US 11,351,502 B2 · Metal foil catalyst for the control of emissions from diesel engines

Abstract

A diesel engine emissions catalyst which may be used to fill a niche between standard oxidation catalyst and diesel particulate filters for control of diesel particulate matter. The catalyst includes a structure (substrate) comprising one or more coated, corrugated micro-expanded metal foil layers. The coated surface may be a high surface area, stabilized, and promoted washcoat layer. The corrugated pattern may include a herringbone-style pattern that, when in use, is oriented in a longitudinal direction of the diesel engine exhaust flow. The micro-expanded metal foil provides small openings or eyes that, as the exhaust flow passes through the catalyst (transverse to the eye opening), particulates in the flow impinge on the surface and becomes trapped in the eyes. The catalyst may be used to treat a locomotive engine exhaust stream and may be used with a selective catalyst reduction system.

Claims15

Dependent claims

A diesel engine emissions catalyst (10) comprising:

a substrate (11) consisting of a plurality of coated, corrugated, micro-expanded metal foil layers (13), each of said layers overlapping an adjacent layer of the plurality to form open flow channels in between, each said layer containing a plurality of eyes (19) with diamond-shaped openings in a range of 0.058 mm to 2.032 mm and arranged in a herringbone pattern;
a coating of each said layer comprising a washcoat layer (23) and a precious metal oxide, the washcoat layer (23) being in a range of 80.5 g/l to 102.5 g/l, including a metal oxide, and having a porous surface area in a range of 100 m2/g to 250 m2/g of the metal oxide, the precious metal being in a range of 0.071 g/l to 1.41 g/l;
and
the open flow channels (27) per unit area of a face of the substrate (11) being in a range of 15 cells/cm2 to 62 cells/cm2.

1 more element

Dependencies are inferred from the claim text.

Metal foil catalyst for the control of emissions from diesel engines

Life of this patent

Metal foil catalyst for the control of emissions from diesel engines

Life of this patent

Abstract

Claims15