US20100115930A1 - Exhaust after treatment system - Google Patents

Exhaust after treatment system Download PDF

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Publication number
US20100115930A1
US20100115930A1 US12/267,003 US26700308A US2010115930A1 US 20100115930 A1 US20100115930 A1 US 20100115930A1 US 26700308 A US26700308 A US 26700308A US 2010115930 A1 US2010115930 A1 US 2010115930A1
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Prior art keywords
catalytic reduction
passages
catalyst
low temperature
selective
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Abandoned
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US12/267,003
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English (en)
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David B. Brown
Jong H. Lee
Shuguang Lu
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Priority to US12/267,003 priority Critical patent/US20100115930A1/en
Application filed by GM Global Technology Operations LLC filed Critical GM Global Technology Operations LLC
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEE, JONG H., BROWN, DAVID B., LU, SHUGUANG
Assigned to UNITED STATES DEPARTMENT OF THE TREASURY reassignment UNITED STATES DEPARTMENT OF THE TREASURY SECURITY AGREEMENT Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Assigned to CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES, CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SECURED PARTIES reassignment CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES SECURITY AGREEMENT Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: UNITED STATES DEPARTMENT OF THE TREASURY
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES, CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SECURED PARTIES
Assigned to UNITED STATES DEPARTMENT OF THE TREASURY reassignment UNITED STATES DEPARTMENT OF THE TREASURY SECURITY AGREEMENT Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Assigned to UAW RETIREE MEDICAL BENEFITS TRUST reassignment UAW RETIREE MEDICAL BENEFITS TRUST SECURITY AGREEMENT Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Priority to DE102009051875A priority patent/DE102009051875A1/de
Priority to CN200910209399A priority patent/CN101732991A/zh
Publication of US20100115930A1 publication Critical patent/US20100115930A1/en
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: UNITED STATES DEPARTMENT OF THE TREASURY
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: UAW RETIREE MEDICAL BENEFITS TRUST
Assigned to WILMINGTON TRUST COMPANY reassignment WILMINGTON TRUST COMPANY SECURITY AGREEMENT Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Assigned to GM Global Technology Operations LLC reassignment GM Global Technology Operations LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • 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
    • F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
    • 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
    • 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
    • F01N2370/00—Selection of materials for exhaust purification
    • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
    • F01N2370/04—Zeolitic material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/40—Engine management systems

Definitions

  • Emission treatment systems for internal combustion engines may include an oxidation catalyst upstream of a Selective Catalytic Reduction system that is useful for remediation of the nitrogen oxides (NO X ) in the exhaust stream.
  • a soot filter that is commonly referred to as a diesel particulate trap may also be included in the system for the removal of particulates from the exhaust gas.
  • Diesel engine exhaust is a heterogeneous mixture which contains not only gaseous emissions such as carbon monoxide (“CO”), unburned hydrocarbons (“HC”) and oxides of nitrogen (“NO X ”), but also condensed phase materials (liquids and solids) which constitute the particulate matter.
  • Catalyst compositions, and substrates on which the catalysts are disposed may be provided in diesel engine exhaust systems to convert certain, or all of these exhaust constituents to non-regulated components.
  • diesel exhaust systems may include one or more of a diesel oxidation catalyst, a diesel particulate filter and a catalyst for the reduction of NO X .
  • DPF diesel particulate filter
  • honeycomb wall flow filters wound or packed fiber filters, open cell foams, sintered metal fibers, etc.
  • the ceramic wall flow filters have experienced significant acceptance in automotive applications.
  • the filter is a physical structure for removing particles from exhaust and, as such, accumulating particles will have the effect of increasing the backpressure on the engine.
  • the DPF is periodically regenerated. Regeneration involves the burning of accumulated particulates in what is typically a high temperature (>600 C), oxygen rich (lean) environment that may result in an increase in the levels of NO X components in the exhaust gas stream.
  • a similar oxygen rich environment may also result in an increase in the levels of NO X components in the exhaust gas.
  • SCR Selective Catalytic Reduction
  • NH 3 ammonia
  • N2 nitrogen
  • urea typically present in an aqueous solution
  • SCR provides efficient conversion of NO X as long as the exhaust temperature is within the active temperature range of the catalyst.
  • An issue with known SCR catalysts is that high exhaust temperatures, such as are experienced during the DPF regeneration event in a diesel system or high load operation in a gasoline engine, may render many SCR catalyst compositions less catalytically effective while cooler, low load temperatures of engine exhaust may have a similar effect on other catalyst compositions.
  • Discrete substrates each containing catalysts to address specific components of the exhaust are available. However, it is desirable to reduce the overall size, complexity and cost of complete systems.
  • One approach to achieve this goal is to coat the DPF with a catalyst composition which is effective for the conversion of the NO X component of the exhaust stream and which is capable of efficient conversion at high and at low temperatures, across the entire range of operation of the DPF.
  • a selective catalytic reduction system for reducing oxides of nitrogen (“NO X ”) in the exhaust gas of an internal combustion engine comprises a ceramic monolith disposed within the exhaust gas and having longitudinally extending exhaust flow passages.
  • a high temperature catalyst composition selected for high temperature catalytic reduction is applied to an inlet portion of the exhaust flow passages and a low temperature catalyst composition selected for low temperature catalytic reduction is applied to an outlet portion of the exhaust flow passages.
  • the high temperature and the low temperature catalytic reduction catalysts operate to reduce oxides of nitrogen at high load and low load operation of the internal combustion engine.
  • FIG. 1 is a schematic view of an exhaust treatment system for an internal combustion engine
  • FIG. 2 is an axial sectional view which schematically shows a ceramic wall flow monolith
  • FIG. 3 is a NO X reduction efficiency curve for the exhaust treatment system of FIG. 1 ;
  • FIG. 4 is an NH 3 oxidation curve for the exhaust treatment system of FIG. 1 ;
  • FIG. 5 is an embodiment of a catalyst loading curve for the exhaust treatment system of FIG. 1 ;
  • FIG. 6 is another embodiment of a catalyst loading curve for the exhaust treatment system of FIG. 1 .
  • an exemplary embodiment of the invention is directed to an exhaust treatment system 10 for the reduction of regulated exhaust constituents of an internal combustion engine, such as diesel engine 12 .
  • the treatment system 10 includes an exhaust conduit 14 that transports the exhaust gas from the diesel engine 12 to the various exhaust treatment components of the exhaust treatment system.
  • the exhaust components may include an oxidation catalyst 16 that is useful in treating unburned gaseous and non-volatile hydrocarbons and carbon monoxide, which are combusted to form carbon dioxide and water.
  • a reductant Downstream of the oxidation catalyst, a reductant may be injected as a spray via injector nozzle 18 , into the exhaust gas flow 20 , in exhaust conduit 14 .
  • Aqueous urea may be used as the ammonia precursor that may be mixed with air in the injector nozzle 18 to aid in dispersion of the injected spray.
  • the exhaust stream containing the added ammonia is conveyed to a Selective Catalyst Reduction (“SCR”) device; in this case, Diesel Particulate Filter (“DPF”) 22 .
  • SCR Selective Catalyst Reduction
  • DPF Diesel Particulate Filter
  • the DPF is operable to filter the exhaust gas to remove carbon and other particulates, and to reduce the oxides of nitrogen (“NO X ”) resident in the exhaust stream through the use of multiple SCR catalysts.
  • the DPF 22 may be constructed with a ceramic wall flow monolith 23 , FIG. 2 , which has a plurality of longitudinally extending passages 24 formed by longitudinally extending walls 26 .
  • the passages 24 include inlet passages 28 that have an open inlet end 30 and a closed outlet end 32 , and outlet passages 4 that have a closed inlet end 36 and an open outlet end 38 .
  • Exhaust gas entering the DPF through the inlet end 30 of the inlet passages 28 is forced to migrate through the longitudinally extending walls 26 to the outlet passages 34 . It is through this wall flow mechanism that the exhaust gas is filtered of carbon and other particulates.
  • the filtered particulates 40 are collected on the walls 26 of the inlet passages 28 .
  • the accumulating particulates will have the effect of increasing the backpressure on the diesel engine 12 .
  • the DPF is periodically regenerated. Regeneration involves burning of the accumulated particulates 40 in what is typically a high temperature (>600 C), oxygen rich (lean) environment that may result in an increase in the levels of the NO X component in the exhaust gas stream.
  • a first SCR catalyst composition 42 preferably contains a zeolite and base metal component such as Iron (“Fe”) which can operate efficiently to convert NO X constituents in the exhaust gas flow 20 at the high temperatures experienced in the DPF 22 during regeneration (i.e. >600 C).
  • Other suitable high temperature metals may include Cobalt (“Co”).
  • the high temperature SCR catalyst composition 42 is applied to the walls of the inlet passages 28 of the ceramic wall flow monolith 23 .
  • a second SCR catalyst composition 44 also preferably containing a zeolite and base metal component such as Copper (“Cu”) which can operate efficiently to convert NO X constituents in the exhaust gas flow 20 at low temperatures experienced in the DPF 22 during low load operation (i.e.
  • FIGS. 3 and 4 illustrate the performance of the two SCR catalyst compositions 42 and 44 across the operating temperature range of the DPF 22 .
  • the NO X reduction efficiency of the high temperature SCR catalyst composition 42 extends the conversion range of the device into the temperature range experienced during high load operation and regeneration of the DPF.
  • the NO X reduction efficiency of the low temperature SCR catalyst composition 44 extends the conversion range of the device into the temperature range experienced during low load or start up operation of the engine.
  • FIG. 1 illustrates the conversion range of the device into the temperature range experienced during low load or start up operation of the engine.
  • the low temperature SCR catalyst composition 44 receives NH 3 that moves past the high temperature SCR catalyst composition 42 .
  • the low temperature SCR catalyst composition 44 utilizes the NH 3 to insure effective NO X reduction.
  • the dual SCR catalyst combination allows the DPF to operate as an effective SCR system which is useful for remediation of the NO X in the engine exhaust stream during high load operation or under DPF regeneration cycles as well as during low temperature, light load operation.
  • application or loading of the high temperature and the low temperature SCR catalysts 42 , 44 may be varied along the axial length of the filter resulting in a relatively uniform total catalyst loading 46 along the length of the ceramic monolith 23 .
  • the concentration of each catalyst varies in an axial direction so as to gradually increase or decrease as the case may be. The result is a uniform total loading of catalysts 42 , 44 respectively.
  • catalyst loading is constant in the axial direction but each catalyst primarily occupies a particular axial portion of the monolith 23 , again resulting in a uniform total loading of catalysts 42 , 44 respectively.
US12/267,003 2008-11-07 2008-11-07 Exhaust after treatment system Abandoned US20100115930A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US12/267,003 US20100115930A1 (en) 2008-11-07 2008-11-07 Exhaust after treatment system
DE102009051875A DE102009051875A1 (de) 2008-11-07 2009-11-04 Abgasnachbehandlungssystem
CN200910209399A CN101732991A (zh) 2008-11-07 2009-11-06 排气后处理系统

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CN (1) CN101732991A (de)
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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110146237A1 (en) * 2008-04-11 2011-06-23 Umicore Ag & Co. Kg Exhaust gas purification system for the treatment of engine exhaust gases by means of scr catalyst
US20120186229A1 (en) * 2011-07-28 2012-07-26 Johnson Matthey Public Limited Company Zoned catalytic filters for treatment of exhaust gas
CN104568762A (zh) * 2015-01-19 2015-04-29 无锡桑尼安科技有限公司 基于图像处理的葡萄水分胁迫检测设备
US9051858B2 (en) 2011-03-30 2015-06-09 Caterpillar Inc. Compression ignition engine system with diesel particulate filter coated with NOx reduction catalyst and stable method of operation
US20160279571A1 (en) * 2013-12-11 2016-09-29 Cataler Corporation Exhaust gas purification material
US20170122175A1 (en) * 2014-07-18 2017-05-04 Cummins Inc. Scr exhaust aftertreatment apparatus, system and methods including multiple washcoat formulations
US20170184003A1 (en) * 2014-07-08 2017-06-29 Toyota Jidosha Kabushiki Kaisha Filter failure diagnostic device for an internal combustion engine
US20180296979A1 (en) * 2013-12-11 2018-10-18 Cataler Corporation Exhaust gas purification material
US10344641B2 (en) 2017-03-09 2019-07-09 Cataler Corporation Exhaust gas purifying catalyst

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DE102013003112B4 (de) * 2013-02-25 2017-06-14 Umicore Ag & Co. Kg SCR-Katalysator mit verbessertem NOx-Umsatz
CN109012177B (zh) * 2018-08-29 2023-06-16 华电电力科学研究院有限公司 一种全负荷内燃机氮氧化物控制系统及其工作方法

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Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8863507B2 (en) * 2008-04-11 2014-10-21 Umicore Ag & Co. Kg Exhaust gas purification system for the treatment of engine exhaust gases by means of SCR catalyst
US20110146237A1 (en) * 2008-04-11 2011-06-23 Umicore Ag & Co. Kg Exhaust gas purification system for the treatment of engine exhaust gases by means of scr catalyst
US9051858B2 (en) 2011-03-30 2015-06-09 Caterpillar Inc. Compression ignition engine system with diesel particulate filter coated with NOx reduction catalyst and stable method of operation
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US20120186229A1 (en) * 2011-07-28 2012-07-26 Johnson Matthey Public Limited Company Zoned catalytic filters for treatment of exhaust gas
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