US20060251548A1 - Exhaust aftertreatment device - Google Patents
Exhaust aftertreatment device Download PDFInfo
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- US20060251548A1 US20060251548A1 US11/123,903 US12390305A US2006251548A1 US 20060251548 A1 US20060251548 A1 US 20060251548A1 US 12390305 A US12390305 A US 12390305A US 2006251548 A1 US2006251548 A1 US 2006251548A1
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- exhaust
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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
- F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
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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
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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
- F01N3/022—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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0222—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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
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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]
- F01N3/208—Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
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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
- F01N2560/00—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
- F01N2560/02—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor
- F01N2560/021—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor for measuring or detecting ammonia NH3
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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
- F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
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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
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
- F01N2610/146—Control thereof, e.g. control of injectors or injection valves
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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
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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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49345—Catalytic device making
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
Description
- The present invention relates to a device for treating exhaust gases from an internal combustion engine. In particular, the exhaust aftertreatment device contains parallel channels of a porous material with about half of the channels being plugged on the upstream end. The device is coated with a SCR (selective catalytic reduction) washcoat.
- Achieving low NOx (NO, nitric oxide, plus NO2, nitrogen dioxide) emissions from lean-burning engines, such as diesels is a challenge. To treat NOx emitted from diesel engines, SCRs and LNTs (lean NOx traps) have been developed. LNTs operate in a lean/rich cycle in which NOx is purged during lean operation and NOx is released and reacted in a shorter period of rich operation. A disadvantage of LNTs is that they significantly degrade diesel fuel economy. Although SCRs do not consume a large amount of extra fuel to react NOx, urea is supplied to the SCR to cause the NOx reaction. For vehicular use, an onboard urea tank and delivery system is used.
- It has been found that SCRs are very effective at converting NOx to N2 and O2 under steady state conditions. However, during transient conditions, such as tip-ins (driver demand for a rapid increase in torque), a high concentration of NOx passes through the SCR unreacted. SCRs have not achieved the extremely low NOx emission levels of gasoline engines with three-way catalysts, largely due to the large NOx breakthrough during transients.
- A need exists for a catalyst system which provides very low NOx emissions without incurring a large fuel consumption penalty.
- Low NOx conversion efficiency of prior art SCRs during transient engine operation is overcome by a substrate comprised of multiple, porous, parallel channels in which about half of the channels are plugged preferably on the upstream end. The substrate is made of cordierite or silicon carbide with a porosity greater than 10%, but preferably 35 to even 65%. The substrate is placed in an engine exhaust with the plugged end preferably closer to the engine. The substrate is wash coated with copper zeolite or other SCR type coatings which provide molecular storage of NH3 for the reduction of NOx. The substrate contains 100 to 600 cells per square inch, with greater than 250 cells per square inch being preferred. In another embodiment, the number of cells in the substrate nears 1000 cells per square inch.
- In one embodiment, flow restrictors are placed in the open channels at the downstream end, i.e., the opposite end in which the plugs are placed. Preferably, the flow restrictors are placed in channels without plugs and not in channels with plugs, but flow restrictions could be placed in both the open or primary flow channels as well as the plugged or secondary flow channels to facilitate fabrication and avoid high cost.
- A method of manufacturing an exhaust aftertreatment device in disclosed in which a porous substrate of multiple, parallel channels is formed. Some, but not all of the channels are plugged near one end of the channels. A washcoat is applied to the substrate after the plugging of some of the channels. The substrate is formed of cordierite. Alternatively, silicon carbide is used. The channels are square in cross-section and alternative channels are plugged on the upstream end. The plug material is the same as the substrate material.
- A SCR according to the present invention provides superior control of NOx during transient operating conditions compared to prior art SCRs when equipped on a diesel vehicle (
FIGS. 7 and 8 ). The NOx breakthrough during transients is reduced one-third to over three-fourths depending on the nature of the tip-in. By controlling transient emissions, overall diesel cycle NOx emissions are halved with the SCR of the present invention compared to the prior art. - Additionally, this concept improves steady state NOx efficiency by providing improved diffusion and subsequent kinetics by the effective storage mechanisms having a deeper penetration into and through the washcoat material applied to either or both sides of the porous substrate material. Washcoats and their placement in the channels can be varied to facilitate cross flow from the primary to the secondary channels. Traditional channel flow diffusion and kinetics with a shared packed bed or wall flow diffusion and kinetics are coupled in the present invention allowing more efficient systems at converting NOx.
- The advantages described herein will be more fully understood by reading an example of an embodiment in which the invention is used to advantage, referred to herein as the Detailed Description, with reference to the drawings wherein:
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FIG. 1 is a schematic of an engine equipped with an exhaust aftertreatment device according to an aspect of the present invention; -
FIG. 2 is a schematic of a diesel particulate filter of the prior art; -
FIG. 3 is a schematic of a SCR catalyst according to an aspect of the present invention; -
FIG. 4 shows an upstream end and a downstream end of a SCR catalyst according to an aspect of the present invention; -
FIG. 5 is a schematic showing a series of aftertreatment devices according to an aspect of the present invention; -
FIG. 6 shows upstream ends of two serial SCR catalysts according to an aspect of the present invention; -
FIG. 7 is a graph of tailpipe NOx concentration from a diesel vehicle during a drive cycle, the aftertreatment system of the diesel engine comprising a SCR catalyst according to the prior art; and -
FIG. 8 is a graph of tailpipe NOx concentration from a diesel vehicle during a drive cycle, the aftertreatment system of the diesel engine comprising a SCR catalyst according to the present invention. - A 4-cylinder
internal combustion engine 10 is shown, by way of example, inFIG. 1 .Engine 10 is supplied air throughintake manifold 12 and discharges spent gases throughexhaust manifold 14. An intake duct upstream of theintake manifold 12 contains athrottle valve 32 which, when actuated, controls the amount of airflow toengine 10.Sensors intake manifold 12 measure air temperature and mass air flow (MAF), respectively.Sensor 31, located inintake manifold 14 downstream ofthrottle valve 32, is a manifold absolute pressure (MAP) sensor. A partially closedthrottle valve 32 causes a pressure depression inintake manifold 12. When a pressure depression exists inintake manifold 12, exhaust gases are caused to flow through exhaust gas recirculation (EGR)duct 19, which connectsexhaust manifold 14 to intakemanifold 12. Within EGRduct 19 is EGRvalve 18, which is actuated to control EGR flow andoptional intercooler 17. Fuel is supplied toengine 10 byfuel injectors 26, in a port fuel injected alternative. In a second alternative, fuel is supplied throughfuel injectors 30, a configuration commonly called direct injection. Although it is typical for fuel to be supplied by one or the other ofport injectors 26 ordirect fuel injectors 30, other alternatives include: carburetion (not shown because such carburetor would be located upstream of throttle valve 32) and any combination of carburetion, port injection, and direct injection. Eachcylinder 16 ofengine 10 contains aspark plug 26 in embodiments using spark ignition. In another alternative,engine 10 is a diesel or compression ignition engine in which ignition spontaneously occurs upon compression. The crankshaft (not shown) ofengine 10 is coupled to atoothed wheel 20.Sensor 22, placed proximately to toothedwheel 20, detectsengine 10 rotation. - Continuing to refer to
FIG. 1 , electronic control unit (ECU) 40 is provided to controlengine 10. ECU 40 has amicroprocessor 46, called a central processing unit (CPU), in communication with memory management unit (MMU) 48.MMU 48 controls the movement of data among the various computer readable storage media and communicates data to and fromCPU 46. The computer readable storage media preferably include volatile and nonvolatile storage in read-only memory (ROM) 50, random-access memory (RAM) 54, and keep-alive memory (KAM) 52, for example.KAM 52 may be used to store various operating variables whileCPU 46 is powered down. The computer-readable storage media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used byCPU 46 in controlling the engine or vehicle into which the engine is mounted. The computer-readable storage media may also include floppy disks, CD-ROMs, hard disks, and the like.CPU 46 communicates with various sensors and actuators via an input/output (I/O)interface 44. Examples of items that are actuated under control byCPU 46, through I/O interface 44, are fuel injection timing, fuel injection rate, fuel injection duration,throttle valve 32 position,spark plug 26 timing (in an alternate embodiment related to a spark ignition engine),EGR valve 18 position, andurea injector 64 opening. Variousother sensors 42 and specific sensors (engine speed sensor 22, in-line torque sensor, cylinder pressure transducer sensor,engine coolant sensor 38, manifoldabsolute pressure sensor 31, exhaustgas component sensors air temperature sensor 34, and mass airflow sensor 36) communicate input through I/O interface 44 and provide signals from which engine rotational speed, vehicle speed, coolant temperature, manifold pressure, pedal position, cylinder pressure, throttle valve position, air temperature, exhaust temperature, exhaust stoichiometry, exhaust component concentration, and air flow can be computed. SomeECU 40 architectures do not containMMU 48. If noMMU 48 is employed,CPU 46 manages data and connects directly toROM 50,RAM 54, andKAM 52. The present invention could utilize more than oneCPU 46 to provide engine control andECU 60 may containmultiple ROM 50,RAM 54, andKAM 52 coupled toMMU 48 orCPU 46 depending upon the particular application. - Continuing with
FIG. 1 , exhaust gases fromengine 10 pass throughexhaust aftertreatment device 38.Sensor 24, inexhaust manifold 14 located upstream ofexhaust aftertreatment device 38, is an exhaust gas component sensor. In one embodiment,exhaust aftertreatment device 38, is a SCR catalyst.Urea tank 60 containsurea 62 which is supplied to the engine exhaust throughinjector 64.Urea injector 64 is controlled by ECU 40 (electrical connection between the two not shown). Downstream ofSCR 38 is exhaustgas component sensor 25, which senses ammonia.Urea 62 is supplied toSCR 38 to cause NOx to react to N2 and O2. It is desirable to provide nomore urea 62 toSCR 38 than is reacted withinSCR 38.Unreacted urea 62 breaking throughSCR 38 is detected bysensor 25.Urea sensor 64 can be feedback controlled to avoidurea 62 breakthrough. -
Exhaust aftertreatment device 38, shown inFIG. 1 , is alternatively a LNT. In this embodiment,sensors sensor 24 is a wide-range exhaust gas oxygen sensor or a combination NOx and wide-range exhaust gas oxygen sensor. - As shown in
FIG. 1 ,engine 10 is naturally aspirated. However, the present invention is not limited to naturally-aspirated engines. The present invention is compatible with pressure charging of the intake gases as accomplished by a turbocharger, supercharger, or any combination of these devices and other know pressure charging device. - In
FIG. 2 , a schematic of a portion of a diesel particulate filter (DPF)substrate 70 is shown. DPFs are known to contain multiple,parallel channels 72. Half of the channels containplugs 76 at a first end.Channels 72 not plugged at the first end are plugged at the opposite end.Walls 74 ofchannels 72 are porous to allow gases to pass through, but particulate matter (soot) is trapped onwalls 74. As can be seen inFIG. 2 , the exhaust gas must pass through awall 74 to exitsubstrate 70. Thereby, all exhaust gases are filtered. DPFs are known to be constructed of cordierite and of silicon carbide. - In
FIG. 3 is shown an exhaust aftertreatment device according to the present method.Substrate 80, made of cordierite, contains multiple,parallel channels 82 withporous walls 84. About half ofchannels 82 containplugs 86 at one end.Plugs 86 allow almost no soot to pass through, but are porous enough to allow some smaller molecules, such as ammonia, NH3, to pass. In one embodiment, the plugs are made of the substrate material. But, because they are thicker than the walls, they provide a greater barrier to larger particles such as soot to pass. In contrast to a DPF, insubstrate 80, about half ofchannels 82 do not have plugs.Substrate 80 contains awashcoat 90. Some of the inlet gases traverse throughsubstrate 80 without passing throughwalls 84. Some gases do pass throughwalls 84 prior to exitingsubstrate 80. To encourage more flow throughwalls 84, one embodiment includesflow restrictors 88 providing more pressure drop in unplugged channels. In the present invention, restrictors 88 do not occlude the cross-section of the channel. In contrast, plugs 86 do extend across the cross-section of the channel. - In one embodiment, the primary channel walls, i.e., without plugs, have
washcoat 90. Secondary channels, i.e, those containing plugs are impregnated with the washcoat materials. In this way, three diffusion and kinetic mechanisms favoring NOx conversion are encouraged: primary channel flow, secondary channel flow, and very slow packed bed flow through the wall. To this end, it is desirable to have small channels: preferably above 250 cells per square inch. Furthermore, to facilitate flow throughwalls 84, porous walls (>50% porosity) are desired. It is desirable to have the ratio of primary (through nonplugged channels) flow to secondary (plugged channels) flow to be around the ratio of 2:1. One alternative is to select the porosity to provide such flow ratio. - To further encourage flow into and through
wall 84, the length ofsubstrate 80 is extended as much as possible within manufacturing feasibility, i.e., to avoid substrate cracking. A long substrate increases back pressure and encourages cross-flow diffusion and kinetics. Preferably, the substrate length is more than 1.5 times the diameter of the substrate. This provides an alternative or complementary embodiment to the use ofrestrictors 82. - In yet another embodiment, primary channels (no plugs) utilize coarser grain washcoat and thicker walls, whereas secondary channels (with plugs) utilize finer grain washcoat and thinner walls. Furthermore, secondary channels are less than fully coated to encourage cross-flow.
- In a preferred embodiment,
substrate 80 is coated with an acidic material, such acidic material selected to rendersubstrate 80 an SCR. There are many different and evolving SCR washcoats which are suitable depending on activation temperature, maximum temperature, porosity requirements, contamination, etc. The application of these washcoats to maximize wall-flow diffusion by regions, thicknesses, and zone coating are a part of this invention. - An
upstream cross-section 92 ofsubstrate 80 is shown inFIG. 4 , in which the cross-section of the channels are square and every other channel is plugged, as in a checkerboard fashion. Also inFIG. 4 is the downstream cross-section ofsubstrate 80, in which no channels are plugged. The illustration inFIG. 4 is for example only and not intended to be limiting. Alternatively, the channels are hexagonal or other tessellating shapes. - In the example shown in
FIG. 4 , half of the channels are plugged. However, alternatively less than half of the channels are plugged. In yet another alternative, more than half of the channels are plugged, which increases diffusion by increasing pressure drop. -
Multiple aftertreatment units FIG. 5 . In one embodiment,units substrates 80 according to the present invention. Alternatively,aftertreatment unit 39 is a conventional SCR andaftertreatment unit 41 is a conventional TWC (three-way catalyst). The inventors of the present invention contemplate many alternatives in whichdevices - In
FIG. 6 , two SCRs of the present invention are shown in which theupstream face 96 of one of the units has all the interior channels plugged and all of the exterior channels unplugged. Directly behind an SCR of this configuration is a second SCR in which theupstream face 98 has all interior channels unplugged ad the exterior channels plugged. This configuration causes flow to traverse from the exterior channels toward the interior channels as it moves from the first SCR to the second SCR. - In an alternative embodiment,
substrate 80 has alternately tapered channels such that crossover flow is encouraged. In particular, the nonplugged channels are wider on an upstream end and reduce in diameter along the length of the substrate. The plugged channels increase in diameter from the plugged end to a nonplugged end (downstream end). - In an alternate embodiment,
substrate 80 is made of silicon carbide. Silicon carbide is known to be less brittle, thus more durable, than cordierite, with a penalty of higher cost and weight. Silicon carbide, being more durable, is more able to be extruded to a longer length. A longer length allows more opportunity for diffusion. A length of at least 1.5 times the diameter is preferred. - It is desirable to decrease the size of
substrate 80 to facilitate packaging. The cross-sectional size ofsubstrate 80 is designed such that a tolerable pressure drop acrosssubstrate 80 is experienced at the highest flow conditions. In one embodiment, fewer than half of the channels are plugged at one end. It is desirable that each open channel have contact with a plugged channel, encouraging flow through the walls. By plugging fewer than half of the channels, flow throughsubstrate 80 is restricted less than if half are plugged. The advantage is that the cross-sectional area ofsubstrate 80 can be reduced. Alternatively, by plugging more than half of the channels, the pressure drop is increased, thereby promoting better diffusion. - In
FIG. 3 , flow is shown entering at the end containing plugs 86. This is desirable for an application in which there might be particulate matter in the exhaust gases, such as diesel engines. Ifplugs 86 were installed in the downstream end of thesubstrate 80, particulate matter would collect insubstrate 80. It is intended to filter particulate matter in a DPF in which collected particles are regularly incinerated to regenerate the DPF. If there is no intention of regeneratingsubstrate 80, it is desired to avoid collection of particles by adopting the orientation shown inFIG. 3 . In another embodiment in which there are few particles, such as a gasoline engine, it may be found to be advantageous to placesubstrate 80 in the flow in the opposite direction to that shown inFIG. 3 . - In a preferred embodiment,
substrate 80 contains awashcoat 90 which causes it to be a SCR. Aninjector 64 coupled to a urea tank 62 (injector and tank shown inFIG. 1 ) sprays an initial aqueous solution containing dissolved NH3. Under exhaust heat and reaction with water in the exhaust deposit NH3 typically to the acidic sites of the SCR wash coat. The urea solution coats and saturatessubstrate 80 and upon adsorption leaves the solid acidic matter on the surface ofsubstrate 80 as well as inside the porous walls and eventually on secondary walls also. It is the nature of NH3 to be both physio-adsorbed and chemi-adsorbed. In use, the acidic material attracts the reductant, which is basic. In the case of an SCR, urea converted to NH3 is typically the reductant material. The reductant is adsorbed on the solid acidic material of the washcoat available to react with NOx on a continuous basis. - Referring to
FIGS. 7 and 8 , the NOx concentration at the tailpipe of a diesel equipped vehicle is shown for a prior art SCR (FIG. 5 ) and a SCR of the present invention (FIG. 7 ). The spikes in the both figures correspond to tip-ins, driver demand for additional torque for acceleration, hill climb, highway passing, or other purposes. The magnitude of the spikes inFIG. 6 is greatly diminished over those shown inFIG. 5 . The resulting NOx emission over the drive cycle for a SCR of the present invention is a marked improvement over the prior art. - Alternately,
substrate 80 has aLNT washcoat 90. Such washcoat contains three components: a first component that facilitates oxidation of NO to NO2, a second component that traps NO2 on the surface (NO2 forming a nitrate on the surface), and a third component of precious metals, often rhodium, which reduces released NOx (under rich operating conditions) to N2. - In another alternative,
substrate 80 is used in place of traditional gasoline TWC substrates. This provides a precious metal cost save due to the enhanced diffusion and kinetics over traditional channel flow designs of TWCs. This embodiment provides diminished tip-in emission spikes. - This invention is also useful in non-automotive applications where diffusion, slow kinetics, and transients are problematic for catalysis, synthesis, and other chemical processes.
- Although the invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that modifications, substitutions, and additions and deletions may be made, without departing from the spirit or scope of the invention as defined in the appended claims.
Claims (34)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
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US11/123,903 US20060251548A1 (en) | 2005-05-06 | 2005-05-06 | Exhaust aftertreatment device |
GB0608498A GB2425740A (en) | 2005-05-06 | 2006-05-02 | An exhaust treatment device |
US11/670,449 US7833495B2 (en) | 2005-05-06 | 2007-02-02 | Exhaust treatment device facilitating through-wall flow |
US12/908,901 US8133842B2 (en) | 2005-05-06 | 2010-10-21 | Exhaust treatment device facilitating through-wall flow |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US11/123,903 US20060251548A1 (en) | 2005-05-06 | 2005-05-06 | Exhaust aftertreatment device |
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US11/670,449 Continuation-In-Part US7833495B2 (en) | 2005-05-06 | 2007-02-02 | Exhaust treatment device facilitating through-wall flow |
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US20060251548A1 true US20060251548A1 (en) | 2006-11-09 |
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US11/123,903 Abandoned US20060251548A1 (en) | 2005-05-06 | 2005-05-06 | Exhaust aftertreatment device |
US11/670,449 Expired - Fee Related US7833495B2 (en) | 2005-05-06 | 2007-02-02 | Exhaust treatment device facilitating through-wall flow |
US12/908,901 Expired - Fee Related US8133842B2 (en) | 2005-05-06 | 2010-10-21 | Exhaust treatment device facilitating through-wall flow |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
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US11/670,449 Expired - Fee Related US7833495B2 (en) | 2005-05-06 | 2007-02-02 | Exhaust treatment device facilitating through-wall flow |
US12/908,901 Expired - Fee Related US8133842B2 (en) | 2005-05-06 | 2010-10-21 | Exhaust treatment device facilitating through-wall flow |
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Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100050604A1 (en) * | 2008-08-28 | 2010-03-04 | John William Hoard | SCR-LNT CATALYST COMBINATION FOR IMPROVED NOx CONTROL OF LEAN GASOLINE AND DIESEL ENGINES |
US20100175372A1 (en) * | 2009-01-09 | 2010-07-15 | Christine Kay Lambert | Compact diesel engine exhaust treatment system |
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Cited By (24)
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US20100050604A1 (en) * | 2008-08-28 | 2010-03-04 | John William Hoard | SCR-LNT CATALYST COMBINATION FOR IMPROVED NOx CONTROL OF LEAN GASOLINE AND DIESEL ENGINES |
US9194273B2 (en) | 2008-10-31 | 2015-11-24 | Cummins Inc. | Apparatus, system, and method for aftertreatment control and diagnostics |
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US8223337B2 (en) * | 2008-10-31 | 2012-07-17 | Cummins Inc. | Apparatus, system, and method for aftertreatment control and diagnostics |
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US20100175372A1 (en) * | 2009-01-09 | 2010-07-15 | Christine Kay Lambert | Compact diesel engine exhaust treatment system |
US8844274B2 (en) | 2009-01-09 | 2014-09-30 | Ford Global Technologies, Llc | Compact diesel engine exhaust treatment system |
US20100266471A1 (en) * | 2009-04-17 | 2010-10-21 | Ford Global Technologies, Llc | Exhaust aftertreatment system and method of treating exhaust gas |
US8062618B2 (en) | 2009-04-17 | 2011-11-22 | Ford Global Technologies, Llc | Exhaust aftertreatment system and method of treating exhaust gas |
US9120056B2 (en) | 2010-02-16 | 2015-09-01 | Ford Global Technologies, Llc | Catalyst assembly for treating engine exhaust |
US9339800B2 (en) | 2010-02-16 | 2016-05-17 | Ford Global Technologies, Llc | Methods for treating engine exhaust |
US20110200505A1 (en) * | 2010-02-16 | 2011-08-18 | Ford Global Technologies, Llc | Catalyst Assembly for Treating Engine Exhaust |
US8842283B2 (en) | 2010-06-18 | 2014-09-23 | Cummins Inc. | Apparatus, system, and method for detecting engine fluid constituents |
US20120048305A1 (en) * | 2010-08-26 | 2012-03-01 | Alcini William V | Loose Fiber Cleaning Apparatus and Process |
US9441517B2 (en) | 2010-09-02 | 2016-09-13 | Ford Global Technologies, Llc | Diesel engine exhaust treatment system |
US20110138776A1 (en) * | 2010-09-02 | 2011-06-16 | Ford Global Technologies, Llc | Diesel engine exhaust treatment system |
US8137648B2 (en) | 2010-10-12 | 2012-03-20 | Ford Global Technologies, Llc | Diesel engine exhaust treatment system and method including a platinum group metal trapping device |
US20110138777A1 (en) * | 2010-10-12 | 2011-06-16 | Hungwen Jen | Diesel engine exhaust treatment system and method including a platinum group metal trapping device |
US20130220467A1 (en) * | 2012-02-28 | 2013-08-29 | Norma U.S. Holding Llc | Automotive selective catalytic reduction (scr) system sensor holder and assembly |
US9388932B2 (en) * | 2012-02-28 | 2016-07-12 | Norma U.S. Holding Llc | Automotive selective catalytic reduction (SCR) system sensor holder and assembly |
CN103256102A (en) * | 2013-04-24 | 2013-08-21 | 河南科技大学 | Diesel engine SCR urea solution jet device and jet amount control method thereof |
US20160222896A1 (en) * | 2013-07-04 | 2016-08-04 | Toyota Jidosha Kabushiki Kaisha | Exhaust gas purification system of internal combustion engine |
US10047689B2 (en) * | 2013-07-04 | 2018-08-14 | Toyota Jidosha Kabushiki Kaisha | Exhaust gas purification system of internal combustion engine |
Also Published As
Publication number | Publication date |
---|---|
US7833495B2 (en) | 2010-11-16 |
US20070128088A1 (en) | 2007-06-07 |
GB2425740A (en) | 2006-11-08 |
GB0608498D0 (en) | 2006-06-07 |
US8133842B2 (en) | 2012-03-13 |
US20110035941A1 (en) | 2011-02-17 |
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