CN105899773A - 催化器组件、含有组件的用于净化内燃机废气的装置、用于组件的模块系统和用于制造组件的方法 - Google Patents

催化器组件、含有组件的用于净化内燃机废气的装置、用于组件的模块系统和用于制造组件的方法 Download PDF

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CN105899773A
CN105899773A CN201580004006.9A CN201580004006A CN105899773A CN 105899773 A CN105899773 A CN 105899773A CN 201580004006 A CN201580004006 A CN 201580004006A CN 105899773 A CN105899773 A CN 105899773A
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catalyst converter
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modular system
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H-J·布吕内
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Bayerische Motoren Werke AG
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Abstract

一种用于净化内燃机、尤其柴油机的废气的装置的催化器组件(20),包括SCRF催化器(26)和设置在所述SCRF催化器(26)的上游的SCR催化器(24),所述SCRF催化器和SCR催化器布置在一个共同的催化器壳体(28)中。催化器壳体(28)、SCRF催化器(26)和SCR催化器(24)可以针对内燃机的不同变型方案从一个模块系统中选出。

Description

催化器组件、含有组件的用于净化内燃机废气的装置、 用于组件的模块系统和用于制造组件的方法
技术领域
本发明涉及一种用于净化内燃机、尤其柴油机的废气的装置的催化器组件,该催化器组件包括可再生的颗粒过滤器和集成在颗粒过滤器上的用于选择性还原氮氧化物的催化器(SCRF催化器)。此外,一种用于催化器组件的模块系统、一种含有催化器组件的装置以及一种用于制造催化器组件的方法是本发明的主题。
背景技术
为了净化现代机动车、尤其柴油车的废气,通常使用由氧化催化器或NOx存储催化器和颗粒过滤器的组合组成的催化器设施。布置在发动机附近的氧化催化器和颗粒过滤器通常安装在一个共同的壳体中。为了遵守更严格的废气极限值,氧化催化器可以在同样的结构空间中被NOx存储催化器取代。
在氧化催化器中,一氧化碳和挥发性碳氢化合物被氧化成二氧化碳。氧化催化器通常由金属的或陶瓷的、具有催化活性涂层的载体基材组成,所述涂层由铂族金属、例如铂和/或钯制成。因为柴油机的废气温度明显低于汽油机的废气温度,所以用于柴油机的氧化催化器(DOC)优选安装到排气弯管附近。
壁流式过滤器和旁流式过滤器可以作为可再生的颗粒过滤器使用。在壁流式过滤器中,碳黑颗粒和其它存在于废气流中的固体通过附着吸附在多孔的过滤器壁上。如果排气背压由于颗粒嵌入而达到预定的阈值,则开启颗粒过滤器的再生。为此,例如可以将燃料补充喷射到废气流中,以便提高废气温度并且使嵌入过滤器中的碳黑颗粒燃烧。在旁流式过滤器技术中,一部分废气流转向并且被引导通过无纺布层。在此,碳黑颗粒被过滤出来。通常,在旁流式过滤器中进行连续的再生。
对于重型车辆,由氧化催化器和颗粒过滤器组成的催化器设施还可以附加地利用SCR催化器补充。SCR(选择性催化还原)在此指的是对来自内燃机废气的氮氧化物(NOx)的选择性催化还原。这样的SCR催化器例如在EP 1 203 611 B1或EP 1 837 494 B1中描述。
为了运行SCR催化器,在催化器的上游将用于氮氧化物的还原剂、例如在市场中作为“AdBlueTM”可购得的尿素水溶液喷射到废气流中。在SCR催化器中,在第一步骤中尿素溶液水解为氨并且在第二步骤中氨和NOx转化为水和氮。
由DE 103 23 607 A1、WO 2005/016497和US 2011/0078997分别已知如下的催化器,这些催化器在唯一的基材上具有由SCR催化器和颗粒过滤器组成的组合。这些催化器一般被称为SCRF催化器(过滤器上的SCR)并且不仅可以吸附碳黑颗粒,还可以将氮氧化物NOx还原成氮。
DE 10 2012 209 852 A1示出一种催化器设施,其中,SCRF系统在下游扩展了一个SCR催化器,所述SCR催化器具有用于碳氢化合物的附加的存储功能。在SCR催化器的下游布置有氧化催化器,所述氧化催化器可以氧化碳氢化合物和一氧化碳。
在DE 10 2009 038 835 A1中公开了一种废气净化设备,所述废气净化设备在氧化催化器和颗粒过滤器的上游具有第一SCR催化器并且在颗粒过滤器的下游具有一个另外的SCR催化器。
由DE 10 2011 079 785已知一种废气设备,其中设有第一氧化催化器(DOC),沿废气的流动方向在该第一氧化催化器下游布置有SCR装置和第二DOC。通过所述系统应当实现较低的碳氢化合物排放。SCR装置可以通过连接在下游的SCRF催化器补充。
所提到的催化器设施设计用于遵守内燃机废气中的氮氧化物和碳氢化合物加载量的变严格的极限值。
然而,布置在发动机附近的SCRF催化器的缺点在于,SCRF催化器的构件体积与迄今为止使用的用稀有金属涂覆的并且也被称为“Coated Soot Filter”(CSF)的颗粒过滤器相比变大。用于CSF的设计参数在过去是所谓的“灰尘嵌入能力”和内燃机的最大废气质量流量。对于SCRF催化器,附加地还要考虑NOx转化量,这导致更大的构件体积。但SCRF催化器的更大的构件体积造成增加的重量、增加的成本和增加的热惯性。
发明内容
本发明的任务是,提供一种在所有的运行情况中可靠的且可成本低廉地制造的废气净化系统,通过该废气净化系统能够避免上述缺点。
本发明通过按照权利要求1的用于净化内燃机、尤其柴油机的废气的装置的催化器组件实现。
本发明的有利的实施形式在从属权利要求中给出,这些从属权利要求可选择性地相互组合。
按照本发明,所述催化器组件包括可再生的颗粒过滤器和集成在颗粒过滤器上的用于选择性还原氮氧化物的催化器(SCRF催化器)。在SCRF催化器的上游设有用于选择性还原氮氧化物的催化器(SCR催化器),其中,所述SCRF催化器和所述SCR催化器布置在一个共同的催化器壳体中。
因此,本发明的核心是一种混合结构方式,所述混合结构方式包括在自身的载体基材上的SCR催化器和连接在下游的具有构件体积的SCRF催化器,所述构件体积对应于对于相应的内燃机变型方案常见的CSF的体积。所述混合结构方式具有如下优点,即,能够提供用于不同车辆的模块系统,在所述模块系统中根据车辆大小或者发动机变型方案相同地确定SCRF催化器的尺寸并且改变SCR催化器的尺寸。因此,催化器组件的制造可以用更低的成本实现。
按照本发明的催化器组件的其它优点由以下得出,即,SCR催化器由于其较小的热惯性在正常运行中显示出SCR功能的较快的起动性能并且在排放循环中显示出更好的NOx转化。由此,在相同的总体积的情况下催化器组件的效率得到改善。此外,通过颗粒过滤器的较小的体积得到较小的总重量。此外,混合系统的成本更低,因为SCR催化器可以比颗粒过滤器更有利地制造。在颗粒过滤器的再生运行中,组件的加热由于SCR过滤器的较小的热容量而可以更快地完成。
按照一种优选的实施形式,SCR催化器包括金属的或陶瓷的通流基材。所述通流基材典型地是具有一序列长形通道的蜂窝单体,这些通道延伸穿过该蜂窝单体,其中,这些通道在两端是敞开的。这样的通流基材能够用低的成本制造成具有不同的轴向延伸尺寸。以该方式能够使SCR催化器的NOx转化容易地匹配于不同的发动机变型方案。不同轴向延伸尺寸的差别在此大于在制造用于催化器的基材单体时通常出现的加工误差。
SCRF催化器优选构造为起过滤器作用的单体,特别优选构造为壁流式过滤器,例如形式为陶瓷的多孔的过滤器基材,该过滤器基材包括多个流入通道和多个流出通道,这些流入通道相互平行地布置,其中,每个流入通道和每个流出通道部分地通过多孔结构的陶瓷壁限定。每个流入通道在此通过多孔结构的陶瓷壁交替地与一个流出通道分开,反之亦然。换言之,壁流式过滤器是蜂窝设施,该蜂窝设施限定了多个在上游侧的端部封闭的第一通道和多个在上游侧的端部未封闭、但是在下游侧的端部封闭的第二通道。与第一通道在竖直方向上和在横向方向上相邻的通道在下游侧的端部封闭。当从这些端部中的一个端部观察时,通道的交替封闭和敞开的端部具有棋盘的外观。
SCRF催化器可以构造为完全挤压型材或者经涂覆的载体基材。合适的催化活性物质包括钒和钛的混合氧化物、含铁和铜的沸石及其混合物。
SCR催化器的通流基材优选是盘形的蜂窝单体,尤其是具有基本上圆柱形的或多边形的、优选矩形的横截面的蜂窝单体。通流基材的几何优选匹配于SCRF催化器的外部尺寸。
作为用于SCR催化器的催化活性成分,可以使用常见的在现有技术中已知的涂层和完全挤压型材。例如含铜的化合物、混合氧化物和氧化钒与二氧化钛的混合氧化物以及可选的氧化钨、氧化钼和二氧化硅、含铁和铜的沸石以及可以部分地与金属离子置换的酸性沸石及其混合物适合作为用于选择性还原氮氧化物的催化剂。
特别优选,在SCR催化器和SCRF催化器或者催化器壳体的轴向壁面之间设有至少一个间隔元件。利用所述间隔元件能够在保持催化器壳体和SCRF催化器的体积不变的情况下补偿SCR催化器的不同的轴向延伸尺寸。坚固的间隔垫片和/或无纺布材料、针织物和编织物可以用作间隔元件,所述间隔垫片和/或无纺布材料、针织物和编织物通常也用于补偿催化器基材的加工误差。耐热的金属丝织物是优选的。
此外,按照权利要求5的用于催化器组件的模块系统也是本发明的主题。
按照本发明的模块系统用于供内燃机、尤其柴油机的多种变型方案使用并且包括多个催化器壳体和SCRF催化器以及一组多个不同的SCR催化器,所述催化器壳体和SCRF催化器对于内燃机的多种变型方案而言分别与发动机变型方案无关地确定尺寸,所述SCR催化器对于内燃机的多种变型方案而言分别与发动机变型方案相关地确定尺寸并且具有不同的外部尺寸。
优选,所述模块系统的SCRF催化器和催化器壳体分别具有相同的、适合于与多种发动机变型方案共同使用的外部尺寸。优选,模块中的这些催化器壳体和SCRF催化器可以分别具有相同的体积和/或相同的长度与横截面积之比。
相同的外部尺寸或者说相同的体积或相同的长度与横截面积之比在此意味着,模块中的SCRF催化器和/或催化器壳体的尺寸仅仅在常见的加工误差之内波动。与多种发动机变型方案的匹配通过优化和确定催化器壳体和SCRF催化器的尺寸或者说确定其大小来实现,从而对于模块的所有发动机变型方案而言无需附加的SCRF催化器就在遵守预定的极限值的情况下实现充分地减少有害物质。
模块系统中的所述多个SCR催化器的尺寸优选选择成,使得相应的SCR催化器具有与所属的发动机变型方案和可选地与SCRF催化器的尺寸匹配的轴向延伸尺寸。通过选择具有适合于相应发动机变型方案的轴向延伸尺寸的SCR催化器,便能够尤其是使废气流中的氮氧化物下降到法定极限值以下的值。
附加地,模块系统可以包括一组不同的间隔元件,所述间隔元件与所述多个SCR催化器的尺寸匹配。因为根据发动机变型方案使用不同地确定尺寸的SCR催化器,所以能够补偿可能在催化器壳体中产生的空的空间。间隔元件可以是坚固的间隔垫片、例如间隔环,或者可以使用也用于补偿加工误差的具有不同壁厚的耐热的金属丝织物。
本发明还包括一种按照权利要求10的用于净化内燃机的废气的、具有按照本发明的催化器组件的装置。
所述装置尤其可以含有用于供给还原剂、尤其是氨或氨前体的机构,该机构布置在催化器组件的上游。还原剂优选是在市场中作为“AdBlueTM”可购得的尿素溶液,其成分在国际上是标准化的。在用于供给还原剂的机构的下游并且在催化剂组件上游可以设有混合元件或蒸发器,该混合元件或蒸发器引起还原剂均匀分布在废气流中。
此外,所述装置可以包括已知的氧化催化器和/或NOx存储催化器,所述氧化催化器和/或NOx存储催化器在排气管路中分别布置在所述组件和用于供给还原剂的机构的上游。
作为一种另外的优选的实施形式,所述装置可以包含连接在由SCR催化器和SCRF催化器组成的组件后面的氨截止催化器,所述氨截止催化器布置在所述组件的下游。所述氨截止催化器防止由于所谓的氨逃逸而出现的气味干扰,这些气味干扰可能由于还原剂的过度配量而产生。
按照本发明的用于由用于内燃机、尤其柴油机的多种变型方案的模块系统制造催化器组件的方法包括以下步骤:
a)提供分别具有相同尺寸的多个催化器壳体和多个SCRF催化器;
b)从一组不同的SCR催化器中选出一个与相应的发动机变型方案相关地确定尺寸的SCR催化器;和
c)将选出的SCR催化器与SCRF催化器组装在催化器壳体中,以便构成催化器组件。
利用按照本发明的方法能够实现催化器组件的模块式的结构方式。因为仅仅改变成本低廉的SCR催化器,所以不仅所述组件的仓储管理成本而且制造成本都可以总体下降。
按照所述方法的另一种实施形式,所述模块附加地包含一组不同地确定尺寸的补偿元件,根据所述SCR催化器的尺寸从这组补偿元件中为相应的发动机变型方案选出至少一个补偿元件并且将其安装在催化器壳体中。
附图说明
本发明的其它优点由下面参照附图对一种优选实施形式的描述得出。
在附图中,唯一的图示出用于净化内燃机废气的具有按照本发明的催化器组件的装置的示意图。
具体实施方式
在图中示意示出的装置10尤其用于净化柴油机(未示出)的废气12并且在废气的流动方向上包括:
——已知的废气涡轮增压器14;
——已知的氧化催化器16,所述氧化催化器可以被NOx存储催化器取代或者与NOx存储催化器组合;
——已知的用于供给用于氮氧化物的还原剂的装置18,例如用于尿素溶液的具有接在后面的混合元件(未示出)的喷射装置;
——按照本发明的催化器组件20;和
——已知的氨截止催化器22,净化后的废气可以从所述氨截止催化器被排放到环境中。取代氨截止催化器或者附加于氨截止催化器,可以设有另外的SCR催化器、氧化催化器或者由SCR催化器和氧化催化器组成的组合,如这在现有技术中是已知的。
按照本发明的催化器组件包括SCR催化器24和连接在SCR催化器后面的布置在下游的SCRF催化器26。
SCR催化器24用于选择性还原氮氧化物并且优选构造为没有过滤功能的通流基材,尤其是构造为盘形的蜂窝单体。
SCRF催化器26由可再生的颗粒过滤器和集成在颗粒过滤器上的用于选择性还原氮氧化物的催化器构成。
SCR催化器24和SCRF催化器26布置在一个共同的催化器壳体28中。
按照本发明可以由模块系统组装催化器组件20。所述模块系统能够实现催化器组件20的模块式的结构方式,所述模块式的结构方式可以用于内燃机、尤其柴油机的多种变型方案。
模块包括多个催化器壳体28和多个SCRF催化器26,所述催化器壳体和SCRF催化器对于内燃机的多种变型方案而言分别与发动机变型方案无关地确定尺寸,即具有相同的外部尺寸。在常见的加工误差范围内的偏差在这里被视为相同的尺寸。
此外,模块包括一组不同的SCR催化器24,所述SCR催化器对于内燃机的多种变型方案而言分别与发动机变型方案相关地确定尺寸。
优选,模块中的各催化器壳体28和SCRF催化器26可以具有相同的体积和/或相同的长度与横截面积之比。
模块系统中的不同的SCR催化器的尺寸优选选择成,使得相应的SCR催化器具有与所属的发动机变型方案匹配的轴向延伸尺寸并且可选地具有与SCRF催化器的外部尺寸相匹配的几何。
附加地,模块系统可以包括一组多个不同的与不同SCR催化器的尺寸匹配的间隔元件(未示出)。所述间隔元件用于补偿可能在催化器壳体中产生的空的空间,所述空的空间可能由于使用具有不同尺寸的SCR催化器24而产生。作为间隔元件可以使用坚固的间隔垫片、例如间隔环或者也用于补偿加工误差的耐热的具有不同壁厚的金属丝织物。
为了由模块系统制造按照本发明的催化器组件20,首先提供具有预定的与多个发动机变型方案匹配的尺寸的催化器壳体28和SCRF催化器。接着根据相应的发动机变型方案从一组具有不同尺寸或轴向延伸尺寸的SCR催化器中选出一个适当确定尺寸的SCR催化器24。然后将催化器壳体28、SCRF催化器26和从模块中选出的SCR催化器24选择性地与同样从该模块选出的间隔元件一起组装成催化器组件20。
与用于排量为2.0dm3的柴油机的传统柴油颗粒过滤器(CSF)的对比可以用作确定催化器组件20的尺寸的例子:
CSF体积=2.8dm3
在维持最佳的CSF的长度与横截面积之比的情况下,由此对于SCRF催化器得到3.5dm3的体积。
由SCR催化器24和SCRF催化器26组成的催化器组件20的混合系统由此可以具有以下体积:
混合系统体积=SCR体积+SCRF体积
=0.7dm3+2.8dm3=3.5dm3
为了与另一种发动机变型方案共同使用,维持SCRF体积并且仅改变SCR体积或者说SCR通流基材的轴向延伸尺寸。因此,利用按照本发明的模块系统能够实现催化器组件的成本低廉的模块化的结构方式。同时也得到技术上的优点,因为SCR通流基材具有较小的热容量并且展现出更好的热起动性能。此外,在总容量相同的情况下,催化器组件的效率可以得到改善,因为SCR催化器的NOx转化量更大。

Claims (15)

1.用于净化内燃机、尤其柴油机的废气的装置(10)的催化器组件(20),包括可再生的颗粒过滤器和集成在颗粒过滤器上的用于选择性还原氮氧化物的催化器(SCRF催化器)(26),其特征在于,在所述SCRF催化器(26)的上游设有用于选择性还原氮氧化物的催化器(SCR催化器)(24)并且所述SCRF催化器(26)和所述SCR催化器(24)布置在一个共同的催化器壳体(28)中。
2.根据权利要求1所述的催化器组件(20),其特征在于,所述SCR催化器(24)包括金属的或陶瓷的通流基材。
3.根据权利要求1或2之一所述的催化器组件(20),其特征在于,所述通流基材是盘形的蜂窝单体。
4.根据权利要求1或2之一所述的催化器组件(20),其特征在于,在所述SCR催化器(24)和所述SCRF催化器(26)或所述催化器壳体(28)的轴向壁面之间设有至少一个间隔元件。
5.用于根据权利要求1至4之一所述的催化器组件(20)的、用于供内燃机、尤其柴油机的多种变型方案使用的模块系统,所述模块系统包括多个催化器壳体(28)和SCRF催化器(26),所述催化器壳体和SCRF催化器对于内燃机的所述多种变型方案而言分别与发动机变型方案无关地确定尺寸,并且所述模块系统包括一组不同的SCR催化器(24),所述SCR催化器对于内燃机的所述多种变型方案而言分别与发动机变型方案相关地确定尺寸并且具有不同的外部尺寸。
6.根据权利要求5所述的模块系统,其特征在于,所述模块系统的SCRF催化器(26)具有相同的长度与横截面积之比。
7.根据权利要求5或6所述的模块系统,其特征在于,所述模块系统的SCRF催化器(26)具有相同的外部尺寸。
8.根据权利要求5至7之一所述的模块系统,其特征在于,所述不同的SCR催化器(24)具有不同的与相应的发动机变型方案匹配的轴向延伸尺寸。
9.根据权利要求5至8之一所述的模块系统,所述模块系统还包括一组不同的间隔元件,所述间隔元件与所述多个SCR催化器(24)的尺寸相匹配。
10.用于净化内燃机的废气的装置(10),包括根据权利要求1至4之一所述的催化器组件(20)。
11.根据权利要求10所述的装置(10),其中,在所述催化器组件(20)的上游布置有用于供给还原剂、尤其是氨或氨前体的机构(18)。
12.根据权利要求11所述的装置,其中,在所述催化器组件(20)和所述用于供给还原剂的机构(18)的上游布置有氧化催化器(16)和/或NOx存储催化器。
13.根据权利要求10至12之一所述的装置(10),其中,在所述催化器组件的下游布置有氨截止催化器(22)。
14.用于由根据权利要求5至9之一所述的用于供内燃机、尤其柴油机的多种发动机变型方案使用的模块系统制造催化器组件(20)的方法,所述方法包括以下步骤:
提供分别具有相同尺寸的多个催化器壳体(28)和SCRF催化器(26);
从一组不同的SCR催化器中选出一个与相应的发动机变型方案相关地确定尺寸的SCR催化器(24);和
将选出的SCR催化器(24)与所述SCRF催化器(26)组装在所述催化器壳体(28)中,以便构成催化器组件(20)。
15.根据权利要求14所述的方法,其特征在于,根据SCR催化器(24)的尺寸从一组不同的补偿元件中选出一个补偿元件并且将该补偿元件安装在催化器壳体(28)中。
CN201580004006.9A 2014-04-22 2015-03-18 用于催化器组件的模块系统和用于制造催化器组件的方法 Active CN105899773B (zh)

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