US20100050616A1 - Exhaust aftertreatment system - Google Patents
Exhaust aftertreatment system Download PDFInfo
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- US20100050616A1 US20100050616A1 US12/203,573 US20357308A US2010050616A1 US 20100050616 A1 US20100050616 A1 US 20100050616A1 US 20357308 A US20357308 A US 20357308A US 2010050616 A1 US2010050616 A1 US 2010050616A1
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- washcoat
- hydrocarbon
- particulate filter
- selective
- filter device
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation 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
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation 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
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—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
- 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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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- 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
- F01N3/103—Oxidation catalysts for HC and CO only
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- 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
- F01N3/18—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 characterised by methods of operation; Control
- F01N3/20—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 characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/20—Reductants
- B01D2251/208—Hydrocarbons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1021—Platinum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1023—Palladium
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2255/10—Noble metals or compounds thereof
- B01D2255/104—Silver
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20761—Copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/209—Other metals
- B01D2255/2092—Aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/50—Zeolites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/42—Platinum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/48—Silver or gold
- B01J23/50—Silver
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/064—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof containing iron group metals, noble metals or copper
- B01J29/072—Iron group metals or copper
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/065—Surface coverings for exhaust purification, e.g. catalytic reaction for reducing soot ignition temperature
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/12—Hydrocarbons
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/03—Adding substances to exhaust gases the substance being hydrocarbons, e.g. engine fuel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
- F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
- F01N3/0253—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust adding fuel to exhaust gases
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- This disclosure is related to exhaust aftertreatment systems for internal combustion engines operating lean of stoichiometry.
- An internal combustion engine operating lean of stoichiometry can generate an exhaust gas feedstream including NOx emissions and particulate matter. There is a need for an exhaust aftertreatment system to manage the exhaust gas feedstream.
- An apparatus for treating an exhaust gas feedstream from an internal combustion engine operating lean of stoichiometry comprises a particulate filter device comprising a porous substrate element having a hydrocarbon-selective catalytically reactive washcoat.
- the hydrocarbon-selective catalytically reactive washcoat comprises a silver-oxide catalytic material on an alumina-based washcoat.
- An injection device is operative to inject a hydrocarbon reductant upstream of the particulate filter device.
- FIGS. 1 , 2 , and 3 are schematic diagrams of engine and exhaust aftertreatment systems, in accordance with the present disclosure.
- FIGS. 1 , 2 and 3 schematically depict an internal combustion engine 10 , control module (‘ECM’) 5 , and embodiments of an exhaust aftertreatment system in accordance with the disclosure.
- ECM control module
- Like numerals refer to like elements in FIGS. 1 , 2 , and 3 and the embodiments described herein.
- the exemplary engine 10 comprises a multi-cylinder internal combustion engine operative in a repetitive combustion cycle which can comprise intake, compression, power, and exhaust strokes.
- the engine 10 is selectively operative at an air/fuel ratio that is lean of stoichiometry.
- the engine 10 can be one of a compression-ignition engine and a spark-ignition engine that is operative lean of stoichiometry.
- the engine 10 can operate in one or more combustion modes including compression-ignition, spark-ignition, and controlled auto-ignition combustion modes.
- the engine 10 includes a plurality of reciprocating pistons attached to a crankshaft, which is operably attached to a transmission and a vehicle driveline to deliver tractive torque thereto, none of which are shown.
- the engine 10 generates an exhaust gas feedstream containing constituents that can be transformed by the aftertreatment system, including, e.g., hydrocarbons (hereafter ‘HC’), carbon monoxide (hereafter ‘CO’), nitrides of oxygen (hereafter ‘NOx’), and particulate matter (hereafter ‘PM’).
- HC hydrocarbons
- CO carbon monoxide
- NOx nitrides of oxygen
- PM particulate matter
- the exhaust aftertreatment system comprises an integrated system for converting the constituents of the exhaust gas feedstream to other forms in the presence of catalytically reactive materials through oxidation and reduction processes.
- An exhaust manifold (not separately labeled) entrains and directs exhaust gas flow to the exhaust aftertreatment system.
- the exhaust aftertreatment system of FIG. 1 includes a catalytic device 14 , an injection device 16 , and a particulate filter device 20 .
- the exhaust aftertreatment system of FIG. 2 includes catalytic device 14 , injection device 16 , particulate filter device 20 and a second catalytic device 24 downstream from the particulate filter device 20 .
- the exhaust aftertreatment system of FIG. 3 includes particulate filter device 20 and second catalytic device 24 downstream from the particulate filter device 20 .
- the aforementioned devices are preferably fluidly connected in series using pipes and connectors.
- One or more sensing devices can be adapted to monitor the exhaust gas feedstream.
- the exhaust gas feedstream can be monitored at various locations in the exhaust aftertreatment system, with the locations shown being monitored by various ones of sensors 12 , 18 , 22 , 26 and 28 .
- An application of the exhaust aftertreatment system can include one or more of the sensors 12 , 18 , 22 , 26 and 28 .
- the sensors 12 , 18 , 22 , 26 and 28 monitor parameters of the exhaust gas feedstream that can be correlated to constituents and/or temperature of the exhaust gas feedstream, and generate signals that are transmitted to the control module 5 .
- This may include sensor 12 which monitors the exhaust gas feedstream output from the engine 10 , preferably including one of NOx concentration and air/fuel ratio.
- Sensor 26 may monitor the exhaust gas feedstream downstream from the catalytic device 14 , preferably including a parameter corresponding to one of NOx concentration, air/fuel ratio, and temperature. A specific embodiment of the system that includes sensor 12 may not include sensor 26 .
- Sensor 18 may monitor the exhaust gas feedstream output from the catalytic device 14 and downstream of the injection device 16 , preferably including a parameter corresponding to one of NOx concentration and temperature.
- Sensor 22 may monitor the exhaust gas feedstream downstream from the particulate filter device 20 , preferably including a parameter corresponding to one of NOx concentration, temperature, and ammonia (NH 3 ). As shown in FIGS.
- sensor 28 may monitor the exhaust gas feedstream downstream from the second catalytic device 24 in the second embodiment, preferably a parameter corresponding to one of NOx concentration, temperature, and ammonia.
- the control module 5 monitors the signals from the specific sensors 12 , 18 , 22 , 26 and 28 and uses the signals to control of the engine 10 and the injection device 16 , and to monitor operation of the engine 10 , the injection device 16 , the catalytic device 14 , the particulate filter device 20 , and the second catalytic device 24 to diagnose faults therein.
- a virtual NOx sensing system comprising an executable algorithm resident in the control module 5 can be used to determine the NOx concentration in the exhaust gas feedstream based upon engine speed/load operating characteristics.
- the catalytic device 14 depicted in the embodiments shown in FIGS. 1 and 2 preferably comprises an oxidation catalyst.
- the catalytic device 14 is preferably constructed of a substrate (not shown) on which a washcoat and a catalytically reactive material, e.g., platinum or palladium, are applied.
- the substrate can be a metal foil device or a sintered ceramic device having a plurality of flow channels through which the exhaust gas feedstream can pass during operation of the engine 10 .
- the coated substrate is assembled into a metallic structure that is an element of the exhaust aftertreatment system.
- the injection device 16 depicted in the embodiments shown in FIGS. 1 and 2 preferably comprises a solenoid-operated fluid flow control valve that has a fluid outlet adapted to inject a hydrocarbon reductant into the exhaust gas feedstream downstream of the catalytic device 14 comprising the oxidation catalyst and sensor 26 and upstream of the particulate filter device 20 .
- the injection device 16 is operatively connected to the control module 5 , which controls timing and mass or quantity of the hydrocarbon reductant injected into the exhaust gas feedstream.
- the hydrocarbon reductant is preferably supplied from a fuel tank of the vehicle via a fluidic connection, none of which are shown.
- the particulate filter device 20 comprises a filtering device that is coated with a hydrocarbon-selective catalytically reactive washcoat for NOx emission reduction.
- the filtering device traps particulate matter contained in the exhaust gas feedstream.
- the particulate filter device 20 is constructed in a manner which causes the exhaust gas entering the filter inlet 19 to pass through a portion of the particulate filter device 20 to reach the filter outlet 21 .
- the particulate filter device 20 can include a multi-channel monolithic substrate element (not shown) constructed of a porous material.
- each of the channels is either capped on an end proximal to the filter inlet 19 or capped on an end proximal to the filter outlet 21 , with adjacent channels capped on alternate ends.
- the porosity of the substrate element is about 40% to 55%, indicating that 40% to 55% of the volume of the substrate element comprises pores and not substrate material.
- the pores can have diameters that are less than about 3 microns on average.
- the porous material of the substrate element can be formed from ceramic material, e.g., cordierite that is extruded and sintered.
- the porous material of the multi-channel substrate is coated with the hydrocarbon-selective catalytically reactive washcoat.
- the hydrocarbon-selective catalytically reactive washcoat also referred to as an HC-SCR washcoat, includes a chemically reactive material that reacts with the injected hydrocarbon reductant to reduce NOx gases to N 2 0.
- the hydrocarbon-selective catalytically reactive washcoat can comprise an alumina-based washcoat material with the chemically reactive material comprising a selective catalyst reduction catalyst.
- the selective catalyst reduction catalyst can comprise a silver alumina (hereafter “AgAl”) catalytic material, of a pre-selected weight percent of Ag 2 O supported on an alumina washcoat.
- One range for the selective catalyst reduction catalyst can be applied at a 1 to 4 wt. % Ag in AgAl, with a washcoat loading in a range 0.5 to 4 g/in 3 supported on the multi-channel substrate.
- the selective catalyst reduction catalyst can comprise copper on a washcoat at a copper mass loading and applied onto a substrate device.
- the coated substrate of the particulate filter device 20 is assembled into a metallic structure that is a part of the exhaust aftertreatment system.
- the second catalytic device 24 depicted in the embodiments shown in FIGS. 2 and 3 preferably includes a selective catalyst reduction device comprising a multi-channel ceramic monolithic substrate coated with a catalytically reactive washcoat that reacts with the exhaust gas feedstream output from the particulate filter device 20 .
- the catalytically reactive washcoat reacts with ammonia slip that can result from the NOx reduction occurring in the particulate filter device 20 .
- the catalytically reactive washcoat can comprise a selective catalyst reduction catalyst comprising a copper-zeolite catalytic material of a pre-selected weight percent and supported on an alumina washcoat.
- the second catalytic device 24 provides reaction sites to reduce NOx in the exhaust gas feedstream using ammonia output from the catalytic device 14 .
- the second catalytic device 24 may further include an oxidation catalyst, comprising a multi-channel ceramic monolithic substrate coated with a catalytically reactive washcoat containing Pt and/or Pd on Al 2 O 3 washcoat.
- the loading of the washcoat may be 1-3 g/in 3 , with Pt loadings of 3-150 g/ft 3 .
- the control module 5 is preferably an element of a distributed architecture comprising a plurality of control modules adapted to provide coordinated control of the engine 10 and other systems when the engine 10 and exhaust aftertreatment system are applied onto a vehicle (not shown).
- a user interface (‘UI’) 13 signally connects to a plurality of devices through which a vehicle operator controls and directs operation of the vehicle, including the engine 10 .
- Exemplary devices through which the vehicle operator provides input to the user interface 13 include an accelerator pedal, a brake pedal, transmission gear selector, and vehicle speed cruise control, none of which are separately illustrated.
- the control module 5 preferably communicates with the user interface 13 via a local area network bus 6 .
- the local area network bus 6 allows for structured communication of control parameters and commands between the various processors, control modules, and devices. The specific communication protocol utilized is application-specific.
- the control module 5 comprises a general-purpose digital computer including a microprocessor or central processing unit, storage mediums comprising non-volatile memory including read only memory and electrically programmable read only memory, random access memory, a high speed clock, analog to digital and digital to analog circuitry, input/output circuitry, and devices and appropriate signal conditioning and buffer circuitry.
- the control module 5 has a set of control algorithms, comprising resident program instructions and calibrations stored in the non-volatile memory and executed to provide the respective functions for controlling the engine 10 .
- the algorithms are preferably executed during preset loop cycles such that each algorithm is executed at least once each loop cycle.
- Algorithms are executed by the central processing unit and are operable to monitor inputs from the aforementioned sensing devices and execute control and diagnostic routines to control operation of actuators, using preset calibrations. Loop cycles are preferably executed at regular intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during ongoing engine and vehicle operation. Alternatively, algorithms may be executed in response to occurrence of an event.
- control module 5 monitors inputs from sensing devices, synthesizes information, and executes algorithms to control actuators to achieve control targets, including fuel economy, emissions, performance, driveability, and protection of hardware.
- the engine 10 is preferably operated lean of stoichiometry, generating a lean exhaust gas feedstream that passes through the exhaust aftertreatment system.
- the control module 5 monitors engine speed and load and air/fuel ratio to determine a mass flow concentration of NOx emissions, and controls the injection device 16 to control timing and mass or quantity of the hydrocarbon reductant injected into the exhaust gas feedstream based upon the mass flow concentration of NOx emissions.
- the quantity of the injected hydrocarbon reductant is controlled to react with the NOx emissions and reduce to nitrogen in the presence of the selective catalyst reduction catalyst.
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Abstract
Description
- This disclosure is related to exhaust aftertreatment systems for internal combustion engines operating lean of stoichiometry.
- The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
- An internal combustion engine operating lean of stoichiometry can generate an exhaust gas feedstream including NOx emissions and particulate matter. There is a need for an exhaust aftertreatment system to manage the exhaust gas feedstream.
- An apparatus for treating an exhaust gas feedstream from an internal combustion engine operating lean of stoichiometry comprises a particulate filter device comprising a porous substrate element having a hydrocarbon-selective catalytically reactive washcoat. The hydrocarbon-selective catalytically reactive washcoat comprises a silver-oxide catalytic material on an alumina-based washcoat. An injection device is operative to inject a hydrocarbon reductant upstream of the particulate filter device.
- One or more embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:
-
FIGS. 1 , 2, and 3 are schematic diagrams of engine and exhaust aftertreatment systems, in accordance with the present disclosure. - Referring now to the drawings, wherein the showings are for the purpose of illustrating certain exemplary embodiments only and not for the purpose of limiting the same,
FIGS. 1 , 2 and 3 schematically depict aninternal combustion engine 10, control module (‘ECM’) 5, and embodiments of an exhaust aftertreatment system in accordance with the disclosure. Like numerals refer to like elements inFIGS. 1 , 2, and 3 and the embodiments described herein. - The
exemplary engine 10 comprises a multi-cylinder internal combustion engine operative in a repetitive combustion cycle which can comprise intake, compression, power, and exhaust strokes. Theengine 10 is selectively operative at an air/fuel ratio that is lean of stoichiometry. Theengine 10 can be one of a compression-ignition engine and a spark-ignition engine that is operative lean of stoichiometry. Theengine 10 can operate in one or more combustion modes including compression-ignition, spark-ignition, and controlled auto-ignition combustion modes. Theengine 10 includes a plurality of reciprocating pistons attached to a crankshaft, which is operably attached to a transmission and a vehicle driveline to deliver tractive torque thereto, none of which are shown. Theengine 10 generates an exhaust gas feedstream containing constituents that can be transformed by the aftertreatment system, including, e.g., hydrocarbons (hereafter ‘HC’), carbon monoxide (hereafter ‘CO’), nitrides of oxygen (hereafter ‘NOx’), and particulate matter (hereafter ‘PM’). - The exhaust aftertreatment system comprises an integrated system for converting the constituents of the exhaust gas feedstream to other forms in the presence of catalytically reactive materials through oxidation and reduction processes. An exhaust manifold (not separately labeled) entrains and directs exhaust gas flow to the exhaust aftertreatment system. The exhaust aftertreatment system of
FIG. 1 includes acatalytic device 14, aninjection device 16, and aparticulate filter device 20. The exhaust aftertreatment system ofFIG. 2 includescatalytic device 14,injection device 16,particulate filter device 20 and a secondcatalytic device 24 downstream from theparticulate filter device 20. The exhaust aftertreatment system ofFIG. 3 includesparticulate filter device 20 and secondcatalytic device 24 downstream from theparticulate filter device 20. The aforementioned devices are preferably fluidly connected in series using pipes and connectors. - One or more sensing devices can be adapted to monitor the exhaust gas feedstream. The exhaust gas feedstream can be monitored at various locations in the exhaust aftertreatment system, with the locations shown being monitored by various ones of
sensors sensors sensors control module 5. This may includesensor 12 which monitors the exhaust gas feedstream output from theengine 10, preferably including one of NOx concentration and air/fuel ratio.Sensor 26 may monitor the exhaust gas feedstream downstream from thecatalytic device 14, preferably including a parameter corresponding to one of NOx concentration, air/fuel ratio, and temperature. A specific embodiment of the system that includessensor 12 may not includesensor 26.Sensor 18 may monitor the exhaust gas feedstream output from thecatalytic device 14 and downstream of theinjection device 16, preferably including a parameter corresponding to one of NOx concentration and temperature.Sensor 22 may monitor the exhaust gas feedstream downstream from theparticulate filter device 20, preferably including a parameter corresponding to one of NOx concentration, temperature, and ammonia (NH3). As shown inFIGS. 2 and 3 ,sensor 28 may monitor the exhaust gas feedstream downstream from the secondcatalytic device 24 in the second embodiment, preferably a parameter corresponding to one of NOx concentration, temperature, and ammonia. Thecontrol module 5 monitors the signals from thespecific sensors engine 10 and theinjection device 16, and to monitor operation of theengine 10, theinjection device 16, thecatalytic device 14, theparticulate filter device 20, and the secondcatalytic device 24 to diagnose faults therein. Alternatively, a virtual NOx sensing system comprising an executable algorithm resident in thecontrol module 5 can be used to determine the NOx concentration in the exhaust gas feedstream based upon engine speed/load operating characteristics. - The
catalytic device 14 depicted in the embodiments shown inFIGS. 1 and 2 preferably comprises an oxidation catalyst. Thecatalytic device 14 is preferably constructed of a substrate (not shown) on which a washcoat and a catalytically reactive material, e.g., platinum or palladium, are applied. The substrate can be a metal foil device or a sintered ceramic device having a plurality of flow channels through which the exhaust gas feedstream can pass during operation of theengine 10. The coated substrate is assembled into a metallic structure that is an element of the exhaust aftertreatment system. - The
injection device 16 depicted in the embodiments shown inFIGS. 1 and 2 preferably comprises a solenoid-operated fluid flow control valve that has a fluid outlet adapted to inject a hydrocarbon reductant into the exhaust gas feedstream downstream of thecatalytic device 14 comprising the oxidation catalyst andsensor 26 and upstream of theparticulate filter device 20. Theinjection device 16 is operatively connected to thecontrol module 5, which controls timing and mass or quantity of the hydrocarbon reductant injected into the exhaust gas feedstream. The hydrocarbon reductant is preferably supplied from a fuel tank of the vehicle via a fluidic connection, none of which are shown. - The
particulate filter device 20 comprises a filtering device that is coated with a hydrocarbon-selective catalytically reactive washcoat for NOx emission reduction. The filtering device traps particulate matter contained in the exhaust gas feedstream. There is afilter inlet 19 and afilter outlet 21. Theparticulate filter device 20 is constructed in a manner which causes the exhaust gas entering thefilter inlet 19 to pass through a portion of theparticulate filter device 20 to reach thefilter outlet 21. By way of example, theparticulate filter device 20 can include a multi-channel monolithic substrate element (not shown) constructed of a porous material. Each of the channels is either capped on an end proximal to thefilter inlet 19 or capped on an end proximal to thefilter outlet 21, with adjacent channels capped on alternate ends. By way of example, the porosity of the substrate element is about 40% to 55%, indicating that 40% to 55% of the volume of the substrate element comprises pores and not substrate material. The pores can have diameters that are less than about 3 microns on average. The porous material of the substrate element can be formed from ceramic material, e.g., cordierite that is extruded and sintered. - The porous material of the multi-channel substrate is coated with the hydrocarbon-selective catalytically reactive washcoat. The hydrocarbon-selective catalytically reactive washcoat, also referred to as an HC-SCR washcoat, includes a chemically reactive material that reacts with the injected hydrocarbon reductant to reduce NOx gases to N20. The hydrocarbon-selective catalytically reactive washcoat can comprise an alumina-based washcoat material with the chemically reactive material comprising a selective catalyst reduction catalyst. The selective catalyst reduction catalyst can comprise a silver alumina (hereafter “AgAl”) catalytic material, of a pre-selected weight percent of Ag2O supported on an alumina washcoat. One range for the selective catalyst reduction catalyst can be applied at a 1 to 4 wt. % Ag in AgAl, with a washcoat loading in a range 0.5 to 4 g/in3 supported on the multi-channel substrate. Alternatively, the selective catalyst reduction catalyst can comprise copper on a washcoat at a copper mass loading and applied onto a substrate device. The coated substrate of the
particulate filter device 20 is assembled into a metallic structure that is a part of the exhaust aftertreatment system. - The second
catalytic device 24 depicted in the embodiments shown inFIGS. 2 and 3 preferably includes a selective catalyst reduction device comprising a multi-channel ceramic monolithic substrate coated with a catalytically reactive washcoat that reacts with the exhaust gas feedstream output from theparticulate filter device 20. The catalytically reactive washcoat reacts with ammonia slip that can result from the NOx reduction occurring in theparticulate filter device 20. The catalytically reactive washcoat can comprise a selective catalyst reduction catalyst comprising a copper-zeolite catalytic material of a pre-selected weight percent and supported on an alumina washcoat. The secondcatalytic device 24 provides reaction sites to reduce NOx in the exhaust gas feedstream using ammonia output from thecatalytic device 14. The secondcatalytic device 24 may further include an oxidation catalyst, comprising a multi-channel ceramic monolithic substrate coated with a catalytically reactive washcoat containing Pt and/or Pd on Al2O3 washcoat. The loading of the washcoat may be 1-3 g/in3, with Pt loadings of 3-150 g/ft3. - The
control module 5 is preferably an element of a distributed architecture comprising a plurality of control modules adapted to provide coordinated control of theengine 10 and other systems when theengine 10 and exhaust aftertreatment system are applied onto a vehicle (not shown). A user interface (‘UI’) 13 signally connects to a plurality of devices through which a vehicle operator controls and directs operation of the vehicle, including theengine 10. Exemplary devices through which the vehicle operator provides input to theuser interface 13 include an accelerator pedal, a brake pedal, transmission gear selector, and vehicle speed cruise control, none of which are separately illustrated. Thecontrol module 5 preferably communicates with theuser interface 13 via a localarea network bus 6. The localarea network bus 6 allows for structured communication of control parameters and commands between the various processors, control modules, and devices. The specific communication protocol utilized is application-specific. - The
control module 5 comprises a general-purpose digital computer including a microprocessor or central processing unit, storage mediums comprising non-volatile memory including read only memory and electrically programmable read only memory, random access memory, a high speed clock, analog to digital and digital to analog circuitry, input/output circuitry, and devices and appropriate signal conditioning and buffer circuitry. Thecontrol module 5 has a set of control algorithms, comprising resident program instructions and calibrations stored in the non-volatile memory and executed to provide the respective functions for controlling theengine 10. The algorithms are preferably executed during preset loop cycles such that each algorithm is executed at least once each loop cycle. Algorithms are executed by the central processing unit and are operable to monitor inputs from the aforementioned sensing devices and execute control and diagnostic routines to control operation of actuators, using preset calibrations. Loop cycles are preferably executed at regular intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during ongoing engine and vehicle operation. Alternatively, algorithms may be executed in response to occurrence of an event. - During operation of the
engine 10, thecontrol module 5 monitors inputs from sensing devices, synthesizes information, and executes algorithms to control actuators to achieve control targets, including fuel economy, emissions, performance, driveability, and protection of hardware. Theengine 10 is preferably operated lean of stoichiometry, generating a lean exhaust gas feedstream that passes through the exhaust aftertreatment system. - The
control module 5 monitors engine speed and load and air/fuel ratio to determine a mass flow concentration of NOx emissions, and controls theinjection device 16 to control timing and mass or quantity of the hydrocarbon reductant injected into the exhaust gas feedstream based upon the mass flow concentration of NOx emissions. The quantity of the injected hydrocarbon reductant is controlled to react with the NOx emissions and reduce to nitrogen in the presence of the selective catalyst reduction catalyst. - The disclosure has described certain preferred embodiments and modifications thereto. Further modifications and alterations may occur to others upon reading and understanding the specification. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.
Claims (18)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US12/203,573 US20100050616A1 (en) | 2008-09-03 | 2008-09-03 | Exhaust aftertreatment system |
DE102009039512A DE102009039512A1 (en) | 2008-09-03 | 2009-08-31 | Exhaust gas after-treatment system |
CN200910172810A CN101666255A (en) | 2008-09-03 | 2009-09-03 | Exhaust aftertreatment system |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US12/203,573 US20100050616A1 (en) | 2008-09-03 | 2008-09-03 | Exhaust aftertreatment system |
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US20100050616A1 true US20100050616A1 (en) | 2010-03-04 |
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US12/203,573 Abandoned US20100050616A1 (en) | 2008-09-03 | 2008-09-03 | Exhaust aftertreatment system |
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US (1) | US20100050616A1 (en) |
CN (1) | CN101666255A (en) |
DE (1) | DE102009039512A1 (en) |
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Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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KR102149735B1 (en) * | 2012-10-18 | 2020-08-31 | 존슨 맛쎄이 퍼블릭 리미티드 컴파니 | Close-coupled scr system |
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Also Published As
Publication number | Publication date |
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DE102009039512A1 (en) | 2010-04-08 |
CN101666255A (en) | 2010-03-10 |
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