WO2002071030A1

WO2002071030A1 - Particulate and gaseous emission testing method and apparatus

Info

Publication number: WO2002071030A1
Application number: PCT/AU2002/000232
Authority: WO
Inventors: Peter Anyon
Original assignee: Parsons Advanced Technologies Inc.
Priority date: 2001-03-02
Filing date: 2002-03-04
Publication date: 2002-09-12
Also published as: AUPR347901A0

Abstract

Testing particulate and gaseous exhaust emissions by withdrawing a relatively small sample of raw exhaust (8) from a raw exhaust stream (4), mixing a first portion of the withdrawn raw exhaust sample with a diluting gas in a predetermined constant proportion (12), testing a second portion of the withdrawn raw exhaust sample to measure gaseous emissions (11), and testing the mixed raw exhaust sample and diluting gas to measure particulate emissions (14).

Description

"PARTICULATE AND GASEOUS EMISSION TESTING METHOD AND

APPARATUS"

Technical field

This invention relates to a method of and an assembly for sampling, preconditioning and measuring the concentrations and mass flow of gases and/or fine particle levels in a fluid stream.

The invention has particular but not exclusive application to the measurement of concentrations and mass flow of gases and/or fine particles in the exhaust stream of a combustion process.

For illustrative purposes the invention will be described with reference to internal combustion engines.

Background of Invention

Over recent years, health and environmental authorities around the world have placed increased emphasis on reducing the adverse health impacts of airborne particulate and gaseous pollutants.

Research has shown that exhaust emissions from motor vehicles and other equipment using internal combustion engines are a dominant source of many pollutants of concern. Most notable of these are fine particulates and a range of chemical substances that combine to precipitate the formation of photochemical smog.

Industrial processes, domestic and industrial heating systems, electrical power generation plants and other processes involving combustion or the release of chemicals to the atmosphere also contribute to undesirable levels of airborne pollutants. Particulate emissions, most commonly from diesel internal combustion engines, have been widely acknowledged to be one of the most significant pollutant health threats to humans. Diesel particulate emissions, comprising a mixture of very finely divided carbonaceous matter, sulfates and highly toxic compounds, are carcinogenic and can affect the neurological and reproductive systems of humans.

Although research-grade laboratory instrumentation and test methods for diesel emissions have been developed, they are very expensive and time- consuming, making them unsuitable for use or adaptation to the low-cost, high volume measurements required to rapidly assess the emissions performance of in- use vehicles and industrial plant.

To accurately and repeatably measure gaseous and particulate emission rates in an exhaust flow, it is preferable, inter alia that:

• total exhaust mass flow rate be accurately measured or controlled;

• the exhaust sample be pre-conditioned to meet specified temperatures in order to achieve correct particulate formation; and

• vapour-to-liquid condensation in sample lines and/or measuring equipment be avoided.

The most commonly used known method of meeting the above criteria is to entrain the full exhaust stream (or a known portion of the stream) with a flow of dilution air, and to draw the sample/diluent mixture through a critical flow venturi such that the sum of the instantaneous exhaust flow, plus the dilution air flow, remains constant. This is known as a Constant Volume Sampler. Depending on the level of dilution required, a two-stage, or secondary dilution tunnel is frequently employed, together with its own mass-flow controllers and measurement systems.

FIG 1 schematically illustrates a known Constant Volume Sampling Emissions

Measuring System. Note that, for ease of understanding, details of the emissions measuring instrumentation and any mass flow controllers and sensors associated with the primary and secondary dilution tunnels have been omitted from FIG 1.

Although the total flow through the venturi remains constant, the flow rate of the raw exhaust gas stream entering the dilution tunnel may vary considerably over the sampling period. Hence this arrangement can be characterised as a "constant volume, variable dilution" system.

The known method achieves three outcomes:

^• the critical flow (sonic) venturi maintains a nominally constant (and known) total flow of sample/diluent mixture; • if the sample exhaust is hot (as is often the case) the dilution air can reduce the temperature of the mixture to a level that published standards require for valid measurements to be obtained (ie, below 52deg Celsius for diesel particulate matter measurement); and

• provided the dilution air is relatively dry and the dilution ratio is sufficiently high, the sample mixture will remain above the dew point of water vapour and thus avoid water condensation in the sample lines.

After suitable pre-conditioning as outlined above, the sample mixture may be analysed using known gaseous and particulate measuring systems to determine the concentration of each emission of interest. Multiplying the total exhaust/diluent flow rate by the concentration of pollutant, either on a second-by-second basis or integrated over a period of time, delivers a mass emission rate for the whole exhaust stream.

Alternatively, a sample of the diluted exhaust stream may be drawn off, at a constant volumetric rate, into a bag or similar receptacle over the required total sampling period. In this case, the concentration of emissions measured as a homogenous mixture in the sample bag, multiplied by the total flow through the venturi over the sampling period, delivers the total emissions of each pollutant over the same period. Summary of Invention

The present invention aims to provide an alternative to known methods of and apparatus for testing particulate and gaseous exhaust emissions. This invention in one aspect resides broadly in a method of testing particulate and gaseous exhaust emissions, the method including:- withdrawing a relatively small sample of raw exhaust from the raw exhaust stream; mixing a first portion of the withdrawn raw exhaust sample with a diluting gas in a predetermined constant proportion; testing a second portion of the withdrawn raw exhaust sample to measure gaseous emissions, and testing the mixed raw exhaust sample and diluting gas to measure particulate emissions. It is preferred that the method includes controlling the flow rate of the mixed raw exhaust sample and diluting gas.

It is preferred that the flow rate is controlled by applying a negative pressure to the mixed raw exhaust sample and diluting gas.

It is preferred that the mixing is performed at relatively low flow rates. It is preferred that the withdrawn raw exhaust sample and the diluting gas are respectively passed through substantially identical apertures.

It is also preferred that the proportions of the withdrawn raw exhaust sample and the diluting gas are controlled by passing each through a respective predetermined number of the apertures. The withdrawn raw exhaust sample may be mixed with the diluting gas in the predetermined proportion by:- introducing a first portion of the withdrawn raw exhaust sample and diluting gas into respective inlet means, and passing the first portion of the withdrawn raw exhaust sample and the diluting gas through a plurality of apertures into outlet means for receiving the mixed raw exhaust sample and diluting gas; the proportion of withdrawn raw exhaust sample to diluting gas being determined by the ratio of the total area of the apertures through which the withdrawn raw exhaust sample is passed to the total area of the apertures through which the diluting gas is passed.

It is further preferred that the method includes substantially equalising the temperature of the withdrawn raw exhaust sample and diluting gas prior to mixing. It is also preferred that the temperature equalising is achieved by passing the withdrawn raw exhaust sample and diluting gas along coaxial pipes or the like.

In another aspect this invention resides broadly in an apparatus for testing particulate and gaseous exhaust emissions, the apparatus including:- sampling means for withdrawing a relatively small sample of raw exhaust from the raw exhaust stream; mixing means for mixing a first portion of the withdrawn raw exhaust sample with a diluting gas in a predetermined constant proportion; gas testing means for testing a second portion of the withdrawn raw exhaust sample to measure gaseous emissions, and particulate testing means for testing the mixed raw exhaust sample and diluting gas to measure particulate emissions.

It is preferred that the apparatus includes flow rate control means for controlling the flow rate of the mixed raw exhaust sample and diluting gas.

It is preferred that the flow rate control means includes pump means for applying a negative pressure to the mixed raw exhaust sample and diluting gas.

It is also preferred that the mixing means includes a plurality of substantially identical apertures for having passed through respective ones thereof the withdrawn raw exhaust sample and the diluting gas.

It is also preferred that the mixing means includes respective inlet means for receiving the withdrawn raw exhaust sample and the diluting gas and outlet means for receiving the mixed raw exhaust sample and diluting gas.

It is preferred that the number of apertures through which the withdrawn raw exhaust sample and diluting gas are respectively passed is in the proportion in which the withdrawn raw exhaust sample and diluting gas are to be mixed. Thus the mixing means may include:- respective inlet means for receiving the first portion of the withdrawn raw exhaust sample and the diluting gas and outlet means for receiving the mixed raw exhaust sample and diluting gas, and a plurality of apertures for having passed through respective ones thereof the withdrawn raw exhaust sample and the diluting gas; wherein the predetermined proportion is the ratio of the total area of the apertures for having passed therethrough the withdrawn raw exhaust sample to the total area of the apertures for having passed therethrough the diluting gas.

It is preferred that the inlet and outlet means comprise coaxial pipes or the like whereby the temperature of the withdrawn raw exhaust sample and diluting gas is substantially equalised prior to mixing.

It is also preferred that the mixing means includes baffle plate means the apertures forming passages therethrough.

It is preferred that the baffle plate means separates the inlet means and the outlet means.

Description of Drawings

In order that this invention may be more easily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention, wherein:-

• FIG 2 is a schematic diagram showing the elements of the invention connected to an internal combustion engine exhaust system

• FIG 3 is a sectioned diagram of an example of a diluter for mixing a controlled portion of the raw exhaust stream with a controlled amount of diluent gas.

Description of Preferred Embodiment of Invention

Referring to FIG 2, in this example the internal combustion engine exhaust pipe (1) is connected via a gas-tight sleeve (2) to a length of flexible hose (3). This hose is, in turn, connected to a circular duct (4), of sufficient length to minimise turbulence and to establish substantially laminar flow of the exhaust stream. Towards the outlet end of the duct an averaging pitot-static tube assembly (5) is positioned to sense the stagnation and static pressures in the duct created by flow of the exhaust gases. The pitot-static outputs are in turn connected to a differential pressure transducer (6), which measures the difference between the stagnation and static pressures in the duct.

A fast-response thermocouple and associated signal conditioning assembly (7) measures the temperature of the exhaust stream in the duct.

Both the differential pressure transducer and the thermocouple outputs are transmitted to a computer (not shown), which uses the measurements to calculate the instantaneous average velocity of the exhaust stream and hence, as the diameter of the duct is known, the mass flow of exhaust in the duct.

A sample line (8) allows a portion of the exhaust stream to be directed to the various analysers and instruments used to measure emissions of interest. This sample line may be heated or insulated, as required, to prevent precipitation of water in the line through condensation due to cooling of the sample.

A known exhaust opacity meter (9) may optionally be connected to the sample line to continuously or periodically measure opacity (visible smoke) levels of the exhaust stream.

Known low-cost gas analysers (11), suitable for measuring gaseous concentrations of specific gases in a raw exhaust stream, may also be arranged to communicate with the sample line. In this example, the sample for gaseous analysis is first passed through a filter (10) to remove smoke and particulates which could contaminate the optical systems in the gas analyser(s). An arrangement for drying or de-watering the gaseous sample (not shown) may optionally be fitted in series with the filter.

For measurements of fine particulate matter in the exhaust stream, a sample of the exhaust stream is drawn through a diluter assembly (12) described in more detail below with reference to FIG 3. The diluted stream is then conducted to a known means of measuring particulate matter concentration (14). Dilution of the raw exhaust sample is achieved using a suitable, substantially non-reactive gas such as dry nitrogen or dried and filtered air. If ambient air is at low relative humidity levels, it is feasible to only filter the air to remove background particulate contamination.

A pump (15), optionally a vane or diaphragm type, draws both the dilution gas and the exhaust sample through the diluter assembly, wherein the two streams are mixed in a known proportion.

Reference is now made to FIG 3 in order to more readily understand the operation of the diluter assembly. FIG 3 is a sectioned diagram of one embodiment of a diluter for mixing a controlled portion of the raw exhaust stream with a controlled amount of diluent gas.

Inner rigid tube (16) is connected to the raw gas sample line. An outer casing (17), is located substantially coaxial with the inner tube and is fitted with an inlet tube (23) for dilution gas towards the end in closest proximity to the raw exhaust sample inlet. A threaded cap (18) is connected to the outer casing (17) such that the assembly comprises a chamber, which is closed except for the two inlet tubes and one outlet tube.

The threaded cap and the outer casing locate and engage an orifice plate (20), which, through the use of appropriate seals (not shown) permits the axial flow of dilution gas only through a number of small holes (21) normal to the face of orifice plate (20). The orifice holes (21) may optionally be arranged in a circular pattern coaxial with the body of the diluter assembly.

At the downstream end of the raw exhaust sample tube, a second orifice plate (19) is retained by a threaded cap and again sealed to only perrήit the axial passage of exhaust sample through one or more small orifice holes (22) normal to the face of orifice plate (19).

This arrangement allows ready dismantling and cleaning, as necessary, of any components likely to require maintenance. It is convenient, but not essential, that both orifice plates are of the same thickness and that all orifice holes are of substantially the same diameter and finish.

Both the dilution gas line and the raw exhaust sample line are arranged such that they are maintained at substantially ambient atmospheric pressure.

In operation, a negative pressure is applied to the diluted sample outlet of the diluter assembly, using a suitable pumping means (15). Because this negative pressure acts on both orifice plates (19 & 20) and their corresponding orifice holes (22 and 21), an axial flow of raw exhaust sample and dilution gas is induced.

Because in this example the differential pressure applied to each orifice plate, the thickness of each orifice plate, and the orifice hole geometry in each plate are all substantially the same, the flow rate of dilution gas relative to the flow rate of exhaust sample will be predetermined and in the ratio of the number of orifice holes in each plate, respectively. This predetermined dilution ratio will be maintained regardless of the actual level of pressure differential applied.

To minimise the potential for differences in temperature between the dilution and sample streams to cause differences in flow rates across the orifice holes, the dilution and sample streams in this example run coaxially for a suitable distance prior to passing through the orifices. This technique promotes temperature equalisation between the two streams.

If operating circumstances dictate, insulation or external heating, or both, may be applied to the sample tubes, dilution gas tubes and/or diluter body to avoid the exhaust sample from reaching a temperature lower than its dew point.

It will thus be appreciated that the present invention in the above described preferred embodiments:

^• dilutes and pre-conditions only a very small proportion of the total exhaust flow, sufficient to meet only the flow requirements of a particulate measuring instrument; • controls diluent and raw exhaust sample flow rates using passive flow control devices capable of operating at low pressure differential, thereby avoiding the need for a venturi and high-pressure generating devices;

• provides a constant and predetermined dilution ratio between the raw exhaust sample and the diluent gas; and

• optionally provides for the measurement of gaseous emissions and smoke opacity in the raw exhaust stream using low-cost analysers, simultaneous with diluted stream measurement of particulate emissions.

The assembly includes a means of connecting the exhaust outlet of an internal combustion engine to an emissions measuring apparatus such that either a portion (or optionally the total) of the exhaust gas flow is conducted to the emissions measuring apparatus. Means are provided to continuously or periodically measure the total exhaust mass flow of the engine.

For the measurement of particulate concentrations a tubular sample probe, or the like, is arranged in the emissions measuring apparatus to conduct a portion of the exhaust stream to a means of diluting the exhaust stream with a known proportion of suitable dilution gas.

The dilution means is arranged such that the predetermined ratio of diluent to exhaust sample remains substantially constant regardless of the temperature and/or pressure of the diluent and the exhaust sample.

The means for controlling the flow of both exhaust sample and diluent gas also includes means for mixing the exhaust sample and the diluent in such a manner as to achieve a substantially homogenous mixture that is at a temperature consistent with that prescribed in applicable standards or regulations pertaining to the measurement of particles in an exhaust stream.

The predetermined ratio of diluent gas to exhaust sample is controlled at a rate such that the dew point temperature of the mixture is lower than the actual temperature of the mixture as it passes into and through the particulate measuring instrument. This ensures that particulates in the sample stream are not entrapped by condensed vapours in the sample line, nor can small condensed water particles entrained in the sample stream lead to erroneous particle concentration measurements.

In direct contrast to the Constant Volume Sampling system described in FIG 1 which can be characterised as a " constant volume, variable dilution" system, the present invention can be characterised as a " variable volume, constant dilution" system.

The total volumetric flow rate of diluent/exhaust sample mixture is limited to only what is required for correct operation of the known particulate emissions measuring instrument or apparatus.

For the measurement of gaseous emissions, similar tubular sample probes or the like, communicate directly with the gaseous emissions measuring instruments. If known gaseous emissions measuring instruments are used that are affected by the presence of smoke, particulates or water content in the sample, means are provided to filter and/or de-water the sample prior to entry into the instruments. Such de-watering may optionally be achieved through the use of a water trap, desiccant absorber, chiller or the like.

If it is required to also measure the opacity of the exhaust stream, suitable known means of measuring opacity shall be arranged to communicate directly with a portion of the raw exhaust stream.

It will be appreciated that the present invention, which provides a reliable and accurate measurement of emission rates of fine particulates in the exhaust stream of combustion processes, has a number of advantages over known systems and methods.

The present invention provides a significant advance in the performance/cost ratio of emissions measuring equipment by enabling the use of both raw and diluted exhaust stream measurement in a single unit.

The system and its principal components described above constitute a compact, simple, reliable and low cost alternative to existing arrangements for measuring, controlling and pre-conditioning the flow of exhaust constituents prior to determining the concentration of emissions in the stream using known emission measuring instruments.

For example, the present invention does not require the use of large, bulky and expensive ducts, fans and venturi as are commonly employed in existing systems utilised for similar tasks.

The present invention can, if required, be packaged into a compact, lightweight container capable of being lifted readily by a human and is thus highly suitable for remote site testing or on-vehicle measurements of emissions.

In addition, because the present invention has no moving parts except for a simple and rugged pump, the system is much more amenable to transportation than other arrangements that are simply miniaturised versions of the full-scale prior art described above.

Known equipment is expensive, complex, and can consume high levels of power to move large volumes of exhaust/diluent while generating a pressure differential across the venturi sufficient to achieve sonic conditions at the choke point.

Known systems are also, in general, physically large and typically require a laboratory at least 6 meters in length and several highly skilled operators. As a result, such systems are not readily adapted for use in mobile or on-site emission measurements. Miniaturised, partial flow versions have been developed, using the same physical principles, but these also are complex, expensive and have only very limited portability.

in addition, because the exhaust gases are often highly diluted, the gaseous emissions measuring instruments must be very sensitive and of a much higher grade than would be required to obtain acceptably accurate measurements of undiluted, raw exhaust gas concentrations.

It will of course be realised that whilst the above has been given by way of an illustrative example of this invention, many modifications and variations thereto will

I be apparent to persons skilled in the art. For example, some alternatives to the system described above include:

• in those instances where it may be desirable to lower the temperature in the hose (3) connecting the exhaust pipe to the flow measurement duct (4), it is feasible to dispense with the gas-tight collar (2) and allow some ambient air to be entrained with the raw exhaust;

• means such as a vane or turbine anemometer, hot wire anemometer, plate orifice or the like may be used to measure air velocity in the flow measurement duct;

• the dilution gas and exhaust stream orifices may be arranged in alternative configurations to FIG 3. For instance the dilution orifices may be located on a cylindrical or conical section of the outer casing, such that their axes are directed towards the axis of revolution of the outer casing.

These and all such and other modifications and variations thereto, as would be apparent to persons skilled in the art, are deemed to fall in the broad scope and ambit of this invention as is hereinafter claimed.

Claims

The claims defining the invention are as follows:-

1. A method of testing particulate and gaseous exhaust emissions, the method including:- withdrawing a relatively small sample of raw exhaust from the raw exhaust stream; mixing a first portion of the withdrawn raw exhaust sample with a diluting gas in a predetermined constant proportion; testing a second portion of the withdrawn raw exhaust sample to measure gaseous emissions, and testing the mixed raw exhaust sample and diluting gas to measure particulate emissions.

2. A method as claimed in claim 1 , and including:- controlling the flow rate of the mixed raw exhaust sample and diluting gas.

3. A method as claimed in claim 2, wherein the flow rate is controlled by applying a negative pressure to the mixed raw exhaust sample and diluting gas.

4. A method as claimed in claim 3, wherein the mixing is performed at relatively low flow rates.

5. A method as claimed in claim 1 , wherein the withdrawn raw exhaust sample and the diluting gas are respectively passed through substantially identical apertures.

6. A method as claimed in claim 5, wherein the proportions of the withdrawn raw exhaust sample and the diluting gas are controlled by passing each through a respective predetermined number of the apertures .

7. A method as claimed in claim 1 , and including:- substantially equalising the temperature of the withdrawn raw exhaust sample and diluting gas prior to mixing.

8. A method as claimed in claim 7, wherein the temperature equalising is achieved by passing the withdrawn raw exhaust sample and diluting gas along coaxial pipes or the like.

9. A method as claimed in claim 1 , wherein the withdrawn raw exhaust sample is mixed with the diluting gas in the predetermined proportion by:- introducing a first portion of the withdrawn raw exhaust sample and the diluting gas into respective inlet means, and passing the withdrawn raw exhaust sample and the diluting gas through a plurality of apertures into outlet means for receiving the mixed raw exhaust sample and diluting gas; the proportion of withdrawn raw exhaust sample to diluting gas being ^' determined by the ratio of the total area of the apertures through which the withdrawn raw exhaust sample is passed to the total area of the apertures through which the diluting gas is passed.

10. An apparatus for testing particulate and gaseous exhaust emissions, the apparatus including:- sampling means for withdrawing a relatively small sample of raw exhaust from the raw exhaust stream; mixing means for mixing a first portion of the withdrawn raw exhaust sample with a diluting gas in a predetermined constant proportion; gas testing means for testing a second portion of the withdrawn raw exhaust sample to measure gaseous emissions, and particulate testing means for testing the mixed raw exhaust sample and diluting gas to measure particulate emissions.

11. An apparatus as claimed in claim 10, and including:- flow rate control means for controlling the flow rate of the mixed raw exhaust sample and diluting gas.

12. An apparatus as claimed in claim 11 , wherein the flow rate control means includes pump means for applying a negative pressure to the mixed raw exhaust sample and diluting gas.

13. An apparatus as claimed in claim 10, wherein the mixing means includes a plurality of substantially identical apertures for having passed through respective ones thereof the withdrawn raw exhaust sample and the diluting gas.

14. An apparatus as claimed in claim 10, wherein the mixing means includes respective inlet means for receiving the withdrawn raw exhaust sample and the diluting gas and outlet means for receiving the mixed raw exhaust sample and diluting gas.

15. An apparatus as claimed in claim 13, wherein the number of apertures through which the withdrawn raw exhaust sample and diluting gas are respectively passed is in the proportion in which the withdrawn raw exhaust sample and diluting gas are to be mixed.

16. An apparatus as claimed in claim 13, wherein the mixing means includes baffle plate means the apertures forming passages therethrough.

17. An apparatus as claimed in claim 16, wherein the baffle plate means separates the inlet means and the outlet means.

18. An apparatus as claimed in claim 10, wherein the inlet and outlet means comprise coaxial pipes or the like whereby the temperature of the withdrawn raw exhaust sample and diluting gas is substantially equalised prior to mixing.

19. An apparatus as claimed in claim 10, wherein the mixing means includes:- respective inlet means for receiving the first portion of the withdrawn raw exhaust. sample and the diluting gas and outlet means for receiving the mixed raw exhaust sample and diluting gas, and a plurality of apertures for having passed through respective ones thereof the withdrawn raw exhaust sample and the diluting gas; wherein the predetermined proportion is the ratio of the total area of the apertures for having passed therethrough the withdrawn raw exhaust sample to the total area of the apertures for having passed therethrough the diluting gas.