System and method for improved emission control of internal combustion engines using pulsed fuel flow

A power generation system, comprising:

• a diesel engine operative to produce an exhaust stream containing excess O2;
• and
• a fuel processor for generating a reductant in at least a portion of the exhaust stream and configured to be rapidly heated under overall lean conditions while within the exhaust stream by combustion of hydrocarbon fuel in the exhaust stream and configured to be operated to reform at least a portion of hydrocarbon fuel within the exhaust stream under overall rich conditions;
• wherein the fuel processor comprises
• an exhaust stream inlet;
• an exhaust stream outlet;
• a monolith structural support between the inlet and the outlet, the monolith structural support being formed from metal foils having a thickness of 100 microns or less;
• and
• one or more catalytic coatings applied to the monolith structural support, the coatings consisting essentially of substrates and 0.1-20% by weight catalytically active elements;
• wherein the catalytically active elements of the fuel processor as a whole are primarily oxidation catalysts, primarily reforming catalysts, or primarily oxidation and reforming catalysts;
• and
• the substrates are selected from the group consisting of aluminum oxide, silicon oxide, zirconium oxide, and mixtures thereof, optionally containing additives, and optionally stabilized and have a surface area of at least 15 m2/g;
• wherein the fuel processor is effective at a temperature in the range from 500° C. to 700° C. to catalyze reaction of diesel engine fuel with H2O and CO2 to produce H2 and CO.