wt %, or about 2 wt % to about 3 wt %, about 5 wt %, about 7 wt %, about 9 wt %, about 10 wt %, about 12 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, or about 20 wt %, based on the total weight of the oxidation catalyst composition.

[0080] In some embodiments, the oxidation catalyst composition further comprises a metal component selected from alkali metals, alkaline earth metals and combinations thereof. In some embodiments, the alkali metal may be selected from one or more of lithium, sodium, potassium, rubidium or cesium. In some embodiments, the alkaline earth metal may be selected from one or more of magnesium, calcium, strontium or barium. In some embodiments, the alkali metal includes lithium, sodium, potassium, rubidium, cesium or a combination thereof. In some embodiments, the alkali metal is sodium. In some embodiments, the alkali metal is lithium. In some embodiments, the alkali metal is potassium. In some embodiments, the alkali metal is rubidium. In some embodiments, the alkali metal is cesium. In some embodiments, the alkali metal is a combination of one or more of sodium and lithium, potassium, rubidium or cesium.

[0081] In some embodiments, the alkaline earth metal comprises magnesium, calcium, strontium, barium, or a combination thereof. In some embodiments, the alkaline earth metal is magnesium. In some embodiments, the alkaline earth metal is calcium. In some embodiments, the alkaline earth metal is strontium. In some embodiments, the alkaline earth metal is barium.

[0082] In some embodiments, the oxidation catalyst composition comprises a metal component selected from an alkali metal, an alkaline earth metal, or a combination thereof, present in an amount of about 0.1 wt%, about 0.3 wt%, about 0.5 wt%, or about 1.0 wt% to about 1.5 wt%, about 2.0 wt%, about 2.5 wt%, about 3.0 wt%, about 3.5 wt%, or about 4.0 wt%, based on the total weight of the oxidation catalyst composition.

[0083] In some embodiments, the oxidation catalyst composition may optionally further comprise one or more additional catalytically active metals selected from copper, iron, chromium, manganese, cobalt, nickel, and combinations thereof. In some embodiments, the additional catalytically active metal is manganese.

[0084] In some embodiments, the PGM component of the oxidation catalyst composition is supported on a support material. The PGM component may, for example, be supported on a refractory metal oxide and / or a molecular sieve.

[0085] In some embodiments, the support material on which the catalytically active PGM component is supported comprises a refractory metal oxide that exhibits chemical and physical stability at high temperatures, such as those associated with gasoline or diesel engine exhaust. Exemplary refractory metal oxides include alumina, silica, zirconia, titania, ceria, praseodymium oxide, tin oxide, and the like, as well as physical mixtures or chemical combinations thereof, including atomically doped combinations and including high surface area or active compounds, such as activated alumina.

[0086] High surface area refractory metal oxides suitable for supporting PGM components include alumina, titania, and zirconia; mixtures of alumina with one or more of titania, zirconia, and ceria; and ceria coated on alumina; or titania coated on alumina. The refractory metal oxide may contain oxides or mixed oxides such as silica-alumina, aluminosilicates that may be amorphous or crystalline, alumina-zirconia, alumina-chromia, alumina-ceria, and the like. In some embodiments, the refractory metal oxide is selected from gamma alumina, silica-alumina, ceria coated on alumina, titania coated on alumina, zirconia coated on alumina, and combinations thereof. Combinations of metal oxides are included, such as silica-alumina, ceria-zirconia, praseodymium-ceria, alumina-zirconia, alumina-ceria-zirconia, lanthanum-alumina, lanthanum-zirconia-alumina, barium-alumina, barium-lanthanum-alumina, barium-lanthanum-neodymia-alumina, and alumina-ceria. Exemplary aluminas include macroporous boehmite, gamma-alumina, and delta / theta alumina. Useful commercial aluminas used as starting materials in the exemplary methods include activated aluminas, such as high bulk density gamma-alumina, low or medium bulk density macroporous gamma-alumina, and low bulk density macroporous boehmite and gamma-alumina.

[0087] High surface area metal oxide supports, such as alumina support materials also known as "gamma alumina" or "activated alumina", typically exhibit BET surface areas in excess of 60 m 2 / g, usually up to about 200m 2 / g or more. Exemplary refractory metal oxides include those having a specific surface area of ​​about 50 to about 300 m 2 / g of high surface area gamma-alumina. Such activated alumina is typically a mixture of gamma and delta phases of alumina, but may also contain significant amounts of η, κ, and θ alumina phases. "BET surface area" has its usual meaning: it refers to the Brunauer-Emmett-Teller method of determining surface area by N2 adsorption measurements. Unless otherwise indicated, "surface area" refers to the BET surface area. In some embodiments, the specific surface area of ​​the activated alumina is about 60 m 2 / g to about 350m 2 / g, for example, about 90m 2 / g to about 250m 2 / g.

[0088] In some embodiments, the refractory metal oxide support that can be used for the oxidation catalyst composition disclosed herein is a doped alumina material such as Si-doped alumina material (including but not limited to 1-10 wt. % SiO2 doped Al2O3), a doped titania material such as Si-doped titania material (including but not limited to 1-10 wt. % SiO2 doped TiO2), or a doped zirconium oxide material such as Si-doped ZrO2 (including but not limited to 5-30 wt. % SiO2 doped ZrO2). For example, in some embodiments, the metal oxide support is 1 wt. % SiO2 doped Al2O3 or 8-14 wt. % SiO2 doped TiO2.

[0089] In some embodiments, the refractory metal oxide carrier can be doped with one or more other basic metal oxide materials, such as lanthanum, barium, praseodymium, neodymium, samarium, strontium, calcium, magnesium, niobium, hafnium, gadolinium, terbium, dysprosium, erbium, ytterbium, tin, zinc or a combination thereof. In some embodiments, the metal oxide dopant can be selected from lanthanum oxide, barium oxide, strontium oxide, calcium oxide, magnesium oxide and a combination thereof. In some embodiments, the metal oxide dopant is present in an amount of about 1 to about 20 weight % based on the gross weight of the oxidation catalyst composition. Without wishing to be bound by theory, the dopant oxide material can be used to improve the high temperature stability of the refractory metal oxide carrier or be used as an adsorbent for acidic gases such as NO2, SO2 and / or SO3.

[0090] For example, the dopant metal oxide may be introduced using an incipient wetness impregnation technique or by using colloidal mixed oxide particles. In some embodiments, the dopant metal oxide is selected from colloidal barium oxide-alumina, barium oxide-zirconia, barium oxide-titania, zirconium oxide-alumina, barium oxide-zirconia-alumina, lanthanum oxide-zirconia, mixtures thereof, and the like. In some embodiments, the refractory metal oxide or refractory mixed metal oxide in the oxidation catalyst composition is selected from alumina, zirconium oxide, silica, titania, ceria, and mixtures thereof, such as, for example, bulk ceria, manganese oxide, zirconium oxide-alumina, ceria-zirconia, ceria-alumina, lanthanum oxide-alumina, barium oxide-alumina, silica, silica-alumina, and combinations thereof. These refractory metal oxides may be further doped with base metal oxides, such as barium oxide-alumina, barium oxide-zirconia, barium oxide-titania, zirconium oxide-alumina, barium oxide-zirconia-alumina, lanthanum oxide-zirconia, and the like. In some embodiments, the oxidation catalyst composition may include ceria, alumina, and zirconia or doped combinations thereof.

[0091] The oxidation catalyst composition may include any of the refractory metal oxides described above in any amount. For example, based on the total dry weight of the oxidation catalyst composition, the refractory metal oxide may be present in the oxidation catalyst composition in an amount of about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt % or about 35 wt % to about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %. The oxidation catalyst composition may, for example, include about 10 wt % to about 99 wt % of aluminum oxide, about 15 wt % to about 95 wt % of aluminum oxide or about 20 wt % to about 85 wt % of aluminum oxide.

[0092] The PGM component can be dispersed on the refractory metal oxide support, for example by dispersing a soluble precursor (e.g., palladium nitrate) thereon. Alternatively, as opposed to being dispersed on the support, the PGM component can be provided in the composition in particulate form, such as in the form of fine particles as small as 1 to 15 nanometers or less in diameter.

[0093] In some embodiments, the oxidation catalyst composition may further include one or more hydrocarbon storage components for adsorbing hydrocarbons (HC). Any known HC storage material can be used, for example, a microporous material such as a zeolite or a zeolite-like material. In some embodiments, the hydrocarbon storage material is a zeolite. The zeolite can be a natural or synthetic zeolite, such as faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, ZSM-5 zeolite, offretite, beta zeolite, or a mixture thereof. In some embodiments, the zeolite adsorbent material has a high silica to alumina ratio, such as, for example, a silica to alumina molar ratio of at least about 25: 1 or at least about 50: 1. In some embodiments, the molar ratio of silica to alumina is from about 25: 1 to about 1000: 1, from about 50: 1 to about 500: 1, or from about 25: 1 to about 300: 1. Preferred zeolites include ZSM-5 zeolite, Y zeolite, and beta zeolite. Particularly preferred adsorbents may include beta zeolite of the type disclosed in U.S. Patent No. 6,171,556, which is incorporated herein by reference in its entirety. When present, the zeolite or other HC storage component is typically present at about 0.05 g / in 3 About 1g / in 3 Amount used.

[0094] In some embodiments, the catalytic article described herein includes a first oxidation catalyst composition that coats at least a portion of each passage of the first oxidation zone of the substrate. In some embodiments, the first oxidation catalyst composition is configured to provide relatively high oxidation activity. In some embodiments, the first oxidation catalyst composition may include at least one platinum group metal (PGM) component and a first support material that supports the at least one PGM component. In some embodiments, the first oxidation catalyst composition comprises platinum. In some embodiments, the first oxidation catalyst composition may comprise platinum and palladium. In some embodiments, the weight ratio of Pt:Pd in ​​the first oxidation catalyst composition is about 1:0 to about 1:1, for example, for example, about 4:1 to about 2:1. In some embodiments, the total amount of PGM in the first oxidation catalyst composition is about 0.5 to about 200 g / ft 3 , such as, for example, about 5-150 g / ft 3 , or about 10-100g / ft 3 .

[0095] In some embodiments, the catalytic article described herein further comprises a second oxidation catalyst composition that coats at least a portion of each passage of the second oxidation zone of the substrate. In some embodiments, the second oxidation catalyst composition is configured to provide an oxidation activity lower than that of the first oxidation catalyst composition, so that the second oxidation zone of the substrate provides an oxidation activity lower than that of the first oxidation zone of the substrate. In some embodiments, the second catalyst composition comprises at least one platinum group metal (PGM) component and a second carrier material, and the at least one PGM component is loaded on the second carrier material. In some embodiments, the second oxidation catalyst composition comprises platinum and palladium. In some embodiments, the second oxidation catalyst composition is substantially free of platinum. In some embodiments, the weight ratio of Pt:Pd in ​​the second catalyst composition ranges from about 0:1 to about 4:1, for example, for example, from about 0:1 to about 1:1, or from about 0:1 to about 1:4. In some embodiments, the total amount of PGM in the second oxidation catalyst composition is from about 0.5 to about 200 g / ft 3 , such as, for example, about 5-150 g / ft 3 , or about 10-60g / ft 3 In some embodiments, the weight is expressed in g / ft 3 The amount of platinum in the measured first oxidation catalyst composition is greater than the amount of platinum in the second oxidation catalyst composition. In some embodiments, the weight ratio of Pt:Pd in ​​the first oxidation catalyst composition is greater than the weight ratio of Pt:Pd in ​​the second oxidation catalyst composition.

[0096] In some embodiments, preparing the oxidation catalyst composition includes impregnating a porous support (e.g., a refractory oxide support material in particulate form, such as, for example, particulate alumina) with a PGM or base metal solution. Multiple metal components (e.g., platinum and palladium) can be impregnated simultaneously or separately, and can be impregnated on the same support particles or separate support particles using an incipient wetness technique. The support particles are typically dried enough to absorb substantially all of the solution to form a wet solid. An aqueous solution of a water-soluble compound or complex of the metal component is typically used, such as palladium nitrate or platinum nitrate, tetraammine palladium nitrate or platinum nitrate, tetraammine palladium acetate or platinum acetate, copper (II) nitrate, manganese (II) nitrate, and ammonium cerium nitrate. In certain embodiments, colloidal platinum can be used in embodiments of the catalyst composition described herein. After treating the support particles with the metal solution, the particles are dried, such as by heat treating the particles at an elevated temperature (e.g., 100-150° C.) for a period of time (e.g., 1-3 hours), and then calcined to convert the metal component to a more catalytically active form. An exemplary calcination process involves heat treatment in air at a temperature of about 400-550°C for 1-3 hours. The above process can be repeated as needed to achieve the desired impregnation level. The resulting material can be stored as a dry powder or in slurry form.

[0097] Fig.10 An exemplary catalyst support 910 coated according to the methods described herein is depicted. Support 910 includes a plurality of oxidized regions or segments that can have any shape or size. In some embodiments, a first oxidized region includes a circular central region and a second region includes an annular outer region concentric with the first region; however, the regions are not limited to circular shapes or concentric first central region and outer annular second region, such as Fig.10 Generally shown. In addition, in some embodiments, the carrier 910 may include a front zone and a rear zone, such as a front radial zone 902, a front peripheral zone 904, and a rear zone 906. In addition, in some embodiments, a zone may have a pie-shaped wedge or other irregular shape, such as accommodated by a correspondingly designed cover assembly. The shape or configuration of the subsets of channels defining different zones is not meant to be limited. For example, the zones can be configured as chords, semicircles, or other shapes known in the art. The level of oxidation activity in a given zone and the number of passages in a first zone compared to a second zone are factors that affect the overall oxidation activity of the catalytic article.

[0098] In some embodiments, the first region may include about 10-70%, or about 30-60%, or about 25-40% of the plurality of passages in the substrate. In some embodiments, the second region may include about 30-90, or about 40-70, or about 60-75% of the plurality of passages in the substrate. In some embodiments, the ratio of the number of passages in the first region to the number of passages in the second region may be in the range of about 10:90 to about 90:10, or about 20:80 to about 80:20, or about 30:70 to about 70:30. In some embodiments, the ratio of the surface area of ​​the catalyst support coated with the catalyst composition in the first region to the surface area of ​​the substrate coated with the catalyst composition in the second region may be in the range of about 10:90 to about 90:10, or about 20:80 to about 80:20, or about 30:70 to about 70:30. The ratio of the substrate defined by each different oxidation region may affect the NO2 / NO ratio of the gas leaving the catalytic article. x ratio.

[0099] At least a portion of each passageway of a subset of passageways in each region may be coated with a catalyst composition. Different catalyst compositions may be used to coat each region of a catalyst carrier. In some embodiments, the same catalyst composition may be applied as a catalyst coating to more than one region of a catalyst carrier. In some embodiments, the entire axial length of each passageway, i.e., from the inlet end to the outlet end of the catalyst carrier, may be coated with a catalyst composition. In some embodiments, only a portion of the axial length of each passageway may be coated with a catalyst composition. In some embodiments, the axial length of each passageway may be coated with two or more catalyst compositions in a transverse partition. In some embodiments, one or more regions may not have a catalyst coating and / or may not have a catalyst coating based on a PGM.

[0100] In some embodiments of the present disclosure, the first oxidation catalyst composition coats at least a portion of each passage of the first region of the substrate. In some embodiments, the first catalyst composition is a high oxidation catalyst composition, which means that the exhaust gas in contact with the first catalyst composition undergoes high levels of oxidation of hydrocarbons and carbon monoxide present in the inlet gas flow. In some embodiments, the first catalyst composition can be positioned as the only PGM-containing catalyst layer in each passage in the first subset of channels or a partitioned portion thereof defining the first oxidation region. In some embodiments, the first catalyst composition can be positioned as a top, bottom, or middle PGM-containing catalyst layer in each passage in the first subset of channels or a partitioned portion thereof defining the first oxidation region. The first catalyst composition is positioned so that the exhaust gas on the inlet side of the substrate flowing into the first oxidation region contacts the first catalyst composition.

[0101] In some embodiments, the second oxidation catalyst composition coats at least a portion of each passage of the second region of the substrate. In some embodiments, the second catalyst composition is a low oxidation catalyst composition in terms of oxidation activity compared to the first oxidation catalyst composition. In some embodiments, the second catalyst composition can be positioned in the second oxidation region as the only PGM-containing catalyst layer, in each passage in the second subset of channels or a partitioned portion thereof defining the second oxidation region. In some embodiments, the second catalyst composition can be positioned as a top, bottom, or middle PGM-containing catalyst layer in each passage in the second subset of channels or a partitioned portion thereof defining the second oxidation region. The second catalyst composition is positioned so that the exhaust gas flowing into the inlet side of the substrate in the second oxidation region contacts the second catalyst composition.

[0102] In some embodiments of the present disclosure, the total weight ratio of Pt:Pd in ​​the first oxidized region (i.e., the highly oxidized region) is about 1:0 to about 1:1, such as, for example, about 4:1 to about 2:1. The total amount of PGM in the first oxidized region may be about 0.5 ft 3 About 200g / ft 3 , about 5-150g / ft 3 or about 10-100g / ft 3 The total weight ratio of Pt:Pd in ​​the second oxidation region (ie, low oxidation region) may be about 0:1 to about 1:0, or about 0:1 to about 4:1. The total amount of PGM in the second oxidation region may be about 0.5 ft 3 About 200g / ft 3 , about 5-150g / ft 3 or about 10-100g / ft 3 The overall weight ratios and total amounts are based on the total dry weight of PGM in each zone, regardless of whether a single catalyst composition or multiple catalyst compositions are applied to the passages of each zone.

[0103] Figure 2 Shows NO2:NO at the DOC outlet X Ratio, from engine testing of DOCs with and without radially partitioned oxidation zones. For a conventional DOC design without radial coatings (“on-engine reference”), NO2:NO X The ratio lights off rapidly in the temperature range of 200°C to 300°C and then reaches a thermodynamic limit in the temperature range of 300°C to 400°C. For radial coating designs (“on-engine HGA2”) according to some embodiments of the present disclosure, NO2:NO XThe ratio increases gradually in the temperature range between 200°C and 300°C without a steep rise curve and stabilizes in the temperature range between 300°C and 400°C.

[0104] In some embodiments, the catalytic article prepared according to the present disclosure can be provided in an exhaust gas treatment system, such as an exhaust gas treatment system for treating an exhaust gas stream from a diesel engine. In some embodiments, the exhaust gas treatment system can further include one or more catalysts selected from a selective catalytic reduction (SCR) catalyst (e.g., a zeolite-based SCR catalyst), a soot filter, an ammonia oxidation (AMO) catalyst, a catalytic reduction ... X ) catalyst, lean NO X Additional catalytic products of trapping agents (LNT) and combinations thereof.

[0105] Exemplary embodiments:

[0106] Without limitation, some embodiments of the present disclosure include:

[0107] Embodiment 1. A method for coating a catalyst support, the method comprising the following steps:

[0108] The catalyst slurry is provided via a tray comprising:

[0109] a reservoir configured to receive the slurry;

[0110] a sealing cover configured to receive the catalyst support; and

[0111] a plurality of spring-loaded levers configured to couple the cover to the tray;

[0112] introducing the catalyst carrier into the sealing cover;

[0113] introducing the open input end of the catalyst support into the catalyst slurry;

[0114] Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier;

[0115] removing the catalyst support from the catalyst slurry;

[0116] rotating the catalyst support relative to the disk; and

[0117] The catalyst slurry in the catalyst carrier is introduced to the open output end of the catalyst carrier.

[0118] Embodiment 2. A method for coating a catalyst support, the method comprising the following steps:

[0119] providing a catalyst slurry via a slurry pan;

[0120] coupling a sealing cover to the slurry pan via a plurality of spring-loaded rods, wherein the sealing cover is configured to receive the catalyst support and seal at least a portion thereof;

[0121] introducing the catalyst carrier into the sealing cover;

[0122] introducing the open input end of the catalyst support into the catalyst slurry;

[0123] Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier;

[0124] removing the catalyst support from the catalyst slurry;

[0125] rotating the catalyst support relative to the disk; and

[0126] The catalyst slurry in the catalyst carrier is introduced to the open output end of the catalyst carrier.

[0127] Embodiment 3. A method for coating a catalyst support, the method comprising the following steps:

[0128] coupling a sealing cap to a clamping mechanism configured to engage the catalyst carrier, wherein the sealing cap is configured to receive the catalyst carrier and seal at least a portion thereof and includes a plurality of spring-loaded rods configured to engage a slurry pan;

[0129] introducing the catalyst carrier into the sealing cover;

[0130] introducing the open input end of the catalyst carrier into the catalyst slurry in the slurry tray;

[0131] Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier;

[0132] removing the catalyst support from the catalyst slurry;

[0133] rotating the catalyst support relative to the disk; and

[0134] The catalyst slurry in the catalyst carrier is introduced to the open output end of the catalyst carrier.

[0135] Embodiment 4. A method according to any one of Embodiments 1-3, wherein the catalyst support is rotated about 180 degrees relative to the disk.

[0136] Embodiment 5. A method according to any one of Embodiments 1-4, wherein the cover includes an impermeable sealing surface configured to seal at least one of the front face or circumferential edge of the input end of the catalyst carrier to prevent contact between the outer surface of the catalyst carrier and the catalyst slurry.

[0137] Embodiment 6. The method of embodiment 5, wherein the cover is further configured to prevent axial flow of the slurry through a radial portion of the front face.

[0138] Embodiment 7. A method according to Embodiment 6, wherein the cover is configured to prevent axial flow of the catalyst slurry through an outer annular region of the front face.

[0139] Embodiment 8. A method according to Embodiment 5, wherein the orientation of the cover is adjustable relative to the tray.

[0140] Embodiment 9. A method according to any one of Embodiments 1-8, wherein the step of introducing the catalyst carrier into the cover includes transporting the catalyst carrier through a clamping mechanism, which is configured to press the catalyst carrier into the cover to form a seal therebetween.

[0141] Embodiment 10. The method of any one of Embodiments 1-9, wherein the step of introducing the open input end of the catalyst carrier into the catalyst slurry includes compressing the spring-loaded rod to provide a sealing force against the catalyst carrier.

[0142] Embodiment 11. A method according to any one of Embodiments 1-10, wherein the step of directing a certain amount of catalyst slurry through the input end includes applying a pressure difference between the input end of the catalyst support and the output end of the catalyst support.

[0143] Embodiment 12. The method of any one of Embodiments 1-11, wherein the step of removing the catalyst support from the catalyst slurry comprises separating the catalyst support from the cover.

[0144] Embodiment 13. A method according to any one of Embodiments 1-12, wherein the step of rotating the catalyst carrier is performed by a clamping mechanism, which is fixed to the catalyst carrier by a rotating mechanism.

[0145] Embodiment 14. A method according to any one of Embodiments 1-13, wherein the step of directing the catalyst slurry within the catalyst carrier to the open output end of the catalyst carrier includes directing an air flow to the open input end.

[0146] Embodiment 15. The method according to any one of embodiments 1-14, further comprising the following steps:

[0147] introducing the catalyst support into a second sealing cap, the second sealing cap being configured to seal different portions of the catalyst support;

[0148] introducing the open output end or the open input end of the catalyst support into the second catalyst slurry;

[0149] directing an amount of a second catalyst slurry into a second interior portion of the catalyst support;

[0150] removing the catalyst support from the second catalyst slurry;

[0151] rotating the catalyst support relative to the disk; and

[0152] The catalyst slurry in the catalyst carrier is introduced toward the open end of the catalyst carrier.

[0153] Embodiment 16. An apparatus for enabling radial coating of a catalyst support, the apparatus having a coating station including a slurry disk and a clamping mechanism, the apparatus comprising:

[0154] a sealing cover configured to releasably hold the catalyst support and seal the front face or circumference of the input end of the catalyst support to prevent contact between the outer surface of the catalyst support and the catalyst slurry; and

[0155] A plurality of spring loaded rods are configured to couple the sealing cover to the slurry pan.

[0156] Embodiment 17. An apparatus for enabling radial coating of a catalyst support, the apparatus having a coating station including a slurry disk and a clamping mechanism, the apparatus comprising:

[0157] a sealing cover configured to seal a front face or a circumference of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry; and

[0158] A plurality of spring loaded rods are configured to engage the slurry pan, wherein the sealing cover is configured to couple to a clamping mechanism configured to releasably retain the catalyst carrier.

[0159] Embodiment 18. The apparatus of Embodiment 16 or 17, wherein the sealing cover is configured to prevent axial flow of the slurry through a radial portion of the front face of the catalyst support.

[0160] Embodiment 19. An apparatus according to Embodiment 18, wherein the sealing cover is configured to prevent the catalyst slurry from flowing axially through the outer annular region of the front face.

[0161] Embodiment 20. The apparatus according to Embodiment 16 or 17 further comprises a rotating mechanism coupled to the clamping mechanism and configured to rotate the catalyst carrier 180 degrees.

[0162] Embodiment 21. The device according to Embodiment 20 further includes an actuator connected to the rotating mechanism and configured to drive the rotation of the catalyst carrier.

[0163] Embodiment 22. A coating station for applying a catalyst composition to at least a portion of an interior surface region of a catalyst support, the station comprising:

[0164] a platform including a slurry pan in which a catalyst slurry may be located;

[0165] a clamping mechanism configured to releasably grasp the catalyst support and provide relative movement thereof with respect to the slurry pan;

[0166] a sealing cover configured to seal a front face or a circumference of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry; and

[0167] A plurality of spring loaded rods are configured to engage the slurry pan.

[0168] Embodiment 23. A coating station according to Embodiment 22, wherein the sealing cover is further configured to prevent contact with a portion of the front face and any axial channels extending therefrom.

[0169] Embodiment 24. The coating station of Embodiment 22, wherein the sealing cover is configured to be releasably coupled to the clamping mechanism.

[0170] Embodiment 25. The coating station of Embodiment 22 further comprises a second sealing cover also configured to be releasably coupled to the clamping mechanism, wherein the sealing cover is interchangeable to provide different sealing configurations to the surface of the catalyst support.

[0171] Embodiment 26. The coating station of Embodiment 22, wherein the plurality of spring-loaded rods are configured to couple the sealing cover to the slurry pan.

[0172] Embodiment 27. The coating station of Embodiment 22, wherein the clamping mechanism is further configured to provide vertical movement to the catalyst support so as to immerse the open end of the catalyst support into the slurry pan and also remove it therefrom.

[0173] Embodiment 28. The coating station of Embodiment 22 further comprises a rotation mechanism coupled to the clamping mechanism and configured to rotate the catalyst carrier 180 degrees.

[0174] Embodiment 29. The coating station of Embodiment 28 further comprises an actuator connected to the rotation mechanism and configured to drive rotation of the catalyst support.

[0175] Embodiment 30. The coating station according to Embodiment 22 further includes a movable cover configured to sealingly contact at least one of the upper open end of the catalyst carrier, the upper surface of the clamping mechanism, or the upper surface of the platform to apply pressure to the volume enclosed by the cover.

[0176] Embodiment 31. The coating station according to embodiment 22 further comprises:

[0177] a second platform including a second slurry tray in which a second catalyst slurry may be located;

[0178] A second sealing cap is configured to seal different portions of the front face of the input end of the catalyst support to prevent contact between the second catalyst slurry and both the outer surface of the catalyst support and portions of the front face and any axial passages extending therefrom.

[0179] Embodiment 32. The apparatus of Embodiment 16 or 17, wherein the coating station is a conventional coating station.

[0180] Having now described some illustrative embodiments of the present invention, it should be clear to those skilled in the art that the foregoing is merely illustrative and not restrictive, and is presented only by way of example. Many modifications and other embodiments are within the scope of those of ordinary skill in the art and are considered to fall within the scope of the present disclosure. In particular, although many of the examples presented here relate to specific combinations of method actions or system elements, it should be understood that those actions and those elements can be combined in other ways to achieve the same goal.

[0181] In addition, it should be understood by those skilled in the art that the parameters and configurations described herein are exemplary, and that the actual parameters and / or configurations will depend on the specific application in which the systems and techniques of the present invention are used. Those skilled in the art should also recognize or be able to determine the equivalents of specific embodiments of the present invention using only routine experimentation. Therefore, it should be understood that the embodiments described herein are presented only as examples and within the scope of any appended claims and their equivalents; the present invention may be implemented in a manner other than that specifically described.

[0182] The words and terms used herein are for descriptive purposes and should not be considered as limiting. As used herein, the term "plurality" refers to two or more items or components. The terms "comprise", "include", "carry", "have", "contain" and "involve", whether in a written specification or claims, are open terms, i.e., meaning "including but not limited to." Therefore, the use of such terms is intended to cover the items listed thereafter, their equivalents, and additional items. For any claim, only the transition phrases "consisting of..." and "consisting essentially of..." are closed or semi-closed transition phrases, respectively. The use of sequential terms such as "first", "second", "third" and the like in the claims to modify the claim elements themselves does not imply any priority, priority or order of one claim element relative to another or the temporal order of the actions of the execution method, but is only used as a label to distinguish a claim element with a specific name from another element with the same name (but using ordinal terms) to distinguish the claim elements.

Claims

1. A method for coating a catalyst carrier, the method comprising the following steps: The catalyst slurry is provided via a tray comprising: a reservoir configured to receive the slurry; a sealing cover configured to receive the catalyst support; and a plurality of spring-loaded levers configured to couple the cover to the tray; introducing the catalyst carrier into the sealing cover; introducing the open input end of the catalyst support into the catalyst slurry, which includes compressing the spring loaded rod to provide a sealing force against the catalyst support; Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier; removing the catalyst support from the catalyst slurry; rotating the catalyst support relative to the disk; and directing the catalyst slurry in the catalyst carrier to the open output end of the catalyst carrier, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

2. A method for coating a catalyst carrier, the method comprising the following steps: providing a catalyst slurry through a slurry pan; coupling a sealing cover to the slurry pan via a plurality of spring-loaded rods, wherein the sealing cover is configured to receive the catalyst support and seal at least a portion thereof; introducing the catalyst carrier into the sealing cover; introducing the open input end of the catalyst support into the catalyst slurry, which includes compressing the spring loaded rod to provide a sealing force against the catalyst support; Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier; removing the catalyst support from the catalyst slurry; rotating the catalyst support relative to the disk; and directing the catalyst slurry in the catalyst carrier to the open output end of the catalyst carrier, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

3. A method for coating a catalyst carrier, the method comprising the following steps: coupling a sealing cap to a clamping mechanism configured to engage the catalyst carrier, wherein the sealing cap is configured to receive the catalyst carrier and seal at least a portion thereof and includes a plurality of spring-loaded rods configured to engage a slurry pan; introducing the catalyst carrier into the sealing cover; introducing the open input end of the catalyst support into the catalyst slurry in the slurry tray, which includes compressing the spring loaded rod to provide a sealing force against the catalyst support; Directing a certain amount of the catalyst slurry through the input end and into the interior of the catalyst carrier; removing the catalyst support from the catalyst slurry; rotating the catalyst support relative to the disk; and directing the catalyst slurry in the catalyst carrier to the open output end of the catalyst carrier, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

4. A method according to any one of the preceding claims, wherein the catalyst support is rotated about 180 degrees relative to the disc.

5. The method of any one of claims 1-4, wherein the cover is configured to prevent axial flow of the catalyst slurry through an outer annular region of the front face.

6. The method of any one of claims 1-4, wherein the orientation of the cover relative to the tray is adjustable.

7. A method according to any one of the preceding claims, wherein the step of introducing the catalyst support into the cover comprises transporting the catalyst support by a clamping mechanism configured to press the catalyst support into the cover to form a seal therebetween.

8. A method according to any one of the preceding claims, wherein the step of directing a quantity of catalyst slurry through an input end comprises applying a pressure differential between an input end of the catalyst support and an output end of the catalyst support.

9. A method according to any one of the preceding claims, wherein the step of removing the catalyst support from the catalyst slurry comprises separating the catalyst support from the cover.

10. The method according to any of the preceding claims, wherein the step of rotating the catalyst support is performed by a clamping mechanism which is fixed to the catalyst support by a rotating mechanism.

11. A method according to any one of the preceding claims, wherein the step of directing the catalyst slurry within the catalyst support towards an open output end of the catalyst support comprises directing a flow of air towards the open input end.

12. The method according to any one of the preceding claims, further comprising the steps of: introducing the catalyst support into a second sealing cap, the second sealing cap being configured to seal different portions of the catalyst support; introducing the open output end or the open input end of the catalyst support into the second catalyst slurry; directing an amount of a second catalyst slurry into a second interior portion of the catalyst support; removing the catalyst support from the second catalyst slurry; rotating the catalyst support relative to the disk; and The catalyst slurry in the catalyst carrier is introduced toward the open end of the catalyst carrier.

13. An apparatus for enabling radial coating of a catalyst support, the apparatus having a coating station comprising a slurry disc and a clamping mechanism, the apparatus comprising: a sealing cap configured to releasably hold the catalyst support and seal the front face or circumference of the input end of the catalyst support to prevent contact between the outer surface of the catalyst support and the catalyst slurry; and a plurality of spring loaded rods configured to couple the sealing cover to the slurry pan and to be compressed to provide a sealing force against the catalyst support, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

14. An apparatus for enabling radial coating of a catalyst support, the apparatus having a coating station comprising a slurry disc and a clamping mechanism, the apparatus comprising: a sealing cover configured to seal the front face or circumference of the input end of the catalyst support to prevent contact between the outer surface of the catalyst support and the catalyst slurry; and a plurality of spring loaded rods configured to engage the slurry pan and be compressed to provide a sealing force against the catalyst carrier, wherein the sealing cap is configured to couple to a clamping mechanism configured to releasably retain the catalyst carrier, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

15. The apparatus of claim 13 or 14, wherein the sealing cover is configured to prevent axial flow of the catalyst slurry through an outer annular region of the front face.

16. The apparatus of claim 13 or 14, further comprising a rotation mechanism coupled to the clamping mechanism and configured to rotate the catalyst carrier 180 degrees.

17. The apparatus of claim 16, further comprising an actuator connected to the rotating mechanism and configured to drive rotation of the catalyst carrier.

18. A coating station for applying a catalyst composition to at least a portion of an interior surface region of a catalyst support, the station comprising: a platform including a slurry pan in which a catalyst slurry may be located; a clamping mechanism configured to releasably grasp the catalyst support and provide relative movement thereof with respect to the slurry pan; a sealing cover configured to seal the front face or circumference of the input end of the catalyst support to prevent contact between the outer surface of the catalyst support and the catalyst slurry; and a plurality of spring loaded rods configured to couple the sealing cover to or engage the slurry pan and configured to be compressed to provide a sealing force against the catalyst carrier, The cover includes an impermeable sealing surface configured to seal at least one of a front face or a circumferential edge of an input end of the catalyst support to prevent contact between an outer surface of the catalyst support and the catalyst slurry, The cover is also configured to prevent axial flow of the slurry through a radial portion of the front face.

19. The coating station of claim 18, wherein the sealing cover is further configured to prevent contact with a portion of the front face and any axial passage extending therefrom.

20. The coating station of claim 18, wherein the sealing cover is configured to releasably couple to the clamping mechanism.

21. The coating station of claim 18, further comprising a second sealing cover also configured to releasably couple to the clamping mechanism, wherein the sealing cover is interchangeable to provide different sealing configurations to the surface of the catalyst support.

22. The coating station of claim 18, wherein the clamping mechanism is further configured to provide vertical movement to the catalyst support so as to immerse the open end of the catalyst support into and also remove it from the slurry pan.

23. The coating station of claim 18, further comprising a rotation mechanism coupled to the clamping mechanism and configured to rotate the catalyst support 180 degrees.

24. The coating station of claim 23, further comprising an actuator connected to the rotation mechanism and configured to drive rotation of the catalyst support.

25. The coating station of claim 18, further comprising a movable cover configured to sealingly contact at least one of an upper open end of the catalyst carrier, an upper surface of the clamping mechanism, or an upper surface of the platform to apply pressure to a volume enclosed by the cover.

26. The coating station of claim 18, further comprising: a second platform including a second slurry tray in which a second catalyst slurry may be located; A second sealing cap is configured to seal different portions of the front face of the input end of the catalyst support to prevent contact between the second catalyst slurry and both the outer surface of the catalyst support and portions of the front face and any axial passages extending therefrom.

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