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Diesel oxidation catalysts and particulate filters are recognized as proven solutions for reducing diesel emission levels. However, such systems now operate under extreme and unique conditions in order to meet even more demanding emission regulations. Long term cold holding performance, erosion resistance and high temperature stability are issues that must be addressed to assure a robust design in diesel oxidation catalysts and diesel particulate filters. This paper will describe the application of new concepts for support mat systems and results from internal lab testing. It will describe three different case histories, present the design parameters, and compare results with traditional support mat systems.

A major challenge facing the automotive industry today is substantially lower emissions from internal combustion engines. In the face of the 1990 Clean Air Act passed by the US Government, various approaches are being researched and developed to meet that challenge. A simple solution can result if one has available a high temperature stable catalyst system that can be installed close to the engine exhaust manifold. Such a simple catalyst system has been discovered(1)* and is being developed for commercial use. This system is based on a thermodynamically stable, alpha-alumina monolith onto which are deposited noble metals. These alpha-alumina monoliths do not require a wash-coat. The noble metal loadings are typically equal to or less than those currently employed in commercial automotive catalysts.