Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
  • F23J1/00—Removing ash, clinker, or slag from combustion chambers
• • 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
  • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
  • B01D53/86—Catalytic processes
  • B01D53/90—Injecting reactants
• • 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
  • B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L1/00—Liquid carbonaceous fuels
  • C10L1/10—Liquid carbonaceous fuels containing additives
• • C—CHEMISTRY; METALLURGY
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  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L10/00—Use of additives to fuels or fires for particular purposes
  • C10L10/02—Use of additives to fuels or fires for particular purposes for reducing smoke development
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  • C10L10/00—Use of additives to fuels or fires for particular purposes
  • C10L10/06—Use of additives to fuels or fires for particular purposes for facilitating soot removal
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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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  • C10L10/00—Use of additives to fuels or fires for particular purposes
  • C10L10/14—Use of additives to fuels or fires for particular purposes for improving low temperature properties
• • 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
• • 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
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—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
  • F01N3/022—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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
• • 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
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—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
  • F01N3/023—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 using means for regenerating the filters, e.g. by burning trapped particles
  • F01N3/0231—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 using means for regenerating the filters, e.g. by burning trapped particles using special exhaust apparatus upstream of the filter for producing nitrogen dioxide, e.g. for continuous filter regeneration systems [CRT]
• • 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
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—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
  • 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
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
  • F23J7/00—Arrangement of devices for supplying chemicals to fire
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
  • F23K5/00—Feeding or distributing other fuel to combustion apparatus
  • F23K5/02—Liquid fuel
  • F23K5/08—Preparation of fuel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2255/00—Catalysts
  • B01D2255/10—Noble metals or compounds thereof
  • B01D2255/102—Platinum group metals
  • B01D2255/1021—Platinum
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2255/00—Catalysts
  • B01D2255/20—Metals or compounds thereof
  • B01D2255/206—Rare earth metals
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2255/00—Catalysts
  • B01D2255/20—Metals or compounds thereof
  • B01D2255/207—Transition metals
  • B01D2255/20738—Iron
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L1/00—Liquid carbonaceous fuels
  • C10L1/10—Liquid carbonaceous fuels containing additives
  • C10L1/12—Inorganic compounds
  • C10L1/1208—Inorganic compounds elements
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L1/00—Liquid carbonaceous fuels
  • C10L1/10—Liquid carbonaceous fuels containing additives
  • C10L1/14—Organic compounds
  • C10L1/18—Organic compounds containing oxygen
  • C10L1/1814—Chelates
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L1/00—Liquid carbonaceous fuels
  • C10L1/10—Liquid carbonaceous fuels containing additives
  • C10L1/14—Organic compounds
  • C10L1/18—Organic compounds containing oxygen
  • C10L1/188—Carboxylic acids; metal salts thereof
  • C10L1/1881—Carboxylic acids; metal salts thereof carboxylic group attached to an aliphatic carbon atom
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L1/00—Liquid carbonaceous fuels
  • C10L1/10—Liquid carbonaceous fuels containing additives
  • C10L1/14—Organic compounds
  • C10L1/30—Organic compounds compounds not mentioned before (complexes)
  • C10L1/305—Organic compounds compounds not mentioned before (complexes) organo-metallic compounds (containing a metal to carbon bond)
• • 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
  • F01N2330/12—Metallic wire mesh fabric or knitting
• • 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
  • F01N2370/00—Selection of materials for exhaust purification
  • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
• • 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
  • F01N2430/00—Influencing exhaust purification, e.g. starting of catalytic reaction, filter regeneration, or the like, by controlling engine operating characteristics
  • F01N2430/04—Influencing exhaust purification, e.g. starting of catalytic reaction, filter regeneration, or the like, by controlling engine operating characteristics by adding non-fuel substances to combustion air or fuel, e.g. additives
• • 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
  • F01N2510/00—Surface coverings
  • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
  • F01N2510/065—Surface coverings for exhaust purification, e.g. catalytic reaction for reducing soot ignition temperature
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
  • F23K2300/00—Pretreatment and supply of liquid fuel
  • F23K2300/10—Pretreatment
  • F23K2300/103—Mixing with other fluids
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
  • F23K2900/00—Special features of, or arrangements for fuel supplies
  • F23K2900/05081—Treating the fuel with catalyst to enhance combustion

Definitions

• the invention concerns a new process for to reduce emission of pollutants of the type generated by incomplete combustion, e.g., particulates, unburned hydrocarbons and carbon monoxide, while avoiding increasing the production of NO 2 .
• Diesel engines have a number of important advantages over engines of the Otto type. Among them are fuel economy, ease of repair and long life. From the standpoint of emissions, however, they present problems more severe than their spark-ignition counterparts. Emission problems relate to particulate matter (PM), nitrogen oxides (NO x ), unburned hydrocarbons (HC) and carbon monoxide (CO). NO x is a term used to describe various chemical species of nitrogen oxides, including nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ), among others. NO is of concern because it is believed to undergo a process known as photo-chemical smog formation, through a series of reactions in the presence of sunlight and hydrocarbons, and is significant contributor to acid rain.
• PM particulate matter
• NO x nitrogen oxides
• HC unburned hydrocarbons
• CO carbon monoxide
• NO x is a term used to describe various chemical species of nitrogen oxides, including nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ), among others. NO is of concern because it
• NO 2 on the other hand has a high potential as an oxidant and is a strong lung irritant. Particulates (PM) are also connected to respiratory problems. As engine operation modifications are made to reduce particulates and unburned hydrocarbons on diesel engines, the NO 2 emissions tend to increase.
• DPFs diesel particulate filters
• DOCs diesel oxidation catalysts
• NO 2 being a strong oxidant
• Cooper, et al., U.S. Pat. No. 4,902,487 implements this reaction through the use of a heavily catalyzed DOC upstream of an uncatalyzed DPF.
• the heavily catalyzed DOC converts NO present in the exhaust to NO 2 , which oxidizes carbon particulates to help regenerate the filter.
• a conventional ceramic monolith supported catalyst was employed containing approximately 80 gm/ft 3 Pt. Typical loadings of platinum are reportedly 30 to 90 gm/ft 3 of DOC volume.
• a yet further object of the invention is to provide an emissions control system that is durable and able to oxidize soot at low exhaust temperatures without a need for frequent cleaning.
• the invention provides a method for reducing particulate emissions from a diesel engine while also controlling emissions of NO 2 as a percent of exhaust total nitrogen oxides, comprising: adding a fuel borne catalyst comprising platinum and cerium and/or iron at a total metal concentration of from 2 to 15 ppm in the fuel to a diesel fuel; and passing exhaust produced by the combustion through a diesel particulate filter having substrate with a precious metal catalyst thereon, the catalyst be present on the substrate in an amount of less than 15 grams per cubic foot of substrate.
• the invention provides a new robust diesel particulate control system involves the use of a lightly catalyzed wire mesh filter used in conjunction with a low dose rate FBC comprising platinum in combination with cerium and/or iron at total catalyst levels of under 15 ppm and preferably 4-8 ppm.
• This system has demonstrated high levels of particulate reduction of 60-75% especially when used with ULSD ( ⁇ 15 ppm S) without the substantial increase in NO 2 emissions accompanying heavily catalyzed devices that rely on the formation of upstream NO 2 to oxidize soot collected in a downstream filter.
• the invention provides improved systems for diesel operation and preferably employs an FBC and an emissions after treatment device comprising a lightly catalyzed diesel particulate filter, DPF, e.g., of conventional or wire mesh construction.
• DPF diesel particulate filter
• FBC refers to fuel borne catalyst, which is typically a fuel soluble or suspended composition having a metal component that is released to the combustion chamber in active form during the combustion of the fuel in the diesel engine.
• DPF and FBC will all be explained in greater detail below and are also known to the art as evidenced by the above citations.
• the invention employs an emissions after treatment device treatment comprising a catalyst substrate that can be a DPF alone or with a DOC, the catalyst substrate being lightly catalyzed with precious metal, e.g., a platinum group metal.
• the catalyst loading will be less that the art has seen the need for to convert NO to NO 2 for use as a soot oxidant, preferably having a metal loading of less than 15 gm/ft 3 platinum group metal loading, desirably less than 10 gm/ft 3 , and most preferably 3 to 5 gm/ft 3 .
• These low catalyst loadings aid in burning soot, without creating so much NO 2 that excessive emission of the NO 2 becomes an environmental problem.
• suitable precious metals for catalyzing the DPF are those identified in the Cooper, et al., patent identified above, and particularly comprises platinum group metal.
• a lightly catalyzed DPF contains less than 15 grams per cubic foot (gm/ft 3 ) platinum group metal loading, desirably less than 10 gm/ft 3 , and preferably 3 to 5 gm/ft 3 , used with a platinum and cerium FBC at 0.015-0.5 ppm Pt and 0.5-8 ppm Ce and/or iron. Higher and lower levels of additives may be employed for portions of a treatment or operation cycle. A further discussion of FBC compositions is provided below.
• the improved systems of the invention significantly reduce PM, e.g., by 50 to 90% in preferred embodiments, e.g., when used with ultra low sulfur diesel fuel and does not increase NO 2 above baseline and has demonstrated the ability to maintain low NO 2 emissions, e.g., to below 35%, e.g., preferably to below 25%, of total nitrogen oxide species while also minimizing the use of platinum group metals.
• diesel fuels suitable for use in the invention are those which typically comprise a fossil fuel, such as any of the typical petroleum-derived fuels including distillate fuels.
• the diesel fuel can be of any of those formulations disclosed in the above priority patent applications, which are incorporated by reference herein in their entireties.
• a fuel can be one or a blend of fuels selected from the group consisting of distillate fuels, including diesel fuel, e.g., No. 2 Diesel fuel, No. 1 Diesel fuel, jet fuel, e.g., Jet A, or the like which is similar in boiling point and viscosity to No.
• Diesel fuel, ultra low sulfur diesel fuel (ULSD) and biologically-derived fuels such as those comprising a “mono-alkyl ester-based oxygenated fuel”, i.e., fatty acid esters, preferably methyl esters of fatty acids derived from triglycerides, e.g., soybean oil, Canola oil and/or tallow.
• a “mono-alkyl ester-based oxygenated fuel” i.e., fatty acid esters, preferably methyl esters of fatty acids derived from triglycerides, e.g., soybean oil, Canola oil and/or tallow.
• Jet A and Diesel No. 1 are deemed equivalent for applications of the invention, but are covered by different American Society For Testing and Materials (ASTM) specifications.
• the diesel fuels are covered by ASTM D 975, “Standard Specification for Diesel Fuel Oils”. Jet A has the designation of ASTM D 1655, “Standard Specification for Aviation Turbine Fuels”.
• the term ultra low sulfur diesel fuel (ULSD) means No. 1 or No. 2 diesel fuels with a sulfur level no higher than 0.0015 percent by weight (15 ppm) and some jurisdictions require a low aromatic hydrocarbon content e.g., less than ten percent by volume.
• the process of the invention employs a fuel-soluble, multi-metal catalyst, i.e., an FBC, preferably comprising fuel-soluble platinum and either cerium or iron or both cerium and iron.
• a fuel-soluble, multi-metal catalyst i.e., an FBC
• the cerium and/or iron are typically employed at concentrations of from 0.5 to 20 ppm and the platinum from 0.0005 to 2 ppm, with preferred levels of cerium and/or iron being from 5 to 10 ppm, e.g., 7.5 ppm, and the platinum being employed at a level of from 0.0005 to 0.5 ppm, e.g., less than 0.15 ppm.
• the treatment regimen can call for the utilizing higher catalyst concentrations initially or at defined intervals or as needed—but not for the whole treatment as has been necessary in the past.
• the cerium and/or iron are preferred at levels of cerium and/or iron being from 2 to 10 ppm, e.g., 3-8 ppm, and the platinum being employed at a level of from 0.05 to 0.5 ppm, e.g., from 0.1 to 0.5 ppm, e.g., 0.15 ppm, for typical operations.
• the tests below run at these levels show surprising results in terms emissions utilizing a lightly catalyzed DPF.
• the cerium and/or iron FBC is preferred at concentrations of 1 to 15 ppm cerium and/or iron w/v of fuel, e.g., 4 to 15 ppm.
• a preferred ratio of cerium and/or iron to platinum for the FBC is from 100:1 to 3:1, e.g., more typically will be from 75:1 to 10:1.
• a formulation using 0.15 ppm platinum with 7.5 ppm cerium and/or iron is exemplary.
• An advantage of low levels of catalyst is the reduction in ultra fine particles resulting from metal oxide emissions.
• Data published under the European VERT program show that at high FBC dose rates of 20 ppm, or 100 ppm, cerium the number of ultra fine particles increases dramatically above baseline. However, for a bimetallic used at 0.5/7.5 or 0.25/4 ppm there is no significant increase in the ultra fine particle number. It has been found that at low levels of FBC there is not a separate ultrafine oxide particle peak and metal oxides are contained in the soot over the entire particle size distribution.
• a further advantage of the low dose rates prescribed by the current invention is a reduction in the contribution of metal ash to overall engine emissions.
• particulate emissions are limited to 100,000 ⁇ g/hp-hr (0.1 gram/hp-hr).
• a cerium FBC used at 30 ppm in fuel represents a metal catalyst input loading to the engine of 6000 ⁇ g/hp-hr of metal or roughly 6% of untreated engine emissions. Therefore, low levels of catalyst used in the present invention of less than 8 ppm and preferably 4 ppm as a bimetallic or trimetallic FBC will, for example, contribute only 800-1600 ⁇ g/hp-hr of catalyst loading to the engine or 0.8-1.6% of baseline soot emissions. This has the advantage of reduced metal ash emissions and reduces the contribution of the FBC to overall particulate mass emissions or loading of metal ash to downstream emission control devices.
• the fuel can contain detergent (e.g., 50-300 ppm), lubricity additive (e.g., 25 to about 500 ppm), other additives, and suitable fuel-soluble catalyst metal compositions, e.g., 0.1-2 ppm fuel soluble platinum group metal composition, e.g., platinum COD or platinum acetylacetonate and/or 2-20 ppm fuel soluble cerium or iron composition, e.g., cerium as a soluble compound or suspension, cerium octoate, ferrocene, iron oleate, iron octoate and the like.
• the fuel as defined, is combusted without the specific need for other treatment devices although they can be used especially for higher levels of control on diesels.
• cerium III acetylacetonate cerium III napthenate
• cerium octoate cerium oleate and other soaps such as stearate, neodecanoate, and other C 6 to C 24 alkanoic acids, and the like.
• the cerium is supplied as cerium hydroxy oleate propionate complex (40% cerium by weight) or a cerium octoate (12% cerium by weight). Preferred levels are toward the lower end of this range.
• iron compounds include ferrocene, ferric and ferrous acetyl-acetonates, iron soaps like octoate and stearate (commercially available as Fe(III) compounds, usually), iron napthenate, iron tallate and other C 6 to C 24 alcanoic acids, iron penta carbonyl Fe(CO) 5 and the like.
• platinum group metal compositions e.g., 1,5-cyclooctadiene platinum diphenyl (platinum COD), described in U.S. Pat. No. 4,891,050 to Bowers, et al., U.S. Pat. No. 5,034,020 to Epperly, et al., and U.S. Pat. No. 5,266,083 to Peter-Hoblyn, et al., can be employed as the platinum source.
• platinum COD 1,5-cyclooctadiene platinum diphenyl
• platinum group metal catalyst compositions include commercially-available or easily-synthesized platinum group metal acetylacetonates, including substituted (e.g., alkyl, aryl, alkyaryl substituted) and unsubstituted acetylacetonates, platinum group metal dibenzylidene acetonates, and fatty acid soaps of tetramine platinum metal complexes, e.g., tetramine platinum oleate.
• substituted e.g., alkyl, aryl, alkyaryl substituted
• unsubstituted acetylacetonates platinum group metal dibenzylidene acetonates
• platinum group metal dibenzylidene acetonates platinum group metal dibenzylidene acetonates
• fatty acid soaps of tetramine platinum metal complexes e.g., tetramine platinum oleate.
• the invention can employ a DPF alone or it can be used with other devices including DOCs, particulate reactors, partial filters or NO x adsorbers can also be used and benefit from reduced engine out emissions of the current invention. See the examples below, for the engine out results and the benefits of the FBC with catalyzed DPF devices to reduce NO 2 and particulate emissions. While not wishing to be bound by any theory, the unexpectedly good results with after treatment devices as well as for engine out emissions, may be because the platinum is not present in amounts sufficient to produce excessive amounts of NO 2 and yet produces some NO 2 or other chemical species which is sufficient to foster oxidation of the carbon in the particulates in the presence of low levels of cerium and/or iron.
• NO 2 is a strong lung irritant and can be generated in large quantities by traditional use of heavily catalyzed aftertreatment devices such as DOCs, DPFs or combinations.
• the net result of the limited NO 2 production due to low platinum concentrations and the cerium and/or iron being present in low but sufficient amounts is to produce greater than expected reductions in particulates (as well as other species resulting from incomplete oxidation) and at the same time control the amount of NO 2 generated and released.
• the invention has found that high NO 2 production rates are not necessary and, indeed, has found a way to provide emissions less irritating to humans.
• the preferred CWMF is a stainless steel wire mesh filter with an alumina wash coat that is catalyzed with a light coating of precious metal.
• this catalytic loading is under 15 gr/cu ft and typically 7-14 gr/cu ft which has the advantages of reduced cost, lower conversion of sulfur to sulfate and reduced NO 2 emissions.
• Used with an FBC the CWMF exhibits good PM reductions of 45-75% as well as low temperature soot oxidation without the need for upstream NO 2 generation.
• a typical CWMF filtration unit employs multiple rings of wire mesh formed from a mat of wire mesh as described in EP Application EP1 350 933 A1. That EP Application describes the use of a catalyzed wire mesh filter in conjunction with an upstream oxidation catalyst to generate NO 2 . It also teaches the use of wire diameter, the formation of the mat, compression density and other features to adjust filter performance.
• a wire diameter of 0.35 mm is preferred to give a good balance of filtration, durability and backpressure.
• Each wire mesh ring has a hollow center core and multiple rings are compressed together between two end plates to form a filter module core.
• the filter module is placed inside a stainless steel can with gas flow directed around the outside circumference of the wire mesh by a distribution cone on the front plate of the filter module.
• the module is supported in the can such that gases travel length wise along the axis of flow between the filter module and stainless steel can.
• the module diameter is less than the can such that an air space exists between the module and the can.
• the exit plate of the filter module fits tightly against the steel can preventing gases from escaping.
• a preferred embodiment will comprise a six section wire mesh assembly that is 232.5 mm long and 274 mm in diameter. It is compressed between two end plates using eight bolts and nuts spaced equally around the end plate circumference.
• the filter module has a distribution cone on the front plate to direct gas flow to the outer circumference of the filter module.
• the module is placed inside a stainless steel can with the eight bolts and spacer bars suspending the module inside of the can to allow gas to flow around the outside circumference and through the depth of the filter rings.
• the slightly larger diameter end plate prevents gases from escaping without passing through the wire mesh.
• a preferred wire diameter is 0.35 mm although 0.2 mm to 0.5 mm can be used.
• the wire mesh mat is wound around a hollow center core of 90 mm diameter.
• the wire mesh is coated with an alumina wash coat and catalyzed with 14 gr/cu ft of platinum although levels of 7-10 gr/cu ft or lower can be used effectively with a FBC treated fuel.
• the FBC comprises a fuel additive containing platinum in conjunction with cerium, iron or combinations of cerium and iron.
• a cerium FBC can be used with the CWMF at dose rates of 2-15 ppm although bimetallic and trimetallic compositions incorporating a platinum FBC are preferred.
• HCDOC heavily catalyzed diesel oxidation catalyst
• LCWMF lightly catalyzed wire mesh filter
• PGM platinum group metal
• ULSD fuel produced reduction in particulates of 59%, but increased NO 2 emissions to 58% of total nitrogen oxide species.
• the cerium additive was cerium hydroxy oleate and the platinum additive was platinum COD.
• a preferred system will contain a wire mesh DPF of the type of EP 1350933, having a loading of 14 gm/ft 3 of platinum metal.
• This device with its construction and loading is of a type not heretofore known.
• Data from a 1990 (Certified 1991 Emissions) Cummins 8.3 liter engine were generated over replicate hot start test cycles on an engine dymamometer.
• Baseline particulate emissions for No. 2D and ULSD were similar at 0.202 gr/hp-hr and 0.201 gr/hp-hr.
• Overall NO 2 emissions as a percentage of total nitrogen oxides were also similar for the baseline fuels at 15% and 14%.
• This example presents engine dynamometer data generated on a 1995 DT 466 Navistar engine over a single cold and triplicate hot test cycles.

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• 2005
  • 2005-01-19 US US11/038,288 patent/US20050164139A1/en not_active Abandoned
• 2006
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