CN101298845B - 用于从scr催化剂中去除尿素沉积的基于车辆的战略 - Google Patents

用于从scr催化剂中去除尿素沉积的基于车辆的战略 Download PDF

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CN101298845B
CN101298845B CN2008100966280A CN200810096628A CN101298845B CN 101298845 B CN101298845 B CN 101298845B CN 2008100966280 A CN2008100966280 A CN 2008100966280A CN 200810096628 A CN200810096628 A CN 200810096628A CN 101298845 B CN101298845 B CN 101298845B
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regeneration
scr
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CN101298845A (zh
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徐立峰
威廉·刘易斯·亨德森·沃特金斯
夏恩·埃尔沃特
乔治·韦德·格雷厄姆
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Ford Global Technologies LLC
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Abstract

本发明提供了用于从SCR催化剂中去除尿素沉积的基于车辆的战略，更具体地提供了用于操作连接到内燃发动机的下游的后处理装置的方法，该后处理装置包括基于尿素的选择性催化还原(SCR)催化剂。该方法包括建立对于SCR催化剂的再生的阈值尿素沉积累积；确定在SCR催化剂中的阈值尿素沉积累积已满足；及响应于该确定，通过将SCR催化剂保持在预定的再生温度持续预定时间间隔使SCR催化剂再生。

Description

用于从SCR催化剂中去除尿素沉积的基于车辆的战略
技术领域
本申请涉及用于改进车辆的排气后处理系统性能的系统及方法，更具体地本申请涉及用于使基于尿素的选择性催化还原(SCR)催化剂再生以改进NOx转化效率的系统及方法。
背景技术
柴油发动机驱动的车辆必须装备有稀排气(lean exhaust)后处理装置如基于尿素的选择性催化还原(SCR)催化剂以还原NOx排放物。基于尿素的SCR催化剂需要尿素的喷射以提供氨(NH3)作为还原NOx的还原剂。主要按照如下所示的两个步骤从尿素分解中产生氨：
(1)NH2-CO-NH2(气态或液态)＝NH3(气态)+HNCO(气态)
(2)HNCO(气态)+H2O(气态)＝NH3+CO2(气态)
第一步骤(1)是热分解反应，第二步骤(2)是水解反应。在300℃以下的温度尿素的热分解缓慢且为限速步骤。因此，当排气温度是在300℃以下时，喷射到SCR催化剂的尿素溶液大部分以尿素相关化合物(compound)沉积在SCR上而没有完全分解。
当在城市驾驶循环中驾驶柴油机车辆时，柴油机排气温度较低(例如小于300℃)。因此，尿素相关沉积可以在SCR催化剂上形成。该尿素相关沉积会阻塞涂层(washcoat)中的孔并减少催化剂的表面积和催化剂的活性。此外，在催化剂上的阻塞可能增加催化剂上的背压，从而负面影响发动机性能及增加燃料消耗。
美国专利6,892,530号公开了通过将碳氢化合物的温度保持在碳氢化合物的沸点之上以去除碳氢化合物沉积而使基于尿素的SCR催化剂再生的方法。然而，本发明人在此认识到上述方法不能充分去除尿素相关沉积。例如，在‘530专利中使用的用于去除碳氢化合物沉积的温度和时间间隔对于去除基于尿素的沉积不是有效的。
发明内容
在本发明的一个方面中，提供了用于操作连接到内燃发动机下游的后处理装置的方法。该后处理装置包括基于尿素的选择性催化还原(SCR)催化剂。该方法包括确定用于SCR催化剂再生的阈值尿素沉积累积；确定是否在SCR催化剂中的阈值尿素沉积累积已经满足；及响应于该确定，通过将SCR催化剂保持在预定再生温度或高于预定再生温度持续预定时间间隔使SCR催化剂再生。在一个示例中，时间间隔和/或预定温度可以随着尿素沉积量的改变而改变。
在本发明的另一个方面中，提供了使连接到内燃发动机下游的后处理装置的基于尿素的选择性催化还原(SCR)催化剂再生的方法。该方法包括评估在SCR催化剂中的尿素沉积累积以确定SCR催化剂的再生的正时以去除尿素沉积累积；将SCR催化剂的温度升高到预定温度并保持预定温度持续预定时间间隔以使SCR催化剂再生；及调节进入SCR催化剂的排气流率以改进在SCR催化剂中的热传递和尿素沉积累积的去除。
在本发明的再一个方面中，车辆的系统包括内燃发动机；连接到内燃发动机下游的基于尿素的选择性催化还原(SCR)催化剂；及配置为调节操作参数以使SCR催化剂再生的控制器，其中控制器随着在SCR催化剂上尿素沉积的量的改变而改变SCR催化剂再生时的温度，及控制器随着所述尿素沉积的量的改变而改变SCR催化剂再生的持续期。例如，通过协调相应于尿素沉积负载的再生持续期和温度(例如，较长/较短的再生时间和/或较低/较高的温度)，可以根据在SCR催化剂上的尿素沉积的具体性质实现改进的再生。
附图说明
图1A是发动机的示例实施例的示意图。
图1B是发动机的替代实施例。
图2是连接到内燃发动机下游的后处理装置的示意图。
图3示出本公开的一个实施例中的用于操作连接到内燃发动机的下游的后处理装置的示例方法200。
具体实施方式
图1A和图1B是发动机的示意图。如图1A所示，内燃发动机10包括多个汽缸、图1A中示出其中的一个汽缸，由发动机电子控制器12控制。发动机10包括燃烧室30及汽缸壁32，活塞36位于汽缸壁32中并连接到曲轴40。燃烧室30如图所示分别通过进气门52和排气门54与进气歧管44和排气歧管48连通。进气歧管44如图所示具有燃料喷射器80连接到其中用于按照来自控制器12的信号脉冲宽度(FPW)成比例地输送液体燃料。如下描述由信号FPW控制的燃料量和喷射正时均由控制器12调节。燃料通过包括燃料箱、燃料泵、及燃料导管(未示出)的燃料系统(未示出)输送到燃料喷射器80。
控制器12如图1A所示为包括微处理单元102、输入/输出端口104、只读存储器106、随机存储器108、及数据总线的微计算机。控制器12如图所示接收来自连接到发动机10的传感器的各种信号，除了上述信号之外，包括来自连接到冷却套管114的温度传感器112的冷却剂温度(ECT)、来自连接到进气歧管44的压力传感器116的歧管压力(MAP)的测量值、来自温度传感器117的歧管温度的测量值(AT)、及来自连接到曲轴40的发动机转速传感器118的发动机转速信号(RPM)。后处理装置20连接到排气歧管48，描述具体参考图2。
现参考图1B，如图所示的替代实施例，其中发动机10是直喷式发动机，其中定位喷射器80以直接喷射燃料到汽缸30中。
现参考图2，后处理装置20包括基于尿素的选择性催化还原(SCR)催化剂14，该基于尿素的选择性催化还原(SCR)催化剂14能够减少在富氧环境中的NOx。还原剂如水合尿素(aqueous urea)储存在存储器中(未示出)且通过连接到SCR催化剂14的上游的排气系统的还原剂输送系统16输送。还原剂由泵通过控制阀计量输出，其中泵和控制阀两者由控制器12控制。或者，可以使用将还原剂供应到排气后处理装置中的本领域技术人员所知的任何其他合适的方法。加热器22可以连接到SCR催化剂以提供热量用于SCR催化剂的再生。
控制器12配置为基于传感器测量的信息或基于评估的参数，控制SCR催化剂的操作，如再生。例如，SCR催化剂的温度由温度传感器24测量，且可以用作评估尿素沉积累积或控制SCR催化剂再生等的一个参数。一个或多个NOx传感器，如SCR催化剂的上游NOx传感器17和SCR催化剂下游的传感器18可以连接在进入和离开SCR催化剂的排气路径中。这些传感器的输出可以由控制器12读出且可以用来评估在SCR催化剂上的尿素沉积。
虽然通常提供了两个NOx传感器，但是应理解可以仅提供一个NOx传感器。例如，在一个实施例中，仅提供了下游NOx传感器18且控制器12配置为基于来自下游NOx传感器18的输出和一个或多个发动机操作参数及尿素喷射参数评估在SCR催化剂上的尿素沉积。例如，在对进入SCR催化剂的NOx的评估中，控制器可以使用发动机转速、负荷、排气温度、或影响发动机NOx产生的本领域技术人员所知的任何其他参数。此外，控制器12可以使用通过SCR催化剂的压力降以评估尿素沉积。可以使用一个或多个压力传感器26和压力传感器27来测量压力降。此外，可以通过流量计29测量进入SCR催化剂的排气流率。
氧化催化剂13连接到SCR催化剂的上游且可以是贵金属催化剂，优选地为含铂的催化剂。氧化催化剂放热燃烧在引入的发动机的排气中的碳氢化合物(HC)从而供应热量以快速加热SCR催化剂14。控制器12通过延迟喷射正时、增加EGR(排气再循环)和调节进气节流(intake throttling)或本领域技术人员所知的增加排气温度的任何其他适当的方法升高SCR催化剂的温度。或者，在图1B中所示的直喷式发动机中，在发动机的动力冲程或排气冲程的一个或两者中通过汽缸内喷射可以将额外的碳氢化合物喷射到氧化催化剂用于SCR催化剂预热。微粒过滤器15连接到SCR催化剂14的下游。如下文所述，来自微粒过滤器再生的热量可以用来加热SCR催化剂。
应注意可以获得用于后处理装置的各种实施例。例如，虽然所述的微粒过滤器15设置在SCR催化剂的下游，但应理解微粒过滤器15可以设置在SCR催化剂的上游。
图3示出本发明的一个实施例中用于操作连接到内燃发动机的下游的后处理装置的示例方法200。如上所述，后处理装置可以包括基于尿素的SCR催化剂、氧化催化剂、及微粒过滤器。可以使用方法200通过去除尿素沉积或尿素沉积累积使SCR催化剂再生。首先，在202，该方法包括建立SCR催化剂的再生的阈值尿素沉积累积。如上所述，尿素沉积累积会阻塞在SCR催化剂上的涂层中的孔及减少有效的催化剂面积和催化剂活性。该阈值尿素沉积累积可以是在SCR催化剂不能实现去除NOx的期望的效果的水平。
接下来，在204，该方法确定是否SCR催化剂的温度小于预定温度。如上所述，从尿素分解产生氨的第一步骤是热分解反应。较低的温度会降低尿素分解的速率并促使形成尿素相关固体化合物。将尿素溶液喷射到SCR催化剂上时，在较低温度下可以形成尿素沉积累积。例如，当排气温度在300℃以下时，可以形成尿素沉积，这可以阻塞催化剂。因此，该方法可以将温度用作确定与尿素沉积累积相关的SCR催化剂再生的需要的阈值。在一些实施例中，预定温度可以在300-350℃的范围内。优选地，预定温度可以是350℃。当温度在350℃以下时，尿素沉积会较慢地气化及倾向于在SCR催化剂上累积。或者，步骤202可以不经过步骤204直接进行步骤206。可以通过阈值尿素沉积累积确定SCR催化剂再生。
此外，应注意当温度低于特定的水平时，喷射到SCR催化剂中的尿素不能充分地以足以用作还原剂的足够高的速率分解。因此，在一些实施例中，在较低的排气温度，如在165℃或165℃以下可以停用尿素喷射。
接下来，在206，该方法确定是否阈值尿素沉积累积已满足。确定在SCR催化剂上的阈值尿素沉积累积已满足包括评估尿素沉积累积及确定评估的尿素沉积累积满足或超过阈值尿素沉积累积。可以使用各种方法评估尿素沉积累积。例如，在208，基于SCR催化剂的工况来评估尿素沉积累积可确定是否阈值已满足。例如，尿素沉积累积可以是操作变量如操作温度、尿素流率、排气流率、排气压力、通过SCR催化剂的压力差(pressure difference)、氨比NOx的比例(用于控制喷射到排气系统中的尿素的量的参数)等的函数。因此，基于一个或多个上述的变量，通过控制器可以评估尿素沉积累积。
或者，在210，通过评估尿素沉积累积可确定是否阈值已满足。因为尿素沉积累积可以影响SCR催化剂的效率，尿素沉积累积可以是NOx排放的函数。因此，根据NOx传感器的输出可以评估尿素沉积累积。例如，基于来自图2中所示的SCR催化剂的上游的NOx传感器17的输出和来自图2中所示的SCR催化剂的下游的NOx传感器18的输出可以评估NOx转换效率。或者，可以除去NOx传感器17，基于发动机转速、负荷、排气温度、或本领域技术人员所知的影响发动机NOx产生的任何其他的合适的参数推断进入SCR催化剂的排气混合物中的NOx的量。可选择地或可增加地，操作变量的一个或多个，如工作温度、尿素流率、排气流率、排气压力、通过SCR催化剂的压力差、当量比(equivalence ratio)等可以与NOx传感器输出一起用在尿素沉积累积的评估中。
或者，在212，通过检测通过SCR催化剂的压力降可确定是否阈值已满足。因为尿素沉积累积会增加催化剂上的背压，通过SCR的压力降可以对应于在SCR催化剂中尿素沉积累积。因此，确定在SCR催化剂中的阈值尿素沉积累积已满足可以包括检测通过SCR的压力降是否满足或超过对应于阈值尿素沉积累积的预定压力降阈值。
接下来，在214，该方法确定是否微粒过滤器再生或脱硫事件临近。若步骤214的回答为“否”，在216启动SCR再生。该方法包括将SCR催化剂的温度升高到预定再生温度且保持再生温度持续预定时间。尿素沉积可以在350℃或350℃以下缓慢地气化。另一方面，尿素沉积在400℃或更高的温度下可以快速地气化。在一些实施例中，再生温度可以在360-450℃的范围内。在该温度范围内可以显著地去除尿素沉积。
通过各种方法可以完成SCR催化剂温度的升高。在218，通过将燃料喷射到氧化催化剂中以引发放热反应可以完成升高温度，这可以产生足够的热量以升高催化剂的温度。燃料喷射量和喷射持续期可以通过基于发动机工况，如发动机转速、负荷、催化剂温度、排气温度等预存的关系图表(prestored map)或任何其他合适的方法确定。或者，在220，通过用电子加热器加热SCR催化剂温度可以升高温度。在222，通过调节发动机相关措施如喷射正时的延迟、增加排气再循环(EGR)、关闭进气节气门等可以完成升高SCR催化剂的温度。
确定再生的持续期以便将尿素沉积去除到任何残留的尿素沉积不影响SCR催化剂的性能的程度。在一些实施例中，再生时间至少为两分钟，两分钟对于有效的SCR催化剂再生是充足的时间。
接下来，在224，该方法可以包括调节进入SCR催化剂的排气流率。在某些工况下，可以降低排气流率或空间速度以改进去除在SCR催化剂上的尿素沉积的有效性。
另一方面，若在214回答为“是”，在226，该方法包括延迟SCR催化剂再生直到微粒过滤器再生或脱硫事件的完成，微粒过滤器再生和脱硫事件的温度通常大于600℃。因此，由于微粒过滤器再生或脱硫事件在排气系统中产生的热量会清除SCR催化剂中尿素沉积。应注意在大多数低操作温度工况下尿素沉积累积会快速产生(例如温度小于300℃)。因此，微粒过滤器或脱硫事件可能不按要求去除尿素沉积累积。SCR催化剂再生会比微粒过滤器再生或脱硫事件发生更频繁。因为要考虑微粒过滤器再生或脱硫事件，要求去除尿素沉积的再生的情况会减少。因此，可以减少用于SCR催化剂的再生的能量，且可以增加SCR催化剂的正常操作的持续期。
从步骤226或步骤224继续，在228，该方法包括在SCR再生期间和/或之后评估尿素沉积累积。在一些实施例中，以下方程可以用来进行评估：
尿素沉积累积(在再生期间和/或之后)＝在再生之前评估的或测量的尿素沉积-评估的去除的尿素沉积的量。
可以分别用在步骤208中和步骤210中的描述的方法评估或测量尿素沉积累积。类似地，可以评估通过再生过程去除的尿素的量。
在再生完成后，在23O，该方法可以包括冷却SCR催化剂。接下来，在232，该方法包括确定喷射过量尿素到SCR催化剂中的需要。该确定可以包括确定在SCR再生期间或之后的尿素沉积累积是否低于在234的预定的剩余量。在234的预定尿素沉积量可以是因为储存的氨的量不适合于期望的NOx的还原而在SCR催化剂不按要求运行的水平。或者，在226该确定可以包括确定是否超过预定的时间间隔。
通常尿素溶液需要连续地喷射到SCR催化剂中以去除尿素沉积，包括在再生期间。除非在SCR温度在600℃以上的微粒过滤器或脱硫事件期间的时期。这是因为SCR催化剂在650℃以上的温度不具有活性。在一些实施例中，当SCR催化剂处在储存足够的来自尿素的分解的氨(NH3)的温度(例如小于300℃)时，SCR催化剂可以具有对NOx还原优选的(或最好的)性能。然而，当催化剂加热到再生温度(例如在360℃到450℃的范围内)时，储存的氨在再生期间可能减少。因此，在SCR再生之后需要喷射过量的尿素。
因此，在238，该方法包括喷射过量尿素到SCR催化剂。基于发动机工况，如转速、负荷、催化剂温度、质量空气流量等确定喷射的过量尿素。
应注意在SCR催化剂温度偶然接近于再生温度的一些工况下可以执行步骤234到238。在这些工况下，需要过量的尿素以保持在SCR催化剂中期望的N0x还原或转化效率。
根据本公开的方法可以通过经再生去除尿素相关沉积提高SCR催化剂的NOx转化效率。通过减少由于尿素沉积阻塞增加的背压也可以改进发动机性能和燃料经济性。此外，该方法考虑通过微粒过滤器再生或脱硫事件去除尿素的沉积，从而减少基于尿素沉积累积的SCR催化剂再生要求的时间。此外，通过在再生事件之后调节氨喷射可以在再生(例如，SCR催化剂再生，微粒过滤器再生)之后的冷却期间使NOx的漏过最小化。
本领域普通技术人员应理解，本文上述流程图的具体例程和框图可以表示任何数量的处理策略中的一种或多种，如事件驱动、中断驱动、多任务、多线程等。因此，所示的各种步骤或功能可以按所示的顺序执行、并行执行，或在一些情况下略去。类似地，处理的顺序不是实现本文中所述的示例实施例的特征和优点所必需，而是为便于演示和说明而提供。虽然没有详细描述，本领域普通技术人员应认识到取决于所使用的具体策略，可以重复执行所示步骤或功能中的一个或多个。此外，所述步骤可以在图形上表示编程到在控制器12中的计算机可读存储介质中的代码。
应理解，在本文中公开的配置和例程本质上是示例性的，且这些具体实施例不应被视为具有限制意义，因为大量的变体是可能的。本发明的主题包括在本文中公开的各种凸轮轴和/或气门正时、燃料喷射正时、及其他特征、功能，和/或属性的所有新颖和非易见的组合及子组合。
本发明的权利要求特别指出视为新颖和非显而易见的特定组合及子组合。这些权利要求可能引用“一个”元素或“第一”元素或其等价物。这样的权利要求应被理解为包括对一个或一个以上这样的元素的结合，而不是要求或排除两个或两个以上这样的元素。喷射、气门正时、温度方法、过程、设备、和/或其他的特征、功能、元素和/或属性的其他组合及子组合可以通过本发明权利要求的修改或通过在本申请或相关申请中提出新的权利要求来请求保护。这样的权利要求，无论是在范围上比原始权利要求更宽、更窄、等价或不同，都应被视为包括在本发明公开的主题之内。

Claims (15)

1.一种用于车辆的系统，包括：
内燃发动机；
连接到所述内燃发动机的下游的基于尿素的选择性催化还原(SCR)催化剂；及
配置为调节操作参数以使所述SCR催化剂再生的控制器，其特征在于所述控制器随着所述SCR催化剂上尿素沉积的量的改变而改变所述SCR催化剂再生的温度以及所述SCR催化剂再生的持续期。
2.如权利要求1所述的系统，其特征在于，所述控制器还配置为确定去除在所述SCR催化剂上的尿素沉积累积的阈值已满足，其中在做出这样的确定时，所述控制器还配置为在响应于所述确定去除在所述SCR催化剂上的尿素沉积累积的阈值已满足而在预定温度下使所述SCR催化剂再生持续预定时间，其中所述阈值基于通过所述SCR催化剂的压力降。
3.一种用于操作连接到内燃发动机下游的后处理装置的方法，所述后处理装置包括基于尿素选择性催化还原(SCR)催化剂和微粒过滤器，其特征在于，所述方法包括：
建立对于所述SCR催化剂的再生的阈值尿素沉积累积；
确定在所述SCR催化剂中的所述阈值尿素沉积累积已满足；及
响应于所述确定，通过将所述SCR催化剂保持在预定的再生温度持续预定时间间隔以使所述SCR催化剂再生；
其中所述持续的预定时间间隔和所述预定的再生温度随着所述SCR催化剂上的尿素沉积量的改变而改变。
4.如权利要求3所述的方法，其特征在于，确定在所述SCR催化剂中的所述阈值尿素沉积累积已满足包括：
基于所述SCR催化剂的工况评估尿素沉积累积；及
确定评估的所述尿素沉积累积满足或超过所述阈值尿素沉积累积。
5.如权利要求4所述的方法，其特征在于，所述工况包括操作温度、尿素流率、排气流率、排气压力、及通过所述SCR催化剂的压力差中的一个。
6.如权利要求3所述的方法，其特征在于，确定在所述SCR催化剂中的所述阈值尿素沉积累积已满足包括操作温度、尿素流率、排气流率、排气压力、及通过所述SCR催化剂的压力差中的一个以及使用NOx传感器测量NOx排放。
7.如权利要求3所述的方法，其特征在于，确定在所述SCR催化剂中的所述阈值尿素沉积累积已满足包括检测通过所述SCR催化剂的压力降满足或超过对应于所述阈值尿素沉积累积的预定的压力降阈值。
8.如权利要求3所述的方法，其特征在于，所述预定的再生温度为360-450℃。
9.如权利要求3所述的方法，其特征在于，所述持续的预定的时间间隔为至少两分钟。
10.如权利要求3所述的方法，其特征在于，使用SCR催化剂加热器加热所述SCR催化剂将所述SCR催化剂的温度升高到并保持在所述再生温度。
11.如权利要求3所述的方法，其特征在于，所述后处理装置还包括氧化催化剂，通过将燃料喷射到氧化催化剂以产生放热反应将所述SCR催化剂的温度升高到并保持在所述再生温度。
12.如权利要求3所述的方法，其特征在于，还包括当所述再生之后的所述温度冷却时，基于对所述再生之后的尿素沉积累积低于预定残留量的评估向所述SCR催化剂喷射过量的尿素，其中基于所述SCR催化剂的工况确定所述的过量的尿素喷射。
13.如权利要求12所述的方法，其特征在于，所述评估包括评估由再生去除的尿素沉积的量，且从所述再生之前评估的或测量的尿素沉积累积减去评估的去除的尿素沉积的量，以获得对在所述再生之后的尿素沉积累积的所述评估。
14.如权利要求3所述的方法，其特征在于，还包括在确定超过所述预定的再生时间间隔时，当所述温度在所述再生之后冷却时向所述SCR催化剂喷射过量的尿素，其中基于所述SCR催化剂的工况确定所述过量的尿素喷射。
15.如权利要求3所述的方法，其特征在于，所述后处理装置还包括微粒过滤器，还包括在确定在所述SCR催化剂中所述阈值尿素沉积累积已满足之后延迟所述SCR催化剂再生直到在所述微粒过滤器中执行的再生完成。
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US8739517B2 (en) 2014-06-03
US8171724B2 (en) 2012-05-08
CN103470345B (zh) 2016-02-10
US20120216510A1 (en) 2012-08-30
US20080271440A1 (en) 2008-11-06
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CN101298845A (zh) 2008-11-05
GB0808016D0 (en) 2008-06-11

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