A process for preparing a silver-containing catalyst for the oxidation of ethylene to ethylene oxide (EO) including the steps of: providing a support having pores; providing a silver-containing impregnation solution; adding an amount of surfactant to the impregnation solution; contacting the support with the surfactant-containing impregnation solution; and removing at least a portion of the impregnation solution prior to fixing the silver upon the carrier in a manner which preferentially removes impregnation solution not contained in the pores. The use of the surfactant results in improved drainage of the silver impregnation solution from the carrier exteriors during the catalyst synthesis. As a result, the amount of silver-containing impregnation solution necessary for the synthesis of the EO catalyst was reduced by up to 15% without reducing the catalyst performance.

Disclosed herein are catalyst compositions having improved mercury intrusion volume and surface areas and processes for making these compositions. The enhanced compositions disclosed herein contain zirconium, cerium, optionally yttrium, and optionally one or more rare earths other than cerium and yttrium. Further disclosed are processes of producing these compositions involving supercritical drying after addition of mesitylene. The compositions can be used as a catalyst and/or as part of a catalyst system in an automobile exhaust system.

A multilayer supported oxidative coupling of methane (OCM) catalyst composition (support, first single oxide layer, one or more mixed oxide layers, optional second single oxide layer) characterized by formula A.sub.aZ.sub.bE.sub.cD.sub.dO.sub.x/support; A is alkaline earth metal; Z is first rare earth element; E is second rare earth element; D is redox agent/third rare earth element; the first, second, third rare earth element are not the same; a=1.0; b=0.1-10.0; c=0.1-10.0; d=0-10.0; x balances oxidation states; first single oxide layer (Z.sub.b1O.sub.x1, b1=0.1-10.0; x1 balances oxidation states) contacts support and one or more mixed oxide layers; one or more mixed oxide layers (A.sub.a2Z.sub.b2E.sub.c2D.sub.d2O.sub.x2, a2=1.0; b2=0.1-10.0; c2=0.1-10.0; d2=0-10.0; x2 balances oxidation states; A.sub.aZ.sub.bE.sub.cD.sub.dO.sub.x and A.sub.a2Z.sub.b2E.sub.c2D.sub.d2O.sub.x2 are different) contacts first single oxide layer and optionally second single oxide layer, and second single oxide layer (AO), when present, contacts one or more mixed oxide layers and optionally first single oxide layer.

An exhaust gas control apparatus includes a honeycomb substrate and an inlet cell-side catalyst layer. The honeycomb substrate includes a porous partition wall that defines a plurality of cells extending from an inlet-side end face to an outlet-side end face. The cells include an inlet cell and an outlet cell that are adjacent to each other with the partition wall therebetween. The inlet cell is open at its inlet-side end and is sealed at its outlet-side end. The outlet cell is sealed at its inlet-side end and is open at its outlet-side end. The inlet cell-side catalyst layer is provided on a surface on the inlet cell side of the partition wall and extends from an inlet-side end of the partition wall. Porosity of the inlet cell-side catalyst layer is in a specific range.

The invention relates to a method for producing a pellet, in particular for a catalytic convertor and/or static mixer. The method comprises a trimming and/or deforming of at least one layer of metal foam material into a pellet shape.

Provided is a catalyst for oxidative dehydrogenation, a method of preparing the catalyst, and a method of performing oxidative dehydrogenation using the catalyst. The catalyst for oxidative dehydrogenation has improved durability and fillability by including a porous support coated with a metal oxide (AB.sub.2O.sub.4) according to Equation 1:
X wt %+Y wt %=100 wt %,  <Equation 1> wherein X is a content of AB.sub.2O.sub.4 and is 5 or more and less than 30, and Y is a content of the porous support and is more than 70 and 95 or less,
wherein the metal oxide exhibits activity during oxidative dehydrogenation. Therefore, when the catalyst is used in oxidative dehydrogenation of butene, the conversion rate of butene and the selectivity and yield of butadiene may be greatly improved.

A catalyst-coated, plugged honeycomb body having a honeycomb structure with a matrix of porous walls forming a plurality of channels, at least some of the plurality of channels being plugged to form inlet channels and outlet channels. At least some of the porous walls are filtration walls and at least some of the porous walls are non-filtration walls. A catalyst is preferentially disposed on the non-filtration walls, wherein the catalyst being preferentially disposed comprises CR<0.2 wherein CR is a coating ratio defined as an average percent loading of a washcoat containing the catalyst on and within the filtration walls divided by an average percent loading of the washcoat containing the catalyst on and within the non-filtration walls. Methods and apparatus configured to preferentially apply a catalyst-containing slurry to the non-filtration walls are provided, as are other aspects.

Catalyst particles and methods for making same are disclosed herein. The catalyst particles can include a ceramic support containing silica and alumina. The ceramic support can have a macropore concentration of about 15% to about 45%, a mesopore concentration of about 20% to 50%, and a micropore concentration of about 8% to about 30% based on the total pore volume of the ceramic support. The ceramic support can also have a surface area of about 0.5 m.sup.2/g to about 50 m.sup.2/g. The catalyst particles can have a long term permeability at 7,500 psi of at least about 10 D in accordance with ISO 13503-5.

A particulate filter disclosed herein includes a wall-flow structure substrate 10 and a wash coat layer 20 held inside a partition 16 of the substrate 10. The wash coat layer 20 includes an inlet layer 22 formed to have predetermined length L.sub.A and thickness T.sub.A from near an end thereof on an exhaust gas inflow side X1, and an outlet layer 24 formed to have predetermined length L.sub.B and thickness T.sub.B from near an end thereof on an exhaust gas outflow side X2. The inlet layer 22 and the outlet layer 24 partially overlap each other. In the particulate filter disclosed herein, the inlet layer 22 contains a precious metal catalyst, while the outlet layer 24 contains substantially no precious metal catalyst. The length L.sub.A of the inlet layer is 50% or more and 75% or less of a total length L of the partition 16. Thus, the particulate filter is capable of achieving both PM collection performance and pressure-drop reduction performance at high levels.

A method of coating a substrate with a foam is described. The method comprises: (a) introducing a foam into a substrate comprising a plurality of channels through open ends of the channels at a first end of the substrate; and (b) applying at least one of (i) a vacuum to open ends of the channels at a second end of the substrate and (ii) a pressure to the open ends of the channels at the first end of the substrate; wherein the foam comprises a particulate material, and wherein the foam is particle stabilized.