CN110741141B - 试剂分布的基于温度的控制 - Google Patents

试剂分布的基于温度的控制 Download PDF

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CN110741141B
CN110741141B CN201880039542.6A CN201880039542A CN110741141B CN 110741141 B CN110741141 B CN 110741141B CN 201880039542 A CN201880039542 A CN 201880039542A CN 110741141 B CN110741141 B CN 110741141B
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reagent
heater
diesel exhaust
temperature
heated
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CN110741141A (zh
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马克·丹尼斯·埃弗利
保罗·道格拉斯·弗里
杰弗里·迪斯特尔迈尔
安德鲁·D·塞尔维
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Watlow Electric Manufacturing Co
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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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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  • Engineering & Computer Science (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
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  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

本公开提供了一种处理柴油机排气系统的方法，该方法包括：将试剂加热到一定温度以使得试剂的至少一部分被加热成气相，在催化剂上游将试剂注射到柴油机排气流中，以及通过催化剂使柴油机排气与加热的试剂进行反应以将NOx转化为N2和H2O。该加热通过将试剂的物质状态至少部分地转换成气相来调节试剂的质量流率，并且呈气态形式的加热的试剂减少了柴油机排气系统内的沉积物的形成。

Description

试剂分布的基于温度的控制
相关申请的交叉引用
本申请要求于2017年6月16日提交的序列号为62/520,959的美国临时申请的优先权和权益。上述申请的公开内容通过引用而整体并入本文。
技术领域
本公开涉及柴油机排气后处理系统，并且更具体地涉及用于在催化剂上游将尿素注射到柴油机排气流中以减少有害排放物的系统。
背景技术
该部分中的陈述仅提供与本公开相关的背景信息，并且可不构成现有技术。
许多柴油机排气后处理系统使用SCR(选择性催化还原)来减少NOx(氮的氧化物)排放物。SCR系统使用催化剂来促进NOx与氨反应生成N2和H2O。通常，氨是通过尿素在催化剂上游的排气中的注射和随后分解(以尿素在水中的水溶液形式)而供应给催化剂的。由于系统从排气中去除NOx的效率取决于氨在催化剂中的适当分布，并且由于氨的分布取决于注射过程所产生的尿素的分布，因此对尿素的分布的控制是提高SCR系统的转换效率的因素。
除了对氨在催化剂中的分布的敏感性外，SCR系统还存在与尿素的注射相关联的沉积物形成问题。撞击不够暖的表面的注射的尿素会在排气系统的内部形成持久性沉积物，其可导致系统失效。为了防止这些沉积物，尿素的注射通常仅限于排气流足够暖以防止沉积物形成的操作条件。仅在排气流足够暖时注射尿素会降低系统的整体效率(因为它在某些操作条件下无法有效运行)。为了减轻NOx转化效率的降低，系统设计人员使用各种方法来提高排气温度(通常以节省燃料为代价)或注射点周围对排气结构加热。另外，系统设计者还必须考虑DEF(柴油机排气处理液)的量，即在任何给定时间需要被注射到系统中的尿素。在需要注射更高量的DEF的条件下，例如通常与更高水平的NOx相关联的条件下，系统设计人员采用各种方法来减少或最小化DEF喷柱(spray plume)与排气系统内部的表面的接触。这有助于减少沉积物形成，例如使注射过程脉冲化或改变DEF的注射压力。这些方法通常在防止沉积物形成方面略有成功。
发明内容
在本公开的一种形式中，提供了一种处理柴油机排气系统的方法，该方法包括将试剂加热至一定温度以使得试剂的至少一部分被加热成气相，在催化剂的上游将试剂注射到柴油机排气流中，并利用催化剂使柴油机排气与加热的试剂进行反应，以将NOx转化为N2和H2O。加热步骤通过将试剂的物质状态至少部分地转换成气相来调节试剂的质量流率，并且呈气态形式加热的试剂减少了柴油机排气系统内的沉积物形成。
在另一种形式中，加热是通过加热器、来自柴油机的热量、来自发动机冷却剂的热量以及来自柴油机排气流的热量中的至少一种来进行的。加热器可以选自由两线式加热器、管式加热器、筒式加热器和分层加热器组成的组。
在另一种形式中，该方法包括控制功率以完成以下中的至少一项：将试剂加热到期望的设定点温度和基于操作数据来加热试剂。
当试剂被加热到期望的设定点温度时，设定点温度基于以下中的至少一项：发动机转速、发动机负荷、至发动机的燃料流率、排气温度(EGT)、排气流率、EGT和排气流率的历史值、催化剂温度、试剂注射导管温度、试剂压力、试剂质量流率(mass flow rate)、试剂质量(quality)、环境空气温度、海拔高度、NOx传感器数据、排气压力以及至少来自发动机控制单元和车辆控制器中的至少一个的预期的发动机状态，以及其组合。
当基于操作数据加热试剂，并且操作数据选自温度、发动机转速、发动机负载、到发动机的燃料流率、排气温度(EGT)、排气流量、催化剂温度、试剂注射导管温度、试剂压力、试剂质量流率、试剂质量、环境空气温度、海拔高度、NOx传感器数据、排气压力及其组合。
在另一种形式中，由与发动机控制单元和车辆控制器中的至少一个进行通信的控制器来执行至加热器的功率的控制，并且试剂的温度根据由发动机控制单元控制控制的发动机参数和由车辆控制器控制的车辆参数中的至少一种的函数来控制。
在又一种形式中，在试剂被注射到柴油机排气流之前或之后进行试剂的物质状态的转换。
在另一种形式中，试剂的质量流率由布置在催化剂上游的至少一个喷嘴调节。在一种形式中，喷嘴包括用于试剂的低质量流率的第一级喷嘴和用于试剂的较高质量流率的第二级喷嘴。在喷嘴的另一变型中，多个注射喷嘴以同心模式布置。在又一喷嘴变型中，至少一个孔的尺寸设计成通过将试剂流的一部分转换成气态或通过改变流过喷嘴的试剂的性质来适应试剂的质量流率的调节，其中，调节试剂的质量流率是发动机参数或车辆参数中的至少一项的函数。喷嘴可以进一步包括孔，以产生试剂的阻塞流，该孔选自由环形孔和临界流量孔组成的组。
在又一形式中，该方法还包括使用连接到试剂源的泵来控制试剂的质量流率。
还提供了根据本公开的各种方法中的至少一种方法操作的柴油动力设备。
根据本文提供的描述，其他应用领域将变得显而易见。应当理解，描述和具体示例仅旨在用于说明的目的，并不旨在限制本公开的范围。
附图说明
并入说明书并形成其一部分的附图示出了本公开的几个方面，并且与说明书一起用于解释本公开的原理。图中的部件不一定是按比例绘制的。在图中：
图1是根据本公开的教导的柴油机排气后处理系统的示意图，并且该柴油机排气后处理系统具有可操作地连接到试剂源的加热器。
具体实施方式
以下描述本质上仅是示例性的，且绝不旨在限制本公开、其应用或用途。还应当理解，在不改变本公开的原理的情况下，方法内的步骤可以以不同的顺序执行。
参考图1，示出了根据本公开的教导的柴油机排气后处理系统，并且其总体上由附图标记20表示。柴油机排气后处理系统20包括流体注射导管24，该流体注射导管24在催化剂16(其以这种形式是选择性催化还原(SCR))的上游联接至试剂源18并且联接至柴油机排气流12。系统20还包括可操作地连接到注射导管24的加热器26，其中，在一种形式中，加热器26加热流过注射导管24的试剂，以在被注射到柴油机排气流中之前将试剂的物质状态至少部分地转换成气态。如本文所用的，术语“试剂”应被解释为指可以与催化剂16结合以产生减少柴油机排气流12内的NOx量的化学反应的任何物质/材料。例如，这种材料可包括任何柴油机排气处理液(DEF)或尿素水溶液，其用在催化剂16中以还原NOx。
加热器26可以是任何类型的加热器构造，包括但不限于管式加热器、筒式加热器或分层加热器等。此外，除了本文所述的其他形式之外，加热器26可以是自调节的。
如进一步所示的，柴油机排气后处理系统20还包括与加热器26连通的控制器28，其中，控制器28可操作用于调节至加热器26的功率以将试剂加热至期望的设定点温度。设定点温度基于以下各项中的至少一项：发动机转速、发动机负荷、至发动机的燃料流率、排气温度(EGT)、排气流率、EGT和排气流率的历史值、催化剂温度、试剂注射导管温度、试剂压力、试剂质量流率、试剂质量、环境空气温度、海拔高度、NOx传感器数据、排气压力和来自发动机控制单元和车辆控制器中的至少一个的预期的发动机状态，及它们的组合。
柴油机排气后处理系统20还包括连接至试剂源18的泵22，其中控制器28与泵22连通以控制试剂的质量流率。
至少一个温度传感器25可以邻近加热器26布置以感测试剂的温度。可替代地，加热器26可以是“两线式(two-wire)”加热器，其中该加热器用作加热器和温度传感器这两者，从而消除了对离散温度传感器的需要。在专利号为7,196,295的美国专利中示出和描述了这种两线式加热器，该美国专利与本申请是共同所有的，并且其内容通过引用而整体并入本文。
在一种形式中，控制器28从温度传感器25(或两线式加热器)接收温度数据，并相应地调节至加热器26的功率。而且，控制器28可以从温度传感器25接收温度数据并且相应地调节试剂的质量流率。在另一种形式中，至少一个温度传感器(未示出)布置在加热器26的上游或下游，其中控制器28基于从温度传感器和加热器26接收的温度数据来调节试剂的质量流率和提供至加热器26的功率中的至少一个。柴油机排气后处理系统20还可以包括另一个加热器(未示出，位于排气导管14内或注射导管24内)，并且控制器28基于从这两个加热器接收的温度数据来调整试剂的质量流率和提供至加热器26的功率中的至少一个。
加热器26可以限定至少两个区域，并且控制器28基于从该至少两个加热器区域接收的温度数据来调节试剂的质量流率和提供至加热器26的功率中的至少一个。这种分区的加热器可以包括专利号为9,113,501的美国专利中公开的配置，该美国专利与本申请是共同所有的，其内容通过引用而整体并入本文。
在又一种形式中，第一温度传感器布置在加热器26的下游，并且第二温度传感器布置在加热器26的上游，其中控制器28基于从第一温度传感器和第二温度传感器接收的温度数据来调节试剂的质量流率和提供至加热器26的功率中的至少一个。
在一种形式中，控制器28与发动机控制单元30和车辆控制器32中的至少一个进行通信，并且试剂的温度分别根据由发动机控制单元30和车辆控制器中的至少一个控制的发动机参数或车辆参数而被控制。
如进一步所示的，柴油机排气后处理系统20还包括至少一个注射喷嘴40，用于将加热的试剂在催化剂16上游输送到柴油机排气流。喷嘴40可以采取任何形式或形式的组合，其包括多级喷嘴，该多级喷嘴具有用于试剂的低质量流率的第一级喷嘴和用于试剂的高质量流率的第二级喷嘴。在本公开的另一种形式中，可以存在以同心模式布置的多个注射喷嘴。
每个喷嘴具有孔，并且该孔可以选自由环形孔和临界流量孔组成的组，以产生试剂的阻塞流。此外，喷嘴包括可调节的孔尺寸。
通常，喷嘴40包括至少一个孔，该孔的尺寸被设计成通过将试剂流的一部分转换成气态或通过改变流过喷嘴的试剂的性质来适应试剂的质量流率的调节，其中调节试剂的质量流率是发动机参数或车辆参数中的至少一个的函数。
本公开还包括具有如本文所述的柴油机排气后处理系统20的柴油动力设备，例如示例性的机动车辆或发电机组。
与加热器26通信的控制器28也可操作用于基于操作数据来调节至加热器的功率以加热试剂。操作数据选自由以下组成的组：温度、发动机转速、发动机负荷、至发动机的燃料流率、排气温度(EGT)、排气流率、催化剂温度、试剂注射导管温度、试剂压力、试剂质量流率、试剂质量、环境空气温度、海拔高度、NOx传感器数据、排气压力及它们的组合。
在其他形式中，控制器28可以使用来自离散传感器或作为两线式加热器的加热器的温度输入，来实现多种控制和诊断功能。例如，温度数据可用于与系统模型或设定点进行比较，以验证预期的质量流率是实际呈现的。诊断可以包括检测到流量不足(较高的上升率)或控制器28可能不起作用、加热器26可能正在退化或传感器不起作用(例如，温度差与系统模型不对应)。
无论传感器是否是离散的和/或加热器26是否为两线式的，控制器28都还可被配置为提供“级联控制”，或使用两个控制器和相关的传感器。
此外，温度数据可用于提供上限设定点功能，以在异常情况下抑制加热器26的损坏/故障。
应当理解，本公开还包括一种形式，其中加热器26加热流过注射导管24的试剂，以在被注射到柴油机排气流12中之后将试剂的物质状态至少部分地转换为气态。在另一种形式中，加热器26加热流过注射导管状态的试剂，并且可操作用于通过将试剂的物质状态至少部分地转换成气相来调节试剂的质量流率。该转化可以在被注射到柴油机排气流12之前或之后进行。热源可以是加热器26、来自柴油机的热量和来自发动机冷却剂的热量中的至少一种。
在又一种形式中，比例阀50可操作地连接到加热和/或未加热的试剂流，该加热和/或未加热的试剂流将加热和未加热的试剂流混合，以实现试剂的气态或蒸汽质量与气态的期望比例。
此外，在另一种形式中，排气导管14涂覆有为水解催化剂的材料。这样的材料，例如作为示例的TiO2，是疏水材料，并因此将排斥水溶液，即试剂。根据本文的教导，除了将试剂的物质状态至少部分地转换为气态之外，涂覆排气导管14还抑制了在排气导管14内形成沉积物。
还提供了一种减少来自柴油机排气系统的NOx的方法，该方法包括以下步骤：
将试剂加热至一定温度，以使得试剂的至少一部分被加热至气相；
在催化剂上游将试剂注射到柴油机排气流中；和
利用催化剂使柴油机排气与加热的试剂进行反应，以将NOx转化成N2和H2O，
其中，加热通过将试剂的物质状态至少部分地转换成气相来调节试剂的质量流率，并且呈气态形式的加热的试剂减少了柴油机排气系统内的沉积物形成。
本公开内容可选择地使用来自排气流的热量(例如来自催化剂下游的热量)来充当试剂的热源(部分或完全替代电热量)。对于不带电加热器的系统，流量比例阀可用于将加热的流和未加热的流进行混合，以达到所需的温度或蒸汽质量。
向排气增加热量(特别是通过发动机控制)用于加速预热并减少防止低怠速的温度。本公开内容适合于允许在启动/预热条件期间减少注射尿素的时间，包括向排气中增加热量的系统，从而减少在预热时间段期间的NOx排放物。对于为峰值燃料(或流体)经济性而控制的发动机来说，在当排气温度不期望地低时的预热期间和怠速期间，都可以减少向排气增加热量的趋势，从而改善发动机效率和燃油经济性。
本公开提供了在管理试剂喷柱长度上的强大的新自由度。这是暖化试剂以减少其蒸发时间的能力，其使喷柱长度减小。在轻负荷和低发动机转速下，过量的喷柱长度对于当前系统来说是一个问题，本发明加热试剂直到其离开喷嘴后立即沸腾。这大大减小了喷柱长度，并大大增强了混合。
在一种形式中，本公开提供了在注射入排气流体流系统之前对试剂进行加热。排气流体流系统可以是柴油机系统的一部分。认识到注射喷嘴上游和泵下游的试剂将处于高压下，因此可以在排气管内部存在的压力下将试剂加热到沸点以上的温度。
在一种形式中，加热的试剂在注射时可以至少部分地闪蒸成蒸汽，从而影响形成的所得液滴的尺寸。对于给定的排气后处理系统，除了排气温度和流率之外，液滴从喷嘴尖端的行进距离还取决于其尺寸和速度。由于排气温度和流率在绝大多数应用中会发生变化(很少有发动机在其使用寿命内以相同的速度和负荷运行)，因此液滴的行进距离将随发动机的工作条件而发生变化，并且由此试剂在催化剂中的分布也将随发动机的操作条件而发生变化。
通过控制试剂的温度(和/或注射的试剂的蒸汽质量)来补偿发动机操作条件的变化，可以改善催化剂中的氨分布，并且由此可以在各种发动机操作条件下提高系统NOx转化效率。由于这种控制方法向进入排气流的试剂流增加了热量，因此还可以在较低的排气温度下进行注射而没有沉积物形成的风险。这增加了可以安全地注射试剂的发动机操作条件，并因此提高了许多柴油机的NOx的总体转化。它还允许较高的试剂注射速率，同时减少试剂喷柱撞击排气系统表面，从而降低在较高NOx条件下沉积物形成的风险。
本公开的描述本质上仅是示例性的，因此，不背离本公开的实质的变化旨在处于本公开的范围内。这种变化不应被视为背离本公开的精神和范围。

Claims (5)

1.一种处理柴油机排气系统的方法，所述方法包括：
在将液态试剂注射到柴油机排气流中之前，通过加热器将所述试剂加热到一定温度，以使得所述试剂被加热成部分气相；
根据试剂质量控制至所述加热器的功率以加热试剂；
在催化剂上游将呈部分气相的经加热的所述试剂注射到柴油机排气流中；和
通过所述催化剂使柴油机排气与加热的所述试剂进行反应，以将NOx转化成N2和H2O，
其中，所述加热通过将所述试剂的物质状态部分地转换成气相来调节所述试剂的质量流率。
2.根据权利要求1所述的方法，其中，所述加热器选自由两线式加热器、管式加热器、筒式加热器和分层加热器组成的组。
3.根据权利要求1所述的方法，其中，由控制器控制至所述加热器的功率，所述控制器与发动机控制单元和车辆控制器中的至少一个进行通信，并且根据由所述发动机控制单元控制的发动机参数和由所述车辆控制器控制的车辆参数中的至少一个的函数来控制经加热的所述试剂的蒸汽质量。
4.根据权利要求1所述的方法，其中，在注射之前，所述液态试剂在所述柴油机排气流内部在一定压力下被加热到所述试剂的沸点或沸点以上。
5.一种柴油动力设备，所述柴油动力设备根据权利要求1所述的方法来操作。
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