Low pressure drop extruded catalyst filter

Patent metadata

Field	Value
Publication number	US-9764284-B2
Application number	US-201313863673-A
Country	US
Kind code	B2
Filing date	Apr 16, 2013
Priority date	Feb 26, 2010
Publication date	Sep 19, 2017
Grant date	Sep 19, 2017

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.

First claim

What is claimed is:

1. An extruded and fired honeycomb catalyst filter article comprising:
15 to 55 wt % of a nano-zeolite having a primary particle size of from 10 to 100 nm;
30 to 70 wt % a micron sized inorganic filler;
0.25 to 0.90 wt % Fe 2 O 3 ; and
10 to 20 wt % SiO 2 from a silica source other than the inorganic filler, and the extruded and fired honeycomb catalyst filter article has:
a rounded porosity of 50 to 70 wt %,
a median pore size of from 3 to 8 microns,
the nano-zeolite is on the surface of inorganic filler, and the nano-zeolite on the surface of inorganic filler is dispersed throughout the walls of the filter article and on the surface of the walls of the filter article, and
the catalyst in the extruded and fired honeycomb catalyst filter article is an ion impregnated or metal ion exchanged zeolite.

2. The article of claim 1 wherein the pore size has a narrow distribution measured by d breadth of less than 1.5.

3. The article of claim 1 wherein the walls of the article have a minimum thickness of 8 mils.

4. A method for engine exhaust gas particulate control comprising:
passing engine exhaust gas through an extruded and fired honeycomb catalyst filter article comprising:
15 to 55 wt % of a nano-zeolite having a primary particle size of from 10 to 100 nm;
30 to 70 wt % of a micron sized inorganic filler;
0.25 to 0.90 wt % Fe 2 O 3 ; and
10 to 20 wt % SiO 2 from a silica source other than the inorganic filler, and the extruded and fired catalyst filter article has:
a rounded porosity of 50 to 70 wt %,
a median pore size is from 3 to 8 microns,
the nano-zeolite is on the surface of inorganic filler, and the nano-zeolite on the surface of inorganic filler is dispersed throughout the walls of the filter article and on the surface of the walls of the filter article, and
the catalyst in the extruded and fired honeycomb catalyst filter article is an ion impregnated or metal ion exchanged zeolite.

5. The method of claim 4 wherein the exhaust gas back pressure is less than 5 KPa at 5 g/L soot loading for an article having a 300/8 geometry and 8.35 cfm/in 2 flow rate.

6. The method of claim 4 wherein the NOx reduction is greater than 50%, and the permeability of the article is from 0.8 to 2.0.

Assignees

• Corning Inc

Inventors

• Lu Yanxia Ann
• Ogunwumi Steven Bolaji

Classifications

• B01J37/0018

  Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat) · CPC title

• B01J37/04

  Mixing {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01D2255/9155

  Wall flow filters · CPC title

• B01D2257/404

  Nitrogen oxides other than dinitrogen oxide · CPC title

• B01J29/7215 Primary

  Zeolite Beta · CPC title