CN114173910A - 用于恢复催化剂性能的系统和方法 - Google Patents
用于恢复催化剂性能的系统和方法 Download PDFInfo
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- CN114173910A CN114173910A CN202080054227.8A CN202080054227A CN114173910A CN 114173910 A CN114173910 A CN 114173910A CN 202080054227 A CN202080054227 A CN 202080054227A CN 114173910 A CN114173910 A CN 114173910A
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Abstract
一种恢复催化剂性能的方法包括提供钒选择性催化还原(VSCR)催化剂。该方法包括在20℃‑100℃的范围内的第一温度,将VSCR催化剂暴露于在50%‑100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段。该方法包括在300℃‑600℃的范围内的第二温度热处理VSCR催化剂持续至少一小时的第二时间段。
Description
相关申请的交叉引用
本申请要求于2019年7月31日提交的美国临时申请第62/880,824号的权益,其全部内容通过引用并入本文。
技术领域
本申请总体上涉及用于内燃发动机的后处理系统的领域。
背景
对于内燃发动机诸如柴油发动机,氮氧化物(NOx)化合物可以在排气(exhaust)中被排放。为了减少NOx排放物,可以实施选择性催化还原(SCR)工艺,以在催化剂和液体还原剂的帮助下将NOx化合物转化成更中性的化合物,诸如双原子氮、水或二氧化碳。催化剂可以被包含在排气系统的催化剂室中,诸如交通工具或发电单元的催化剂室中。液体还原剂,诸如无水氨、氨水、柴油排气流体(diesel exhaust fluid)(DEF)或含水尿素,通常在催化剂室之前被引入废气流(exhaust gas flow)中。
在一些应用中,钒SCR催化剂可以通过表面氧化钒烧结或结块成更大的氧化钒的簇(cluster of vanadium oxide)而变得失活。
概述
本文描述的实施方案总体上涉及用于恢复催化剂性能的系统和方法。
在一些实施方案中,恢复催化剂性能的方法包括提供钒选择性催化还原(VSCR)催化剂;在20℃-100℃的范围内的第一温度,将VSCR催化剂暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段;以及在300℃-600℃的范围内的第二温度热处理VSCR催化剂持续至少一小时的第二时间段。
在一些实施方案中,第一湿度水平在50%-95%相对湿度的范围内。在一些实施方案中,第二温度在400℃-600℃的范围内。在一些实施方案中,第二温度在500℃-600℃的范围内。在一些实施方案中,在提供VSCR催化剂的步骤中,VSCR催化剂包括氧化钒的簇。在一些实施方案中,将VSCR催化剂暴露于第一湿度水平的步骤使氧化钒分散。
在一些实施方案中,第一时间段包括至少5小时。在一些实施方案中,第二时间段包括小于或等于48小时。在一些实施方案中,提供VSCR催化剂的步骤包括提供VSCR催化剂作为交通工具系统的一部分。在一些实施方案中,提供VSCR催化剂的步骤包括在环境室(environmental chamber)中提供VSCR催化剂。
在一些实施方案中,制造钒选择性催化还原(VSCR)催化剂的方法包括:烧结氧化钒;在20℃-100℃的范围内的第一温度,将氧化钒暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段;以及在300℃-600℃的范围内的第二温度热处理氧化钒持续至少一小时的第二时间段。
在一些实施方案中,第一湿度水平在50%-95%相对湿度的范围内。在一些实施方案中,第二温度在400℃-600℃的范围内。在一些实施方案中,第二温度在500℃-600℃的范围内。在一些实施方案中,氧化钒包括氧化钒的簇。在一些实施方案中,将VSCR催化剂暴露于第一湿度水平的步骤使氧化钒的簇分散。在一些实施方案中,第一时间段包括至少5小时。在一些实施方案中,第二时间段包括小于或等于48小时。在一些实施方案中,第一湿度水平在70%-95%相对湿度的范围内。
附图简述
在附图和下文的描述中阐述了一种或更多种实施方式的细节。本公开内容的其他特征、方面和优点从描述、附图和权利要求书中将变得明显,在附图中:
图1图示了根据实施方案的示例性后处理系统的框图,该后处理系统具有用于排气系统的示例性还原剂输送系统。
图2图示了根据实施方案的恢复催化剂性能的示例性方法的流程图。
图3图示了根据实施方案的制造VSCR催化剂的示例性方法的流程图。
图4图示了根据实施方案的转换频率(turnover frequency)和多个样品的图。
图5图示了根据实施方案的多个样品的拉曼光谱数据的图。
将认识到,附图中的一些或全部附图是为了说明目的的示意性表示。附图是为了说明一种或更多种实施方式的目的而被提供,并且明确理解它们将不用于限制权利要求书的范围或含义。
详述
接着下文是与用于恢复催化剂性能的方法、设备和系统相关的多种构思以及用于恢复催化剂性能的方法、设备和系统的实施方式的更详细描述。上文介绍的和下文更详细地讨论的多种构思可以以多种方式中的任何一种来实施,因为所描述的构思不限于任何特定的实施方式。具体的实施方式和应用的实例主要为了说明的目的而被提供。
I.综述
内燃发动机(例如柴油内燃发动机等)产生经常在后处理系统中处理的废气。这种处理通常包括用还原剂和SCR催化剂处理(例如,定量供给(dosing)等)废气,以将NOx排放物转化成更中性的化合物。在一些应用中,持续持久时间段的高温可能导致钒SCR催化剂的失活,这可以降低系统性能。
本文描述的实施方式涉及恢复催化剂性能的方法,该方法包括提供钒选择性催化还原(VSCR)催化剂。该方法可以包括在20℃-100℃的范围内的第一温度,将VSCR催化剂暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段。该方法可以包括在300℃-600℃的范围内的第二温度热处理VSCR催化剂持续至少一小时的第二时间段。
本文描述的方法可以恢复VSCR催化剂的性能并且延长VSCR催化剂的寿命,这可以通过延迟或避免完全更换VSCR催化剂来降低成本。
II.后处理系统的综述
图1描绘了具有用于排气系统190的示例性还原剂输送系统110的后处理系统100。排气系统190接收来自内燃发动机(例如柴油内燃发动机等)的废气。后处理系统100包括颗粒过滤器(例如,柴油颗粒过滤器(DPF)102)、还原剂输送系统110、分解室104(例如,反应器等)和选择性催化还原单元106(例如催化剂室)。选择性催化还原(SCR)单元106可以包含催化剂(例如SCR催化剂、VSCR催化剂)。后处理系统100还可以包括传感器150。
DPF 102被配置成从在排气系统190中流动的废气中去除颗粒物质,诸如烟灰。DPF102包括入口和出口,在入口处(例如,从发动机歧管等)接收废气,在出口处在颗粒物质大体上从废气过滤掉和/或将颗粒物质转化成二氧化碳之后,废气离开。在一些实施方式中,可以省略DPF 102。
分解室104被配置成将还原剂,诸如尿素或DEF,转化成氨。分解室104包括还原剂输送系统110,该还原剂输送系统110具有被配置成将还原剂定量供给到分解室104中的定量供给模块112(例如,定量供给器等)。在一些实施方式中,还原剂在SCR单元106的上游被注入。然后,还原剂液滴经历蒸发、热解和水解的过程,以在排气系统190内形成气态氨。分解室104包括与DPF 102流体连通以接收包含NOx排放物的废气的入口,以及用于使废气、NOx排放物、氨和/或还原剂流向SCR单元106的出口。
分解室104包括安装到分解室104的定量供给模块112,使得定量供给模块112可以将还原剂定量供给到在排气系统190中流动的废气中。定量供给模块112可以包括绝缘体(insulator)114,该绝缘体114被置于定量供给模块112的一部分和其上安装有定量供给模块112的分解室104的部分之间。定量供给模块112被流体地联接到一个或更多个还原剂源116(例如,罐、容器等)。在一些实施方式中,可以使用泵118以对来自还原剂源116的还原剂加压,用于输送到定量供给模块112。
定量供给模块112还被流体地联接到一个或更多个空气源115。例如,空气源115可以是进气口或空气存储装置(例如,罐等)。使用泵117(例如提升泵(lift pump)等)以对来自空气源115的空气加压,用于输送到定量供给模块112(例如,经由加压导管等)。定量供给模块112将来自空气源115的空气和来自还原剂源116的还原剂混合,并且将空气-还原剂混合物提供到分解室104中。
定量供给模块112、泵117和泵118还被电联接或通信联接到控制器120。控制器120被配置成控制定量供给模块112以将空气-还原剂混合物定量供给到分解室104中。控制器120还可以被配置成控制泵117和/或泵118。例如,控制器120可以控制泵117和泵118,以获得提供给分解室104的空气和还原剂的目标混合物。在一些实施方式中,可以省略泵117和空气源115。在这些实施方式中,定量供给模块112不接收加压空气。
控制器120可以包括微处理器、专用集成电路(ASIC)、现场可编程门阵列(FPGA)等或它们的组合。控制器120可以包括存储器,存储器可以包括但不限于能够向处理器、ASIC、FPGA等提供程序指令的电子装置、光学装置、磁性装置或任何其他存储装置或传输装置(transmission device)。存储器可以包括存储器芯片、电可擦除可编程只读存储器(EEPROM)、可擦除可编程只读存储器(EPROM)、闪速存储器或控制器120可以从其中读取指令的任何其他合适的存储器。指令可以包括来自任何合适的编程语言的代码。
SCR单元106被配置成通过加速氨和废气的NOx之间的NOx还原过程来帮助NOx排放物还原成双原子氮、水和/或二氧化碳。SCR单元106包括与分解室104流体连通的入口和与排气系统190的端部流体连通的出口,废气和还原剂从该入口被接收。SCR单元106可以包括VSCR催化剂。
排气系统190还可以包括与排气系统190流体流通的氧化催化器(例如柴油氧化催化器(DOC))(例如,在SCR单元106的下游或在DPF 102的上游),以氧化废气中的碳氢化合物和一氧化碳。
在一些实施方式中,DPF 102可以被定位在分解室104的下游。例如,DPF 102和SCR单元106可以组合成单个单元。在一些实施方式中,定量供给模块112可以替代地被定位在涡轮增压器的下游或涡轮增压器的上游。
传感器150可以被联接到排气系统190,以检测流过排气系统190的废气的状况。在一些实施方式中,传感器150可以具有设置在排气系统190内的一部分;例如,传感器150的尖端可以延伸到排气系统190的一部分中。在其他实施方式中,传感器150可以通过另一个导管接收废气,所述导管诸如从排气系统190延伸的一个或更多个样品管。虽然传感器150被描绘为定位在SCR单元106的下游,但是应当理解,传感器150可以被定位在排气系统190的任何其他位置,包括在DPF 102的上游、在DPF 102内、在DPF 102和分解室104之间、在分解室104内、在分解室104和SCR单元106之间、在SCR单元106内或者在SCR单元106的下游。此外,可以使用两个或更多个传感器150用于检测废气的状况,诸如两个、三个、四个、五个或六个传感器150,其中每个传感器150位于排气系统190的前述位置中的一个位置。在一些实施方式中,可以省略传感器150。
III.用于恢复催化剂性能的示例性方法
图2图示了根据实施方案的恢复催化剂性能的示例性方法的流程图。简言之,方法200包括提供VSCR催化剂(步骤202);在20℃-100℃的范围内的第一温度,将VSCR催化剂暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段(步骤204);以及在300℃-600℃的范围内的第二温度热处理VSCR催化剂持续至少一小时的第二时间段(步骤206)。
在提供VSCR催化剂的步骤(步骤202)中,VSCR催化剂可以包括氧化钒的簇。例如,氧化钒的簇可以包括氧化钒(II)、氧化钒(III)、氧化钒(IV)、氧化钒(V)、具有式VnO2n+1的氧化钒的相(例如,V2O5、V3O7、V4O9和V6O13)、具有式VnO2n-1的氧化钒的相(例如,V4O7、V5O9、V6O11、V7O13和V8O15)或非化学计量的氧化钒的相。在一些实施方案中,方法200包括提供VSCR催化剂作为交通工具系统的一部分。VSCR催化剂可以包括基于钒的SCR催化剂。VSCR催化剂可以将NOx排放物转化成更中性的化合物。
如上文讨论的,方法200包括在20℃-100℃的范围内的第一温度,将VSCR催化剂暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段(步骤204)。第一湿度水平可以在50%-95%相对湿度的范围内、或者在70%-95%相对湿度的范围内、或者在80%-95%相对湿度的范围内。将VSCR催化剂暴露于第一湿度水平的步骤可以使成簇的氧化钒分散。将VSCR催化剂暴露于第一湿度水平可以使氧化钒的簇分散。第一温度可以在20℃-80℃的范围内、或者在30℃-70℃的范围内、或者在40℃-60℃的范围内。第一时间段可以是至少2小时、或至少3小时、或至少4小时、或至少5小时、或至少10小时、或至少1天、或至少2天、或至少1周、或至少2周、或至少1个月。
如上文讨论的,方法200包括在300℃-600℃的范围内的第二温度热处理VSCR催化剂持续至少一小时的第二时间段(步骤206)。第二温度可以在400℃-600℃的范围内、或者在500℃-600℃的范围内、在525℃-600℃的范围内、或者在525℃-575℃的范围内。第二时间段可以是至少2小时、或至少3小时、或至少4小时、或至少5小时。第二时间段可以小于或等于48小时。
在一些实施方案中,在进行方法200之前,从交通工具的后处理系统100中移除VSCR催化剂。例如,VSCR催化剂可以从交通工具的后处理系统100中移除,并且被放置在环境室(例如,气候室(climate chamber)、气候室(climatic chamber)等)中来进行方法200。环境室可以包括具有受控的温度和湿度的外壳(enclosure)。
在其他实施方案中,当进行方法200时,VSCR催化剂可以留在交通工具中。例如,交通工具可以在具有第一湿度和第一温度的大气中停放持续第一时间段,并且然后VSCR催化剂可以在第二温度被热处理持续第二时间段,同时VSCR催化剂保留在交通工具上。热处理可以作为主动再生的一部分来进行,在所述主动再生中,燃料定量供给阀将燃料注入到排气系统190中以升高温度。热处理可以作为专门针对再生催化剂性能而定制的再生过程的一部分进行。
图3图示了根据实施方案的制造VSCR催化剂的示例性方法的流程图。简言之,方法300包括:烧结氧化钒(步骤302);在20℃-100℃的范围内的第一温度,将氧化钒暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段(步骤304);以及在300℃-600℃的范围内的第二温度热处理氧化钒持续至少一小时的第二时间段(步骤306)。
在烧结氧化钒的步骤(步骤302)中,氧化钒可以包括氧化钒的簇。例如,氧化钒可以包括氧化钒(II)、氧化钒(III)、氧化钒(IV)、氧化钒(V)、具有式VnO2n+1的氧化钒的相(例如,V2O5、V3O7、V4O9和V6O13)、具有式VnO2n-1的氧化钒的相(例如,V4O7、V5O9、V6O11、V7O13和V8O15)或非化学计量的氧化钒的相。
如上文讨论的,方法300包括在20℃-100℃的范围内的第一温度,将氧化钒暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段(步骤304)。第一湿度水平可以在50%-95%相对湿度的范围内、或者在70%-95%相对湿度的范围内、或者在80%-95%相对湿度的范围内。将氧化钒暴露于第一湿度水平的步骤可以使成簇的氧化钒分散。第一温度可以在20℃至80℃的范围内、或者在30℃至70℃的范围内、或者在40℃至60℃的范围内。第一时间段可以是至少3小时、或至少4小时、或至少5小时、或至少10小时、或至少1天、或至少2天、或至少1周、或至少2周、或至少1个月。
如上文讨论的,方法300包括在300℃-600℃的范围内的第二温度热处理氧化钒持续至少一小时的第二时间段(步骤306)。第二温度可以在400℃-600℃的范围内、或者在500℃-600℃的范围内、在525℃-600℃的范围内、或者在525℃-575℃的范围内。第二时间段可以是至少2小时、或至少3小时、至少4小时、或至少5小时。第二时间段可以小于或等于48小时。
图4图示了根据实施方案的转换频率(TOF)和多个催化剂样品的图。转换频率代表催化剂的归一化的反应性。测试的样品的子集在多个温度被烧结(被称为略微老化(degreening)的过程),以使催化剂的性能稳定。样品在以下条件下被制备。将样品402在40℃的第一温度暴露于95%相对湿度的第一湿度水平持续两周的第一时间段,并且没有被热处理。将样品404、样品406、样品408、样品410和样品412在40℃的第一温度暴露于95%相对湿度的第一湿度水平持续两周的第一时间段。此外,样品404在350℃的温度被热处理(例如,略微老化)持续1小时。样品406在500℃的温度被热处理持续1小时。样品408在550℃的温度被热处理持续4小时。样品410在575℃的温度被热处理持续1小时。样品412在600℃的温度被热处理持续1小时。样品422没有暴露于第一湿度水平,并且没有被热处理。样品424、样品426和样品428没有暴露于第一湿度水平,并且被热处理。样品424在350℃的温度被热处理持续1小时。样品426在500℃的温度被热处理持续1小时。样品428在550℃的温度被热处理持续4小时。
该图示出了以转换频率表示的催化剂反应性。在200℃测量催化剂的转换频率。该图表明,在给定热处理条件下暴露于第一湿度水平持续第一时间段的催化剂比在相同热处理条件下没有暴露于第一湿度水平持续第一时间段的催化剂具有更低的转换频率,并且因此具有更低的反应性。例如,样品424比样品404具有更高的转换频率,样品404已经暴露于第一湿度水平持续第一时间段。此外,对于暴露于第一湿度水平持续第一时间段的样品,较高温度的热处理通常与较高的转换频率相关联,表明随着热处理温度的升高,催化位点的效率增加。然而,在500℃的温度被热处理持续1小时的样品406比在350℃的温度被热处理持续1小时的样品404具有更低的转换频率。这样的结果表明,对于其中温度在约350℃和550℃之间的温和的略微老化过程,催化剂的反应性与较低温度的略微老化过程相比可能降低。对于其中温度约高于550℃的较高温度的略微老化过程,催化剂的反应性与较低温度的略微老化过程相比可能增加。在图4中所示的实例中,转换频率在500摄氏度降低。
图5图示了根据实施方案的多个样品的拉曼光谱数据的图。该图示出了经湿度处理的商品V2O5-WO3/TiO2催化剂的原位拉曼光谱。催化剂在350℃、500℃或550℃被进一步(水)热处理。在970cm-1-1034cm-1的带与表面VOx和WOx物质的V=O和W=O伸缩振动相关。在渐进的(水)热处理时,所有的带向更高的波数移动(例如,从1030cm-1至1034cm-1),表明随着温度的升高,表面VOx和WOx物质两者较大程度的低聚。在湿度处理之后,表面氧化钒(vanadia)物质可以被分散。该图示出,较高温度的热处理诱导VOx和WOx物质的较大程度的低聚。较高温度的热处理与较高的催化剂的反应性相关联,表明较大程度的低聚与较高的催化剂的反应性相关联。
IV.示例性实施方案的构造
虽然本说明书包含许多特定的实施方式细节,但是这些不应被解释为对可以被要求保护的内容的范围的限制,而是应被解释为特定的实施方式所特有的特征的描述。在本说明书中在单独的实施方式的上下文中描述的某些特征也可以组合地在单个实施方式中实施。相反,在单个实施方式的上下文中描述的多种特征也可以单独地或以任何合适的子组合在多种实施方式中实施。此外,尽管特征可以被描述为以某些组合起作用且甚至最初被这样要求保护,但是来自所要求保护的组合的一个或更多个特征在一些情况下可以从该组合删除,并且所要求保护的组合可以涉及子组合或子组合的变型。
如本文使用的,术语“大体上”和类似的术语意图具有与本公开内容的主题所属的领域中的普通技术人员常见和接受的用法一致的宽泛的含义。查阅本公开内容的本领域的技术人员应理解,这些术语意图允许对所描述和要求保护的某些特征的说明,而不将这些特征的范围限制到所提供的精确的数值范围。因此,这些术语应被解释为指示所描述和要求保护的主题的非实质性或无关紧要的修改或改变被认为在如所附权利要求中叙述的本发明的范围内。
如本文使用的术语“联接”、“连接”及类似术语意指两个部件彼此直接地或间接地连结(joining)。这样的连结可以是固定的(例如,永久的)或可移动的(例如,可移除的或可释放的)。这样的连结可以用两个部件或这两个部件与任何另外的中间部件彼此一体地形成为单个整个主体(single unitary body)来实现,或者用两个部件或这两个部件与任何另外的中间部件彼此附接来实现。
如本文使用的术语“流体地联接”、“流体连通”及类似术语意指两个部件或对象具有在这两个部件或对象之间形成的通路,流体(例如,排气、水、空气、气态还原剂、气态氨等)可以在干扰或不干扰部件或对象的情况下在该通路中流动。用于实现流体连通的流体联接或构造的实例可以包括管、通道或用于实现流体从一个部件或对象到另一部件或对象的流动的任何其他合适的部件。
重要的是要注意,在多种示例性实施方式中示出的系统的构造和布置在性质上仅是说明性的而非限制性的。出现在所描述的实施方式的精神和/或范围内的所有变化和修改期望受到保护。应当理解,一些特征可能不是必要的,并且缺少多种特征的实施方式可以被预期为在本申请的范围内,该范围由所附权利要求限定。当语言“一部分”被使用时,该项可以包括一部分和/或整个项,除非特别相反地陈述。
Claims (20)
1.一种恢复催化剂性能的方法,包括:
提供钒选择性催化还原(VSCR)催化剂;
在20℃-100℃的范围内的第一温度,将所述VSCR催化剂暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段;以及
在300℃-600℃的范围内的第二温度热处理所述VSCR催化剂持续至少一小时的第二时间段。
2.根据权利要求1所述的方法,其中:
所述第一湿度水平在50%-95%相对湿度的范围内。
3.根据权利要求1所述的方法,其中:
所述第二温度在400℃-600℃的范围内。
4.根据权利要求1所述的方法,其中:
所述第二温度在500℃-600℃的范围内。
5.根据权利要求1所述的方法,其中:
在提供所述VSCR催化剂的步骤中,所述VSCR催化剂包括氧化钒的簇。
6.根据权利要求5所述的方法,其中:
将所述VSCR催化剂暴露于所述第一湿度水平的步骤使所述氧化钒的簇分散。
7.根据权利要求1所述的方法,其中所述第一时间段是至少5小时。
8.根据权利要求1所述的方法,其中所述第二时间段小于或等于48小时。
9.根据权利要求1所述的方法,其中:
提供所述VSCR催化剂的步骤包括提供所述VSCR催化剂作为交通工具系统的一部分。
10.根据权利要求1所述的方法,其中:
提供所述VSCR催化剂的步骤包括在环境室中提供所述VSCR催化剂。
11.根据权利要求1所述的方法,其中:
所述第一湿度水平在70%-95%相对湿度的范围内。
12.一种制造钒选择性催化还原(VSCR)催化剂的方法,包括:
烧结氧化钒;
在20℃-100℃的范围内的第一温度,将所述氧化钒暴露于在50%-100%相对湿度的范围内的第一湿度水平持续至少两小时的第一时间段;以及
在300℃-600℃的范围内的第二温度热处理所述氧化钒持续至少一小时的第二时间段。
13.根据权利要求12所述的方法,其中:
所述第一湿度水平在50%-95%相对湿度的范围内。
14.根据权利要求12所述的方法,其中:
所述第二温度在400℃-600℃的范围内。
15.根据权利要求12所述的方法,其中:
所述第二温度在500℃-600℃的范围内。
16.根据权利要求12所述的方法,其中所述氧化钒包括氧化钒的簇。
17.根据权利要求12所述的方法,其中:
将所述VSCR催化剂暴露于所述第一湿度水平的步骤使所述氧化钒的簇分散。
18.根据权利要求12所述的方法,其中所述第一时间段是至少5小时。
19.根据权利要求12所述的方法,其中所述第二时间段小于或等于48小时。
20.根据权利要求12所述的方法,其中:
所述第一湿度水平在70%-95%相对湿度的范围内。
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