US20180347426A1 - Exhaust gas systems utilizing pre-turbine reductant injectors and methods for controlling the same - Google Patents
Exhaust gas systems utilizing pre-turbine reductant injectors and methods for controlling the same Download PDFInfo
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- US20180347426A1 US20180347426A1 US15/615,107 US201715615107A US2018347426A1 US 20180347426 A1 US20180347426 A1 US 20180347426A1 US 201715615107 A US201715615107 A US 201715615107A US 2018347426 A1 US2018347426 A1 US 2018347426A1
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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
- F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
- F01N11/007—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus
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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
- F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
- F01N3/106—Auxiliary oxidation catalysts
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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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- 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]
- F01N3/2073—Selective catalytic reduction [SCR] with means for generating a reducing substance from the exhaust gases
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by 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
- F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
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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
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/40—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a hydrolysis catalyst
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- 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
- F01N2340/00—Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses
- F01N2340/06—Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses characterised by the arrangement of the exhaust apparatus relative to the turbine of a turbocharger
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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
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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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- 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)
- Materials Engineering (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
Exhaust gas systems and method for controlling the same are provided. Systems include a hydrolysis catalyst device (HCD) in fluid communication with an exhaust gas conduit, a turbocharger turbine disposed downstream from the HCD and in fluid communication therewith via the conduit, a selective catalytic reduction device (SCR) disposed downstream from the turbine and in fluid communication therewith via the conduit; and a reductant injector configured to inject reductant into the conduit upstream from the HCD. The HCD can comprise TiO2, V2O5, A12O3, and SiO2. Methods can include injecting reductant upstream from turbine, such as while the SCR is below a NOx light-off temperature and/or a reductant decomposition temperature. The system can further include a second reductant injector configured to inject reductant into the conduit at a second injection location downstream from the turbine and upstream from the SCR, and the method can include injecting reductant via the second injector.
Description
- During a combustion cycle of an internal combustion engine (ICE), air/fuel mixtures are provided to cylinders of the ICE. The air/fuel mixtures are compressed and/or ignited and combusted to provide output torque. After combustion, pistons of the ICE force exhaust gases in the cylinders out through exhaust valve openings and into an exhaust system. The exhaust gas emitted from an ICE, particularly a diesel engine, is a heterogeneous mixture that contains gaseous emissions such as carbon monoxide (CO), unburned hydrocarbons (HC), and oxides of nitrogen (NOx), and oxides of sulfur (SOx) as well as condensed phase materials (liquids and solids) that constitute particulate matter.
- Exhaust gas treatment systems may employ catalysts in one or more components configured for accomplishing an after-treatment process such as reducing NOx to produce more tolerable exhaust constituents of nitrogen (e.g., N2) and water. One type of exhaust treatment technology for reducing NOx emissions is a selective catalytic reduction device (SCR), which generally includes a catalytic composition capable of reducing NOx species. A reductant, such as urea, is typically sprayed into hot exhaust gases upstream of the SCR, decomposed into ammonia, and absorbed by the SCR device. The ammonia then reduces the NOx to nitrogen and water in the presence of the SCR catalyst. Another type of exhaust treatment device is an oxidation catalyst (OC) device, which is commonly positioned upstream from a SCR to serve several catalytic functions, including oxidizing HC and CO species. Further, OCs can convert NO into NO2 to alter the NO:NOx ratio of exhaust gas in order to increase the NOx reduction efficiency of the downstream SCR.
- According to an aspect of an exemplary embodiment, an exhaust gas system is provided. The system can include a hydrolysis catalyst device (HCD) in fluid communication with an exhaust gas conduit, a turbocharger turbine disposed downstream from the HCD and in fluid communication therewith via the exhaust gas conduit, a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit, and a reductant injector configured to inject reductant into the exhaust gas conduit upstream from the HCD. The HCD can include one or more of TiO2 and V2O5. The HCD can include one or more of TiO2, V2O5, A1 2O3, and SiO2. Reductant can include urea and/or a nitrogen-rich substance capable of decomposing into ammonia. A decomposition temperature threshold of the reductant can be higher than a light-off temperature of the SCR. The SCR can be close-coupled to the turbocharger turbine.
- According to another aspect of an exemplary embodiment, an internal combustion engine (ICE) exhaust gas system is provided. The system can include an ICE configured to emit exhaust gas to an exhaust gas conduit, a turbocharger turbine disposed downstream from the ICE and in fluid communication therewith via the exhaust gas conduit, a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit, and a first reductant injector configured to inject reductant into the exhaust gas conduit at a first injection location upstream from the turbocharger turbine. A decomposition temperature threshold of the reductant can be higher than a light-off temperature of the SCR. The system can further include a hydrolysis catalyst device (HCD) in fluid communication with the exhaust gas conduit and disposed between the reductant injection location and the turbocharger turbine. The HCD can include one or more of TiO2, V2O5, A1 2O3, and SiO2. The system can further include a second reductant injector configured to inject reductant into the exhaust gas conduit at a second injection location downstream from the turbocharger turbine and upstream from the SCR. The ICE can be a diesel ICE. The reductant can include urea and/or a nitrogen-rich substance capable of decomposing into ammonia. The system can further include an oxidation catalyst device in fluid communication with the exhaust gas conduit and disposed downstream from the SCR.
- According to another aspect of an exemplary embodiment, a method for controlling an internal combustion engine (ICE) exhaust gas system is provided. The system can include an ICE configured to emit exhaust gas to an exhaust gas conduit, a turbocharger turbine disposed downstream from the ICE and in fluid communication therewith via the exhaust gas conduit, a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit, and a first reductant injector configured to inject reductant into the exhaust gas conduit at a first injection location upstream from the turbocharger turbine. A decomposition temperature threshold of the reductant can be higher than a light-off temperature of the SCR. Reductant can include urea and/or a nitrogen-rich substance capable of decomposing into ammonia. The method can include injecting reductant upstream from turbocharger turbine. Injecting reductant upstream from the turbocharger turbine can occur while the SCR is below a NOx light-off temperature and/or a reductant decomposition temperature threshold. The method can further include subsequently ceasing injection of reductant upstream from the turbocharger turbine after the SCR achieves a NOx light-off temperature and/or a reductant decomposition temperature threshold. The system can further include a second reductant injector configured to inject reductant into the exhaust gas conduit at a second injection location downstream from the turbocharger turbine and upstream from the SCR, and the method further can further include injecting reductant via the second injector after the SCR achieves a NOx light-off temperature and/or a reductant decomposition temperature threshold.
- Although many of the embodiments herein are describe in relation to ICE exhaust gas systems, the embodiments herein are generally suitable for all systems capable of accepting and treating NOx species using selective oxidation/reduction catalysts.
- Other objects, advantages and novel features of the exemplary embodiments will become more apparent from the following detailed description of exemplary embodiments and the accompanying drawings.
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FIG. 1 illustrates a schematic view of an exhaust gas treatment system, according to one or more embodiments; -
FIG. 2 illustrates a method for controlling an exhaust gas system, according to one or more embodiments. - Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
- Generally, this disclosure pertains to exhaust gas treatment systems utilizing turbochargers, selective catalytic reduction devices (SCR), and reductant injectors configured to inject reductant upstream from the turbocharger. Injecting reductant upstream from turbochargers provides better reductant decomposition and increases SCR performance, particularly at low temperatures. The exhaust gas treatment systems described herein can be implemented in various ICE systems that can include, but are not limited to, diesel engine systems, gasoline direct injection systems, and homogeneous charge compression ignition engine systems. The ICEs will be described herein for use in generating torque for vehicles, yet other non-vehicular applications are within the scope of this disclosure. Therefore when reference is made to a vehicle, such disclosure should be interpreted as applicable to any application of an ICE. Moreover, exhaust gas treatment systems are described in combination with an optional ICE for the purposes of illustration only, and the disclosure herein is not to be limited to gas sources provided by ICEs. It should be further understood that the embodiments disclosed herein may be applicable to treatment of any exhaust streams including oxides of nitrogen (NOx) or other chemical species which are desirably reduced by SCRs.
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FIG. 1 illustrates anexhaust gas system 100 including aturbocharger 10 configured to receive exhaust gas 8 via exhaust gas conduit 9, and an SCR 20 configured to receive exhaust gas 8 and reductant 36 via exhaust gas conduit 9. Reductant 36 can be injected into exhaust gas conduit 9 viainjector 30 at a reductant injection location. Exhaust gas 8 can be generated and communicated by ICE 1, for example.System 100 can further optionally include a hydrolysis catalyst device (HCD) 40 in fluid communication with the exhaust gas conduit 9 and disposed between the reductant injection location and theturbocharger 10.System 100 can further optionally include an oxidation catalyst device (OC) 50 configured to receive exhaust gas 8. As used herein, “upstream” and “downstream” can be defined in relation to the direction of the flow of exhaust gas 8 from ICE 1; accordingly, a component located upstream relative to a downstream component generally means that it is relatively closer to ICE 1, or that exhaust gas 8 arrives at the upstream component prior to the downstream component. - ICE 1 can include one or
more cylinders 2 capable of each accepting a piston (not shown) which can reciprocate therein. Air and fuel are combusted in the one or more cylinders thereby reciprocating the appurtenant pistons therein. Air 4 can be supplied to one ormore cylinders 2 via an air intake manifold 3, for example. The pistons can be attached to a crankshaft (not shown) operably attached to a vehicle driveline (not shown) in order to deliver tractive torque thereto, for example. ICE 1 can be of a spark ignition or a compression ignition design and can generally include any number of cylinder arrangements and a variety of reciprocating engine configurations including, but not limited to, V-engines, inline engines, and horizontally opposed engines, as well as both overhead cam and cam-in-block configurations. ICE I can comprise any engine configuration or application, including various vehicular applications (e.g., automotive, marine and the like), as well as various non-vehicular applications (e.g., pumps, generators and the like), - Exhaust gas 8 can generally include carbon monoxide (CO), unburned hydrocarbons (HC), water, NOx species, and optionally oxides of sulfur (SOx). Constituents of exhaust gas, as used herein, are not limited to gaseous species. As used herein, “NOx” refers to one or more nitrogen oxides. NOx species can include NyOx species, wherein y>0 and x>0. Non-limiting examples of nitrogen oxides can include NO, NO2, N2O, N2O2, N2O3, N2O4, and N2O5. HC refers to combustable chemical species comprising hydrogen and carbon, and generally includes one or more chemical species of gasoline, diesel fuel, or the like.
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Turbocharger 10 includes aturbine 11, for example disposed within a turbine housing (not shown), and acompressor 12, for example disposed within a compressor housing (not shown).Turbine 11 andcompressor 12 are mechanically coupled via a common rotatable shaft 13.Turbine 11 is configured in fluid communication with ICE 1 in order to receive exhaust gas 8 therefrom. In operation, theturbine 11 receives exhaust gas 8 from ICE 1, for example via a turbine exhaust intake (not shown). The intake can communicate exhaust gas to a circumferential volute, or scroll, which receives the exhaust gas 8 and directs the same toturbine 11, whereafter exhaust gas 8 is expelled from the turbine housing.Turbine 11 captures kinetic energy from the exhaust gases and spins thecompressor 12 via common shaft 13. Volumetric restrictions of the exhaust gas within the turbine housing further convert thermal energy into additional kinetic energy which is similarly captured by theturbine 11. Such a conversion results in a temperature differential (ΔT) acrossturbine 11. For example, under normal ICE 1 operating conditions, the temperature of exhaust gas 8 may be 400° C. upstream fromturbine compressor 12 via thecommon shaft 30 draws in air 4 through a compressor intake (not shown) which is compressed and delivered to the intake manifold 3 of ICE 1. Turbochargers are commonly used to enhance the efficiency and/or performance of ICEs, and are ideally close-coupled to an appurtenant ICE such that exhaust gas 8 kinetic energy and/or thermal energy is maximized prior to contactingturbine 11. As used herein, “close-coupled” refers to a close orientation of a device (e.g., turbine 11) relative to another (e.g., ICE 1), such as within 1 meter of linear exhaust gas conduit 9, or within the engine compartment of a vehicle. - In general, the
SCR 20 includes all devices which utilize areductant 36 and a catalyst to reduce NOx species to desired chemical species, including diatomic nitrogen, nitrogen-containing inert species, or species which are considered acceptable emissions, for example. Thereductant 36 can be ammonia (NH3), such as anhydrous ammonia or aqueous ammonia, or generated from a nitrogen and hydrogen rich substance such as urea (CO(NH2)2). For example, thereductant 36 can comprise urea and/or a nitrogen-rich substance capable of decomposing into ammonia. Additionally or alternatively, thereductant 36 can be any compound capable of decomposing or reacting in the presence of exhaust gas 8 and/or heat to form ammonia. Thereductant 36 can be diluted with water in various implementations. In implementations where thereductant 36 is diluted with water, heat (e.g., from the exhaust) evaporates the water, and ammonia is supplied to theSCR 20. Non-ammonia reductants can be used as a full or partial alternative to ammonia as desired. In implementations where thereductant 36 includes urea, the urea reacts with the exhaust to produce ammonia, and ammonia is supplied to theSCR 20. Equation (1) below provides an exemplary chemical reaction of ammonia production via urea decomposition. -
CO(NH2)2+H2O→2NH3+CO2 (1) - It should be appreciated that Equation (1) is merely illustrative, and is not meant to confine the urea or
other reductant 36 decomposition to a particular single mechanism, nor preclude the operation of other mechanisms. Efficient decomposition urea to NH3 typically requires temperatures in excess of about 200° C., and, depending on the amount of urea injected, for example relative to a flow rate of exhaust gas 8, urea can crystalize in temperatures less than about 200° C. Accordingly,reductant 36 injection events and/or dosing quantities are typically determined based upon system temperature and exhaust gas 8 flow rate, among others, such that urea decomposition yield is maximized and urea crystallization is minimized. Areductant 36 decomposition threshold can accordingly refer to a temperature threshold below which reductant 36 crystalizes and/or does not suitably decompose. - Equations (2)-(6) provide exemplary chemical reactions for NOx reduction involving ammonia.
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6NO+4NH3→5N2+6H2O (2) -
4NO+4NH3+O2→4N2+6H2O (3) -
6NO2+8NH3→7N2+12H2O (4) -
2NO2+4NH3+O2→3N2+6H2O (5) -
NO+NO2+2NH3→2N2+3H2O (6) - It should be appreciated that Equations (2)-(6) are merely illustrative, and are not meant to confine
SCR 20 to a particular NOx reduction mechanism or mechanisms, nor preclude the operation of other mechanisms.SCR 20 can be configured to perform any one of the above NOx reduction reactions, combinations of the above NOx reduction reactions, and other NOx reduction reactions. In some instances,SCR 20 comprises a NOx oxidizing temperature threshold above which SCR 20 can oxidizereductant 36 and/or its decomposition products (e.g., urea, NH3) into NOx. A NOx oxidizing temperature threshold can be 500° C., for example. -
SCR 20 includes a catalytic composition (CC) and can be packaged in a shell or canister in fluid communication with exhaust gas conduit 9 and configured to receive exhaust gas 8 andreductant 36 at upstream side. The shell or canister can comprise a substantially inert material, relative to the exhaust gas constituents, such as stainless steel. CC can comprise, be disposed on, or impregnated into a porous and high surface area material which can operate efficiently to convert NOx constituents in the exhaust gas 8 in the presence of areductant 36, such as ammonia. For example, the catalyst composition can contain a zeolite impregnated with one or more base metal components such as iron (Fe), cobalt (Co), copper (Cu), vanadium (V), sodium (Na), barium (Ba), titanium (Ti), tungsten (W), and combinations thereof. In a particular embodiment, the catalyst composition can contain a zeolite impregnated with one or more of copper, iron, or vanadium. In some embodiments the zeolite can be a β-type zeolite, a Y-type zeolite, a ZM5 zeolite, or any other crystalline zeolite structure such as a Chabazite or a USY (ultra-stable Y-type) zeolite. In a particular embodiment, the zeolite comprises Chabazite. In a particular embodiment, the zeolite comprises SSZ. Suitable CCs can have high thermal structural stability, particularly when used in tandem with particulate filter (PF) devices or when incorporated into selective catalytic reduction filter devices (SCRF), which are regenerated via high temperature exhaust soot burning techniques. CC can optionally further comprise one or more base metal oxides as promoters to further decrease the SO3 formation and to extend catalyst life. The one or more base metal oxides can include WO3, Al2O3, and MoO3, in some embodiments. In one embodiment, WO3, Al2O3, and MoO3 can be used in combination with V2O5. -
SCR 20 can have a light-off temperature above which CC exhibits desired or suitable catalytic activity or yield (e.g., reduction of NOx species). The light-off temperature can be dependent upon the type of catalytic materials of which CC is comprised, and the amount of catalytic materials present inSCR 20, among other factors. For example, a CC comprising V2O5 can have a light off temperature of about 300° C. In another example, a CC comprising Fe-impregnated zeolite can have a light off temperature of about 350° C. In another example, a CC comprising Cu-impregnated zeolite can have a light off temperature of about 150° C. WhenSCR 20 operates at a temperature below its light-off temperature, undesired NOx breakthrough and NH3 slip can occur wherein NOx and/or NH3 pass throughSCR 20 unreacted or unstored. NOx breakthrough and NH3 slip can be particularly problematic immediately after engine startup and in cold conditions. NOx breakthrough can also be exacerbated by lean burn strategies commonly implemented in diesel engines, for example. Lean burn strategies coordinate combustion at higher than stoichiometric air to fuel mass ratios to improve fuel economy, and produce hot exhaust with a relatively high content of O2 and NOx species. The high O2 content can further inhibit or prevent the reduction of NOx species in some scenarios. WhileSCRs 20 with low NOx light-off temperatures can reduce or prevent NOx breakthrough,reductant 36 decomposition thresholds ultimately limitSCR 20 performance. - Exhaust gas treatment devices which reduce the pressure and/or temperature of exhaust gas 8, such as
SCR 20, are commonly positioned downstream fromturbine 11 in order to maximizeturbocharger 10 performance. In some instances,SCR 20 is preferably positioned downstream fromturbine 11 because, under some ICE 1 operation conditions, exhaust gas 8 upstream fromturbine 11 can exceedSCR 20 NOx oxidizing thresholds.Reductant 36 can be supplied from a reductant reservoir (not shown) and is commonly injected into the exhaust gas conduit 9 at a location upstream fromSCR 20 via aninjector 30, or other suitable delivery means. Specifically,system 100 includesinjector 30 configured to injectreductant 36 into exhaust gas conduit 9 at an injection location upstream fromturbine 11 where exhaust gas 8 temperatures are higher.Reductant 36 injection upstream fromturbine 11 better facilitatesreductant 36 heating and/or decomposition and utilizesturbine 11 as a mixer/vaporizor, thereby allowingreductant 36 to be injected sooner in an ICE 1 operating cycle and eliminating or reducingreductant 36 crystallization, for example. In order to maximize the benefits ofupstream turbine 11reductant 36 injection, in someembodiments SCR 20 is close-coupled toturbine 11. - The position of
injector 30 is particularly advantageous during vehicle cold starts and in operating conditions wherein the temperature ofsystem 100 and/or the ambient is below thereductant 36 decomposition threshold. Specifically, injection ofreductant 36 upstream fromturbine 11 allowsreductant 36 to contact higher-temperature exhaust gas 8 and effect greater decomposition and mixing/vaporization, and the disposition ofSCR 20 downstream fromturbine 11 does not depriveturbine 11 of thermal energy. As used herein, a cold start refers to an ICE 1 start or operating period that occurs while the temperature of one or more exhaust gas 8 treatment devices (e.g., SCR 20) is lower than the ideal or suitable operating temperature of the device. Particularly, the temperature ofSCR 20 can refer to the average temperature of the CC. Additionally or alternatively a cold start can be identified by an ambient temperature threshold (e.g., below 40° C.), or an ambient temperature less than an ideal or suitable operating temperature ofSCR 20 CC. - In some embodiments, in order to increase
turbocharger 10 performance, increaseSCR 20 performance, optimizereductant 36 decomposition, and/or reduce wear to theturbine 11 caused byupstream reductant injection 36,system 100 can further comprise asecond injector 30′ configured to injectreductant 36 at a second injection location downstream fromturbine 11 and upstream fromSCR 20. Accordingly,reductant 36 can be supplied byinjector 30 under certain conditions, andreductant 36 can be supplied byinjector 30′ the same certain conditions and/or other conditions. For example,reductant 36 can be supplied byinjector 30 during a vehicle cold start, andreductant 36 can subsequently be supplied by 30′ aftersystem 100 has achieved a desired temperature.Reductant 36 can be supplied toinjectors -
Optional HCD 40 is configured to accept exhaust gas 8, for example via exhaust gas conduit 9, and facilitate and/or encourage the decomposition ofreductant 36 into desired chemical species. In particular,HCD 40 is configured to decompose urea into NH3.HCD 40 comprises a CC which can be packaged in a shell or canister configured to receive exhaust gas 8 at upstream side. The shell or canister can comprise a substantially inert material, relative to the exhaust gas constituents, such as stainless steel. CC can comprise, be disposed on, or impregnated into a porous and high surface area material, and can comprise one or more of TiO2, V2O5, Al2O3, and SiO2. In one embodiment, the CC comprises TiO2 and/or V2O5. For example the CC can be disposed on a porous monolith substrate, such as those discussed above. TheHCD 40, and in particular the CC substrate, can be configured to exhibit a low pressure differential (AP) across the device. The volume ofHCD 40 and the amount of CC can depend on many factors including the type of ICE 1, the volumetric flow of exhaust gas 8, and the amount ofreductant 36 normally injected, for example. While theHCD 40 may exacerbate pre-turbine 11 heat lost andturbocharger 10 lag, its disposition upstream fromturbine 11 serves to effect enhanced decomposition ofreductant 36 and enhanceSRC 20 performance, particularly in cold conditions. In some embodiments, as an alternative toHCD 40,turbine 11 can compriseHCD 40 CC on one or more outer surfaces such that the CC contacts reductant 36. An HCD, such asHCD 40, can have a similar NOx light-off temperature to an SCR, such asSCR 20. -
Optional OC 50 is a flow-through device comprising a CC and configured to accept exhaust gas 8.OC 50 is generally utilized to oxidize various exhaust gas 8 species, including HC, CO and NOx species. CC can he housed within a housing, such as a metal housing, having an inlet (i.e., upstream) opening and outlet (i.e., downstream) opening, or be otherwise configured to provide structural support and facilitate fluid (e.g., exhaust gas) flow throughOC 50. CC can comprise many various catalytically active materials and physical configurations thereof, and can optionally comprise a substrate such as a porous ceramic matrix or the like. Catalytically active materials can comprise platinum group metal catalysts, metal oxide catalysts, and combinations thereof. Suitable platinum group metals can include Pt, Pd, Rh, Ru, Os or Ir, or combinations thereof, including alloys thereof. In one embodiment, suitable metals include Pt, Pd, and combinations thereof, including alloys thereof. Suitable metal oxide catalyst can include iron oxides, zinc oxides, aluminum oxides, perovksites, and combination thereof, for example. In one embodiment, CC can comprise Pt and Al2O3. In many embodiments, CC comprises zeolite impregnated with one or more catalytically active base metal components. The zeolite can comprise a β-type zeolite, a Y-type zeolite, a ZM5 zeolite, or any other crystalline zeolite structure such as a Chabazite or a USY (ultra-stable Y-type) zeolite. In a particular embodiment, the zeolite comprises Chabazite. In a particular embodiment, the zeolite comprises SSZ. It is to be understood that the CC is not limited to the particular examples provided, and can include any catalytically active device capable of oxidizing HC, CO, and NOx species.OC 50 can store and/or oxidize NOx species in exhaust gas 8, which, for example, may form during the combustion of fuel. For example, in some embodiments,OC 50 can be utilized to convert NO into NO2 in order to optimize the exhaust gas NO:NO2 ratio for downstream SCRs and/or SCRFs which generally operate more efficiently with exhaust gas feed streams having a NO:NO2 ratio of about 1:1. As shown inFIG. 1 , however, OC is disposed downstream from SCR. -
System 100 can further include acontrol module 60 operably connected to monitor and/or control ICE 1,turbocharger 10,SCR 20,injector 30,HCD 40,DOC 50, and combinations thereof. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.Module 60 can controlreductant 36 injection, for example. -
FIG. 2 illustrates amethod 200 for controllingsystem 100.Method 200 will be described in the context ofsystem 100 for the purpose of clarity only, and those of skill in the art will recognize thatmethod 100 is not to be limited thereby.Method 200 comprises injecting 210reductant 36 upstream fromturbine 11 viainjector 30. In some embodiments, injecting 210 can occur whileSCR 20 is below a NOx light-off temperature. In some embodiments, injecting 210 can occur whileSCR 20 is below a reductant decomposition temperature. In some embodiments, injecting 210 can occur whileSCR 20 is below a NOx light-off temperature and/or a reductant decomposition temperature.Method 200 can further comprise subsequently injecting 220reductant 36 downstream fromturbine 11 viainjector 30′. In some embodiments, injecting 220 can occur afterSCR 20 has achieved a NOx light-off temperature. In some embodiments, injecting 220 can occur afterSCR 20 has achieved a reductant decomposition temperature. In some embodiments, injecting 220 can occur afterSCR 20 has achieved a NOx light-off temperature and/or a reductant decomposition temperature.Method 200 can further comprise ceasing 230 injection ofreductant 36 upstream fromturbine 11 viainjector 30. In some embodiments, ceasing 230 injection ofreductant 36 can occur afterSCR 20 has achieved a reductant decomposition temperature. In some embodiments, ceasing 230 injection ofreductant 36 can occur afterSCR 20 has achieved a reductant decomposition temperature. In some embodiments, ceasing 230 injection ofreductant 36 can occur after injecting 220 reductant viainjector 30′. In some embodiments, ceasing 230 injection ofreductant 36 can occur afterSCR 20 has achieved a reductant decomposition temperature, afterSCR 20 has achieved a reductant decomposition temperature, and/or after injecting 220 reductant viainjector 30′. - While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and can be desirable for particular applications.
Claims (20)
1. An exhaust gas system comprising:
a hydrolysis catalyst device (HCD) in fluid communication with an exhaust gas conduit
a turbocharger turbine disposed downstream from the HCD and in fluid communication therewith via the exhaust gas conduit;
a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit; and
a reductant injector configured to inject reductant into the exhaust gas conduit upstream from the HCD.
2. The exhaust gas system of claim 1 , wherein the HCD comprises one or more of TiO2, V2O5, Al2O3, and SiO2.
3. The exhaust gas system of claim 1 , wherein the HCD comprises one or more of TiO2 and V2O5.
4. The exhaust gas system of claim 1 , wherein the reductant comprises urea and/or a nitrogen-rich substance capable of decomposing into ammonia.
5. The exhaust gas system of claim 1 , wherein a decomposition temperature threshold of the reductant is higher than a light-off temperature of the SCR.
6. The exhaust gas system of claim 1 , wherein the SCR is close-coupled to the turbocharger turbine.
7. An internal combustion engine (ICE) exhaust gas system comprising:
an ICE configured to emit exhaust gas to an exhaust gas conduit;
a turbocharger turbine disposed downstream from the ICE and in fluid communication therewith via the exhaust gas conduit;
a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit; and
a first reductant injector configured to inject reductant into the exhaust gas conduit at a first injection location upstream from the turbocharger turbine.
8. The ICE exhaust gas system of claim 7 , wherein a decomposition temperature threshold of the reductant is higher than a light-off temperature of the SCR.
9. The ICE exhaust gas system of claim 7 , further comprising a hydrolysis catalyst device (HCD) in fluid communication with the exhaust gas conduit and disposed between the reductant injection location and the turbocharger turbine.
10. The ICE exhaust gas system of claim 9 , wherein the HCD comprises one or more of TiO2, V2O5, Al2O3, and SiO2.
11. The ICE exhaust gas system of claim 7 , further comprising a second reductant injector configured to inject reductant into the exhaust gas conduit at a second injection location downstream from the turbocharger turbine and upstream from the SCR.
12. The ICE exhaust gas system of claim 7 , wherein the ICE comprises a diesel ICE.
13. The ICE exhaust gas system of claim 7 , wherein the reductant comprises urea and/or a nitrogen-rich substance capable of decomposing into ammonia.
14. The ICE exhaust gas system of claim 7 , further comprising an oxidation catalyst device in fluid communication with the exhaust gas conduit and disposed downstream from the SCR.
15. A method for controlling an internal combustion engine (ICE) exhaust gas system, wherein the system includes an ICE configured to emit exhaust gas to an exhaust gas conduit, a turbocharger turbine disposed downstream from the ICE and in fluid communication therewith via the exhaust gas conduit, a selective catalytic reduction device (SCR) disposed downstream from the turbocharger turbine and in fluid communication therewith via the exhaust gas conduit, and a first reductant injector configured to inject reductant into the exhaust gas conduit at a first injection location upstream from the turbocharger turbine, the method comprising:
injecting reductant upstream from turbocharger turbine.
16. The method of claim 15 , wherein injecting reductant upstream from the turbocharger turbine occurs while the SCR is below a NOx light-off temperature and/or a reductant decomposition temperature threshold.
17. The method of claim 15 , further comprising subsequently ceasing injection of reductant upstream from the turbocharger turbine after the SCR achieves a NOx light-off temperature and/or a reductant decomposition temperature threshold.
18. The method of claim 15 , wherein the system further comprises a second reductant injector configured to inject reductant into the exhaust gas conduit at a second injection location downstream from the turbocharger turbine and upstream from the SCR, and the method further comprises injecting reductant via the second injector after the SCR achieves a NOx light-off temperature and/or a reductant decomposition temperature threshold.
19. The system of claim 15 , wherein a decomposition temperature threshold of the reductant is higher than a light-off temperature of the SCR.
20. The system of claim 15 , wherein the reductant comprises urea and/or a nitrogen-rich substance capable of decomposing into ammonia.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US15/615,107 US20180347426A1 (en) | 2017-06-06 | 2017-06-06 | Exhaust gas systems utilizing pre-turbine reductant injectors and methods for controlling the same |
CN201810513511.1A CN108999680A (en) | 2017-06-06 | 2018-05-24 | Utilize the exhaust system and its control method of turbine pre reduction agent injector |
DE102018113212.3A DE102018113212A1 (en) | 2017-06-06 | 2018-06-04 | Exhaust systems using pilot turbine reducer injections and methods of controlling same |
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US15/615,107 US20180347426A1 (en) | 2017-06-06 | 2017-06-06 | Exhaust gas systems utilizing pre-turbine reductant injectors and methods for controlling the same |
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US20180347426A1 true US20180347426A1 (en) | 2018-12-06 |
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US15/615,107 Abandoned US20180347426A1 (en) | 2017-06-06 | 2017-06-06 | Exhaust gas systems utilizing pre-turbine reductant injectors and methods for controlling the same |
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US (1) | US20180347426A1 (en) |
CN (1) | CN108999680A (en) |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN109603814A (en) * | 2019-01-10 | 2019-04-12 | 中国华电科工集团有限公司 | A kind of SCR denitration and preparation method thereof of anti-arsenic alkali resistant metal poisoning |
CN113864033A (en) * | 2021-09-29 | 2021-12-31 | 广西玉柴机器股份有限公司 | Tail gas emission control system for light vehicle engine |
Families Citing this family (1)
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CN110219718B (en) * | 2019-07-16 | 2023-12-15 | 潍柴动力股份有限公司 | Post-treatment system for urea injection before vortex and control method thereof |
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DE10308287B4 (en) * | 2003-02-26 | 2006-11-30 | Umicore Ag & Co. Kg | Process for exhaust gas purification |
JP2013241859A (en) * | 2012-05-18 | 2013-12-05 | Isuzu Motors Ltd | Exhaust gas purification system and method for purifying exhaust gas |
US20150361842A1 (en) * | 2014-06-11 | 2015-12-17 | Homayoun Ahari | Exhaust system for a vehicle |
WO2016089963A1 (en) * | 2014-12-05 | 2016-06-09 | Cummins, Inc. | Reductant injection in exhaust manifold |
-
2017
- 2017-06-06 US US15/615,107 patent/US20180347426A1/en not_active Abandoned
-
2018
- 2018-05-24 CN CN201810513511.1A patent/CN108999680A/en active Pending
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN109603814A (en) * | 2019-01-10 | 2019-04-12 | 中国华电科工集团有限公司 | A kind of SCR denitration and preparation method thereof of anti-arsenic alkali resistant metal poisoning |
CN113864033A (en) * | 2021-09-29 | 2021-12-31 | 广西玉柴机器股份有限公司 | Tail gas emission control system for light vehicle engine |
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DE102018113212A1 (en) | 2018-12-06 |
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