CN101023248A - 带有柴油发动机的机动车的排气系统 - Google Patents

带有柴油发动机的机动车的排气系统 Download PDF

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CN101023248A
CN101023248A CNA2005800315195A CN200580031519A CN101023248A CN 101023248 A CN101023248 A CN 101023248A CN A2005800315195 A CNA2005800315195 A CN A2005800315195A CN 200580031519 A CN200580031519 A CN 200580031519A CN 101023248 A CN101023248 A CN 101023248A
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vent systems
described particle
filter element
particle collector
collector
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CN100497893C (zh
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马尔科·拉纳利
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Meritor Holdings Spain SA
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ArvinMeritor Emissions Technologies SA
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
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    • F01N3/02Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021Exhaust 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/74General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86Catalytic processes
    • B01D53/8643Removing mixtures of carbon monoxide or hydrocarbons and nitrogen oxides
    • B01D53/8646Simultaneous elimination of the components
    • B01D53/8653Simultaneous elimination of the components characterised by a specific device
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
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    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
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    • F01N13/1816Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body with means permitting relative movement, e.g. compensation of thermal expansion or vibration the pipe sections being joined together by flexible tubular elements only, e.g. using bellows or strip-wound pipes
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Abstract

一种用于带有柴油发动机(10)的机动车的排气系统,其包括颗粒过滤单元(36),接近于所述发动机的颗粒收集器(24)被布置在所述颗粒过滤单元(36)的上游并束缚废气流中所含颗粒的一部分量,而所述废气流中所含颗粒的另一部分量流过所述颗粒收集器(24)至所述颗粒过滤单元(36)。所述颗粒收集器(24)被布置成足够接近所述发动机(10),以致所述颗粒收集器(24)在操作期间由于NO2的氧化作用至少部分地再生。

Description

带有柴油发动机的机动车的排气系统
技术领域
本发明涉及带有柴油发动机的机动车的排气系统,该排气系统包括颗粒过滤单元。
背景技术
这类颗粒过滤器(更简单地可被称为烟灰过滤器)的目的是用来减少废气颗粒的排放。这些颗粒过滤单元的核心部件是一衬底,具体为SiC衬底,其容纳于一分离的外壳体中,排气管在颗粒过滤单元的下游和上游通向壳体。颗粒过滤器插入物本身(即衬底)需要通过过滤器表面上积聚的颗粒的燃烧不时地再生。最有前途的再生可能性之一在于将燃料直接引入靠近颗粒过滤单元上游的废气中;除了其它原因之外,如果可能,燃料应为蒸气形式,以便不会使废气过度冷却。例如,EP 1 369 557 A1对此进行了描述。
此外,人们进行了使颗粒过滤单元更具成本效率的尝试。颗粒过滤单元的成本之所以高,首先是因为衬底的SiC材料非常昂贵,而且因为通过柴油颗粒过滤单元外壳体中的支持垫对衬底进行支持的支持结构比较复杂。就并入壳体中而言,花费尤其是在于因NO2氧化作用,而应将颗粒过滤单元安装成尽可能接近于发动机或者应为其提供加热装置。NO2氧化作用在于,碳在230摄氏度以上的温度下与废气中的NO2进行氧化,生成氮和CO2。在颗粒过滤单元中将会利用这种再生作用,但这种再生作用与和氧进行的燃烧相比效率较低。另一方面,当颗粒过滤单元被布置成接近于发动机时,关于衬底的支持以及衬底和壳体的耐久性要满足极高的要求,因为在排气系统接近于发动机的这一区段中振动很强。此外在发动机附近,排气系统中几乎没有空间可用于体积庞大的颗粒过滤单元。结果是,对于颗粒过滤单元的设计和布局,当着眼于令其配置更具成本效率时,许多因素局部地存在矛盾,而且在人们最初对其进行考虑时,这些因素是相互排斥的。
在颗粒过滤单元本身中(即在相同的外壳体中)容纳一个主过滤器和一个预过滤器的理念,已被公开于US 5 053 062和EP 1 205 228 A1以及EP 0 957 241 A1中。但这些理念并没有为颗粒过滤单元的成本带来真正显著的下降,也没有使将排气系统安装到车辆中的操作明显简化。
发明内容
本发明针对最初提到的那类排气系统提供了这些优势,在该排气系统中,接近于所述发动机的一颗粒收集器被布置在所述颗粒过滤单元的上游并束缚废气流中所含颗粒的一部分量,而所述废气流中所含颗粒的另一部分量流过所述颗粒收集器至所述颗粒过滤单元,所述颗粒收集器被布置成足够接近所述发动机,以致所述颗粒收集器在操作期间由于NO2氧化作用而得以再生。
与上文提到的现有技术不同,现有技术使用了接近于衬底的布置在颗粒过滤单元中的预过滤器,而本发明提供有颗粒收集器,其在结构上与所述颗粒过滤单元分离,并布置在所述颗粒过滤单元之外,该颗粒收集器束缚所述颗粒中的一部分,并通过利用NO2氧化作用以一种“已转化”形式将它们排出。所述颗粒过滤单元(衬底)的过滤器插入物和所述颗粒收集器中的插入物彼此分开的间距在至少300mm的数量级上。所述颗粒收集器不断地吸附这些进入颗粒的一部分量,从而又以CO2将它们的一部分发出。这部分量的颗粒不在需要由所述颗粒过滤单元吸附,以致后者以明显较低的速率填充颗粒,因而很少需要对其进行再生。与实际期望的位置相比,这允许将所述颗粒过滤单元布置在离所述发动机明显更远的位置处。随着离所述发动机的距离增加,所述排气系统中的振动减小,以致于,在一方面,所述颗粒过滤单元可配备价格更低的衬底,而另一方面,也降低了并入所述壳体中所需的花费。所述颗粒收集器在结构上与所述颗粒过滤单元分离,使得将这些组件容纳于车辆中完全不同的部位成为可能,至少鉴于可用空间小,这是人们非常期望的。由于在所述颗粒收集器也会发生一定量烟灰的某种燃烧(尽管其实际上并不是由一分离装置引发的),在根据本发明的排气系统中,在所述颗粒收集器的下游废气温度将会出现增加,这是由所述燃烧造成的。
优选地,所述颗粒收集器无论其填充度(即其中所含颗粒的量)如何,总是允许一定部分量的废气连同颗粒一起从其中穿过,这些废气在到达所述颗粒过滤单元之前不会被捕获。这意味着所述颗粒收集器不能堵塞。在这一方面,所述颗粒收集器不同于现有技术中的常规预过滤器,该预过滤器被设计成在其中捕获较大的颗粒,因而仅有较小的颗粒会到达主过滤器。所述颗粒收集器被设计成积聚尽可能大和尽可能小的颗粒,并允许大颗粒穿过,即使是在填充度高的情况下。这种作用的另一结果是,在根据本发明的排气系统中,不可能出现因过滤器接近于所述发动机且几乎完全填满烟灰而造成某种高的反压力(back pressure)。
根据该优选实施方式,与所述颗粒过滤单元相比,所述颗粒收集器能够仅仅束缚较少量的颗粒。此外,所述颗粒收集器优选被适配成使其束缚流入其内的颗粒中的较少部分量(按重量计小于50%)。这允许将所述颗粒收集器设计成具有相对小的尺寸,以致其能被实际地布置成非常接近于所述发动机。但是随其与所述发动机的接近度的增加,其温度随之上升,这又会提高NO2氧化作用,以致所述颗粒收集器对于颗粒接收能力具有高效率的特征。较小的尺寸和较轻的重量使得对接近于所述发动机的区域中的安装所作的要求较低。此外,较小的尺寸以及体积要求的降低允许使用较高质量的材料。另一方面,所述颗粒过滤单元远离所述发动机的布局允许使用廉价的衬底材料,具体为堇青石。
如上所述,所述颗粒收集器优选通过一排气管与所述颗粒过滤单元流体连通,且在结构上是分离的。当然,所述排气管的外横截面远小于所述颗粒过滤单元的外横截面。
根据该优选实施方式,一隔振装置被提供在所述颗粒过滤单元与所述颗粒收集器之间的排气管中,所述隔振装置将包括所述颗粒过滤单元的区段和包括所述颗粒收集器的区段彼此连接。这一隔振装置本身是已知的;优选地,其将所述排气系统的歧管部分与所谓的下体区段隔离开。这种实施方式允许将所述颗粒过滤单元配置达到一种极大的范围,而这又大大增强了与所述发动机的隔振,且就所述衬底的材料以及并入到所述外壳体中和所述外壳体本身的配置而言,价格更加合理。
该优选实施方式采取了措施,以使所述颗粒收集器被布置在所述歧管区段中或与所述歧管部分直接邻接。
然而,所述颗粒过滤单元应被定位在所述废气净化装置的下体部分中,这里具有更大的空间可用于这个大体积单元。
一涡轮增压器优选被安装在所述排气系统中。所述颗粒收集器应被直接布置在所述涡轮增压器的上游,以便降低所述涡轮增压器由颗粒造成的负载,否则应被直接布置在所述涡轮增压器的下游。这种布局确保在任何情况下所述颗粒收集器都被布置成接近于所述发动机。
如果需要,提供有一再生装置,其被设置在所述颗粒收集器的下游,如果可能,则直接在所述颗粒过滤单元的上游,以用于所述颗粒过滤单元的传感器受控不连续再生,优选作为所述衬底装载水平的函数。这将导致尽可能完成所述颗粒过滤单元中所述衬底的再生。
更具体地,所述再生装置是一流体或燃料引入系统,其中,例如CO或HC被引入以便所积聚的碳进行放热催化氧化和燃烧。
优选地,当然可采用一流体汽化器。
为了升高所述颗粒过滤单元中的温度,所述颗粒过滤单元具有一与其相关联的氧化催化转化器。
这一氧化催化转化器或者可以是连接在所述颗粒过滤单元上游的单元的形式,或者可以是所述颗粒过滤单元一区段的形式。
所述颗粒收集器还可具有一与其相关联的氧化催化转化器,用以升高所述颗粒收集器中的废气温度。当然,在这种情况下,应对所述收集器材料的一部分进行适当涂覆,否则一分离的氧化催化转化器可被连接在所述颗粒收集器的上游。
本发明进一步在具有废气再循环装置的排气系统中提供了优势,所述废气再循环装置被用来使废气再循环到所述发动机。事实上,所述颗粒收集器优选被布置在所述排气系统中,以致被再循环的废气穿过所述颗粒收集器。这意味着能够使包含较少颗粒的废气,以及尤其是仍然热着的废气返回所述发动机。
所述颗粒收集器应被布置在一冷却器的上游,所述冷却器被安装在一废气再循环管中,如果可能,甚至被安装在一连接于所述冷却器上游的旁通阀的上游。这减少了所述冷却器和所述阀上颗粒引起的负载。
如果将一NOx催化转化器连接在所述颗粒收集器的下游,那么将具有进一步的优势,所述NOx催化转化器例如为SCR催化器(选择性的催化还原)或LNT催化器(稀燃NOx吸收装置),也被称为储存催化器。
所述颗粒收集器的一优选实施方式在于使用泡沫陶瓷或金属插入物来积聚所述颗粒。
附图说明
根据下文的描述以及附图,本发明进一步的特征和优势将变得明显,下文的描述参照了附图,且在附图中:
图1示出了一机动车柴油发动机的简图,该发动机具有一根据本发明的排气系统;和
图2示出了一机动车柴油发动机的流程图,该发动机具有一根据第二实施方式的排气系统。
具体实施方式
图1示出了一机动车的柴油发动机10以及连接在下游的排气系统12。排气系统12具有一歧管部分16,其延伸直到凸缘14以及与歧管部分16下游邻接的下体部分18,它们通过隔振装置20彼此连接。
柴油发动机10邻接于一排气管,该排气管具有通往颗粒收集器24的第一管段22,颗粒收集器24接近于所述发动机被布置在排气系统12中。
颗粒收集器24包含插入物26,插入物26由泡沫陶瓷或金属制成,且被设置在颗粒收集器24的外壳体28中。氧化催化转化器30被安装在插入物26的上游。然而,一般不需要氧化催化转化器30,因为对插入物26的上游部分进行了适当涂覆。这意味着氧化催化转化器30通常被集成在插入物26中。
涡轮增压器32被安装在歧管部分16中且直接在颗粒收集器24的下游。作为一种替代性方案,颗粒收集器24和涡轮增压器32的位置可以互换。NOx催化转化器33同样设置在歧管部分16中,更具体地,是设置在颗粒收集器24和涡轮增压器32的下游。由于NOx催化转化器33相对于颗粒收集器24位于下游,所以向前者加载的氮氧化物并不多,因为颗粒收集器24已经减少了一定量的NOx。NOx催化转化器33为,例如SCR(选择性的催化还原)催化器或LNT(稀燃NOx吸收装置)催化器,其也被称为储存催化器。在SCR催化器中,所用的还原剂是水溶液中的脲,或者在为固体的情况下,具体为氨基甲酸铵。在LNT催化器中,NOx被临时积聚。用于使收集器再生的还原剂被提供,如由发动机在短缺、富有的操作阶段期间所生成的。在各再生阶段之间,氮的氧化物以硝酸盐的形式积聚在催化转化器上。替代性地,当然也可省略涡轮增压器32,或者将其布置在NOx催化转化器33的下游。
图1示出了脲注入喷嘴80,82,84的三种可能的布局。喷嘴可被置于颗粒收集器24的上游(喷嘴80),直接在涡轮增压器32的上游(喷嘴82),或直接在NOx催化转化器33的上游(喷嘴84),NOx催化转化器33为SCR催化器的形式。收集器24上游或涡轮增压器32上游的布局的优势在于,收集器24或涡轮增压器32使脲的分布更加均匀。
制造隔振装置20的材料所具有的挠性要使传入歧管部分16的发动机振动优选地不会传递到下体部分18,或者是在至少被大大衰减后才传递到这一部分。下体部分18包括延长的排气管34,其通往颗粒过滤单元36。颗粒过滤单元36为惯用的柴油颗粒过滤器或烟灰过滤器,其具有堇青石制成的衬底或过滤器插入物38以及连接在上游的氧化催化转化器40。在这种情况下,如果过滤器插入物38的上游部分被适当涂覆,那么也可省略氧化催化转化器40。颗粒过滤单元36由分离的外壳体42与外界隔离,外壳体42与排气管34和邻接的排气管管件36相比具有明显较大的横截面尺寸。这样,外壳体28,42被布置成彼此相距一个大的距离,且彼此由至少一个简单的排气管34分隔开。
直接位于氧化催化转化器40上游的是用于颗粒过滤单元36的再生装置43,其具有用于所引入的柴油燃料的汽化器44。作为一种替代性方案,再生装置43也可被集成在颗粒过滤单元36中。
当然,更进一步的过滤器单元可被构建到排气系统12中,然而这些过滤器单元与下面的说明并不直接有关,出于简明起见的原因,省略了这些过滤器单元。
废气经过管22流入氧化催化转化器30,然后流入插入物26中。后者被制成吸附和积聚废气所含颗粒的一部分量,特别是烟灰颗粒。无论其颗粒填充度如何,插入物26总是允许废气(包括未被插入物26束缚的颗粒)从其中流过。这意味着插入物26的颗粒接收能力受到限制。但对于任何情况下都允许颗粒从其中穿过的插入物26,其包括管道,这些管道具有比废气中所含最大烟灰颗粒更大的的尺寸。插入物的不规则内壁可被形象化为,例如具有指向上游的、开放的突出沟壑的壁,颗粒能够附着在其上,且该附着与它们的尺寸无关。
由于颗粒收集器24接近于发动机10,废气以及颗粒收集器24因此在操作期间具有高温。这种高温(其为250摄氏度以上)促进了插入物26中产生的NO2氧化作用。这种作用导致颗粒收集器24在操作期间被连续地再生。
提供氧化催化转化器30用于更进一步升高废气的温度,并由此升高插入物26的温度。插入物26永久性地吸附小于50%的进入颗粒,并允许剩余颗粒从其中穿过。废气到达涡轮增压器32。
废气与剩下的颗粒一起流过排气管34,到达颗粒过滤单元36,如果需要,可能已将氧化过滤器40装于颗粒过滤单元36的外壳体42中。然后,在过滤器插入物38中会从废气中滤出近乎所有的剩余颗粒。这些颗粒沉积于入口管道50中,且不能透过中间壁到达出口管道52。
由于颗粒过滤单元36被布置在下体部分18中,过滤器插入物38仅被加热到一个远低于插入物26的温度,因此发生的NO2氧化作用处于一个相当低的程度,或者优选地,根本不发生NO2氧化作用。因此,颗粒过滤单元36的系统化不连续再生是必然的。如果在过滤器插入物38中发生了NO2氧化作用,那么这将导致在碳首先被氧化的那些部位出现过度的进一步碳氧化,造成流中的波动,最终形成“热点”,而热点对过滤器插入物可能具有有害影响。
因此,过滤器插入物38的接收能力一耗尽,就经由再生装置43和燃料引入系统54将气化燃料引入排气管34中。气化燃料包含HC和CO,其导致燃料在氧化催化转化器40中进行催化氧化,并使废气温度明显升高,而这又会导致过滤器插入物38中的颗粒燃烧。
在根据图2的一实施方式中,提供有废气再循环装置。颗粒收集器24位于涡轮增压器32的上游或下游。在这种情况下,分离的颗粒过滤单元36也被提供在下体部分中,颗粒过滤单元36与颗粒收集器24在空间上分隔开。颗粒过滤单元36又具有一个连接在其下游的消音器60。在颗粒收集器24的下游,已因颗粒收集器24而使所含颗粒量减少的废气由废气再循环管62导向冷却器旁通阀64,废气可由此直接地或经由冷却器66流到所谓的EGR阀68。废气然后流过废气再循环管62,到达空气入口74与空气质量流量传感器76之间的供气管72,空气质量流量传感器76具有一个空气温度传感器78连接在其下游。
颗粒收集器24使废气再循环至发动机10成为可能,发动机10与先前情况相比包含相当少的颗粒。这降低了颗粒对提供于供气管72中的装置(例如空气质量流量传感器76或空气温度传感器78)造成损害的危险。由于废气再循环系统中颗粒或烟灰负载减少,阀64、68上的压力也减少,冷却器66的性能减损很小。结果增加了供气管72中和排气系统中部件的可靠性和使用寿命,这降低了总成本。

Claims (20)

1.一种带有柴油发动机(10)的机动车的排气系统,其包括颗粒过滤单元(36),其特征在于:
接近于所述发动机的颗粒收集器(24)被布置在所述颗粒过滤单元(36)的上游并束缚废气流中所含颗粒的一部分量,而所述废气流中所含颗粒的另一部分量流过所述颗粒收集器(24)至所述颗粒过滤单元(36),所述颗粒收集器(24)被布置成足够接近所述发动机(10),以致所述颗粒收集器(24)在操作期间由于NO2的氧化作用至少部分地再生。
2.根据权利要求1所述的排气系统,其特征在于:所述颗粒收集器(24)被设计成,无论其填充度如何,所述颗粒收集器(24)允许所述废气流中所含颗粒的一部分量到达所述颗粒过滤单元(36)。
3.根据权利要求1或2所述的排气系统,其特征在于:与所述颗粒过滤单元(36)相比,所述颗粒收集器(24)束缚的颗粒量较少。
4.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒收集器(24)经由排气管(34)与所述颗粒过滤单元(36)流体连通。
5.根据权利要求4所述的排气系统,其特征在于:在所述颗粒收集器(24)与所述颗粒过滤单元(36)之间,隔振装置(20)被提供在布置在所述颗粒收集器(24)和所述颗粒过滤单元(36)之间的排气管(34)上。
6.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒收集器(24)被布置在所述排气系统的歧管部分(16)中或与所述歧管部分(16)直接邻接。
7.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒过滤单元(36)被布置在所述排气系统的下体部分(18)。
8.根据前述权利要求中任一项所述的排气系统,其特征在于:一涡轮增压器(32)被提供在所述排气系统中,且所述颗粒收集器(24)被直接布置在所述涡轮增压器(32)的上游或下游。
9.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒过滤单元(36)具有包括堇青石的过滤器插入物(38)。
10.根据前述权利要求中任一项所述的排气系统,其特征在于:在所述颗粒收集器(24)的下游提供再生装置(43),其与所述颗粒过滤单元(36)相关联,且不连续地使所述颗粒过滤单元(36)再生。
11.根据权利要求10所述的排气系统,其特征在于:所述再生装置(43)具有流体引入系统,具体为燃料引入系统(54)。
12.根据权利要求11所述的排气系统,其特征在于:所述再生装置(43)包括流体汽化器(44),用于将蒸气引入所述废气中。
13.根据前述权利要求中任一项所述的排气系统,其特征在于:与所述颗粒过滤单元(36)相关联的是氧化催化转化器(40),以升高所述颗粒过滤单元(36)中的温度。
14.根据前述权利要求中任一项所述的排气系统,其特征在于:与所述颗粒收集器(24)相关联的是氧化催化转化器(30),以升高所述颗粒收集器(24)中废气的温度。
15.根据前述权利要求中任一项所述的排气系统,其特征在于:所述排气系统配备有废气再循环装置,废气通过所述废气再循环装置能被供应到所述发动机(10),所述颗粒收集器(24)被布置在所述排气系统中,以致被再循环的废气通过所述颗粒收集器(24)。
16.根据权利要求15所述的排气系统,其特征在于:所述颗粒收集器(24)被布置在安装于废气再循环管(62)中的冷却器(66)的上游。
17.根据权利要求16所述的排气系统,其特征在于:所述颗粒收集器(24)被安装在旁通阀(64)的上游,所述旁通阀(64)被布置在所述废气再循环管(62)中,且连接所述冷却器(66)的上游。
18.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒收集器(24)具有用于积聚所述颗粒的泡沫陶瓷或金属插入物。
19.根据前述权利要求中任一项所述的排气系统,其特征在于:NOx催化转化器(33)被提供在所述颗粒收集器(24)的下游。
20.根据前述权利要求中任一项所述的排气系统,其特征在于:所述颗粒过滤单元(36)被布置成在操作期间距所述柴油发动机(10)呈这样一个距离,该距离使得在所述颗粒过滤单元(36)中由于操作温度太低而不会发生连续的NO2氧化作用。
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