Low pressure drop extruded catalyst filter
AssigneeCorning Incorporated
InventorsYanxia Ann Lu, Steven Bolaji Ogunwumi
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Abstract
A batch composition for making a highly porous honeycomb ceramic catalytic filter article, including base inorganic components including a mixture of a nano-zeolite powder, and an inorganic filler, in amounts defined herein; and super additives including: a mixture of at least two pore formers; a binder; and a metal salt, in amounts defined herein. Also disclosed are extruded catalyst filter articles and methods for making the articles.
Claims19
A batch composition for making porous honeycomb ceramic, comprising:
- base inorganic components comprising:
- a nano-zeolite powder in an amount from 20 to 80 weight percent of the base inorganic components, and
- an inorganic filler in an amount from 80 to 20 weight percent of the base inorganic components;
- and
- a mixture of at least two pore formers in an amount from 50 to 100 weight percent in superaddition to the base inorganic components;
- a binder in an amount from 10 to 75 weight percent in superaddition to the base inorganic components;
- and
- a metal salt in an amount from 1 to 10 weight percent in superaddition to the base inorganic components.
A method of making a honeycomb green body comprising:
- extruding the combined ingredients of a batch composition comprising:
- base inorganic components comprising:
- a nano-zeolite powder in an amount from 20 to 80 weight percent of the base inorganic components, and
- an inorganic filler in an amount from 80 to 20 weight percent of the base inorganic components;
- and
- a mixture of at least two pore formers in an amount from 50 to 100 weight percent in superaddition to the base inorganic components;
- a binder in an amount from 10 to 75 weight percent in superaddition to the base inorganic components;
- and
- a metal salt in an amount from 1 to 10 weight percent in superaddition to the base inorganic components to form the honeycomb green body.
An extruded catalyst filter article comprising:
- 15 to 55 wt % nano-zeolite
- 30 to 70 wt % inorganic filler;
- 0.25 to 0.90 wt % Fe2O3;
- and
- 10 to 20 wt % SiO2 from a silica source other than the inorganic filler, and having a porosity (% P or volume %) of 50 to 70%.
A method for engine exhaust gas particulate control comprising:
- passing engine exhaust gas through an extruded catalyst filter article comprising:
- 15 to 55 wt % nano-zeolite;
- 30 to 70 wt % inorganic filler;
- 0.25 to 0.90 wt % Fe2O3;
- and
- 10 to 20 wt % SiO2 from a silica source other than the inorganic filler, and having a porosity (% P or volume %) of 50 to 70%.
Dependencies are inferred from the claim text.