GB2342055A - Exhaust treatment device with varying cell density - Google Patents

Exhaust treatment device with varying cell density Download PDF

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Publication number
GB2342055A
GB2342055A GB9920972A GB9920972A GB2342055A GB 2342055 A GB2342055 A GB 2342055A GB 9920972 A GB9920972 A GB 9920972A GB 9920972 A GB9920972 A GB 9920972A GB 2342055 A GB2342055 A GB 2342055A
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GB
United Kingdom
Prior art keywords
treatment device
substrate
cells
exhaust
density
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB9920972A
Other versions
GB9920972D0 (en
Inventor
Seha Son
Peter Li
Jeong-Yeol Kim
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ford Global Technologies LLC
Original Assignee
Ford Global Technologies LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ford Global Technologies LLC filed Critical Ford Global Technologies LLC
Publication of GB9920972D0 publication Critical patent/GB9920972D0/en
Publication of GB2342055A publication Critical patent/GB2342055A/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/74General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86Catalytic processes
    • B01D53/88Handling or mounting catalysts
    • B01D53/885Devices in general for catalytic purification of waste gases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/50Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00Exhaust 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
    • F01N13/009Exhaust 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
    • F01N13/0097Exhaust 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 arranged in a single housing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842Nitrogen oxides
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/24Exhaust 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 characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825Ceramics
    • F01N3/2828Ceramic multi-channel monoliths, e.g. honeycombs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/24Exhaust 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 characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2892Exhaust flow directors or the like, e.g. upstream of catalytic device
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Biomedical Technology (AREA)
  • Toxicology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

An exhaust treatment device 10 for an automobile (eg: for i.c.e.) includes an active section 18 with a substrate 20 having a varying cell density. The densities of the cells is greatest at the axis of the substrate, and least at its periphery. This arrangement promotes even flow distribution through the substrate. Typically the centre portion (20A, Figures 2 and 3) has 600 cells per square inch (cpsi), an intermediate portion (20B, Figure 2 and 3) has 400 cpsi, and the outer portion (20C, Figure 2 and 3) has 200 cpsi. The substrate is typically an extruded ceramic monolith honeycomb, with a catalyst washcoat. The device may function as a catalytic converter, NO<SB>x</SB> trap or thermal reactor.

Description

2342055 AUTOMOTIVE EXHAUST TREATMENT DEVICE WITH VARYING CELL DENSITY The
present invention relates to the treatment, of automotive exhaust to remove various regulated emission components.
As automotive exhaust emission control regulations have become increasingly more stringent, manufacturers of vehicles have sought to improve the efficiency of exhaust emission control converters. As used herein, the term "converter" refers to either a conventional oxidizing catalyst (COC), a three-way catalyst (TWC), a NOx trap, a thermal reactor, or other types of devices having generally axial flowpaths established by either an extruded ceramic monolith or other type of construction.
The inventors of the present invention have determined that the flow characteristics through conventionally constructed ceramic monoliths do not promote efficient operation of a catalyst because of the flow maldistribution which occurs in many converters. For example, in the prior art converter illustrated in Figure 5, which has uniform cell density, shown at Figure 4, of about 400 cells per square inch, flow maldistribution develops as illustrated in Figures 6 and 7. Figure 6, illustrating a side view of the converter of Figure 5, shows that the predominant flow is at the lower part of the substrate; Figure 7 shows that the predominant flow is further confined to the substrate's outer edges with only a small amount of flow passing through the central portion of the substrate. As a result, a large 3C proportion of the substrate is underutilized. The flow illustrated in Figures 6 and 7 results in part from the 900 bend encountered by the gases while entering the converter of Figure 5.
In the event that the converter has a straight flow entry system, as shown in Figures 8 and 9, the results are similar. The highest flow velocities are at the center and fall off to the sides. Thus, there is once again a maldistribution of flow through the converter.
A converter constructed according to the present invention solves the foregoing problems by promoting a more uniform exposure of the catalytic material to the exhaust flow so as to increase conversion efficiency while allowing the exhaust system back pressure to be decreased, thereby promoting better vehicle performance.
According to the present invention there is provided an exhaust treatment device for an automotive vehicle, comprising: an inlet pipe and diffuser section for conducting exhaust gas from an engine to an active section of the treatment device; an exit section for conducting treated exhaust gas from the active section of the treatment device to the downstream portion of an exhaust system; and an active section comprising a substrate having an active washcoat deposited thereon, with said substrate having a plurality of parallel flow paths, with said flow paths comprising at least a first group of cells having a higher density and a second group of cells having a lower density.
The first and second groups of cells are arranged within the substrate such that the first group of cells having a higher density is subjected to exhaust gas flowing at relatively higher velocity, and a second group of cells having a lower density is subjected to exhaust gas having a relatively lower velocity.
The exhaust treatment device may further comprise an active section having a cell-variant substrate having a variable cell density followed by a second substrate having invariant cell density.
It is an advantage of the present invention that an exhaust treatment device constructed according to this invention will provide superior treatment capability because of tne matching of exhaust flow rates to cell density while allowing lower exhaust system back pressure.
It is another advantage of the present invention that an exhaust converter constructed according to the present invention may be packaged in a smaller volume container because of increased efficiency.
It is yet another advantage of the present invention that the device constructed according to the present invention may be built with less precious metal loading at a lower cost.
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Figure 1 illustrates an exhaust treatment device according to the present invention; Figure 2 illustrates a cell-variant monolithic substrate according to one aspect of the present invention; Figure 3 illustrates a second cell-variant monolithic substrate according to the present invention; Figure 4 illustrates a cell-invariant monolithic substrate according to the prior art;
Figure 5 illustrates a prior art exhaust treatment device having a cell-invariant first active section; Figures 6 and 7 illustrate flow patterns with the prior art device of Figure 5; Figures 8 and 9 illustrate flow patterns through a prior art device similar to Figure 5, but having a straight inlet as opposed to a curved inlet; and Figures 10 and 11 illustrate flow through a converter constructed according to Figure 1.
As shown in Figure 1, an exhaust treatment device according to the present invention has an inlet pipe 12 followed by a diffuser 14. After flowing through diffuser 14, exhaust gas passes through cell-variant substrate 20 having a chemically active washcoat deposited thereon. Substrate 20 is illustrated as having three groups of cells with varying densities. As shown more particularly in Figure 2, a first group having a highest density is located near the center of substrate 22. This group, which is labeled 20A, has a density of about 600 cells per square inch (93 cells per square cm). Immediately surrounding the group at 600 cells per square inch is group 20B, hav-,ng a density of about 400 cells per square inch (62 cells per square cm). Finally, group 20C, comprising the balance of substrate 20, has a density of about 200 cells per square inch (31 cells per square cm).
Substrate 20 is followed by substrate 22, which has an invariant cell construction. It has been determined that io flow through first substrate 20 straightens out and evens the flow sufficiently so that a cell-variant construction is not needed for substrate 22.
The effect of the cell variant construction of substrate 20 is illustrated in Figures 10 and 11. As seen is from these figures, the resulting flow is much more consistent across the substrate than with the flows of the prior art substrates shown in Figures 6 and 7. In this manner, the exhaust treatment capability is improved because the flow through various portions of the catalyst is more consistent. Moreover, exhaust system back pressure may be reduced by allowing the density to decrease to a point at which acceptable conversion is achieved, albeit at lower flow restriction.
Figure 3 illustrates an example of a cell-variant substrate according to the present invention for use with an exhaust treatment device not having a 90' inlet bend illustrated in Figure 1. It is noted that the zones of 600, 400, and 200 cells per square inch are centered much more about the geometric center of substrate 24.

Claims (14)

1. An exhaust treatment device for an automotive vehicle, comprising:
an inlet pipe (12) and diffuser section (14) for conducting exhaust gas from an engine to an active section of the treatment device; an exit section (16) for conducting treated exhaust gas from the active section of the treatment device to the downstream portion of an exhaust system; and an active section (18) comprising a substrate (20) having an active washcoat deposited thereon, with said substrate having a plurality of parallel flow paths, with said flow paths comprising at least a first group of cells (20A) having a higher density and a second group of cells (20B) having a lower density.
2. An exhaust treatment device according to Claim 1, wherein said exhaust treatment device comprises a catalytic converter.
3. An exhaust treatment device according to Claim 1, wherein said exhaust treatment device comprises a thermal reactor.
4. An exhaust treatment device according to Claim 1, wherein said exhaust treatment device comprises an Nox trap.
R S. An exhaust treatment device according to Claim 1, wherein said first and second groups of cells are arranged within the substrate such that the first group of cells, having a higher density, is subjected to exhaust gas flowing at a relatively higher velocity, and said second group of cells, having a lower density, is subjected to exhaust gas having a relatively lower velocity.
6. An exhaust treatment device according to Claim 1, wherein the substrate is configured as a cylinder having a generally circular cross section, with higher density cells being located about a central axis of the substrate and lower density cells being located about the periphery of the substrate.
7. An exhaust treatment device according to Claim 1, wherein the substrate is configured as a cylinder having a generally elliptical cross section, with higher density cells being located about a central axis of the substrate and lower density cells being located about the periphery of the substrate.
8. An exhaust treatment device for an automotive vehicle, comprising:
an inlet pipe and diffuser section for conducting exhaust gas from an engine to an active section of the treatment device; an exit section for conducting treated exhaust gas from the active section of the treatment device to the downstream portion of an exhaust system; and an active section comprising a substrate having a plurality of parallel flow paths, with said flow paths comprising a first group of cells having a density of at least. 400 cells per square inch and a second group of cells having a density of about 200 cells per square inch, with said first group of cells being positioned to receive exhaust gas flowing at a higher velocity and said second group of cells being positioned to receive exhaust gas flowing at a lower velocity.
9. An exhaust treatment- device according to Claim 8, wherein said substrate comprises a ceramic monolith.
10. An exhaust treatment device according to Claim 8, wherein said substrate comprises an extruded ceramic monolith.
11. An exhaust treatment device for an automotive vehicle, comprising:
an inlet pipe and diffuser section for conducting exhaust gas from an engine to an active section of the treatment device; an exit section for conducting treated exhaust gas from the active section of the treatment device to the downstream portion of an exhaust system; and an active section comprising a cell-variant substrate, with said substrate having a plurality of axially extending, parallel flow paths, with said flow paths comprising a first group of cells having a density of about 600 cells per square inch, a second group of cells having a density of about 400 cells per square inch, and a third group of cells having a density of about 200 cells per square inch, with said first group of cells being positioned to receive exhaust gas flowing at a higher velocity and said second and third groups of cells being positioned to receive exhaust gas flowing at progressively lower velocities.
12. An exhaust treatment device according to Claim 11, wherein said active section further comprises a second substrate having a chemically active washcoat and an invariant cell density, with said second substrate being positioned downstream from said cell-variant substrate.
13. An exhaust treatment device according to Claim 11, wherein said active section further comprises a chemically active washcoat applied to the substrate.
14. An exhaust treatment device for an automotive vehicle substantially as hereinbefore described with reference to the accompanying drawings.
GB9920972A 1998-09-14 1999-09-07 Exhaust treatment device with varying cell density Withdrawn GB2342055A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15238798A 1998-09-14 1998-09-14

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GB9920972D0 GB9920972D0 (en) 1999-11-10
GB2342055A true GB2342055A (en) 2000-04-05

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DE (1) DE19938038A1 (en)
GB (1) GB2342055A (en)

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GB2398750A (en) * 2002-12-09 2004-09-01 Visteon Global Tech Inc Air induction system incorporating hydrocarbon filter
EP1484483A1 (en) * 2002-02-26 2004-12-08 Ngk Insulators, Ltd. Honeycomb filter
EP1486243A1 (en) * 2002-03-19 2004-12-15 Ngk Insulators, Ltd. Honeycomb filter
EP1491248A1 (en) * 2002-03-29 2004-12-29 Ibiden Co., Ltd. Ceramic filter and exhaust gas decontamination unit
WO2008060563A2 (en) 2006-11-15 2008-05-22 Corning Incorporated Flow-through honeycomb substrate and exhaust after treatment system and method
EP2130606A2 (en) * 2008-05-20 2009-12-09 Ibiden Co., Ltd. Honeycomb structure
EP2130603A3 (en) * 2008-05-20 2010-02-24 Ibiden Co., Ltd. Honeycomb structure
US7673445B2 (en) 2004-11-09 2010-03-09 Ford Global Technologies, Llc Mechanical apparatus having a catalytic NOx storage and conversion device
US7718150B2 (en) 2007-04-17 2010-05-18 Ford Global Technologies, Llc Reverse platinum group metal zoned lean NOx trap system and method of use
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WO2011102596A1 (en) * 2010-02-18 2011-08-25 (주)씨에이테크 Smoke reduction device and smoke reduction method
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US8440155B2 (en) 2011-08-19 2013-05-14 Corning Incorporated Flow modulating substrates for early light-off
US8444752B2 (en) 2009-08-31 2013-05-21 Corning Incorporated Particulate filters and methods of filtering particulate matter
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US9567887B2 (en) 2012-03-10 2017-02-14 Volkswagen Aktiengesellschaft Exhaust gas aftertreatment component with an HC adsorber function and exhaust gas system including such an exhaust gas aftertreatment component
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US3853485A (en) * 1972-12-11 1974-12-10 Corning Glass Works Core member for catalytic oxidation converter
EP0153157A2 (en) * 1984-02-14 1985-08-28 Honda Giken Kogyo Kabushiki Kaisha Catalytic converter
EP0336106A1 (en) * 1988-03-22 1989-10-11 Emitec Gesellschaft für Emissionstechnologie mbH Process for manufacturing a carrier for a catalytic reactor
US5108685A (en) * 1990-12-17 1992-04-28 Corning Incorporated Method and apparatus for forming an article with multi-cellular densities and/or geometries
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