US20060185352A1 - Exhaust system for a lean-burn ic engine - Google Patents

Exhaust system for a lean-burn ic engine Download PDF

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Publication number
US20060185352A1
US20060185352A1 US10/523,771 US52377103A US2006185352A1 US 20060185352 A1 US20060185352 A1 US 20060185352A1 US 52377103 A US52377103 A US 52377103A US 2006185352 A1 US2006185352 A1 US 2006185352A1
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Prior art keywords
filter
soot
metal
flow
engine
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US10/523,771
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English (en)
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Martyn Twigg
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Johnson Matthey PLC
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Johnson Matthey PLC
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Publication of US20060185352A1 publication Critical patent/US20060185352A1/en
Abandoned legal-status Critical Current

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    • 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
    • F01N3/24—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 constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/66—Regeneration of the filtering material or filter elements inside the filter
    • B01D46/80—Chemical processes for the removal of the retained particles, e.g. by burning
    • B01D46/82—Chemical processes for the removal of the retained particles, e.g. by burning with catalysts
    • 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
    • B01D53/88—Handling or mounting catalysts
    • B01D53/885—Devices in general for catalytic purification of waste gases
    • 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
    • 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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
    • F01N13/0093—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series the purifying devices are of the same type
    • 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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
    • 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
    • F01N3/022—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
    • F01N3/0222—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 the structure being monolithic, e.g. honeycombs
    • 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
    • F01N3/031—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 having means for by-passing filters, e.g. when clogged or during cold engine start
    • 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
    • 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
    • F01N3/24—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 constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2251/00—Reactants
    • B01D2251/10—Oxidants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2251/00—Reactants
    • B01D2251/10—Oxidants
    • B01D2251/104—Ozone
    • 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
    • B01D2255/202—Alkali 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
    • B01D2255/206—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
    • B01D2255/20723—Vanadium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/209—Other metals
    • B01D2255/2092—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/012—Diesel engines and lean burn gasoline engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/014—Stoichiometric gasoline engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/42—Platinum
    • 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
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/28—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a plasma reactor
    • 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
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/02—Combinations of different methods of purification filtering and catalytic conversion
    • 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
    • F01N2330/12—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
    • F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
    • F01N2410/10—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device for reducing flow resistance, e.g. to obtain more engine power

Definitions

  • the present invention relates to an exhaust system for a lean-burn internal combustion engine, and in particular to a system for treating a soot-containing gas.
  • metal-based filters were disclosed inter alia in U.S. Pat. No. 4,270,936 and U.S. Pat. No. 4,902,487 and in SAE papers 820184 (Enga et al.) and 890404 (Cooper, Thoss). They reached an advanced stage of development in Johnson Matthey's ‘Catalytic Trap Oxidiser’ (‘CTO’), but appear not to have successfully competed with wall-flow filters in the commercial market. We have recently identified systems in which metal-based filters can be used with advantage.
  • CTO Catalytic Trap Oxidiser
  • an exhaust system for a lean-burn internal combustion engine comprising an exhaust gas treatment system comprising a soot filter packed with a mass of elongate flat, narrow strip metal and means for generating an oxidant more active than molecular oxygen (O 2 ) for combusting soot collected on the filter.
  • an exhaust gas treatment system comprising a soot filter packed with a mass of elongate flat, narrow strip metal and means for generating an oxidant more active than molecular oxygen (O 2 ) for combusting soot collected on the filter.
  • the exhaust gas from such an engine typically contains the gaseous components soot (or particulate matter (PM)) unburned hydrocarbons (HC), carbon monoxide (CO), nitrogen oxides (NO x ), carbon dioxide (CO 2 ), water vapour (H 2 O), O 2 and nitrogen (N 2 ).
  • the means to remove by combustion the soot collected on the filter preferably operates continuously.
  • the oxidant more active than O 2 is for example ozone and/or plasma, most conveniently NO 2 .
  • NO 2 is preferably provided, at least in part, by catalytic oxidation of the NO component of the NOx e.g. on a NO-oxidation catalyst e.g. platinum supported on particulate alumina upstream of the filter.
  • a NO-oxidation catalyst e.g. platinum supported on particulate alumina upstream of the filter.
  • Such catalyst may be supported on a packed flat, narrow strip metal substrate, conveniently of the type used in the filter, but at a lower packing density, to permit
  • the filter packing may carry a layer catalytic for soot oxidation, possibly by a mechanism involving oxidation of NO to NO 2 .
  • soot oxidation catalysts include supported platinum group metals, such as platinum on alumina and/or base metals such as La/Cs/V 2 O 5 . If the engine-out NOx available in the gas is insufficient to combust the soot continuously, more may be introduced, e.g. by introduction of plasma or NOx or nitric acid, possibly as gas produced by oxidation of ammonia on-vehicle.
  • the ozone and/or plasma may be generated by suitable means such as a source of UV light and/or a corona discharge device. It is to be understood that plasma and/or ozone is capable of oxidising NO to NO 2 .
  • the exhaust system comprises both means for generating ozone and/or plasma and as NO oxidation catalyst.
  • the external structure of the filter may have features providing operational advantages. For example, it may be formed as a monolith easily inserted into or withdrawn from a reactor shell. Whether monolithic or not, it may be disposed as a cartridge in an outer shell, easily insertable or withdrawable. It may be capable of electrical conduction as a whole, thus permitting electric heating at cold start. Such electrical conduction may be used in constructing a monolith, by effecting local welding between adjacent strips; if the filter is to be disposed in an outer shell. It may contain an axial metal rod to act during such welding as one electrode, the shell acting as the other. Further external features are mentioned below.
  • the metal of the filter should be capable of withstanding the exhaust treatment process conditions. Since the filter can be replaceable more easily than a ceramic filter, and its material can be recovered for re-use, the use-life of the filter need not be as long as for a ceramic filter. It is possible to envisage replacing the filter at the normal service interval of a vehicle.
  • the metal is a corrosion resistant iron alloy.
  • Typical alloys contain nickel and chromium and minor constituents as in Type 300 or Type 400 stainless steels. Which is used may depend on whether the exhaust gas treatment system is required to operate temporarily in rich conditions, in which some stainless steels are unstable.
  • a preferred iron alloy contains at least 11.5% Cr, 4% Al and 0.02-0.25% minor constituents such as rare earth, zirconium or hafnium.
  • the metal in a filter may be a mixture of different compositions, possibly including a component providing electrical conduction bridges or a welding function.
  • the filter may have, wholly or domain-wise, a regular structure, for example coiled, woven or knitted.
  • the metal strip of the filter may be for example up to 2, especially in the range 0.1 to 0.5 mm, wide. It should be thick enough to afford mechanical strength in the conditions in which it is to be used. Typically its thickness is in the range 0.2 to 0.8 of its width. Suitably its geometric surface area per unit length is in the range 1.2 to 1.5 times that of the same weight of metal in circular cross-section. It is suitably the product of flattening circular-section wire.
  • the metal in a filter unit may be a mixture of strip dimensions and may include circular-section wire as unflattened interlengths or as added sub-units. In one embodiment, the flat narrow, strip metal is of flattened wire.
  • the level of packing can be chosen to provide a desired level of filtration and/or backpressure in the system, and can depend on the width and depth of the flat metal strip. However, we believe that generally a range of packing density of from 2.5 to 30% v/v, such as 5 to 15% v/v can provide the desired result. We have used a packing density of 10% with advantage.
  • a catalytic coating on the filter typically comprises a washcoat of oxide such as alumina with possibly rare earth and an active material especially Pt or Pd or oxides of Cs and V.
  • the coating may contain perovskite.
  • the catalyst typically comprises Pt and/or Pd on such a washcoat.
  • the generator thereof may be for example a corona discharge tube through which air passes between two electrodes kept at a large potential difference; or may comprise a high-energy lamp.
  • the plasma generator may operate for example by corona discharge, surface plasma discharge or dielectric barrier discharge or comprise a dielectric packed bed or electron beam reactor. It may be enhanced by electromagnetic radiation such as microwave radiation.
  • the generator may treat air or the whole of the exhaust gas or part of such gas before or after treatment.
  • filter capacity is large enough so that soot is combusted continuously by the oxidant, that is, with any accumulation during slow running being quickly removed in periods of fast running; the overall trend being continuous combustion.
  • a less expensive filter capacity is sized to accommodate larger accumulations of soot, sufficient to increase pressure-drop significantly before the next period of fast running.
  • Such filter(s) preferably includes a bypass, the pressure-drop through which is equal to the design maximum tolerated pressure-drop.
  • the bypass avoids engine stalling or low power that would result from excessive pressure-drop, but permits some soot emission to atmosphere.
  • a second stage such as a filter or impingement collector and/or an oxidation catalyst may be provided downstream of the bypass.
  • the bypass without or with second stage filter and/or oxidation catalyst, may be part of the filter cartridge.
  • the direction of gas flow through the filter and/or (if used) oxidation catalyst can be or have a component linear or transverse to the general flow direction.
  • Transverse flow may be for example symmetrical, especially inwards to an outflow header axial in a cylindrical filter, or to a plenum in an oval-section or rectangular filter. Alternatively one-way cross-flow may be provided.
  • a succession of filter elements presents to the gas a different soot-treating capacity, for example collecting smaller and smaller particles, and/or providing graded catalytic environments.
  • gas flow in the filter element(s) at the inlet of the succession is, or has a component, transverse to the general direction of flow.
  • successive filter elements may alternate with oxidation catalyst and/or with means to provide plasma or ozone.
  • downstream filter element(s) and (if used) oxidation catalyst(s) may be ceramic.
  • a particularly useful system comprises, in downstreamward order, a plurality of metal-based filters for successively trapping smaller and smaller particles and, optionally, at least one wall-flow filter for trapping yet smaller particles.
  • the pores of the wall-flow filter can be smaller than in single-stage wall-flow trapping, because the preceding metal-based filters have removed the larger particles that may have blinded or blocked, i.e. reduced the gas flow through, them. Any or all of the filters may be catalysed.
  • a distinct NO-oxidation catalyst may be disposed upstream of at least the first filter.
  • Such catalysis on and/or between filters can have the effect of restoring the NO 2 content, which may have had been decreased by reaction with soot in the preceding filter.
  • the filters and, if present, catalysts may be assembled as a single unit within a cartridge.
  • Such NO-oxidation catalysts can be supported on a flow through substrate e.g. a ceramic or metal substrate.
  • the invention provides a system according to the invention wherein the oxidant more active than O 2 is at least one of ozone, plasma or NO 2 .
  • the exhaust treatment system may include other integers as used or proposed, for example a three-way catalyst (TWC), nitrogen oxide (NOx) trap+regeneration means, selective catalytic reduction (SCR) e.g. using hydrocarbon or ammonia as reductant, lean-NOx catalysis, a sulfur oxides (SOx) trap regenerable or disposable.
  • TWC three-way catalyst
  • NOx nitrogen oxide
  • SCR selective catalytic reduction
  • SOx sulfur oxides
  • the lean-burn engine may be any engine currently or potentially producing a soot-containing engine.
  • the engine may be a compression ignition engine, such as diesel engine, or a spark ignition engine such as a lean burn gasoline, e.g. gasoline direct injection (GDITM), engine. It may have exhaust gas recirculation (EGR). It may be for light or heavy duty.
  • EGR exhaust gas recirculation
  • the S content of the fuel used should be less than 500, especially less than 50 ppm w/w S. Low sulfur fuelling and lubrication giving exhaust gas of less than 20 ppm SO 2 is preferred.
  • FIG. 1 shows in schematic section a diesel engine with an exhaust system
  • FIG. 2 is a trace showing exhaust gas aftertreatment component inlet temperature and outlet temperature in the exhaust system of a vehicle against time, also showing vehicle speed;
  • FIG. 3 is a schematic sectional view through an exhaust gas treatment system component for use in the present invention.
  • FIG. 4 is a bar chart showing particulate mass measured over a drive cycle for exhaust gas treatment systems 1 , 2 and 3 ;
  • FIG. 5 shows modal (second by second continuous) analysis of tailpipe NO 2 from an exhaust system comprising systems 1 , 2 and 3 .
  • item 10 indicates a 4-cylinder diesel engine having air inlet 12 and fuel inlet 14 fed with hydrocarbon of 5 ppm sulfur content at an air/fuel weight ratio of about 30 for steady operation but variable as routinely practised.
  • the engine exhaust 16 is fed to a cylindrical treatment reactor indicated generally by 18 and having insulated internal walls 20 . Fitting snugly within walls 20 is filter cartridge 22 .
  • catalyst bed 24 packed with knitted 310 stainless steel flattened wire 0.33 mm wide and 0.2 mm thick to 6% solid by volume, carrying an alumina washcoat and Pt at 70-100 (1.98-2.83 gm ⁇ 3 ), possibly up to 300 (8.50 gm ⁇ 3 ), g/ft 3 of bed volume, giving low-temperature light-off.
  • the next downstream zone of cartridge 22 is occupied by annular feed channel 28 surrounding first filter 30 packed with the same flattened wire as in bed 24 but at 12% volume by volume and carrying a washcoat and soot oxidation catalyst.
  • Filter 30 provides axial-inward gas flow to outlet 32 .
  • Feed channel 28 terminates longitudinally in bypass 34 , the function of which will be explained below.
  • the next downstream zone is second filter 36 , providing longitudinal gas flow.
  • Axial to filter 36 is metal rod 38 , the function of which is to be explained below.
  • Filter 36 is packed with the same flattened wire as used in bed 24 but at 16% volume by volume and carrying a soot oxidation catalyst e.g. La/Cs/V 2 O 5 .
  • Filter 30 and/or 36 may be rigidified, at the time of construction, by electric internal spot welding using respectively the axial outlet or axial rod 38 as one electrode and the outer boundary member as the other electrode
  • Surrounding filter 36 is bypass channel 40 .
  • Bypasses 34 and 40 are shown shaded to indicate the possible inclusion of flow-obstructing material to provide balancing of pressure-drop with that of the filter when the filter is partly soot-bearing.
  • a second oxidation catalyst similar to 24 , between the filters.
  • NO in the exhaust gas entering bed 24 is largely oxidised to NO 2 .
  • Soot in the gas passes through bed 24 and is held on filter 30 where it is oxidised by the NO 2 to CO. If filter 30 is under-designed or an engine upset produces extra soot, soot accumulates in it and obstructs gas flow through it.
  • bypass 34 permits gas to pass through the exhaust system, so that engine operation can continue until soot-oxidising conditions return or remedial action is taken.
  • bypass channel 40 permits gas to pass.
  • Filters as 30 and 36 provide successively increasing geometric surface per unit volume, to trap finer particles or bypassed particles.
  • Such successive filters need not include a bypass, if the entering concentration of soot is sufficiently less than in the first filtering stage.
  • Such further stage(s) may include oxidation catalyst as mentioned above to restore the content of NO 2 following reduction by soot on the preceding filter.
  • the vehicle was placed on a standard chassis rolling road dynamometer and, after 20 seconds idling was accelerated to 120 kph in 100 seconds and maintained at this speed for the remainder of the test. After a further 300-400 seconds the inlet temperature to the catalyst system attained a stable temperature of 330-350° C.
  • the vehicle was then run for a period of 20 minutes at this temperature ( FIG. 2 ).
  • particulate was collected on two sets of filter papers by the standard method (one set for each 10 minute period) to enable an average particulate weight for the test to be calculated.
  • Nitrogen Oxides NO and NO 2
  • FTIR Fourier Transform Infra Red
  • the flow through monolith was removed from the vehicle and replaced by a 5.66 in (144 mm) diameter and 4 in (100 mm) long flow through monolith of the same cell density and wall thickness coated with a platinum catalyst at 75 gft ⁇ 3 (2.6 g litre ⁇ 1 ) followed by a bare flow through monolith 5.66 in (144 mm) diameter and 4 in (100 mm) long.
  • the identical test cycle was conducted and the measurements repeated. This was labelled System 2 .
  • the oxidation catalyst was replaced by one 5.66 (144 mm) diameter and 3 in (76 mm) long flow through monolith coated with platinum at 75 g ft ⁇ 3 (2.6 g litre ⁇ 1 ), and the bare monolith was replaced by a particulate trap of novel design.
  • the total length of the wire bed was 4 in (100 mm) and the packing density was 10% v/v.
  • FIG. 5 shows modal (second by second continuous) analysis of NO 2 at the tailpipe downstream of the three systems.
  • System 1 with a bare monolith has very low NO 2 emissions similar to those from the engine. Higher NO 2 concentrations are measured after System 2 because NO is oxidised over the catalyst, but there is only a small amount of reaction with soot.
  • NO 2 formed over the first oxidation catalyst reacts with soot collected in the first filter bed. The NO not oxidised over the first catalyst passes through the first filter bed and is oxidised to NO 2 over the second catalyst. There may also be some re-oxidation of NO formed from reaction between NO 2 +C ⁇ NO+CO.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Toxicology (AREA)
  • Biomedical Technology (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Ceramic Engineering (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
US10/523,771 2002-08-09 2003-08-08 Exhaust system for a lean-burn ic engine Abandoned US20060185352A1 (en)

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GB0218540.3 2002-08-09
GBGB0218540.3A GB0218540D0 (en) 2002-08-09 2002-08-09 Engine exhaust treatment
PCT/GB2003/003462 WO2004015252A1 (en) 2002-08-09 2003-08-08 Exhaust system for a lean-burn ic engine

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EP (1) EP1540150A1 (enExample)
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US20100275586A1 (en) * 2005-12-01 2010-11-04 Hirohito Hirata Device for cleaning exhaust gas of internal combustion engine
US20100326054A1 (en) * 2009-06-30 2010-12-30 Kabushiki Kaisha Toyota Jidoshokki Exhaust gas purification system
US7862640B2 (en) 2006-03-21 2011-01-04 Donaldson Company, Inc. Low temperature diesel particulate matter reduction system
US20110011065A1 (en) * 2008-05-30 2011-01-20 Deutz Aktiengesellschaft High-efficiency scr catalytic converter
WO2016028290A1 (en) * 2014-08-20 2016-02-25 Cummins Emission Solutions, Inc. Sulfur trioxide trap for use in preventing catalyst deactivation by ammonium sulfate/bisulfate
US10247070B2 (en) 2016-02-16 2019-04-02 Cummins Emission Solutions Inc. System and methods for reducing SOx gases in aftertreatment systems
US12106939B2 (en) 2021-06-02 2024-10-01 Rimere, Llc Systems and methods of plasma generation with microwaves
USRE50464E1 (en) 2017-07-28 2025-06-24 Rimere, Llc Modular plasma reformer treatment system

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JP2006336506A (ja) * 2005-05-31 2006-12-14 Honda Motor Co Ltd 排ガス浄化装置
KR101379955B1 (ko) * 2007-08-10 2014-03-28 에스케이이노베이션 주식회사 다단 저감 방식의 배기가스 정화 장치
CN106481392A (zh) * 2016-12-13 2017-03-08 大连凯泓科技有限公司 用于精细颗粒物的再生过滤装置
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CN106762038A (zh) * 2016-12-13 2017-05-31 大连凯泓科技有限公司 一种过滤器用过滤元件

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US12106939B2 (en) 2021-06-02 2024-10-01 Rimere, Llc Systems and methods of plasma generation with microwaves

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EP1540150A1 (en) 2005-06-15
GB0218540D0 (en) 2002-09-18
AU2003255762A1 (en) 2004-02-25
JP2005535438A (ja) 2005-11-24
CN1675454A (zh) 2005-09-28
CN100416052C (zh) 2008-09-03
WO2004015252A1 (en) 2004-02-19
KR20050062530A (ko) 2005-06-23

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