GB2429417A

GB2429417A - Autoselective regenerating particulate filter

Info

Publication number: GB2429417A
Application number: GB0517428A
Authority: GB
Inventors: Colin Peter Garner
Original assignee: Perkins Engines Co Ltd
Current assignee: Perkins Engines Co Ltd
Priority date: 2005-08-25
Filing date: 2005-08-25
Publication date: 2007-02-28
Anticipated expiration: 2025-08-25
Also published as: WO2007023267A1; US8388711B2; GB0517428D0; GB2429417B; US20100154632A1; DE112006002197T5; CN101273188A; CN101273188B

Abstract

The present invention provides an apparatus and method for removing particulates from a gas stream. The apparatus comprises a ceramic filter 14, at least one electrode 32 and at least one conductor 40. The electrode 32 is located at an end of the filter 14 and produces an atmospheric glow discharge in order to oxidise carbon deposits trapped in the filter 14. The conductor 40 extends at least partially into the filter 14 and acts as a counter electrode. Through various arrangements of the electrodes and conductors, the present invention provides closer connection between the trapped carbon deposits and the electrodes. This improves the regeneration of the filter without increasing the size and/or weight of the apparatus. The conductor may comprise the end cap 15 of a filter cell a conductor extending internally along an axis of a cell or may comprise the housing 12 of the filter. Where individual cells carry HV electrodes these may be arranged in lines within the cell matrix to improve uniform oxidation of particulate matter.

Description

AUTOSELECTIVE REGENERATING PARTICULATE FILTER

1 Technical Field

3 The present invention relates to an apparatus and 4 method for removing particulates from gas streams, the apparatus being autoselectively regenerating 6 (self-cleaning) in use.

8 Background of the Invention

Internal combustion engines and static hydrocarbon 11 burning equipment tend to emit, via their exhaust 12 systems, carbonaceous particles commonly referred to 13 as particulates. Whilst efforts are being expended 14 towards reducing particulate emissions at source, particulate filters (traps) in the exhaust systems of 16 such equipment are becoming useful in helping to meet 17 increasingly strict environmental legislation and 18 public expectations.

2 Particulate filters which may be regenerated are 3 known. It is especially desirable for a particulate 4 filter to be self-regenerating in use, under any load, in order to maintain filtering and gas-flow 6 efficiencies above a certain level whilst keeping 7 filter size to a minimum. It is also desirable that 8 the filter is self-controlled to regenerate when a 9 predetermined level of particulates is present and to do so without requiring any external sensing means.

11 It is further desirable that the regeneration process 12 is economic in the use of any externally supplied 13 energy or material, that the construction of the 14 filter is also economic, and that the system is effective irrespective of types and compositions of 16 fuel and engine operating conditions.

18 WO 01/04467 to the same applicant discloses an 19 apparatus and a method for removing particulates from a gas stream. WO 467 discloses a ceramic monolith 21 filter of depth less than 100mm which uses a first 22 electrode to produce an atmospheric glow discharge 23 near to the first end of the filter. Although the 24 combination of a reduced-depth ceramic filter and atmospheric glow discharge has provided far more 26 efficient particulate removal and filter regeneration 27 performance compared to earlier known arrangements, 28 the applicant has established that performance can be 29 improved still further.

31 Summary of the Invention

1 According to a first aspect of the present invention, 2 there is provided an apparatus for removing 3 particulates from a gas stream, the apparatus 4 comprising: a ceramic filter through which gas may be caused 6 to flow, the filter having a first end and a second 7 end and comprising a plurality of elongate cells 8 extending substantially parallel to the direction of 9 gas flow; at least one electrode located at an end of the 11 filter for producing an atmospheric glow discharge; 12 and 13 at least one conductor spaced away from the at 14 least one electrode and adapted to lead current from the electrode out of the filter; 16 wherein the conductor extends at least 17 partially into the filter.

19 According to a second aspect of the present invention, there is provided an apparatus for 21 removing particulates from a gas stream comprising: 22 a ceramic filter through which gas may be caused 23 to flow, the filter having a first end and a second 24 end and comprising a plurality of elongate cells extending substantially parallel to the direction of 26 gas flow; 27 at least one electrode located at an end of the 28 filter for producing an atmospheric glow discharge; 29 and at least one conductor spaced away from the at 31 least one electrode and adapted to lead current from 1 the electrode out of the filter; 2 wherein the apparatus is mounted within a filter 3 housing, the housing being provided with apertures 4 for the ingress and egress of gas, and wherein the at least one conductor comprises a portion of the 6 housing.

8 According to a third aspect of the present invention, 9 there is provided a method of removal of particulates from a gas stream comprising: 11 causing the gas to flow through a ceramic filter 12 so that particulates are separated from the gas flow 13 and trapped by the filter, wherein the filter has a 14 first end and a second end and comprises a plurality of elongate cells extending substantially parallel to 16 the direction of gas flow; 17 positioning at least one electrode at an end of 18 the filter; 19 positioning at least one conductor at a location spaced away from the at least one electrode, such 21 that the conductor extends at least partially into 22 the filter; 23 generating an atmospheric glow discharge from 24 the electrode; and leading current from the electrode out of the 26 filter through the conductor.

28 Brief Description of the Invention

Preferred embodiments of the invention will now be 31 described, by way of example only, with reference to 1 the accompanying drawings, in which: 3 Figure 1 shows a schematic vertical section 4 through a first embodiment of an apparatus for removing particulate matter from a gas stream; 6 Figure 2 shows a schematic vertical section 7 through a second embodiment of the apparatus; 8 Figure 3 shows a schematic vertical section 9 through a third embodiment of the apparatus; Figure 4 shows a schematic vertical section 11 through a fourth embodiment of the apparatus; and 12 Figure 5 shows a schematic end view of a ceramic 13 filter forming part of the apparatus.

Detailed Description of the Invention

17 Referring to the drawings, each embodiment of the 18 apparatus is shown schematically through a vertical 19 cross-section. In addition, each embodiment of the apparatus is described when in use in the exhaust 21 system of an internal combustion engine. However, it 22 will be understood that the invention is not limited 23 to internal combustion engine applications.

Each embodiment shown has a particulate filter 10 26 including a housing, or canister, 12 in which a 27 filter body 14 is housed. The filter body 14 28 includes a plurality of elongate tubular inlet and 29 outlet cells 16,17 extending across the depth of the filter body 14. In other words, the inlet and outlet 31 cells 16,17 extend substantially parallel to the gas 1 flow through the filter 10. Each cell 16,17 is 2 defined by a porous ceramic wall 18 and each has one 3 end blanked off by a ceramic plug 20. Unless where 4 stated otherwise, the filter body 14 is mounted within the housing 12 on an electrically insulated 6 mounting sleeve 30.

8 Exhaust gases entering the filter via an inlet port 9 22 are compelled to pass into alternate inlet cells 16 of the filter body 14 and through a corresponding 11 wall 18. Depending on the configuration, up to 90% 12 of particulate mass may be filtered by deposition on 13 an inner wall surface 19. The cleaned exhaust gases 14 exit the filter 10 via an outlet port 24.

16 In addition, each of the embodiments that will be 17 described is provided with at least one high voltage 18 (HV) electrode for producing an atmospheric glow, or 19 glow-like, discharge in the filter 10. In the embodiments described, each HV electrode is connected 21 to a power supply (not shown in the drawings) 22 suitable for the particular application of the 23 apparatus. For example, the power supply may be a 24 12V power supply when used for vehicle applications, or a 230V power supply when used for generator 26 applications. In one embodiment, the power supply 27 may be adapted to generate square-wave pulses at a 28 frequency within the range of 1 kHz to 200 kHz.

29 Preferably, the voltage is generated at a frequency within the range of 18 kHz to 30 kHz, and most 31 preferably within the frequency range 20 kHz to 25 1 kHz. An example of a preferred range for the open 2 circuit output voltage provided by the power supply 3 is between 5 kV and 25 kV, although it is most 4 preferably 10 kV. A frequency of 20 kHz is outside of the normal human audio range upper limit of 16-18 6 kHz and is a relatively safe frequency in conjunction 7 with the current flow of the apparatus.

9 The apparatus will also work effectively at higher frequencies, for example 38 MHz, but the 11 aforementioned frequency ranges were selected because 12 of their human comfort and practical advantages. The 13 preferred frequency ranges have a strong advantage 14 over higher frequencies which would be expensive to achieve at the necessary power levels and which would 16 require circuits generally less robust and which 17 cannot readily be miniaturised.

19 Figure 1 shows a first embodiment of an apparatus according to the present invention, including the 21 features already described above. In this first 22 embodiment, the HV electrode is a point electrode 32 23 which is held by a support means 34 axially spaced 24 apart from a first end 13 of the filter body 14. The electrode 32 is axially spaced from the filter body 26 by a distance of between 2 and 5 mm. The support 27 means 34 is perforated to permit the passage of 28 exhaust gases therethrough. In this embodiment, the 29 electrode 32 is manufactured from mild steel rod and can have any suitable diameter, as it is positioned 31 outside the filter.

2 In all of the illustrated embodiments, a conductor is 3 provided at a second (downstream) end 15 of the 4 filter body 14, spaced away from the HV electrode.

The conductor is adapted to lead current from the HV 6 electrode out of the filter and return it to the 7 power supply. For the preferred embodiments 8 illustrated, the conductor takes the form of a 9 counter electrode, except where stated otherwise.

However, it should be understood that other suitable 11 conductors may be used as well as the counter 12 electrodes described. In the embodiment illustrated 13 in Figure 1, the counter electrode is formed by 14 impregnating at least a portion of the filter body 14 adjacent the second end 15 with a conductive material 16 36, such that the impregnated portion extends from 17 the second end 15 of the filter body 14 towards the 18 first end 13 until it has at least passed the ceramic 19 end plugs 20 at the second end 15. As a result of impregnating the filter body 14, electrical contact 21 is made between the counter electrode (the 22 impregnated second end 15 of the filter body 14) and 23 the trapped particulate matter. Thus, when the 24 electrode 32 produces an atmospheric glow discharge in the gap between the electrode 32 and the filter 26 body 14, the trapped particulate matter held by the 27 filter acts as grounding sites for the atmospheric 28 glow discharge, and the discharge oxidises the 29 particulate matter. With the electrical contact between the impregnated filter body 14 and the 31 particulate matter, the penetration of the 1 atmospheric glow discharge from the HV electrode 32 2 into the filter is improved, with more efficient 3 oxidisation of the particulate matter as a result.

Figure 2 shows a second embodiment of the present 6 invention, where a different form of counter 7 electrode is used. The second embodiment shares the 8 majority of its features with the first embodiment, 9 and the same reference numerals are used for the shared features. However, in the second embodiment 11 the filter body is not impregnated with a conductive 12 material in order to form the counter electrode.

13 Instead, in the second embodiment the counter 14 electrode is a conductive wire electrode 40. The conductive wire counter electrode 40 is held by a 16 second support means 42 axially spaced from but near 17 to the second end 15 of the filter body 14.

19 The counter electrode 40 is inserted into one of the outlet channels, or cells, 17 of the filter body 14 21 such that it extends at least partially into the 22 filter 10 from the second end 15. The counter 23 electrode 40 is inserted into the outlet cell 17 24 approximately 25 to 30 mm. This limited insertion is known as a shallow insertion. Such a shallow 26 insertion of the counter electrode 40 again ensures a 27 close connection between particulate matter trapped 28 in the inlet cells 16 and the counter electrode 40, 29 as the particulate matter trapped in the inlet cells 16 is only separated from the counter electrode by 31 the thin porous wall 18 of the filter body 14. Such 1 a close connection again improves the efficiency of 2 the oxidation of the trapped particulate matter.

4 A third embodiment of the present invention is shown in Figure 3. Again, features shared with the first 6 and second embodiments are designated by the same 7 reference numbers. The third embodiment differs from 8 the second embodiment in that both the HV electrode 9 32' and conductive wire counter electrode 40' are now fully inserted into the filter body 14. The HV 11 electrode 32' is inserted into an inlet cell 16 12 whilst the counter electrode 40' is inserted into an 13 outlet cell 17, thus minimising the chances of 14 discharges between the two electrodes 32',40' outside the filter body 14. If desired, the locations of the 16 electrodes 32',40' could be reversed, such that the 17 counter electrode 40' is in an inlet cell 16 and the 18 HV electrode 32' is in an outlet cell 17. This would 19 have no negative effect on the regeneration performance. By fully inserting the electrodes 21 32',40' into the cells 16,17 of the filter body 14, 22 the full length of each cell 16,17 can be 23 regenerated.

Figure 4 shows a fourth embodiment of the present 26 invention. Features shared with the previously 27 described embodiments are again assigned the same 28 reference numbers. In this fourth embodiment, no 29 separate conductor is provided. Instead, the mounting sleeve 30' no longer electrically insulates 31 the filter body 14 from the housing 12. As a result, :ii 1 this allows a portion of the housing 12 to act as the 2 conductor by using the inherent capacitive reactance 3 of the filter body 14 to complete the circuit from 4 the HV electrode 32 to the housing 12.

6 Industrial Applicability

8 The various embodiments of the present invention 9 described herein are intended for use in the exhaust systems of internal combustion engines and the like.

11 The invention offers improved filter regeneration 12 over existing proposals thanks to the close 13 connection between the trapped particulate matter and 14 the HV electrodes and conductors. Using the various types of HV electrodes and conductors described, 16 locating them either partially or fully inside the 17 ceramic filter, and locating the filter within an 18 exhaust system, improves regeneration performance 19 without producing any significant increase in exhaust backpressure. Furthermore, this improvement in 21 regeneration performance does not require an increase 22 in the overall size of the filter. Thus, the 23 improved regeneration performance does not come at a 24 cost in terms of increased weight and/or dimensions.

26 Although various embodiments of the present invention 27 have been described above, further modifications are 28 also possible. For example, the end plugs which 29 close off each cell of the filter body could be made of a conductive material. The end plugs could then 31 act as the HV electrodes and/or conductors for the 1 filter apparatus.

3 Furthermore, although the HV electrode has been 4 described as being a pin electrode, it may also take other forms. For example, a mesh electrode could be 6 used as the HV electrode. The mesh electrode would 7 act as a pin electrode having a large surface area.

8 Thus, the mesh electrode could cover a larger surface 9 area of the filter. In addition, the HV electrode could be formed by impregnating the first end of the 11 filter body, in the same manner as used for the 12 counter electrode in the first embodiment of the 13 invention described above.

With regard to the inserted electrode arrangement of 16 the third embodiment, the inserted electrodes could 17 take a number of forms, rather than the pin 18 electrodes shown. For example, the cells could be 19 coated or impregnated with a conductive material. In addition, the HV electrode of the third embodiment 21 could be located in an outlet cell of the filter 22 body, with the counter electrode formed as a 23 conductive impregnation or coating of the first 24 (upstream) end of the filter body. This would ensure contact between the trapped particulate matter and 26 the counter electrode, whilst preventing direct 27 contact between the HV electrode and particulate 28 matter (which can result in no discharge occurring) As explained above, each embodiment includes at least 31 one HV electrode and at least one conductor. With 1 the exception of the embodiments in which the 2 electrodes are formed by impregnation of the filter, 3 it is preferable for a plurality of HV electrodes to 4 be used in the invention. For example, in one preferred embodiment 30 HV electrodes are utilised.

6 In one embodiment where multiple HV electrodes are 7 utilised, each electrode in the array is provided 8 with a dedicated electrical stabilising element. The 9 stabilising elements preferably stabilise the electrodes by providing a resistance between the ii power supply and each HV electrode. The stabilising 12 elements can be simple resistors, or else they may be 13 elements which provide an inductive or capacitive 14 resistance. The provision of the stabilising elements ensures effective operation of the HV 16 electrodes. Without the stabilising elements, the 17 atmospheric glow discharges could favour particular 18 electrodes and areas of the particulate trap.

A further improvement in regeneration performance can 21 be achieved by pulsing, or modulating, the power 22 supply. This involves switching the power supply on 23 and off for very short periods. As an example, the 24 on and off periods could be in the range of lOms to is, with a maximum cycle time (the beginning of the 26 on period to the end of the off period) of 3s.

27 Unlike with the known mark space ratio, the on and 28 off periods would be variable instead of fixed. By 29 pulsing the power supply in such a manner, thermal damage to the filter caused by the discharge can be 31 reduced or eliminated altogether. The number of 1 complete on/off cycles can also be varied by 2 switching the power supply off for a longer period 3 than the cycle time. This will ensure that the 4 discharge moves about the inlet cells of the filter body and does not remain in one location.

7 As regards the relative positions of the electrodes 8 and conductors and the filter body, the preferred 9 embodiments have described the electrode as being sited at an upstream first end of the filter and the 11 conductor being sited downstream of the electrode.

12 These locations are used by way of example only. It 13 will be appreciated by the skilled person that the 14 invention will still operate with the electrode and conductor in the reverse arrangement. In addition, 16 both the electrode and conductor may be located at 17 the same end of the filter without any reduction in 18 regeneration performance. Such an arrangement is 19 shown schematically in Figure 5 where the downstream end of the filter body 14' is shown.

22 The filter body 14' of the illustrated embodiment is 23 cylindrical and would normal be enclosed by a filter 24 housing, but this has been removed for illustrative purposes. As already described, the filter body 14' 26 is made up of a number of inlet and outlet cells, and 27 the open ends of the outlet cells 17' can be seen in 28 Figure 5. In the arrangement shown, a number of HV 29 electrodes 20' are at least partially inserted into some of the outlet cells 17' of the filter body 14' 31 The HV electrodes 20' are each inserted into 1 particular outlet cells 17' so that the HV electrodes 2 20' are positioned in a linear arrangement. Although 3 Figure 5 shows each HV electrode 20' located in 4 adjacent outlet cells 17', it will be appreciated that the MV electrodes 20' can be arranged in non- 6 adjacent outlet cells 17' and still form a linear 7 arrangement.

9 As well as the HV electrodes 20', a number of conductors in the form of counter electrodes 40' are 11 also inserted into some of the outlet cells 17' of 12 the filter body 14'. Again, the counter electrodes 13 40' are also arranged in the outlet cells 17' so that 14 they form a linear arrangement, and may also be located in non- adjacent outlet cells 17' to form the 16 linear arrangement. The HV and counter electrodes 17 20',40' are arranged in alternate lines across the 18 end of the filter body 14' . By arranging the HV and 19 counter electrodes 20',40' in this way, a more uniform oxidation of particulate matter trapped in 21 the filter is achieved when the HV electrodes produce 22 their atmospheric glow discharges. Alternatively, 23 the linear arrangements of HV and counter electrodes 24 20',40' could be inserted into the cells of the filter such that they form particular shapes, e.g. a 26 substantially hexagonal shape.

28 These and other modifications and improvements may be 29 incorporated without departing from the scope of the invention.

Claims

CLAIMS: 1 1. An apparatus for removing particulates from a
2 gas stream,

the apparatus comprising:
3 a ceramic filter through which gas may be caused 4 to flow, the filter having a first end and a second end and comprising a plurality of elongate cells 6 extending substantially parallel to the direction of 7 gas flow; 8 at least one electrode located at an end of the 9 filter for producing an atmospheric glow discharge; and 11 at least one conductor spaced away from the at 12 least one electrode and adapted to lead current from 13 the electrode out of the filter; 14 wherein the conductor extends at least partially into the filter.

17 2. The apparatus of Claim 1, wherein the at least 18 one conductor comprises a portion of the filter 19 impregnated with a conductive material.

21 3. The apparatus of Claim 1, wherein the at least 22 one conductor is a second point electrode located at 23 least partially within one of the elongate cells.
4. The apparatus of Claim 1, wherein each elongate 26 cell of the filter is closed at either the first or 27 second end of the filter by an end plug.

29
5. The apparatus of Claim 4, wherein the end plugs 1 at the second end are made from a conductive 2 material, and the at least one conductor comprises a 3 conductive end plug.
6. An apparatus for removing particulates from a 6 gas stream comprising:
7 a ceramic filter through which gas may be caused
8 to flow, the filter having a first end and a second
9 end and comprising a plurality of elongate cells extending substantially parallel to the direction of 11 gas flow; 12 at least one electrode located at an end of the 13 filter for producing an atmospheric glow discharge; 14 and at least one conductor spaced away from the at 16 least one electrode and adapted to lead current from 17 the electrode out of the filter; 18 wherein the apparatus is mounted within a filter 19 housing, the housing being provided with apertures for the ingress and egress of gas, and wherein the at 21 least one conductor comprises a portion of the 22 housing.

24 7. The apparatus of any preceding claim, wherein the at least one electrode comprises a first point 26 electrode.

28 8. The apparatus of any preceding claim, wherein 29 the at least one electrode is located near to but spaced apart from an end of the filter.

1 9. The apparatus of any of Claims 1 to 7, wherein 2 the at least one electrode is located at least 3 partially within one of the elongate cells.
10. The apparatus of any of Claims 1 to 6, wherein 6 the at least one electrode comprises a portion of the 7 filter adjacent an end thereof, the portion 8 impregnated with a conductive material.
11. The apparatus of any preceding claim, wherein 11 one of the electrode and conductor is located at the
12 first end of the filter and the other of the 13 electrode and conductor is located at the second end 14 of the filter.

16 12. The apparatus of any of Claims 1 to 10, wherein 17 the electrode and conductor are located at the same 18 end of the filter.
13. The apparatus of Claim 12, wherein the first and 21 second ends of the filter are the upstream and 22 downstream ends, respectively, of the filter, and the 23 electrode and conductor are located at the downstream 24 end of the filter.

26
14. The apparatus of any preceding claim, wherein 27 the at least one electrode is connected to an AC 28 voltage supply generating an AC voltage in a 29 frequency within the range of 1 kHZ to 200]KHZ.

31
15. The apparatus of Claim 14, wherein the voltage 1 supply is pulsed.

3
16. A method of removal of particulates from a gas 4 stream comprising: causing the gas to flow through a ceramic filter 6 so that particulates are separated from the gas flow 7 and trapped by the filter, wherein the filter has a 8 first end and a second end and comprises a plurality 9 of elongate cells extending substantially parallel to the direction of gas flow; 11 positioning at least one electrode at an end of 12 the filter; 13 positioning at least one conductor at a location 14 spaced away from the at least one electrode, such that the conductor extends at least partially into 16 the filter; 17 generating an atmospheric glow discharge from 18 the electrode; and 19 leading current from the electrode out of the filter through the conductor.