Porous catalyst washcoats

摘要

Catalyst washcoats with improved porosity and methods for making the washcoats are provided. The process comprises incorporation of an oil-in-water macroemulsion into the catalyst slurry prior to washcoating the carrier substrate, and calcining the washcoated carrier substrate to remove the oil-in-water macroemulsion. Also provided are catalyst articles comprising the washcoat and methods for abatement of exhaust gas emissions.

主权项

1. A catalyst washcoat composition produced by a process comprising incorporating an oil-in-water macroemulsion into a washcoat slurry comprising at least one catalyst, washcoating a carrier substrate with the slurry incorporating the macroemulsion, and calcining the washcoated carrier substrate, wherein about 30%-100% of oil particles in the macroemulsion are about 15 μm-100 μm in diameter,
wherein the at least one catalyst comprises a platinum group metal, a base metal, an SCR catalyst, a zeolite, or a combination thereof, and wherein the carrier substrate comprises a ceramic monolithic form or a metal substrate in the form of pellets, corrugated sheets, wire mesh, or a monolithic form.