CN107339140B - 发动机排气系统 - Google Patents

发动机排气系统 Download PDF

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CN107339140B
CN107339140B CN201710285856.1A CN201710285856A CN107339140B CN 107339140 B CN107339140 B CN 107339140B CN 201710285856 A CN201710285856 A CN 201710285856A CN 107339140 B CN107339140 B CN 107339140B
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engine exhaust
exhaust system
scr catalyst
exhaust
catalyst device
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CN107339140A (zh
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L·N·迪潘纳
R·阿达尼斯
M·J·小帕拉托
R·米塔尔
J·李
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GM Global Technology Operations LLC
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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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0093—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are of the same type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation 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
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404—Removing only nitrogen compounds
    • B01D53/9409—Nitrogen oxides
    • B01D53/9431—Processes characterised by a specific device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation 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
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459—Removing 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
    • B01D53/9477—Removing 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 with catalysts positioned on separate bricks, e.g. exhaust systems
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    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
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    • F01N3/033—Exhaust 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 in combination with other devices
    • F01N3/035—Exhaust 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 in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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    • F01N3/103—Oxidation catalysts for HC and CO only
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    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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    • 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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • F01N2240/16—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 an electric heater, i.e. a resistance heater
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    • F01N2240/20—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 flow director or deflector
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Abstract

一种发动机排气系统，其包括排气管组件，该排气管组件具有配置成接收发动机排气的发动机排气系统入口和发动机排气系统出口。该系统包括第一选择性催化还原(SCR)催化剂装置，其定位在来自发动机排气系统入口的排气流的下游。第一SCR催化剂装置包括基底，该基底具有涂覆在基底上的金属催化剂。电加热器配置成加热金属催化剂。第二SCR催化剂装置定位在来自第一SCR催化剂装置的发动机排气流的下游以及发动机排气系统出口的上游。第一SCR催化剂装置和排气管组件在基底和第二SCR催化剂装置之间限定空腔室。发动机排气通过空腔室从基底直接流至第二SCR催化剂装置。

Description

发动机排气系统
技术领域
本教示大体包括发动机排气系统。
背景技术
车辆排气系统通常包括排气后处理装置，其在将排气释放到环境中之前过滤或以其它方式处理排气。例如，柴油氧化催化剂(DOC)是这样一种装置，该装置利用化学工艺以分解排气流中来自柴油发动机的气体。DOC氧化一氧化碳、碳氢化合物、一氧化氮(NO)以及柴油颗粒物质。附加地，DOC可在一定程度上还原氮氧化物(NOx)，即使大部分NOx还原通过选择性催化还原(SCR)装置来实现，该选择性催化还原装置通常在排气流中布置在DOC下游。SCR装置将NOx转化成氮和水。SCR装置可涂覆在贵金属催化剂中，该贵金属催化剂设计成触发化学反应以还原气态排放物。
对于发动机起动之后的一定时间段，来自柴油发动机的排气具有相对较低的温度。这些温度通常低于SCR装置以期望的效率操作来还原NOx所需的最低温度。
发明内容
发动机排气系统包括排气管组件，该排气管组件具有配置成接收发动机排气的发动机排气系统入口和发动机排气系统出口。该系统包括第一选择性催化还原(SCR)催化剂装置，其定位在来自发动机排气系统入口的排气流的下游。第一SCR催化剂装置包括基底，该基底具有涂覆在基底上的金属催化剂。电加热器配置成加热金属催化剂。第二SCR催化剂装置定位在来自第一SCR催化剂装置的发动机排气流下游以及发动机排气系统出口的上游。第一SCR催化剂装置和排气管组件在基底和第二SCR催化剂装置之间限定空腔室。发动机排气通过空腔室从基底直接流至第二SCR催化剂装置。
在一实施例中，排气混合器定位在排气管区段中。排气混合器是在发动机排气系统中在发动机排气系统入口和发动机排气系统出口之间的仅有排气混合器。
通过将电辅助第一SCR催化剂装置与由电加热器加热的金属催化剂一起使用，DEF注射比否则在发动机冷起动之后早几秒在废气的较低温度下开始。附加地，通过在第一SCR催化剂装置和第二SCR催化剂装置之间提供空腔室，需要仅仅一个混合器，并且具有相对较低背压的缩短排气系统可实现高的NOx转换效率。第一SCR催化剂装置和第二SCR催化剂装置还由于从DOC至第一SCR催化剂的相对较短长度而经由废气更快速地升温。与能实现类似水平的NOx转换效率的其它排气系统相比，排气系统相对成本较低并且同样还具有低热质量。
本教示的上述特征和优点以及其它特征和优点从以下结合附图对执行本发明的最佳模式的以下详细描述中能够很容易了解。
附图说明
图1是包括发动机和发动机排气系统的车辆的一部分的侧视图中的示意图。
图2是图1的发动机排气系统的示意剖视图。
图3是图1的排气系统的局部剖视图和立体图中的示意图，以示出图1的发动机排气系统的电辅助选择性催化还原装置的入口面。
图4是图1的发动机排气系统的电辅助选择性催化还原装置的出口面的局部剖视图和立体图中的示意图。
图5是图3的入口面的局部视图中的示意图。
图6是用于图1的发动机排气系统的第二选择性催化还原装置的替代实施例的剖视图中的示意图。
具体实施方式
参照附图，其中类似的附图标记指代若干视图中的类似部件，图1示出包括柴油发动机12的车辆10的一部分。柴油发动机12具有带有空气入口16的歧管14，并且具有发动机排气出口18。通过空气入口16接收的新鲜空气20在发动机中燃烧并且燃烧气体(即，发动机排气22)通过发动机排气出口18流动到发动机排气系统24中，该发动机排气系统可操作地连接于发动机12。更确切地说，发动机排气系统24包括排气管组件26，该排气管组件具有固定于发动机排气出口18的发动机排气系统入口28。发动机排气系统入口28配置成通过发动机排气出口18接收来自发动机12的发动机排气22。
排气管组件26包括若干排气管区段26A、26B、26C以及部件壳体26D、26E，它们将排气流从排气系统入口28引导至排气系统出口30。例如，排气管区段26A、26B、26C以及部件壳体26D、26E大体是圆柱形不锈钢的单壁管，这些单壁管在凸缘处或者以其它方式互连。
排气系统24包括柴油氧化催化剂(DOC)34，该柴油氧化催化剂在发动机排气系统24中设置在来自发动机排气系统入口28的发动机排气22的流的下游。DOC 34是流通装置，该流通装置包括作为容纳基底36的储罐的部件壳体26D。基底36可具有蜂窝结构。基底36具有涂覆有活性催化剂材料的大的表面积。例如，活性催化剂材料可包括铂族金属。DOC 34处理排气22，以还原排气22中的一氧化氮(NO)、一氧化碳(CO)和/或碳氢化合物(HC)。DOC 34将排气22中的一定百分比氮氧化物(NOx)转换成氮(N2)和二氧化碳(CO2)或水(H2O)，将一定百分比的一氧化碳(CO)氧化成二氧化碳(CO2)，将一定百分比的未燃烧碳氢化合物(HC)氧化成二氧化碳(CO2)和水(H2O)，并且将一氧化氮(NO)氧化成二氧化氮(NO2)。
DOC 34位于柴油排放流体(DEF)注射器40的发动机排气22的流的上游，该注射器设置在排气管区段26B中。DEF注射器40从流体源42接收柴油排放流体(DEF)44，并且将DEF44直接注射到排气22的流中。DEF 44可以是但不限于尿素和水的混合物。当由发动机排气22加热时，尿素水溶液蒸发并且分解以形成氨(NH3)和二氧化碳(CO2)。
DEF注射器40将排气混合器46正上游的DEF 44注射到发动机排气22的流中。排气混合器46定位在排气管区段26B中。排气混合器46是在发动机排气系统24中设置在发动机排气系统入口28和发动机排气系统出口30之间的仅有排气混合器。换句话说，虽然混合可能通过简单地通过排气流穿过排气管区段的空长度的简单扩散而发生，但混合器46是定位在排气管组件26内的仅有结构混合器，该排气管组件用于主动地混合排气流。混合器46使得所注射的DEF 44与排气流22混合。混合器46在管区段26B内具有结构，该结构可包括凸耳或叶片，这些凸耳或叶片使得DEF 44的液体破裂，从而增强其夹带到排气22的流中。当由排气22中的废气加热时，DEF 44形成氨。
排气管区段26B可操作地连接于第一选择性催化还原(SCR)催化剂装置52的入口50。排气管区段26B以及DEF注射器40和混合器46在来自第一SCR催化剂装置52的排气22的流的上游。第一SCR催化剂装置52定位在来自发动机排气系统入口28、DOC 34、DEF注射器40以及混合器46的排气22的流的下游。从单个混合器46至第一SCR催化剂装置52的距离相对较短，因为第二混合器无需布置在排气管组件24中以实现所期望的NOx转换效率。而是，在第一SCR催化剂装置52下游的空腔室66用于混合废气22。较短的排气管长度意指存在较小的热质量来加热，并且第二SCR催化剂64将因此更快速地加热。而是，
第一SCR催化剂装置52包括基底54，该基底具有涂覆在基底54上的金属催化剂56，例如在图5中最佳示出。基底54可具有蜂窝形状，以形成通过装置52的六边形流动通路55。基底54沿着每个六边形流动通路55的表面涂覆有金属催化剂56。在非限制的示例实施例中，金属催化剂56是具有高操作温度和长使用寿命的不锈钢。例如，金属催化剂可以是铁-铬-铝(FeCrAl)箔片，例如DIN 1.4725不锈钢。金属催化剂具有高导热性，其具有短燃尽时间和低过热风险。金属催化剂还具有相对较薄的壁，这些壁有助于使得通过排气系统24具有相对较小的压降。薄壁还具有大的有效表面积和高机械强度。
第一SCR催化剂装置52还包括电加热器60，该电加热器配置成加热金属催化剂56。电加热器60在排气22的流中位于基底54的上游。电加热器60和第一SCR催化剂装置52容纳在部件壳体26E。电加热器60由诸如车辆电池的电源62通电。在一个实施例中，电加热器60是2000瓦特加热器。电加热器60的通电可通过电子控制单元(未示出)控制，该电子控制单元基于所感测的温度和其它发动机操作参数来控制开关。由于催化剂56是金属催化剂，其快速地加热以增大第一SCR催化剂装置52的效率，甚至当例如在发动机冷起动之后、废气温度相对较低时。如这里所使用的，发动机冷起动是发动机12在发动机已熄火预定时间量之后、即车辆10并不使用时的起动。
第二SCR催化剂装置64定位在来自第一SCR催化剂装置52的发动机排气22的流的下游以及发动机排气系统出口30的上游。第一SCR催化剂装置52和部件壳体26E在基底54和第二SCR催化剂装置64之间限定空腔室66，以使得发动机排气22通过空腔室66从基底流动通路55直接流至第二SCR催化剂64。空腔室66允许排气22由于在空腔室66中导致的涡流、在进入到第二SCR催化剂装置64之前进一步混合。
在图1-5的实施例中，第一SCR装置52的基底54具有大体垂直于发动机排气22的流动方向的入口面70，以及相对于发动机排气22的流动方向成角度的出口面72。发动机排气22在第一SCR催化剂装置52处的流动方向被认为沿着部件壳体26E的中心纵向轴线，并且由表征图1中发动机排气22的流动的每个箭头指示。第一SCR催化剂装置52由图2中实施例的大体圆柱形壳体部件26E粘结。基底54具有大体垂直于发动机排气流的方向的入口面70。入口面70具有根据部件壳体26E的圆柱形内壁的大体圆形周界，入口面70邻抵于该圆柱形壁。入口面70是大体平坦的并且具有用于流动通路55的六边形开口。
出口面72是大体平坦的并且垂直于废气22的流动方向，且如图4所示具有流动通路55的六边形开口。出口面72成角度以使得其并不相对于发动机排气22的流动方向垂直。更确切地说，例如在图2中最佳地示出，出口面72在部件壳体26E内倾斜，以使得出口面72的一部分76进一步在排气22的流的下游而一部分74进一步在排气22的流的上游。出口面72的周界根据部件壳体26E的圆柱形壁是大体椭圆的，出口面72邻抵于该圆柱形壁。通过使得出口面72成角度，产生涡流流动，并且排气流22的对应混合在空腔室66中发生，因为腔室66内的压力在腔室66的缩短下半部中与较大上半部中不同。排气22则流过第二SCR催化剂装置64，该第二SCR催化剂装置还具有基底68。基底68可在入口面80和出口面82处具有六边形开口，在面80、82之间具有大体平直的六边形流动通路85，并且具有涂覆在基底68上的选择性还原催化剂。
通过提供电辅助的第一SCR催化剂装置52，例如在冷起动之后在相对较低温度下的废气22能由第一SCR装置52处理，在空腔室66中进一步混合，并且然后由第二SCR催化剂装置64处理，并且能利用相对紧凑排气系统24(即，具有从入口28至出口30的缩短总体长度)在低背压和仅仅一个混合器46的情形下、来实现期望的NOx转换效率。在图1的实施例中，其上涂覆有金属催化剂56的基底54占据第一容积V1，空腔室66具有大于第一容积的第二容积V2，并且第二SCR催化剂装置64具有大于第二容积V2的第三容积V3。第一容积V1可以是约1升，第二容积V2可以是约1.7升，并且第三容积V3可以是约4升。例如，在一个实施例中，当DEF 44从DEF注射器40的注射速率是约75千克/小时并且在DEF注射器40处的发动机排气22的温度是约160华氏度时，发动机排气系统24具有至少92％的DEF蒸发率，至少0.81的均匀性指数以及在第二SCR催化剂装置64上游至少79％的NOX转换效率。均匀度指数是对废气的组分在排气流垂直于流动方向的横截面上的均匀度的度量。1.0的均匀度指数是完美的均匀度。
通过将电辅助第一SCR催化剂装置52与由电加热器60加热的金属催化剂56一起使用，DEF注射比否则在发动机冷起动之后早几秒在废气22的较低温度下开始。附加地，通过在第一SCR催化剂装置56和第二SCR催化剂装置64之间提供空腔室66，需要仅仅一个混合器46，并且具有相对较低背压的缩短排气系统24可实现高的NOx转换效率。
在替代的实施例中，第二SCR催化剂装置64可由图6中示出的选择性催化还原过滤器(SCRF)催化剂装置64A替代。SCRF催化剂装置64A具有基底，该基底是过滤器，该过滤器具有选择性还原催化剂涂覆在过滤器上。
虽然已详细地描述了用于执行本教示的许多方面的最佳模式，但熟悉这些教示的本领域技术人员会认识到落在所附权利要求的范围内的用于实践本教示的各种替代方面。

Claims (9)

1.一种发动机排气系统，包括：
排气管组件，所述排气管组件具有配置成接收发动机排气的发动机排气系统入口和发动机排气系统出口；
第一选择性催化还原SCR催化剂装置，其定位在来自所述发动机排气系统入口的排气流的下游；
其中，所述第一SCR催化剂装置包括：
基底，所述基底具有涂覆在所述基底上的金属催化剂；
电加热器，所述电加热器配置成加热所述金属催化剂；
第二SCR催化剂装置，所述第二SCR催化剂装置定位在来自所述第一SCR催化剂装置的发动机排气流的下游以及所述发动机排气系统出口的上游；
其中，所述第一SCR催化剂装置、所述排气管组件和所述第二SCR催化剂装置限定空腔室，以使得所述发动机排气流通过所述空腔室从所述基底直接流至所述第二SCR催化剂装置；
其中，所述第一SCR装置的所述基底具有大体垂直于所述发动机排气流的方向的入口面，以及相对于发动机排气流的方向倾斜的出口面。
2.根据权利要求1所述的发动机排气系统，其中，所述排气管组件进一步包括排气管区段，所述排气管区段在来自所述第一SCR催化剂装置的所述发动机排气流的上游并且在来自所述发动机排气系统入口的发动机排气流的下游可操作地连接于所述第一SCR催化剂装置的所述入口，且所述发动机排气系统进一步包括：
排气混合器，所述排气混合器定位在所述排气管区段中。
3.根据权利要求2所述的发动机排气系统，其中，所述排气混合器是在所述发动机排气系统中在所述发动机排气系统入口和所述发动机排气系统出口之间的仅有的排气混合器。
4.根据权利要求2所述的发动机排气系统，进一步包括：
柴油排放流体DEF注射器，其在所述排气管区段中设置在来自所述排气混合器的所述发动机排气流的上游。
5.根据权利要求4所述的发动机排气系统，进一步包括：
柴油氧化催化剂DOC，所述柴油氧化催化剂在所述发动机排气系统中设置在来自所述发动机排气系统入口的所述发动机排气流的下游并且在所述DEF注射器的所述发动机排气流的上游。
6.根据权利要求4所述的发动机排气系统，其中，当来自所述DEF注射器的DEF的注射速率是约75千克/小时并且在所述DEF注射器处的所述发动机排气的温度是约160华氏度时，所述发动机排气系统具有至少92％的DEF蒸发率，至少0.81的均匀性指数以及在所述第二SCR催化剂装置上游具有至少79％的NOX转换效率。
7.根据权利要求1所述的发动机排气系统，其中，所述排气管组件是单壁管。
8.根据权利要求1所述的发动机排气系统，其中，所述第一SCR催化剂装置具有第一效率，而所述第二SCR催化剂装置具有大于所述第一效率的第二效率。
9.根据权利要求1所述的发动机排气系统，其中，其上涂覆有所述金属催化剂的所述基底具有第一容积，所述空腔室具有大于所述第一容积的第二容积，并且所述第二SCR催化剂装置具有大于所述第二容积的第三容积。
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