CN107636271B - 用于除去来自发动机废气的颗粒物质和有害化合物的方法、多功能过滤器和*** - Google Patents

用于除去来自发动机废气的颗粒物质和有害化合物的方法、多功能过滤器和*** Download PDF

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CN107636271B
CN107636271B CN201680026905.3A CN201680026905A CN107636271B CN 107636271 B CN107636271 B CN 107636271B CN 201680026905 A CN201680026905 A CN 201680026905A CN 107636271 B CN107636271 B CN 107636271B
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P·L·T·加里伊斯森
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Yuu Mikkel GmbH & Co
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Abstract

本发明涉及一种用于通过以下顺序步骤而除去来自压燃式发动机的废气的包含氮氧化物、挥发性有机化合物和一氧化碳的有害化合物以及颗粒物质的多功能壁流式过滤器和具有相同功能的一种***：(a)将一定量的尿素水溶液液滴形式的SCR还原剂加入到废气中；(b)将与所述尿素水溶液液滴混合的废气引入至壁流式过滤器的入口通道，并在氧化催化剂的存在下将挥发性有机化合物和一氧化碳氧化成二氧化碳和水以及将一氧化氮氧化成二氧化氮，所述氧化催化剂布置在位于壁流式过滤器入口侧的可渗透的多孔分隔壁上，所述氧化催化剂是活性的；(c)随后将来自步骤(b)的废气中的尿素水溶液液滴蒸发并分解成氨；(d)将含有氨的废气通过壁流式过滤器的可渗透的多孔分隔壁送至过滤器的出口通道，并在面向过滤器入口通道的可渗透的多孔分隔壁的表面上捕获所述颗粒物质；(e)通过与废气中所含的二氧化氮反应，连续除去所捕获的颗粒物质；和(f)随后在布置在气体可渗透的多孔隔壁内和/或面向壁流式颗粒过滤器的出口通道的壁面上的SCR活性催化剂的存在下，通过与氨反应而从废气中除去剩余的二氧化氮。

Description

用于除去来自发动机废气的颗粒物质和有害化合物的方法、 多功能过滤器和***
技术领域
本发明涉及一种用于减少来自稀燃内压燃式发动机的废气中存在的氮氧化物(NOx)和颗粒物质的排放的方法、多功能过滤器和***。
背景技术
具有稀燃发动机的现代汽车的废气***通常配备有氧化催化剂、颗粒过滤器和用于在还原剂存在下选择性还原NOx(SCR)的催化剂。
在有机化合物和一氧化碳的氧化中呈活性的氧化催化剂和SCR催化剂是本领域已知的并且已在许多公开出版物中公开。
在柴油废气清洁***中通常使用的颗粒过滤器(DPF)是具有多个入口和出口通道的壁流式过滤器。入口通道在其出口侧关闭，出口通道在其入口侧封闭，使得流入过滤器的气体强制通过限定通道的多孔壁，由此将颗粒物质从气体中滤出。
为了满足未来关于柴油客车和卡车的排放规定，需要使用柴油颗粒过滤技术和NOx还原催化剂两者。由于其具有燃料优化和NOx去除效率高的潜力，SCR通常是用于NOx还原的优选技术。DOC(柴油氧化催化剂)、DPF(柴油颗粒过滤器)和SCR(选择性催化还原)催化剂在废气***中顺序组合，但这种顺序***配置有几个缺点：1)体积大；2)当DPF置于SCR前面时，在冷启动期间SCR催化剂的温度不足；和3)如果将SCR置于DPF上游，则条件不利于被动式过滤器的再生(较低的NO2和温度)。
积聚在过滤器入口侧的过滤壁上的颗粒物质必须通过主动再生或通过非催化的被动再生来去除，在主动再生中，颗粒物质通过在升高的废气温度下与和废气中的氧气相组合的负载在过滤壁上的氧化催化剂接触而被催化燃烧掉。
通过碳与在上游DOC上形成的NO2在250℃-450℃下的氧化进行被动的过滤器再生，如以下反应所示：
C+NO2→CO+NO (1)
C+2NO2→CO2+2NO (2)
并且由于颗粒物质通常含有作为SOF(可溶性有机馏分)的烃，这里用“CH”代表烃：
“CH”+2.5NO2→CO2+2.5NO+0.5H2O (3)
快速SCR反应
4NH3+2NO+2NO2→4N2+6H2O (4)
与上述碳反应竞争可用的NO2。
通过将DOC和SCR催化剂作为一个多功能单元整合到颗粒过滤器中，可以解决这些问题。
发明内容
将氧化功能整合到一个单元中的挑战之一是它可能在到达SCR催化剂之前消耗或氧化氨还原剂。DOX对于从NO生产NO2是重要的，该NO2用于氧化烟灰过滤器中的烟灰。NO2对烟灰的氧化使过滤器保持清洁，并确保***中的低压降。
附图说明
根据本发明的解决方案是只有过滤器的入口涂覆有DOC功能。作为气体的NO将扩散到催化材料中并与NO2反应，而用作NH3前体并且是液体的尿素将通过具有DOC的区域并在DOC之后水解为NH3，如图1所示。可以通过添加不与尿素反应的更惰性材料的薄涂层来钝化DOC的上层。
具体实施方式
因此，本发明的第一方面在于一种用于除去来自压燃式发动机的废气的有害化合物和颗粒物质的方法，该方法包括以下顺序步骤：
(a)将一定量的尿素水溶液液滴形式的SCR还原剂加入到废气中；
(b)将与所述尿素水溶液液滴混合的废气引入至壁流式过滤器的入口通道，并在氧化催化剂的存在下将挥发性有机化合物和一氧化碳氧化成二氧化碳和水以及将一氧化氮氧化成二氧化氮，该氧化催化剂布置在位于壁流式过滤器入口侧的可渗透的多孔分隔壁上；
(c)随后将来自步骤(b)的废气中的尿素水溶液液滴蒸发并分解成氨；
(d)将含有氨的废气通过壁流式过滤器的可渗透的多孔分隔壁送至过滤器的出口通道，并在面向过滤器入口通道的可渗透的多孔分隔壁的表面上捕获颗粒物质；
(e)通过与废气中所含的二氧化氮反应，连续除去所捕获的颗粒物质；和
(f)随后在布置在气体可渗透的多孔隔壁内和/或面向壁流式颗粒过滤器的出口通道的壁面上的SCR活性催化剂的存在下，通过与氨反应而从废气中除去剩余的二氧化氮。
本发明的第二方面是一种用于清洁来自压燃式发动机的废气的多功能壁流式过滤器，其包括由气体可渗透的多孔分隔壁分隔的多个废气入口流动通道和多个废气出口通道；
布置在废气入口侧的分隔壁上的废气入口流动通道中的柴油氧化催化剂；
以及用于选择性还原氮氧化物的SCR催化剂，该SCR催化剂布置在废气入口侧和出口侧之间的区域内的面向出口通道的分隔壁内和/或分隔壁的表面上，其中柴油氧化催化剂的上层用惰性材料涂层钝化。
本发明的第三方面是一种用于清洁来自柴油发动机的废气的***，包括喷射器和具有多个废气入口流动通道的下游多功能壁流式过滤器，以及由气体可渗透的多孔分隔壁隔开的多个废气出口通道；
布置在废气入口侧的分隔壁上的废气入口流动通道中的柴油氧化催化剂；
以及用于选择性还原氮氧化物的SCR催化剂，该SCR催化剂布置在废气入口侧和出口侧之间的区域内的面向出口通道的分隔壁内和/或分隔壁的表面上，其中喷射器适于将尿素-水溶液液滴注入到多功能壁流过滤器上游的废气中，使得尿素-水溶液以液体形式与柴油氧化催化剂接触，或者所述喷射器布置在距离多功能壁流式过滤器的入口一定距离处，导致尿素-水溶液的液滴尺寸，使得尿素-水溶液以液体形式与所述柴油氧化催化剂接触。
在柴油车辆的情况下，在喷射器距离多功能壁流式过滤器为0.5m的通常距离下，必须提供至少7微米的液滴尺寸，以防止在过滤器上游和DOC内的气相中的液滴的气化。
在尿素-水溶液的液滴尺寸小于7微米时，喷射器的距离必须降低到低于0.5米，以防止溶液在DOC内蒸发。
根据本发明上述方面的方法、多功能过滤器和***的其它优点除了物理分离之外还在于：颗粒物质和NOx反应的热去耦合，因为在180℃至280℃的温度下对于快速SCR反应主要需要NO2，而280℃至450℃的温度下的NO2是用于被动的颗粒物燃烧。在车辆冷启动期间，NO2将完全可用于所需的NOx转化，并且累积的颗粒物质的燃烧可以等待***被加热。
在从属权利要求中讨论本发明的其他优选实施方案。
适用于本发明的氧化和SCR催化剂是本领域公知的。仅举几个例子，V2O5/WO3/TiO2类的基于钒的催化剂制剂显示出高的去氮氧化物性能和耐久性。具有β骨架的铜和铁沸石已经商业化了数年，并且目前被用作柴油机废气净化的SCR催化剂。具有菱沸石结构的Cu-沸石具有高温稳定性和高低温活性的有利组合。其中优选Cu-SAPO-34和Cu-SSZ-13SCR催化剂。
用于本发明的形成二氧化氮的氧化催化剂是铂或铂和钯的混合物。这些金属沉积在氧化铝和/或二氧化钛和/或二氧化硅上。用稀土金属氧化物稳定是有益的。

Claims (17)

1.一种用于除去来自压燃式发动机的废气的包含氮氧化物、挥发性有机化合物和一氧化碳的有害化合物以及颗粒物质的方法，该方法包括以下顺序步骤：
(a)将一定量的尿素水溶液液滴形式的SCR还原剂加入到废气中；
(b)将与所述尿素水溶液液滴混合的废气引入至壁流式过滤器的入口通道，并在氧化催化剂的存在下将挥发性有机化合物和一氧化碳氧化成二氧化碳和水以及将一氧化氮氧化成二氧化氮，所述氧化催化剂布置在位于壁流式过滤器入口侧的可渗透的多孔分隔壁上，所述氧化催化剂是活性的；
(c)随后将来自步骤(b)的废气中的尿素水溶液液滴蒸发并分解成氨；
(d)将含有氨的废气通过壁流式过滤器的可渗透的多孔分隔壁送至过滤器的出口通道，并在面向过滤器入口通道的可渗透的多孔分隔壁的表面上捕获所述颗粒物质；
(e)通过与废气中所含的二氧化氮反应，连续除去所捕获的颗粒物质；和
(f)随后在布置在气体可渗透的多孔隔壁内和/或面向壁流式颗粒过滤器的出口通道的壁面上的SCR活性催化剂的存在下，通过与氨反应而从废气中除去剩余的二氧化氮。
2.根据权利要求1所述的方法，其还包括通过与布置在所述壁流式过滤器的出口通道的出口处的氨逸出催化剂接触来除去废气中包含的过量的氨的步骤。
3.根据权利要求1或2所述的方法，其中所述尿素水溶液的液滴尺寸为至少7微米。
4.根据权利要求1或2所述的方法，其中所述SCR催化剂包括钒和/或钨的氧化物以及二氧化钛。
5.根据权利要求1或2所述的方法，其中所述SCR活性催化剂包含一种或多种铜或铁促进的β-沸石。
6.根据权利要求1或2所述的方法，其中所述SCR活性催化剂包含铜促进的SAPO-34和/或铜促进的SSZ-13。
7.根据权利要求1或2所述的方法，其中所述氧化催化剂包含铂和/或钯。
8.根据权利要求2所述的方法，其中所述氨逸出催化剂包含铂和CuSAPO-34和/或SSZ-13。
9.一种用于清洁来自压燃式发动机的废气以除去包含氮氧化物、挥发性有机化合物和一氧化碳的有害化合物以及颗粒物质的多功能壁流式过滤器，其包括：
气体可渗透的多孔分隔壁；
由气体可渗透的多孔分隔壁分隔的多个废气入口流动通道和多个废气出口通道；
柴油氧化催化剂，其布置在位于壁流式过滤器入口侧的可渗透的多孔分隔壁上，所述氧化催化剂是活性的；
SCR催化剂，其布置在废气入口侧和出口侧之间的区域内面向出口通道的分隔壁内和/或分隔壁的表面上，用于选择性还原氮氧化物；
其中，所述柴油氧化催化剂的上层用惰性材料涂层钝化，且柴油氧化催化剂和SCR催化剂作为一个多功能单元整合到过滤器中；且
其中，在废气入口通道中，在氧化催化剂的存在下与尿素水溶液液滴混合的废气中的挥发性有机化合物和一氧化碳氧化成二氧化碳和水，一氧化氮氧化成二氧化氮，废气中的尿素水溶液液滴蒸发并分解成氨，含有氨的废气其后通过所述气体可渗透的多孔分隔壁送至过滤器的出口通道，颗粒物质在面向过滤器入口通道的可渗透的多孔分隔壁的表面上被捕获，通过与废气中所含的二氧化氮反应，所捕获的颗粒物质被连续除去，在布置在气体可渗透的多孔隔壁内和/或面向壁流式颗粒过滤器的出口通道的壁面上的SCR活性催化剂的存在下，通过与氨反应而从废气中除去剩余的二氧化氮。
10.根据权利要求9所述的多功能壁流式过滤器，其中所述出口通道的出口侧还设置有氨逸出催化剂。
11.根据权利要求9或10所述的多功能壁流式过滤器，其中所述SCR催化剂包含钒和/或钨的氧化物以及二氧化钛。
12.根据权利要求9或10所述的多功能壁流式过滤器，其中所述SCR活性催化剂包含一种或多种铜或铁促进的β-沸石。
13.根据权利要求9或10所述的多功能壁流式过滤器，其中所述SCR催化剂包括铜促进SAPO-34和/或铜促进SSZ-13。
14.根据权利要求9或10所述的多功能壁流式过滤器，其中所述氧化催化剂包含铂和/或钯。
15.根据权利要求10所述的多功能壁流式过滤器，其中所述氨逸出催化剂包括铂和CuSAPO-34和/或SSZ-13。
16.根据权利要求9或10所述的多功能壁流式过滤器，其中惰性层的涂层包括不将尿素水解成氨的材料。
17.一种用于清洁来自柴油发动机的废气的***，包括喷射器和根据权利要求9-16中任一项所述的多功能壁流式过滤器，
其中，喷射器适于将尿素-水溶液液滴注入到多功能壁流过滤器上游的废气中，使得尿素-水溶液以液体形式与柴油氧化催化剂接触，或者所述喷射器布置在距离多功能壁流式过滤器的入口一定距离处以导致尿素-水溶液的一定液滴尺寸，使得尿素-水溶液以液体形式与所述柴油氧化催化剂接触。
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