EP0631647B1 - Catalytic converter - Google Patents

Catalytic converter Download PDF

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Publication number
EP0631647B1
EP0631647B1 EP92914723A EP92914723A EP0631647B1 EP 0631647 B1 EP0631647 B1 EP 0631647B1 EP 92914723 A EP92914723 A EP 92914723A EP 92914723 A EP92914723 A EP 92914723A EP 0631647 B1 EP0631647 B1 EP 0631647B1
Authority
EP
European Patent Office
Prior art keywords
exhaust gas
housing
catalytic converter
gas
catalyst structure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP92914723A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0631647A1 (en
Inventor
Daniel Michael Fischer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of EP0631647A1 publication Critical patent/EP0631647A1/en
Application granted granted Critical
Publication of EP0631647B1 publication Critical patent/EP0631647B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—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
    • 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
    • F01N3/2053—By-passing catalytic reactors, e.g. to prevent overheating
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/10—Fibrous material, e.g. mineral or metallic wool
    • 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
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/24—Methods or apparatus for fitting, inserting or repairing different elements by bolts, screws, rivets or the like
    • 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
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/30—Removable or rechangeable blocks or cartridges, e.g. for filters

Definitions

  • This invention relates to catalytic converters for controlling emission levels from internal combustion engines. More particularly, the invention relates to an auxiliary catalytic converter for controlling emissions from an internal combustion engine during the period of engine warm-up.
  • EPA 0417412 relates to the provision of auxiliary catalyst converters in the exhaust system of an internal combustion engine.
  • the auxiliary converter comprises a catalyst mass having an axial channel therethrough. Flow of exhaust gases through the channel is controlled by a valve. In its open position, the valve exhaust gases bypass the catalyst. When the valve is closed, exhaust gases must pass axially through the catalyst mass.
  • An object of the present invention is to provide an auxiliary catalytic converter for an internal combustion engine which achieves rapid catalytic activity without substantial operating pressure and power losses associated with known warm-up converter systems.
  • the system utilizes a radial flow catalyst system which is placed adjacent or as a part of the exhaust manifold at the coition or "Y" where the cylinder exhaust tubes come together.
  • a catalytic converter for treating exhaust gas pollutants from an internal combustion engine during engine warm-up comprising
  • the converter of this invention comprises a housing defining a gas receiving chamber and has an exhaust gas inlet at one end of the housing adjacent or as a part of the exhaust manifold and an exhaust gas outlet at the other end of the housing.
  • the catalyst comprises a cartridge which has an annular structure and is aligned axially within the housing.
  • the structure has multiple channels or pores through which gases can pass from an internal to an external surface.
  • the cartridge is aligned with the walls of the housing thereby providing a passage between the outer surface of the cartridge and the walls or, alternatively, through the channels or pores in the cartridge, and an axial channel extending from adjacent the exhaust gas inlet to an opening in the outlet.
  • Valve means adjacent the gas outlet are adapted to be opened and closed in response to a predetermined condition of the exhaust gas.
  • the valve In operation the valve is in a closed position restraining exhaust gas flow through the axial channel during start up thereby causing the exhaust gas to flow radially through the catalyst structure and into the annular passage along the outer walls of the housing.
  • the valve opens removing the axial exhaust flow restriction and permitting exhaust gases to flow down the axis and through the cartridge essentially unrestricted. In the open position, little pressure drop occurs in the axial channel, and there is little or no significant catalytic activity.
  • the dimensions of the axial channel, annular passage, inlet and outlet are determined to accommodate pressure drop and flow rate based on the specific requirements for the particular engine involved.
  • catalystic converter 11 is comprised of a housing 13 the walls of which define an exhaust gas receiving chamber 15.
  • Housing 13 may be integral with or form an extension of exhaust manifold 10 of an internal combustion engine, not shown.
  • the engine may be a two or four cycle engine.
  • the chamber has an exhaust gas inlet 17 at one end of the housing and and exhaust gas outlet 19 at the other end of the housing.
  • a catalyst support ring 21 is positioned between the inlet and outlet.
  • the catalyst structure is preferably in the form of an annular cartridge 23 and is spaced from the walls of the housing and axially aligned in the chamber to provide a passage 25 between the outer surface of the catalyst and the walls and an axial channel 27 in communication with exhaust gas inlet 17 and exhaust gas outlet 19.
  • passage 27 could be provided by channels or pores in the catalyst structure provided sufficient gas flow can be established to outlet 19 through the channels and pores when axial channel 27 is closed.
  • the catalyst structure has multiple substantially discrete channels and pores throughout.
  • the structure is held in position between housing 13 at inlet 17 and support ring 21 at outlet 19.
  • Gaskets may be used at either end of the structure to provide a gas tight seal.
  • the support ring is secured between flanges 29 and 31 of housing 13 and outlet pipe 33 using bolts nuts 59 on 57 and gaskets 35 and 37. Alternatively, the components may be welded in place.
  • Valve 41 is positioned adjacent the base of catalyst support ring 21.
  • a ball valve which when opened provides unrestricted flow of exhaust gases out of chamber 15 through axial channel 27 may be used; however, other known types of valves such as butterfly valves may be used.
  • a butterfly valve arrangement is shown in FIG. 1 and FIG 2.
  • Valve 41 rests on sealing surfaces 55 and 55' when in the closed position.
  • heat sensitive coil springs 53 and 53' retain valve 41 in the closed position when the engine is cold and not running. At start-up, springs 53 and 53' prevent valve from opening as exhaust gas enters chamber 15 and impinges on the face of the valve. As shown in FIG. 1, the gas passes through cartridge 23 to annular passage 25.
  • valve 41 As the springs are heated to a predetermined temperature by the exhaust gas, the coil increases in length causing valve 41 to rotate to an open position.
  • the valve is aligned in chamber 25 in such a manner so that once it is opened, the exhaust gas flow causes it to self-center in an open position. When the gas flow ceases, coil tension returns the valve to a near closed position. As the coil cools, the valve goes to a fully closed position.
  • This arrangement is simple and particularly cost effective since it captures the kinetic energy of the system and requires no external control components. It is to be noted, however, that various alternatives based on electrical and magnetic applications can be adapted to open and close the valve.
  • valve 41 which is integral with shaft 39 pivots within the support ring and is shown in the closed postion thus blocking the flow of exhaust gases from channel 27.
  • Multiple openings 47 in support ring 21 communicate with annular passage 25 permitting gases to escape through exhaust gas outlet 19.
  • Holes 61 are provided to accept wets 57 in scurring the catalyst structures in the assemble.
  • the catalyst structure is of the rigid type made from a reticulated annular form comprised of reinforced ceramic fibers.
  • the structure carries a catalyst and provides adequate resistance to both thermal shock and mechanical shock.
  • Suitable structures are disclosed in U.S. 3,949,109, U.S. 3,986,528, U.S. 4,092,194 and U.S. 5,079,064.
  • Other suitable structures such as ceramic and metal foams which provide multiple channels or pores through which gases can pass may be used. Processes for preparing other suitable structures are disclosed in European Patent Applications EP-A-0 493 046 and EP-A-0 493 049, filed December 20, 1991.
  • FIG. 3 shows a segment of catalyst cartridge 23.
  • a series of layers of yarn A, B, C and D, which may be repeated many times form a wall for a catalyst cartridge.
  • Separations "a" of the yarns form openings which permit the passage of exhaust gas.
  • the fibers making up the yarns are substantially alumina generally having diameters in the range of 0.2 to 2.0 mils (0.005 to 0.05 mm).
  • Preparation of refractory oxide fibers and their precursors is disclosed in U.S. 3,808,015 and U.S. 3,853,688.
  • a refractory oxide matrix may be applied to a wound package of the yarns to provide mechanical strength.
  • Reticulated tubes or cartridges useful in this invention exhibit catalytic activity in conversion of exhaust gases to oxidize carbon monoxide, hydrocarbons and/or hydrocarbon residues or reduce nitrogen oxides.
  • This activity may derive from catalytic materials present in the components of the cartridge, i.e. ceramic fibers, ceramic binder or refractory oxide matrix, or by addition of catalysts to the cartridge.
  • the catalyst may be placed on the cartridge by adsorption of a suitable compound of the active component or imbibition of an active material or precursor from a slurry form followed by drying and conversion to the active material.
  • Suitable catalysts include the precious metals (Ru, Ph, Pd, Os, Ir and Pt) in elemental or oxide form and oxides, vanadates, chromates, chromites, manganates, manganites, stannates, molybdates, tungstates, niobates or tantalates of Fe, Co, Ni, Cr, Mn, Cu, Zn, Ag and Cd, and the rare earth salts.
  • Ru, Ph, Pd, Os, Ir and Pt precious metals in elemental or oxide form and oxides, vanadates, chromates, chromites, manganates, manganites, stannates, molybdates, tungstates, niobates or tantalates of Fe, Co, Ni, Cr, Mn, Cu, Zn, Ag and Cd, and the rare earth salts.
  • valve 41 In operation starting with a cold engine, valve 41 is in the closed position.
  • the engine is started and the contaminated exhaust gas enters exhaust gas receiving chamber 15.
  • the exhaust gas fills axial channel 27 and as pressure builds is forced radially through catalyst cartridge 23 which rapidly reaches activation temperature and serves to catalytically oxidize unburned hydrocarbons and carbon monoxide.
  • coil springs lengthen in response to the hot gas causing shaft 39 to turn and valve 41 to rotate to an open position.
  • the valve opens the exhaust gases pass through axial channel 27 and out of chamber 15 through outlet 19 entering the normal exhaust system which includes an under the floor catalytic converter.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Superconductors And Manufacturing Methods Therefor (AREA)
  • Catalysts (AREA)
EP92914723A 1992-03-17 1992-03-17 Catalytic converter Expired - Lifetime EP0631647B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA002132294A CA2132294A1 (en) 1992-03-17 1992-03-17 Radial flow exhaust catalytic converter
PCT/US1992/002180 WO1993019289A1 (en) 1992-03-17 1992-03-17 Radial flow exhaust catalytic converter

Publications (2)

Publication Number Publication Date
EP0631647A1 EP0631647A1 (en) 1995-01-04
EP0631647B1 true EP0631647B1 (en) 1997-12-29

Family

ID=25677495

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92914723A Expired - Lifetime EP0631647B1 (en) 1992-03-17 1992-03-17 Catalytic converter

Country Status (12)

Country Link
EP (1) EP0631647B1 (sv)
JP (1) JPH07504731A (sv)
AT (1) ATE161612T1 (sv)
AU (1) AU2264392A (sv)
BR (1) BR9207106A (sv)
CA (1) CA2132294A1 (sv)
CZ (1) CZ227694A3 (sv)
DE (1) DE69223807T2 (sv)
ES (1) ES2110506T3 (sv)
FI (1) FI944313A0 (sv)
RU (1) RU94044335A (sv)
WO (1) WO1993019289A1 (sv)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018190843A1 (en) * 2017-04-13 2018-10-18 Cummins Emission Solutions Inc. Dosing module for use in aftertreatment systems for internal combustion engines

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388637A (en) * 1971-06-02 1975-03-26 Gould Inc Article for catalytic reduction of nox
GB1519343A (en) * 1974-09-03 1978-07-26 Matsushita Electric Ind Co Ltd Gas purifying devices
DE3930380A1 (de) * 1989-09-12 1991-03-21 Porsche Ag Abgasanlage eines mehrzylinder-verbrennungsmotors
DE9004614U1 (de) * 1990-04-24 1991-03-14 Kuck, Jürgen, 3300 Braunschweig Katalysator

Also Published As

Publication number Publication date
ES2110506T3 (es) 1998-02-16
RU94044335A (ru) 1996-08-20
JPH07504731A (ja) 1995-05-25
FI944313A (sv) 1994-09-16
DE69223807D1 (de) 1998-02-05
CA2132294A1 (en) 1993-09-30
WO1993019289A1 (en) 1993-09-30
BR9207106A (pt) 1995-12-05
ATE161612T1 (de) 1998-01-15
FI944313A0 (sv) 1994-09-16
AU2264392A (en) 1993-10-21
DE69223807T2 (de) 1998-07-23
EP0631647A1 (en) 1995-01-04
CZ227694A3 (en) 1995-06-14

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