CN102132016B - 用于将尿素转化成氨的催化装置 - Google Patents
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Abstract
所披露的是用于处理废气的设备、系统和方法。所披露的设备和系统典型地包括用于将尿素水转化成氨的催化装置。该催化装置可包括用于将尿素水转化成氨的热解催化剂和水解催化剂。该催化装置典型地包括上游面,当该装置放置在选择性催化还原(SCR)系统中时,上游面放置成与废气流呈一个角度。
Description
技术领域
本发明的领域涉及用于内燃机的废气后处理装置。尤其地,本发明的领域涉及包括适合在工业过程、在移动式和固定式柴油、天然气及其它发动机的应用中使用的用于内燃机废气的选择性催化还原(SCR)系统。
背景技术
源于内燃机的废气典型地包括氮的氧化气体,如一氧化氮(NO)、二氧化氮(NO2)和一氧化二氮(N2O),氮的氧化气体共同地称为“NOx”。因为NOx会是一种环境危害,多个系统已经被开发以通过选择性催化还原(SCR)从废气中去除NOx。
在工业过程,还有在固定式柴油发动机的应用中,氮氧化物(NOx)的选择性催化还原(SCR)使用还原剂是已熟知的。氨是在SCR系统中普遍使用的还原剂。NOx与氨反应,并通过SCR催化还原成氮气(N2),伴有作为副产物的水。该反应通常可以表示如下:
NOx+NH3→N2+H2O
该反应可被称为“SCR催化剂”的催化剂所催化。
因为氨是有危害的物质,通常氨不被直接引入到SCR系统。相反地,通过引入较少危害的产氨源到SCR系统,原位产生氨。一种常用的产氨源是尿素水(aqueous urea)。在SCR系统中,尿素水在SCR的上游被注入到废气气流。源于注入溶液的小滴中的水蒸发留下尿素,尿素在高温中分解(即,热解)成异氰酸和氨。在水中,异氰酸然后水解生成氨和二氧化碳。这些反应通常能表示如下:
CO(NH2)2+热量→HNCO+NH3
HNCO+H2O→NH3+CO2
这些反应可被称为“热解催化剂”和“水解催化剂”的催化剂分别催化。因此形成的氨可在SCR反应中反应并还原NOx。
用于移动式应用的SCR催化剂的使用是有问题的。一个妨碍是移动式应用在尺寸上是相对较小的。这使得在废气到达SCR催化剂之前,在SCR催化剂的上游注入尿素溶液到废气并将尿素溶液完全分解和水解成氨(和获得足够高的氨与NOx的比率)很困难。在低的柴油发动机排气温度和高气体流速下(例如,大约每秒20米),在注入器和SCR催化剂之间需要几米的距离(即,0.1到0.3秒的时间)用于尿素水溶液喷出蒸发,用于尿素分解和水解成氨和二氧化碳,和用于在氨进入催化剂以前变得实用均匀地横跨流前端分布。尽管对于这个问题的各种各样的解决办法已经被提出(见,例如,美国专利号6,928,807;6,361,754;和6,203,770;和美国公开申请号2006/0115402),这些解决办法包括在SCR系统之外产生氨和直接将氨引入到废气流。在这些系统中,如果SCR催化剂在这种氨引入之前没有预热,氨将通过SCR催化剂并污染空气。因此,存在适用于移动式应用的改进的SCR系统的需求。
发明内容
所披露的是用于处理废气的设备、系统和方法。所披露的设备、系统和方法典型地包括或采用用于将尿素水溶液转化成氨的催化装置。
所披露的用于处理废气的设备和系统可包括外壳,该外壳具有用于接纳废气的上游入口和用于排放废气的下游出口,其中所述外壳限定废气的轴向流动路径(axial flow path)。所披露的设备和系统可进一步包括注入器,注入器被配置以将尿素溶液注入到废气。所披露的设备和系统典型地包括用于将尿素转化成氨的催化装置,催化装置被放置在轴向流动路径中,位于注入器的的下游(例如,可渗透的催化装置)。所述催化装置具有上游面,上游面放置成与轴向流动路径呈一个角度(例如,与轴向流动路径呈大约20-70度的角度,优选地与轴向流动路径呈大约30-50度的角度)。所述催化装置典型地被配置以在上游面接纳源于注入器的尿素溶液。所披露的设备和系统可进一步包括选择性催化反应器(SCR),选择性催化反应器用于在氨存在下将NOx转化成氮气和水,其中SCR放置在所披露的催化装置的下游。
所披露的还有制造所披露的设备和系统的方法。所述方法可包括制造用于处理废气的设备的方法。所述方法可包括:(a)提供外壳,该外壳具有用于接纳废气的上游入口和用于排放废气的下游出口,其中所述外壳限定废气的轴向流动路径;(b)在外壳内放置用于将尿素溶液注入到废气的注入器;和(c)在注入器的下游放置用于将尿素转化成氨的催化装置。典型地,所述催化装置具有上游面,上游面放置成与所述轴向流动路径呈一个角度(例如,与所述流动路径呈大约20-70度的角度,或优选地与所述流动路径呈大约30-50度的角度)。典型地,所述催化装置被配置成在上游面接纳源于注入器的尿素溶液。可选择地,所述方法可包括:(d)在所述催化装置的下游放置用于在氨存在下将NOx转化成氮气和水的选择性催化反应器。
所披露的方法可包括制造用于将尿素转化成氨的可渗透的催化装置的方法,其中所述装置包括热解催化剂、水解催化剂,或者两种都包括。制造所述装置的方法可包括:(a)制造所述装置的第一部分,其中第一部分包括热解催化剂并具有上游面和下游面;(b)制造所述装置的第二部分,其中第二部分包括水解催化剂并具有上游面和下游面;和(c)放置第一部分的下游面与第二部分的上游面邻接,由此制造所述装置;其中所制造的装置横截面为平行四边形或梯形。可选择地,制造所述装置的方法可进一步包括组合第一部分和第二部分。
所披露的还有采用所披露的设备和系统处理废气的方法。在一些实施方式中,所述方法包括将废气通过所披露的催化装置,其中所述装置包含热解催化剂、水解催化剂,或两种都包含。废气可被动地加热所述催化装置并促进尿素水向氨的转化,其中尿素水被注入到废气流并在催化装置的上游面沉积。
所披露的设备和系统采用用于将尿素转化成氨的催化装置。在一些实施方式中,通过采用所披露的催化装置,在SCR系统中为实现尿素向氨的完全转化,所需要的注入器和催化装置之间的距离被减少。所披露的SCR系统可适用于移动式应用。
附图说明
图1显示现有技术的废气SCR系统。
图2是如本文披露的SCR系统的一个实施方式的剖视图。
图3是如本文披露的SCR系统的另一个实施方式的剖视图。
图4提供了如本文披露的催化装置的4种实施方式(A,B,C,和D)的剖视图。
图5提供了如本文披露的SCR系统的一个实施方式的一个部分的剖视图。
图6提供了如本文披露的SCR系统的另一个实施方式的一个部分的剖视图。
图7提供了如本文披露的催化装置的一个实施方式的透视图。
具体实施方式
所披露的是用于处理废气的设备、系统和方法。所披露的设备、系统和方法典型地包括或采用用于将尿素水溶液转化成氨的催化装置。催化装置可包括热解催化剂、水解催化剂,或两种都包括。催化装置典型地具有上游面,当装置放置在SCR系统中时,上游面放置成与轴向废气流呈一个角度。该上游面典型地放置以接纳从尿素罐喷嘴注入的尿素水溶液。
所披露的设备和系统典型地包括催化装置,催化装置具有上游面,上游面放置成与轴向流动路径呈一个角度。所披露的设备和系统可包括催化装置,催化装置具有下游面,下游面放置成与轴向流动路径呈直角或与轴向流动路径呈90度(±15度)角,例如,如果流分布均匀性不重要并且不需要相同的废气径线长度。在一些实施方式中,所披露的设备和系统可包括催化装置,催化装置具有下游面,下游面放置成与轴向流动路径呈大约20-70度的角度,或者与轴向流动路径呈大约30-50度的角度。在进一步的实施方式中,催化装置的上游面和下游面放置成与轴向流动路径大约成相同的角度。因为催化装置具有上游面,上游面放置成与轴向流动路径呈一个角度,该催化装置横截面典型地不为正方形或长方形。在一些实施方式中,催化装置横截面为梯形或者平行四边形。
在所披露的设备和系统中,注入器可放置成与轴向流动路径不平行或不垂直的角度。在一些实施方式中,注入器放置成与轴向流动路径呈大约20-70度的角度(优选与轴向流动路径呈大约30-50度的角度)。在进一步的实施方式中,注入器可被放置成与所述催化装置的上游面呈大约90度(±15度)的角度。
催化装置催化尿素水向氨的转化。催化装置可包括热解催化剂、水解催化剂,或者两种都包括(优选两种都包括)。装置可为整体式的(也就是,由单个的一块材料组成),或者分段的(也就是,由两块或者更多块分离的材料组成,可选择地,被组合在一起)。在一些实施方式中,催化装置由热解催化剂组成并涂覆水解催化剂。
催化装置可包括上游部分和下游部分,其中上游部分包括热解催化剂,下游部分包括水解催化剂。上游部分和下游部分可为独立的部分,被邻接放置,且可选择地被组合。在一些实施方式中,上游部分和下游部分为独立的部分,横截面为平行四边形。在进一步的实施方式中,上游部分和下游部分为独立的部分,横截面为三角形、梯形、正方形、或者长方形,并被邻接放置以提供横截面为梯形或者横截面为平行四边形的催化装置。
催化装置可包含材料,材料包括但不限于:挤压材料、包装材料(例如,打褶的材料或波纹状材料(pleated or corrugated material))和分层材料。催化装置优选包含选自由整块挤压材料、复合陶瓷材料(例如,像在美国专利号6,582,490和6,444,006,其全文通过引用并入本文)、纤维材料和金属样材料(例如,流通的(flow-through)金属薄片及其类似物)组成的组的材料。优选地,催化装置可为可渗透的或多孔的。在所披露的设备和系统中,催化装置可被废气加热(例如,被动地加到至少大约200℃或大约200-700℃或大约200-300℃的温度)或者被热源(例如,主动地被电加热源)加热以加速蒸发和分解并促进尿素向氨的水解。
催化装置可包括热解催化剂、水解催化剂,或者两者都包括(优选两者都包括)以将尿素转化成氨。催化装置可由可起热解催化剂、水解催化剂,或者同时起两者作用的材料制造。在一些实施方式中,催化装置用起热解催化剂、水解催化剂,或者同时起两者作用的材料涂覆。
热解催化剂包含在高温(例如,在至少大约200℃的温度)存在下催化尿素向氨(或向异氰酸)的转化的材料。合适的热解催化剂可包括但不限于具有相对较高热容的材料,如金属或金属合金。合适的金属和金属合金可包括但不限于铁或铁合金(例如,不锈钢)、铝或铝合金、和铜或铜合金。在一些实施方式中,热解催化剂可被不同的热解催化剂或水解催化剂涂覆。水解催化剂包含在水存在下催化尿素向氨转化(或者在水存在下异氰酸向氨的转化)的材料。合适的水解催化剂可包括但不限于金属和金属氧化物(例如,过渡金属或过渡金属氧化物,如钛、钯、铂、钒、铬、钼、镍,或者它们的氧化物)。
所披露的设备和系统典型地包括用于将尿素水转化成氨的催化装置。所披露的设备和系统还可包括SCR催化剂。SCR催化剂包含催化NOx向氮气和水转化的材料,或者被包含催化NOx向氮气和水转化的材料涂覆或者浸渍。SCR催化剂可包括但不限于活性炭、木炭或焦炭、沸石、氧化钒、氧化钨、氧化钛、氧化铁、氧化铜、氧化锰、氧化铬、贵金属如铂族金属像铂、钯、铑、铱和它们的组合。
本文披露的催化剂,包括热解催化剂、水解催化剂和SCR催化剂,可包含载体材料或可被安装在载体材料上。载体材料可包括但不限于陶瓷物质、沸石、均质的整块材料及金属和金属合金。所披露的催化装置可在SCR废气后处理系统中被采用。SCR系统在美国专利号6,449,947;6,601,385;6,722,123;和7,328,572中披露,专利内容全篇并入本文。
现在参考附图,图1显示现有技术的废气SCR系统。废气从发动机62放出。泵64从罐26抽取尿素水溶液并通过阀66供应,阀66被控制器68控制,控制器68进而被发动机控制。发动机废气首先通过预氧化催化剂70后供应,然后与在72处注入到废气管74的尿素水溶液混合。混合物然后向下游流到水解催化剂76、SCR催化剂28和氧化催化剂30。外壳10在SCR催化剂28处具有给定横截面积,SCR催化剂28横穿废气的轴向流48。
图2是本文披露的SCR系统的一个实施方式的剖视图。废气沿着轴向流动路径148进入系统。尿素罐102通过注入器106注入尿素水溶液104。尿素水溶液沉积在梯形的可渗透的催化装置111的上游面108上。催化装置包含热解催化剂和水解催化剂。废气加热该催化装置,尿素水溶液被蒸发和加热以催化尿素向氨(或异氰酸,随后转化成氨)的转化。废气在下游面114离开催化装置。废气离开系统之前,通过SCR催化剂116和废气催化剂118。
图3是本文披露的SCR系统的另一个实施方式的剖视图。废气沿着轴向流动路径248进入系统。尿素罐202通过注入器206注入尿素水溶液204。尿素水溶液沉积在催化装置的上游面208上,催化装置包含可渗透的热解催化剂210和可渗透的水解催化剂212。废气加热热解催化剂,尿素水溶液被蒸发和加热以催化尿素向氨(或异氰酸,随后转化成氨)的转化。废气通过热解催化剂210到水解催化剂212。水解催化剂包含催化尿素(或异氰酸)水解成氨的试剂,或被该试剂涂覆或浸渍。废气在下游面214离开水解催化剂。废气离开系统之前,通过SCR催化剂216和废气催化剂218。
图4提供了本文披露的催化装置的4种实施方式(A,B,C,和D)的剖视图。在图4A中,催化装置302是整块的,横截面为梯形。该装置包括上游面304,当该装置被放在SCR系统中时,上游面304被配置成用来接纳尿素水溶液并被配置以接纳废气。装置包括下游面306,当该装置被放在SCR系统中时,下游面306被配置成废气离开下游面。图4B说明横截面为平行四边形的催化装置,催化装置包括独立的横截面为梯形的热解催化剂312和独立的横截面为梯形的水解催化剂314。热解催化剂312和水解催化剂314邻接放置,其中热解催化剂的下游面318与水解催化剂的上游面320邻接以构成催化装置。当该装置被放在SCR系统中时,热解催化剂的上游面316被配置成用来接纳尿素水溶液并被配置成用来接纳废气。当该装置被放在SCR系统中时,热解催化剂的下游面322被配置成废气离开下游面。图4C说明横截面为平行四边形的催化装置,催化装置包括独立的横截面为平行四边形的热解催化剂332和独立的横截面为平行四边形的水解催化剂334。热解催化剂332和水解催化剂334被邻接放置,其中热解催化剂的下游面338与水解催化剂的上游面340邻接以构成催化装置。当该装置被放在SCR系统中时,热解催化剂的上游面336被配置成用于接纳尿素水溶液并被配置成用于接纳废气。当该装置被放在SCR系统中时,水解催化剂的下游面342被配置成废气离开下游面。图4D说明横截面为平行四边形的催化装置,催化装置包括独立的横截面为三角形的热解催化剂352和独立的横截面为三角形的水解催化剂354。热解催化剂352和水解催化剂354邻接放置,其中热解催化剂的下游面358与水解催化剂的上游面360邻接以构成催化装置。当该装置被放在SCR系统中时,热解催化剂的上游面356被配置成用于接纳尿素水溶液并被配置成用于接纳废气。当该装置被放在SCR系统中时,水解催化剂的下游面362被配置成废气离开下游面。
图5提供了本文披露的SCR系统的一个实施方式的一部分的剖视图。废气沿着轴向流动路径48进入和离开系统。系统包括催化装置,催化装置包含具有上游面154的热解催化剂150和具有下游面156的水解催化剂154。热解催化剂150和水解催化剂横截面为平行四边形。热解催化剂的上游面放置成与轴向流呈角度α(其中α为大约20-70度的角度,优选大约30-50度)。尿素水溶液通过注入器160引入到系统。注入器放置成与轴向流呈β角度(其中β为大约20-70度的角度,优选大约30-50度)。尿素水溶液在热解催化剂150的上游面154上沉积。废气通过热解催化剂并进入水解催化剂,在下游面156离开水解催化剂。水解催化剂的下游面156放置成与轴向流呈γ角度(其中γ为大约20-70度的角度,优选大约30-50度)。角度α和γ可相同或不同。当角度α和γ相同时,催化装置横截面可为平行四边形。
图6提供了本文披露的SCR系统的另一个实施方式的一部分的剖视图。图6的SCR系统配置为与图5的SCR系统相似。但是,在图6中,热解催化剂170和水解催化剂172横截面为三角形。
图7提供了本文披露的催化装置的一个实施方式的透视图。在图6中,热解催化剂180和水解催化剂182从侧面看具有管的形状,可通过以一个角度横切管状材料来形成。热解催化剂180和水解催化剂182可邻接放置以构成催化装置,其中热解催化剂184的下游面放置成与水解催化剂186的上游面邻接。因此形成的催化装置可具有管状和呈一定角度的上游面和下游面。
在上文的描述中,为简洁、清晰和理解而使用了某些术语。因为这些术语用于描述目的且意欲进行广泛地解释,所以这些术语并不包含超出现有技术需求的不必要的限制。本文描述的不同构造、系统和方法步骤可单独使用或与其它构造、系统和方法步骤组合使用。可预期的是各种各样的等同物、替换物和修改物是可能的。
Claims (16)
1.一种用于处理废气的设备,包括:
外壳,所述外壳具有用于接纳所述废气的上游入口和用于排放所述废气的下游出口,所述外壳限定所述废气的轴向流动路径;
注入器,所述注入器被配置以注入尿素溶液到所述废气中;
用于将尿素转化成氨的可渗透的催化装置,所述催化装置放置在所述轴向流动路径中,位于所述注入器的下游,其中所述催化装置具有上游部分和下游部分,所述上游部分具有上游面和下游面,所述上游面放置成与所述轴向流动路径呈20-70度的角度,所述下游面邻接所述下游部分的上游面,所述催化装置被配置以在所述上游面接纳源于所述注入器的所述尿素溶液;和
用于在氨存在下将NOx转化成氮气和水的选择性催化反应器,其中所述选择性催化反应器放置在所述催化装置的下游,其中所述催化装置横截面为平行四边形或横截面为梯形。
2.如权利要求1所述的设备,其中所述上游面放置成与所述轴向流动路径呈30-50度的角度。
3.如权利要求1所述的设备,其中所述催化装置的所述下游部分具有下游面,所述下游面放置成与所述的轴向流动路径呈直角。
4.如权利要求1所述的设备,其中所述注入器放置成与所述轴向流动路径呈20-70度的角度。
5.如权利要求1所述的设备,其中所述注入器放置成与所述催化装置的所述上游部分的所述上游面呈90±15度的角度。
6.如权利要求1所述的设备,其中所述上游部分为热解催化剂。
7.如权利要求1所述的设备,其中所述下游部分为水解催化剂。
8.如权利要求1所述的设备,其中所述上游部分包含热解催化剂,所述下游部分包含水解催化剂。
9.如权利要求8所述的设备,其中所述上游部分和所述下游部分是独立的。
10.一种处理废气的方法,包含将废气通过如权利要求1所述的设备。
11.一种制造用于处理废气的设备的方法,包含:
提供外壳,所述外壳具有用于接纳所述废气的上游入口和用于排放所述废气的下游出口,所述外壳限定所述废气的轴向流动路径;
所述外壳内放置用于将尿素溶液注入到所述废气的注入器;和
在所述注入器的下游放置用于将尿素转化成氨的催化装置,所述催化装置具有上游部分和下游部分,所述上游部分具有上游面和下游面,所述上游面放置成与所述轴向流动路径呈20-70度的角度,所述下游面邻接所述下游部分的上游面,所述催化装置被配置成在所述上游面接纳源于所述注入器的所述尿素溶液,其中所述催化装置横截面为平行四边形或横截面为梯形。
12.如权利要求11所述的方法,进一步包含:
在所述催化装置的下游放置用于在氨存在下将NOx转化成氮气和水的选择性催化反应器。
13.一种用于将尿素转化成氨的可渗透的催化装置,包含独立的第一部分和独立的第二部分,所述第一部分包含热解催化剂,所述第二部分包含水解催化剂,其中所述第一部分和所述第二部分被放置成相互邻接以构成所述催化装置,所述催化装置为横截面为平行四边形和横截面为梯形中的一种,所述热解催化剂具有上游面,所述上游面放置成与轴向流动路径呈20-70度的角度,所述轴向流动路径穿过所述可渗透的催化装置。
14.一种用于处理废气的设备,包含:
外壳,所述外壳具有用于接纳所述废气的上游入口和用于排放所述废气的下游出口,所述外壳限定所述废气的轴向流动路径;
注入器,所述注入器被配置以注入尿素溶液到所述废气中;
如权利要求13所述的催化装置,所述催化装置放置在所述注入器的下游;和
用于在氨存在下将NOx转化成氮气和水的选择性催化反应器,所述选择性催化反应器放置在所述将尿素转化成氨的催化装置的下游。
15.一种制造用于将尿素转化成氨的可渗透的催化装置的方法,所述装置包含热解催化剂和水解催化剂,所述方法包含:
制造所述装置的第一部分,其中所述第一部分包含所述热解催化剂并具有上游面和下游面,所述上游面放置成与轴向流动路径呈20-70度的角度,所述轴向流动路径穿过所述热解催化剂;
制造所述装置的第二部分,其中所述第二部分包含所述水解催化剂并具有上游面和下游面;和
将所述第一部分的所述下游面放置成邻接所述第二部分的所述上游面,由此构成所述装置;
其中所述所制造的装置横截面为平行四边形或横截面为梯形。
16.如权利要求15所述的方法,进一步包含组合所述第一部分和所述第二部分。
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EP2300697A1 (en) | 2011-03-30 |
EP2300697A4 (en) | 2014-07-30 |
EP2300697B1 (en) | 2017-06-07 |
WO2010008645A1 (en) | 2010-01-21 |
CN102132016A (zh) | 2011-07-20 |
US8071037B2 (en) | 2011-12-06 |
EP2907983B1 (en) | 2016-12-14 |
US20090324453A1 (en) | 2009-12-31 |
EP2907983A1 (en) | 2015-08-19 |
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