CN110073086B - 一种改进的选择性催化还原*** - Google Patents

一种改进的选择性催化还原*** Download PDF

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CN110073086B
CN110073086B CN201780077531.2A CN201780077531A CN110073086B CN 110073086 B CN110073086 B CN 110073086B CN 201780077531 A CN201780077531 A CN 201780077531A CN 110073086 B CN110073086 B CN 110073086B
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ammonia
dosing rate
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hydrolysis catalyst
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CN110073086A (zh
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利奥·谢德
亚历克西斯·伊登
罗纳德·西尔弗
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Perkins Engines Co Ltd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
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    • F01N13/0093—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are of the same type
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    • F01N3/2066—Selective catalytic reduction [SCR]
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    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
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    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/40—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a hydrolysis catalyst
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    • F01N2560/00—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
    • F01N2560/02—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor
    • F01N2560/026—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor for measuring or detecting NOx
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Abstract

提供了使用选择性催化还原***处理排放通道中的排气的方法。该***包括：水解催化器(18)，其在SCR催化器(20)上游的通道(12)中；以及柴油机排放流体(DEF)定量配给单元(16)，其用于以可变DEF定量配给速率将DEF注射到水解催化器上。该方法包括以下步骤：预测用于转化排气中包含的所有氮氧化物(NOx)的初始DEF定量配给速率，以及估计存储在SCR催化器(20)上的氨的量。该方法还包括以下步骤：测量***的NOx转化率，并基于氨存储估计和测量的***的NOx转化率来调节初始DEF定量配给速率，以产生第一调节的DEF定量配给速率。然后，估计存储在水解催化器(18)上的氨当量的量，并基于氨当量存储估计来调节第一调节的DEF定量配给速率，以产生第二调节的DEF定量配给速率。然后，以第二调节的DEF定量配给速率注射DEF。

Description

一种改进的选择性催化还原***
发明领域
本发明涉及用于处理柴油发动机排气的选择性催化还原***。
发明背景
选择性催化还原(SCR)***是已知的，并且通常包括在柴油发动机的排放***中，以便处理这种发动机的排气。这种***涉及将柴油机排放流体(DEF)引入到在发动机的排放通道中流动的排气中。DEF包含尿素，尿素在排放通道内经受水解和/或热解，从而产生氨。氨进入到SCR催化器中，在SCR催化器中氨与排气反应，其中在排气中存在的任何氮氧化物(NOx)在排气排出到大气中之前被转化为氮气和水。
已经提出了将DEF定量配给到排放通道的许多SCR***。这种***有时被称为“湿式喷射(wet spray)”***，并将尿素溶液喷雾注射到排气中，在排气中尿素分解形成氨。这种***的示例在US2008307967A1中示出。US’967公开了一种布置，其中DEF在主排放通道外部的供给通道中被水解。具体而言，将DEF定量配给到水解催化器上并水解成氨。氨向下游流到SCR催化器的入口，在那里氨起到还原NOx的作用。当需要氨来还原NOx时，SCR***(诸如，US’967中公开的SCR***)所遵循的已知控制过程涉及给水解反应器定量配给DEF。
当在某个条件下将DEF定量配给到SCR***中的水解催化器上时，DEF充分冷却催化剂，以减缓或有效防止尿素的热解和异氰酸随后的水解，以及氨和异氰酸的解吸。对氨释放的这种抑制造成水解催化器功能的滞后或延迟。这限制了可对SCR催化器中氨储存和NOx转化施加的控制量。此外，尿素缓慢的或被阻止的热解也可能导致在排放通道中形成尿素沉积物，并且未反应的尿素或氨在氨泄漏事件中(例如，如果排放入口温度升高的话)未经处理地流出排放通道。
本发明的目的是消除或减轻已知SCR排放***的上述缺点中的至少一个。
发明概述
根据本发明的第一方面，提供了使用选择性催化还原***处理排放通道中的排气的方法。该***包括：水解催化器，其在SCR催化器上游的通道中；以及柴油机排气流体(DEF)定量配给单元，其用于以可变DEF定量配给速率将DEF注射到水解催化器上。该方法包括以下步骤：预测用于转化排气中包含的所有氮氧化物(NOx)的初始DEF定量配给速率，以及估计存储在SCR催化器上的氨的量。然后，测量***的NOx转化率。然后，基于氨储存估计和测量的NOx转化率来调节初始DEF定量配给速率，以产生第一调节的DEF定量配给速率。然后，估计储存在水解催化器上的氨当量(ammonia-equivalent)的量。然后，基于氨当量储存估计调节第一调节的DEF定量配给速率，以产生第二调节的DEF定量配给速率。然后，以第二次调节的DEF定量配给速率注射DEF。
根据本发明的第二方面，提供了用于处理排放通道中的排气的选择性催化还原(SCR)***。该SCR***包括：位于排放通道中的水解催化器、用于将DEF注射到水解催化器上的柴油机排气流体(DEF)定量配给单元以及位于水解催化器下游的通道中的SCR催化器。入口温度传感器和第一氮氧化物(NOx)传感器各自位于水解催化器上游的通道中。第二NOx传感器位于SCR催化器下游。控制模块与入口温度传感器、第一NOx传感器和第二NOx传感器以及DEF定量配给单元通信，并且控制模块还读取氨-NOx比率(ANR)图。控制模块基于从传感器接收的信号和从ANR图(map)获得的ANR信息来控制DEF定量配给速率。
根据本发明的第三方面，提供了用于交通工具的排放装置，该装置包括根据本发明的第二方面的SCR***。
根据本发明的第四方面，提供了包括根据本发明的第二方面的SCR***的交通工具。
附图简述
现在将参考附图仅作为示例来描述本发明的优选的实施例，在附图中：
图1是选择性催化还原(SCR)***的示意图；
图2示出了由图1所示的SCR***的ECM使用的主控制器和子控制器；
图3是图示了由构成图2所示的子控制器的一部分的操作模式状态机(operatingregime state machine)所采取的控制过程步骤的流程图；
图4是图示了由构成图3所示的子控制器的一部分的氨控制器所采取的控制过程步骤的流程图；以及
图5图示了由图1所示的SCR***采取的示例性定量配给方案。
附图详述
参考图1，示出了选择性催化还原(SCR)***10。***10位于排放通道12中，该排放通道12将排气从交通工具(未示出)的发动机(未示出)输送出去。排气首先穿过已知类型的柴油机氧化催化器(DOC)14，其可以可选地形成***10的一部分。DOC 14催化排气中碳氢化合物和一氧化碳的氧化反应以产生二氧化碳和水，并且还将一氧化氮氧化成二氧化氮。
柴油机排气流体(DEF)定量配给单元16位于DOC 14的下游，该定量配给单元16被配置成将DEF注射到位于排放通道12中DOC 14下游的水解催化器18上。DEF定量配给单元16是已知的类型，并且以尿素水溶液的形式注射DEF。水解催化器18是已知的类型，并且催化DEF的水解反应，在该水解反应中产生氨和二氧化碳。
位于排放通道12中水解催化器18下游的是SCR催化器20，该SCR催化器20也是已知的类型。SCR催化器20催化排气中的氮氧化物(NOx)和上游产生的氨之间的还原反应，其中NOx被转化为氮气和水。可选地，***10可以包括直接位于SCR催化器20上游的SCR催化器过滤器22。SCR催化器过滤器22被配置成防止排放通道中的较大颗粒进入SCR催化器20。
位于排放通道12中的SCR催化器20下游的是已知类型的可选的氨泄露(AS)催化器24，该氨泄露催化器24被配置成在穿过SCR催化器20的任何未反应的氨从排气排放到大气中之前将其氧化。
***10还包括电子控制模块(ECM)26，该电子控制模块26与DEF定量配给单元16通信，并被配置成控制DEF定量配给单元16将DEF注射到水解催化器18上的速率。***10还包括与ECM 26通信的多个传感器。
入口氮氧化物(NOx)传感器28位于水解催化器18的上游，并被配置成测量排放通道12中的NOx水平。第一NOx传感器28与ECM 26通信。
同样位于水解催化器18上游的是与ECM 26通信的入口温度传感器30。入口温度传感器30被配置成测量水解催化器18上游的排气温度，并将该温度传输给ECM 26。
水解催化器温度传感器32位于水解催化器18和SCR催化器20之间，该水解催化器温度传感器32与ECM 26通信，并且被配置为测量SCR催化器20上游的排气的SCR温度值，并且通过向ECM 26发送信号来向ECM指示SCR温度值。水解催化器氨传感器34也位于水解催化器18和SCR催化器20之间，该水解催化器氨传感器34与ECM 26通信。
该***还包括位于AS催化器24下游的第二NOx传感器36，该第二NOx传感器36被配置成测量SCR***下游的排气尾管中的NOx水平，并将这些NOx水平传输给ECM 26。出口氨传感器38和出口温度传感器40也可以在第二NOx传感器36附近位于排放通道中，以便分别测量尾管氨水平和温度水平，并将这些尾管氨水平和温度水平传输给ECM 26。
工业适用性
具体参照图2-图5，现在将描述***10可以如何用于处理排气的示例。
图2示出了由ECM 26使用的主控制器或标准SCR控制器以及水解催化器子控制器。主控制器100包括前馈ANR图50和SCR催化器存储估计器/校正器52，该估计器/校正器52估计氨存储并将存储估计和温度读数应用于模型/估计器中，以便提供反馈校正。在使用中，ECM 26从第一NOx传感器28获取NOx读数并从入口温度传感器30获取温度读数，并且还以已知的方式计算通道中排气的质量流率。然后，这些入口NOx、温度和质量流的值通过ANR图50，以便预测能将排气中的所有NOx转化为氮气和水的初始DEF定量配给速率。主控制器100还从第一NOx传感器28、第二NOx传感器36和水解催化器温度传感器32获取读数，并将这些读数应用于SCR催化器存储估计器/校正器52。可选地，主控制器100还可以从出口氨传感器38获取读数，并将该氨读数也应用于存储估计器/校正器52。通过将这些读数应用在存储估计器/校正器52中，主控制器100可以估计存储在SCR催化器20上的氨的量，并且还可以测量整个***10的NOx转化率。因此，主控制器100可以基于氨存储估计和NOx转化率来调节从ANR图50获得的初始DEF定量配给速率，以便产生第一调节的DEF定量配给速率。
由于在SCR***10中存在水解催化器18，必须进一步调节DEF定量配给速率，以考虑存储在水解催化器上的氨当量的量。在本公开的上下文中，“氨当量”是指在注射DEF期间以及在随后发生的热解和水解期间的任何阶段留在水解催化器上的物质。因此，“氨当量”是指DEF、尿素、异氰酸和氨中的任何一种。这种附加的调节是通过子控制器102进行的。
子控制器102包含操作模式状态机104、水解催化器存储估计器模型106、氨前馈/反馈控制器108和氨当量存储控制器110。操作模式状态机104接收与以下内容相关的信息：第一调节的DEF定量配给速率、排气的质量流率和由入口温度传感器30测量的入口温度。如下面将参考图3所解释的，状态机104使用该信息来分析***的入口条件以及在稳定或不稳定模式下操作是否合适。来自状态机104的信息可以被馈送到氨当量存储控制器110，因此子控制器102可以确定对DEF定量配给速率的调节是否合适。来自状态机104的信息也可以反馈给主控制器100的存储估计器/校正器52。
水解催化器储存估计器模型106接收与以下内容相关的信息：第一调节的DEF定量配给速率、排气的质量流率、由入口温度传感器30测量的入口温度、由水解催化器氨传感器34测量的氨水平以及由水解催化器温度传感器32测量的水解催化器温度。然后，模型106可以估计水解催化器18中的氨当量储存，并将该信息前馈给氨当量储存控制器110。
氨前馈/反馈控制器108还接收与以下内容相关的信息：第一调节的DEF定量配给速率，以及由水解催化器氨传感器34测量的氨水平。控制器108使用该信息来确定是否需要对第一调节的DEF定量配给速率进一步进行调节，这将在下面参考图4更详细地描述。
因此，子控制器102能够估计存储在水解催化器18上的氨当量的量，然后，如果需要，基于该氨当量存储估计再次调节第一调节的DEF定量配给速率，以便产生第二调节的DEF定量配给速率。然后，DEF定量配给单元16以该第二调节的DEF定量配给速率注射DEF。
图3是图示了可以由子控制器102采取的过程步骤的流程图，其用于分析***的入口条件以及在稳定或不稳定模式下操作是否合适，从而分析是否需要对第一调节的DEF定量配给速率进行附加的调节。在开始步骤200之后，在步骤202状态机104分析入口条件。如上参考图3所解释的，这些入口条件包括排气的质量流率以及入口温度。在判定步骤204，机器确定这些入口条件是否支持在不稳定模式下操作该***。如果入口条件支持在稳定模式下进行操作，则确定步骤206使用水解催化器储存估计器模型106来确定水解催化器的状态。然后，在判定步骤208，过程查看来自估计器模型106的估计信息是否指示不稳定模式。如果该信息确实指示不稳定模式，则在步骤210，子控制器102将第一调节的DEF定量配给速率调节到最小值或托管的低水平定量配给速率，直到条件另有指示为止。如果来自估计器模型106的信息指示稳定模式，则在步骤212，子控制器102将第一调节的DEF定量配给速率传递到DEF定量配给单元16。
如果在判定步骤204的分析确定入口条件支持在不稳定模式下操作，则确定步骤214使用水解催化器储存估计器模型106来确定水解催化器的状态。然后，在判定步骤216，过程查看来自估计器模型106的估计信息是否指示不稳定模式。如果该信息指示稳定模式，则在步骤218，子控制器102将第一调节的DEF定量配给速率调节到最大值或托管的高水平定量配给速率，直到条件另有指示为止。如果来自估计器模型106的信息指示不稳定模式，则在步骤220，子控制器102将利用来自氨当量存储控制器110的存储校正来计算来自氨前馈/反馈控制器108的输出。该计算通过图4所示的子例程执行。
氨前馈/反馈计算和存储校正子例程从开始步骤300开始，并通向判定步骤302，在该判定步骤302中，确定在水解催化器上估计的氨当量存储是否大于预定目标值。如果存储估计小于目标值，则在步骤304氨当量存储控制器110将增加氨输出目标偏差。如果存储估计大于目标值，则在步骤306控制器110将减小氨输出目标偏差。氨输出目标偏差数据308可以作为子例程的一部分被存储和读取。
一旦子例程确定了对目标偏差的调节，就在步骤310将从主控制器100接收的第一调节的DEF定量配给速率信息转换成等效的氨输出目标值。在步骤304或步骤306确定的氨目标偏差在步骤312被添加到等效的氨输出目标值，以产生偏差氨输出目标。然后，在判定步骤314氨当量存储控制器110确定在水解催化器18处的由水解催化器氨传感器34测量的氨浓度是否大于在步骤312计算的该偏差氨输出目标。如果氨浓度小于偏差目标值，则子例程将在步骤316减小DEF定量配给偏差。如果氨浓度大于偏差目标值，则子例程将在步骤318增加DEF定量配给偏差。DEF定量配给偏差数据320可以作为子例程的一部分被存储和读取。
一旦确定了DEF定量配给偏差，该偏差就被添加到第一调节的DEF定量配给速率，因此产生第二调节的DEF定量配给速率。
图5示出了在SCR***的示例操作过程期间***10的各个变量在时间段内的变化。这些变量是排气中的NOx和氨浓度、排气入口温度、DEF定量配给速率和水解催化器上的氨当量储存。为了便于解释，时间段被划分为阶段A-G。在示例操作过程的阶段A中，状态机104通过图3所示的控制过程确定入口条件支持在不稳定模式下操作，但是来自估计器模型106的估计信息没有指示不稳定模式。因此，ECM 26控制DEF定量配给单元16，使得DEF定量配给单元以最大定量配给速率将DEF注射到水解催化器18上，导致水解催化器上的氨浓度和氨当量储存增加。阶段A中的排气温度是恒定的。
在示例操作过程的阶段B中，ECM 26从NOx传感器28接收已经在排气入口中检测到NOx的通信。状态机104现在也使用图3的过程确定入口条件和估计器模型106指示不稳定模式。因此，该过程采用图4所示的子例程利用来自来氨当量存储控制器110的存储校正来计算氨前馈/反馈控制器108的输出。在这种情况下，这导致ECM 26指示DEF定量配给单元16减小对水解催化器18上的DEF定量配给速率。这导致排气中氨浓度的峰值，以便使检测到的NOx被SCR催化器中的氨处理。对水解催化器上DEF定量配给速率的减小也导致水解催化器上氨当量储存量的暂时下降，并因此DEF定量配给偏差增加。
在示例操作过程的阶段C中，状态机过程确定入口条件继续支持在不稳定模式下操作，并且来自状态估计器106的信息指示不稳定模式。接着是子过程步骤220，且减小氨输出目标偏差，并且该过程继续直到目标实现为止。
在示例操作过程的阶段D中，ECM 26再次从NOx传感器28接收已经在排气入口中检测到NOx的通信。状态机104也再次使用图3的操作模式状态过程确定两个入口条件都支持，并且估计器模型106指示不稳定模式。因此，该过程采用图4所示的子例程利用来自来氨当量存储控制器110的存储校正来计算氨前馈/反馈控制器108的输出。在这种情况下，这再次导致ECM 26指示DEF定量配给单元16降低对水解催化器18上的氨输出目标偏差。这导致排气中氨浓度的峰值，因为不再有任何DEF注射来抑制水解催化器中氨当量物质的释放。对水解催化器上的DEF定量配给的降低也再次导致水解催化器上氨当量储存量的暂时下降，导致氨输出目标偏差增加以进行补偿。在阶段E中，跟随相同的过程，但是偏差变化很小，因为入口条件没有变化，并且已经达到期望的氨储存目标。
在示例操作过程的阶段F中，ECM 26评估排气温度升高。最初，操作模式状态机决定条件支持在不稳定模式下操作204，并且ECM 26控制DEF定量配给单元16，使得该DEF定量配给单元16使其将DEF注射到水解催化器上的速率以线性方式朝向最大速率增加，以便继续抑制氨释放，尽管通过目标偏差步骤304排气温度增加。状态机很快评估出排气温度的上升持续了太长时间，氨的释放无法得到进一步抑制。然后，ECM 26控制DEF定量配给单元16，使得其按照步骤210将DEF注射到水解催化器18上的速率降低到零。该步骤可以是渐进的，以避免SCR后下跌的可能性。随着氨和其他物质的释放，排气温度上升导致水解催化器18上的氨当量储存水平降低。
然后，在该示例过程的最后阶段G，ECM 26评估在排气中再次检测到NOx。在这一点上，操作模式状态过程告诉状态机，入口条件和氨当量储存估计都不指示不稳定模式。因此，如图3所示，由主控制器确定的第一调节的DEF定量配给速率被简单地直接传递到DEF定量配给单元16，使得它以常规的方式，以由NOx水平所指示的速率将DEF注射到水解催化器18上。换句话说，当排气温度保持升高并且氨当量储存为零时，当在水解催化器18上游检测到NOx时，DEF被注射到水解催化器18上，并且DEF定量配给速率与水解催化器18上游的NOx水平成比例。
本发明的***和方法不是限制DEF定量配给以避免氨当量储存，而是在催化器上保持合理的氨当量储存的量，这转过来又通过进一步连续定量配给的冷却效果而得到稳定。当需要释放氨时，这通过减少而不是增加DEF定量配给来实现。
此外，由于在本发明的***和过程中保持了大量氨当量物质，当发动机关闭且后处理***冷却时，DEF的水成分将蒸发，留下尿素。这种尿素可以在发动机启动时释放，作为低温定量配给的替代物。
本发明的控制过程具有反直观的操作模式，由此当在SCR催化器的入口处不需要氨时，命令定量配给，并且当需要氨时，停止定量配给。相对大量的氨和氨当量物质被有意储存在水解催化器上。最后，与已知***相比，发动机启动时的NOx转化得到改善，因为从发动机的前一操作阶段起，水解催化器上存储了相对大量的氨当量物质。
在不偏离由所附权利要求限定的本发明的范围的情况下，可以包含修改或改进。

Claims (7)

1.一种使用选择性催化还原***处理排放通道中的排气的方法，所述***包括水解催化器和柴油机排放流体定量配给单元，所述水解催化器在选择性催化还原催化器上游的通道中，所述柴油机排放流体定量配给单元用于以可变柴油机排放流体定量配给速率将DEF注射到所述水解催化器上，所述方法包括以下步骤：
预测用于转化排气中包含的所有氮氧化物的初始柴油机排放流体定量配给速率；
估计存储在所述选择性催化还原催化器上的氨的量；
测量所述***的氮氧化物转化率；
基于所估计的存储的氨的量和所测量的氮氧化物转化率，调节所述初始柴油机排放流体定量配给速率，以产生第一调节的DEF定量配给速率；
估计储存在所述水解催化器上的氨当量的量；
基于所估计的储存的氨当量的量，调节所述第一调节的柴油机排放流体定量配给速率，以产生第二调节的柴油机排放流体定量配给速率；以及
以所述第二调节的柴油机排放流体定量配给速率注射柴油机排放流体。
2.根据权利要求1所述的方法，还包括在所述排放通道中检测到任何氮氧化物之前将柴油机排放流体注射到所述水解催化器上的初始步骤。
3.根据权利要求2所述的方法，还包括当所述氮氧化物转化率增加时增加所述第二调节的柴油机排放流体定量配给速率的步骤。
4.根据权利要求2所述的方法，还包括当所述氮氧化物转化率降低时减小所述第二调节的柴油机排放流体定量配给速率的步骤。
5.根据权利要求3所述的方法，还包括当所述氮氧化物转化率降低时减小所述第二调节的柴油机排放流体定量配给速率的步骤。
6.根据前述权利要求中任一项所述的方法，还包括当在所述***的入口处检测到排气温度升高时，增加所述第二调节的柴油机排放流体定量配给速率的步骤。
7.根据权利要求6所述的方法，还包括以下步骤：
计算将导致氨泄漏事件的排气温度升高的持续时间；
对所述排气温度升高进行计时；以及
如果所述排气温度升高持续超过或超出所计算的持续时间，则逐渐降低所述第二调节的柴油机排放流体定量配给速率。
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