US20120233985A1 - Apparatus comprising lean burn ic engine and an exhaust system therefor - Google Patents

Apparatus comprising lean burn ic engine and an exhaust system therefor Download PDF

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US20120233985A1
US20120233985A1 US13/263,652 US200713263652A US2012233985A1 US 20120233985 A1 US20120233985 A1 US 20120233985A1 US 200713263652 A US200713263652 A US 200713263652A US 2012233985 A1 US2012233985 A1 US 2012233985A1
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substrate
nac
hydrogen sulfide
filter substrate
exhaust gas
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Hai-Ying Chen
Howard Sherman Hess
Andrew Peter Walker
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Johnson Matthey PLC
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Johnson Matthey PLC
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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
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction 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
    • 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
    • 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
    • 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
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • 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 ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • 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 ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 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
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0821—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with 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
    • 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
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • 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
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0871—Regulation of absorbents or adsorbents, e.g. purging
    • F01N3/0885—Regeneration of deteriorated absorbents or adsorbents, e.g. desulfurization of NOx traps
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/91—NOx-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/30—Sulfur compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/30—Sulfur compounds
    • B01D2257/304—Hydrogen sulfide
    • 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
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/12—Combinations of different methods of purification absorption or adsorption, 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
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/14—Combinations of different methods of purification absorption or adsorption, and filtering
    • 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
    • F01N2430/06—Influencing exhaust purification, e.g. starting of catalytic reaction, filter regeneration, or the like, by controlling engine operating characteristics by varying fuel-air ratio, e.g. by enriching fuel-air mixture
    • 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
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/04—Sulfur or sulfur oxides
    • 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
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/03—Adding substances to exhaust gases the substance being hydrocarbons, e.g. engine fuel
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • 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

Definitions

  • the present invention relates to an apparatus comprising a lean burn internal combustion engine, particularly diesel engines and particularly for vehicular applications, and an exhaust system for treating a flowing exhaust gas from the engine.
  • a lean burn internal combustion engine particularly diesel engines and particularly for vehicular applications
  • an exhaust system for treating a flowing exhaust gas from the engine.
  • an apparatus comprising an exhaust system including a NO x adsorber catalyst (NAC) and a catalysed soot filter (CSF).
  • NAC NO x adsorber catalyst
  • CSF catalysed soot filter
  • NAC nitrogen oxides
  • NO x nitrogen oxides
  • lean exhaust gas lean exhaust gas
  • desorb the NO x when the oxygen concentration in the exhaust gas is decreased.
  • Desorbed NO x may be reduced to N 2 with a suitable reductant, e.g. diesel fuel, promoted by a catalyst component, such as rhodium, of the NAC itself or located downstream of the NAC.
  • a suitable reductant e.g. diesel fuel
  • a catalyst component such as rhodium
  • the oxygen concentration can be adjusted by a number of means, e.g. throttling, injection of additional hydrocarbon fuel into an engine cylinder such as during the exhaust stroke or injecting hydrocarbon fuel directly into exhaust gas downstream of an engine manifold. More sophisticated common rail fuel injector systems in diesel engines can be used to meter very precise quantities of fuel to adjust exhaust gas composition.
  • a typical NAC formulation includes a catalytic oxidation component, such as platinum, a NO x -storage component, such as barium, and a reduction catalyst, e.g. rhodium.
  • a catalytic oxidation component such as platinum
  • a NO x -storage component such as barium
  • a reduction catalyst e.g. rhodium.
  • reaction (1) the nitric oxide reacts with oxygen on active oxidation sites on the platinum to form NO 2 .
  • Reaction (2) involves adsorption of the NO 2 by the storage material in the form of an inorganic nitrate.
  • reaction (3) At lower oxygen concentrations and/or at elevated temperatures, the nitrate species become thermodynamically unstable and decompose, producing NO or NO 2 according to reaction (3) below. In the presence of a suitable reductant, these nitrogen oxides are subsequently reduced by carbon monoxide, hydrogen and hydrocarbons to N 2 , which can take place over the reduction catalyst (see reaction (4)).
  • the reactive barium species is given as the oxide.
  • NAC sulfur dioxide
  • SO 2 is oxidised to SO 3 by the oxidation catalyst component of the NAC and the SO 3 is adsorbed on the NO x adsorber by a similar mechanism to that of NO 2 .
  • the presence of sulfate on the NO x storage component reduces the capacity of the NO x storage component as a whole to adsorb NO x . Therefore, in order to retain sufficient NO x storage capability, sulfur must be periodically removed from the NAC.
  • sulfates of NO x storage components such as barium are more stable than nitrates in lean exhaust gas and generally higher temperatures and/or richer conditions for longer periods are required than for desorbing NO x .
  • a significant problem with desulfating a NAC using richer than normal exhaust gas compositions is that the sulfate is removed as hydrogen sulfide. This compound has a characteristic and unpleasant rotten egg odor and accordingly it is desirable to prevent its emission to atmosphere.
  • CSFs are known from, e.g. U.S. Pat. No. 5,100,632 (the entire contents of which are incorporated herein by reference).
  • CSFs are used with mixed passive-active regeneration, wherein the filter regenerates passively under some operating conditions, e.g. at high engine loads.
  • the exhaust gas temperature is actively increased—typically to about 550-600° C.—to trigger periodic regeneration whenever a given soot load is reached in the filter (detected e.g. using a backpressure sensor) or after the vehicle has travelled a pre-determined distance.
  • Increased temperatures are realized through such means as engine management or injection of fuel into the exhaust gas, followed by HC oxidation over a warm-up catalyst (which may be on the CSF itself).
  • a diesel exhaust system comprising a NAC and a downstream CSF is known e.g. from SAE 2001-01-2065 entitled “Cummins Light Truck Diesel Engine Progress Report” (the entire contents of which are incorporated herein by reference).
  • WO 01/12320 discloses a wall-flow filter for an exhaust system of an internal combustion engine, which wall-flow filter comprising an oxidation catalyst on a substantially gas impermeable zone at an upstream filter end.
  • a NO R absorber can be located in a substantially gas impermeable zone at a downstream filter end.
  • the invention provides an apparatus comprising:
  • the enriched state is net rich, i.e. lambda ⁇ 1.
  • the filter substrate can be any suitable for the purpose of trapping and retaining diesel particulate matter, including wall-flow filters, sintered metal filters and partial filters such as those disclosed in EP 1276549 and EP 1057519 (the entire contents of both documents being incorporated herein by reference).
  • the first substrate monolith can be a flow-through monolith substrate or a filter substrate, such as a partial filter substrate.
  • the CSF catalyst can be any suitable for the purpose including platinum and/or palladium supported on a suitable support material including alumina and ceria or a mixed oxide or composite oxide of ceria and zirconia.
  • a suitable support material including alumina and ceria or a mixed oxide or composite oxide of ceria and zirconia.
  • the first substrate monolith is the filter substrate, and the NAC composition performs the function of the CSF catalyst.
  • the NAC will comprise a catalytic oxidation component, such as platinum, palladium or both platinum and palladium, a NO x -storage component, such as an alkaline earth metal oxide, an alkali metal oxide or an oxide of a lanthanide metal, e.g. ceria, lanthana, yttria or mixtures of any two or more of such oxides, and a reduction catalyst, e.g. rhodium, although the rhodium may be located on outlet channels of the filter or downstream of the filter entirely e.g. located on a flow-through substrate downstream.
  • a catalytic oxidation component such as platinum, palladium or both platinum and palladium
  • a NO x -storage component such as an alkaline earth metal oxide, an alkali metal oxide or an oxide of a lanthanide metal, e.g. ceria, lanthana, yttria or mixtures of any two or more of such oxides
  • the NAC is typically applied as a washcoat onto a honeycomb monolith substrate, it is also possible to provide the first substrate monolith as an extruded-type honeycomb. Where the NAC is present as an extrudate, it is possible to coat other catalyst coatings onto the extrudate to combine catalyst functionality in a single “brick”.
  • the enriching means comprises a microprocessor (ECU), which can comprise part of an engine control unit.
  • ECU microprocessor
  • the filter substrate is located upstream of the first substrate monolith.
  • the first substrate monolith comprises the NAC and the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the arrangement can be such that the first substrate monolith has a length extending between an inlet end and an outlet end thereof, wherein the
  • NAC is located in a first zone of substantially uniform length defined at an upstream end by the inlet end of the first substrate monolith and at an downstream end by a point more than one half way along the first substrate monolith measured from the inlet end and the compound effective to remove and/or convert at least some hydrogen sulfide is located in a second zone of substantially uniform length defined at an upstream end by a point more than one half way along the first substrate monolith length measured from the inlet end and at a downstream end by the outlet end of the first substrate monolith.
  • a second substrate monolith is located downstream of the first substrate monolith, which second substrate monolith comprises the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the first substrate monolith is the filter substrate.
  • This combination of exhaust system features promotes space saving within an exhaust system, which is useful in vehicular applications, and heat retention within the filter substrate, which can promote catalysed chemical reactions therewithin.
  • the filter substrate comprises both the NAC and the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the arrangement is such that the filter substrate has a length extending from an inlet end to an outlet end thereof, wherein the NAC is located in a zone of substantially uniform length defined at an upstream end by the inlet end of the filter substrate and at an downstream end by a point more than one half way along the filter substrate measured from the inlet end and the compound effective to remove and/or convert at least some hydrogen sulfide is located in a fourth zone of substantially uniform length defined at an upstream end by a point more than one half way along the filter substrate length measured from the inlet end and defined at a downstream end by the outlet end of the filter substrate itself.
  • a second substrate monolith may be located downstream of the filter substrate, which second substrate monolith comprises the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the filter substrate has an inlet end and an outlet end and the inlet end of the filter substrate is located downstream of the first substrate monolith in a flow direction of the exhaust gas.
  • the compound effective to remove and/or convert at least some hydrogen sulfide can be located on a third substrate monolith disposed between the first substrate monolith and the filter substrate and/or the first substrate monolith can comprise both the NAC and the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the first substrate monolith has a length extending between an inlet end and an outlet end thereof, wherein the NAC is located in a first zone of substantially uniform length defined at an upstream end by the inlet end of the first substrate monolith and at an downstream end by a point more than one half way along the first substrate monolith measured length from the inlet end and the compound effective to remove and/or convert at least some hydrogen sulfide is located in a second zone of substantially uniform length defined at an upstream end by the NAC and at a downstream end by the outlet end of the first substrate monolith.
  • the filter substrate comprises the compound effective to remove and/or convert at least some hydrogen sulfide.
  • the compound can be coated throughout the entire length of the filter substrate, in a zone defined at an upstream end by an inlet end of the filter substrate, in a zone defined at a downstream end by an outlet end of the filter substrate or in a zone at any position between the inlet end and the outlet end of the filter substrate defined neither by the inlet end itself nor the outlet end itself.
  • the filter substrate has a length extending from an inlet end to an outlet end thereof, and the compound effective to remove and/or convert at least some hydrogen sulfide is located in a fifth zone of substantially uniform length defined at an upstream end by the inlet end itself and at a downstream end by a point up to one half way along the filter substrate length measured from the inlet end.
  • the filter substrate has a length extending from an inlet end to an outlet end thereof, wherein the compound effective to remove and/or convert at least some hydrogen sulfide is located in a zone of substantially uniform length defined at an upstream end by a point more than one half way along the filter substrate length measured from the inlet end and defined at a downstream end by the outlet end of the filter substrate itself.
  • a fourth substrate monolith comprising the compound effective to remove and/or convert at least some hydrogen sulfide may be disposed downstream of the filter substrate.
  • the compound effective to remove and/or convert at least some hydrogen sulfide can be located at one of the following positions in the exhaust system:
  • the exhaust system can comprise an oxidation catalyst disposed between the engine and the NAC.
  • the oxidation catalyst can oxidize unburned hydrocarbons and soluble organic fraction hydrocarbons adsorbed on diesel soot particles and carbon monoxide in the exhaust gas.
  • the composition of such oxidation catalysts is well known in the art and includes, for example, U.S. Pat. No. 5,491,120 (the entire contents of which are incorporated herein by reference).
  • the oxidation catalyst can also be formulated to oxidize nitrogen oxide in addition to oxidizing HCs and CO.
  • DOCs are coated on a flow-through monolith substrate, but they may also be coated on a diesel particulate filter to form a catalysed soot filter (CSF).
  • the oxidation catalyst can oxidise NO to NO 2 and particulate matter trapped on the filter substrate can be oxidised in NO 2 , as described in WO 01/12320.
  • the oxidation catalyst can be located on a separate substrate monolith disposed between the engine and the first substrate monolith.
  • the oxidation catalyst can be located in a sixth zone of substantially uniform length defined at an upstream end by the inlet end of the first substrate monolith and at a downstream end by the NAC, i.e. a zone comprising the NAC may be defined at an upstream end by the downstream end of the zone comprising the oxidation catalyst.
  • a zone comprising the NAC may be defined at an upstream end by the downstream end of the zone comprising the oxidation catalyst.
  • the compound effective to remove and/or convert at least some hydrogen sulfide is located in a seventh zone of substantially uniform length defined at an upstream end by a point more than one half way along the first substrate monolith length or the filter substrate length measured from the inlet end and defined at a downstream end by the outlet end of the first substrate monolith or the filter substrate itself.
  • the means for enriching the exhaust gas can comprise an engine management unit configured intermittently to cause the engine to emit an enriched exhaust gas. Alternatively, or additionally, it can comprise an injector for injecting a reductant into a flowing exhaust gas carried by the exhaust system downstream of the engine. Alternatively or additionally, the exhaust gas can be enriched with hydrogen and carbon monoxide formed e.g. by feeding engine fuel and a portion of exhaust gas into a reformer catalyst and then feeding the resulting mixture back into the exhaust gas upstream of the NAC. Catalysts suitable for this reaction are known as reforming catalysts, illustrative examples of which include catalysts based on platinum group metals (PGMs) and nickel (Ni). For further details, reference can be made to D. L. Trimm and Z. I. Onsan in Catalysis Reviews—Science and Engineering, vol. 43 (2001) pp 31-84 (the entire contents of which is incorporated herein by reference).
  • PGMs platinum group metals
  • Ni nickel
  • suitable reforming catalysts with utility include up to 2 wt% , e.g. 1 wt %, rhodium dispersed on a refractory oxide support material which comprises cations of cerium and zirconium—see for example our WO 99/48805, the entire contents of which is included herein by reference.
  • a refractory oxide support material which comprises cations of cerium and zirconium—see for example our WO 99/48805, the entire contents of which is included herein by reference.
  • other catalysts include low loadings of Pt (up to 0.5 wt%, e.g. 0.1 wt %) and Rh-Pt comprising up to 2 wt % Rh (e.g.
  • Rh, Pt, Rh—Pt and Ni include alumina, titania, ceria, zirconia, silica, silica-alumina and mixtures and mixed oxides containing any two or more thereof.
  • the hydrogen sulfide removing and/or adsorbing compound can be any material capable of storing and/or converting hydrogen sulfide under rich conditions.
  • the hydrogen sulfide removing and/or converting compound is selected from the group consisting of NiO, CaO, Fe 2 O 3 and BaO.
  • reaction (5) The adsorption of H 2 S in a hydrogen sulfide removing and/or converting compound is illustrated in reaction (5) and the desorption in lean conditions is illustrated in reaction (6):
  • the hydrogen sulfide removing and/or converting compound may coexist with platinum group metal oxidation catalyst components, e.g. platinum and/or palladium, of the NAC and/or the CSF, the preferred compound, NiO, can poison the hydrocarbon and carbon monoxide activity of the PGM catalyst. Hence, it is desirable to segregate such hydrogen sulfide removing and/or converting compound by locating the materials in separate discreet zones or substrates.
  • platinum group metal oxidation catalyst components e.g. platinum and/or palladium
  • the enriching means can comprise means for controlling a temperature of the NAC during enrichment to remove sulfate from the NAC.
  • the temperature controlling means comprises means for intermittently adjusting the exhaust gas composition to the lean side (lambda>1) during exhaust gas enrichment to remove sulfate adsorbed on the NAC.
  • Such means for intermittently adjusting the exhaust gas composition to the lean side (lambda>1) can control: an engine air-to-fuel ratio; an injector for injecting air into exhaust gas downstream of the engine; and/or supply of diesel fuel and exhaust gas to a reforming catalyst.
  • sulfur stored on the hydrogen sulfide removing and/or converting compound is released as sulfur dioxide, which can be emitted to atmosphere as such, particularly where the hydrogen sulfide removing and/or converting compound is located on the downstream end of the CSF or on a separate substrate monolith disposed downstream of the CSF.
  • Sulfur dioxide released upstream of the CSF can be oxidised to sulfur trioxide on the CSF catalyst, which sulfur trioxide when combined with water (steam) in the exhaust gas can form fine particles of sulfuric acid that can contribute to total particulates detected in a test cycle for meeting a relevant emission standard.
  • contacting the NAC with a rich exhaust gas composition followed by a lean exhaust gas can be accomplished in a cyclical fashion or a non-cyclical manner, e.g. controlled by negative feedback so that the NAC is maintained within a desired temperature window to effect optimum desulfation whilst limiting any hydrothermal deactivation of the NAC itself.
  • the lean burn internal combustion engine can be a diesel engine such as a light-duty diesel engine or a heavy duty diesel engine, as defined by relevant legislation. However, it may also be a gasoline lean burn engine, as desired.
  • the invention provides a vehicle comprising an apparatus according to the invention.
  • the invention provides a method of desulfating a NO x adsorber catalyst (NAC) in an exhaust system of a lean burn internal combustion engine comprising a first substrate monolith comprising a NO x adsorber catalyst (NAC); and a catalysed soot filter (CSF) comprising a filter substrate, which method comprising:
  • the method comprises the step of releasing sulfur dioxide from the compound effective to remove and/or convert at least some hydrogen sulfide from the rich exhaust gas by intermittently contacting said compound with a lean exhaust gas during step (i).
  • FIG. 1 is schematic diagram showing a first embodiment of an apparatus according to the invention
  • FIG. 2 is a schematic diagram showing a second embodiment of an apparatus according to the invention.
  • FIG. 3 is a graph showing H 2 S and SO 2 detected downstream during a rich/lean cycle regime over a 33% NiO/Al 2 O 3 cordierite catalyst powder sample tested in a synthetic catalyst activity test (SCAT) apparatus.
  • SCAT synthetic catalyst activity test
  • FIG. 1 shows an apparatus 10 comprising a fuel injected turbo diesel engine 12 and an exhaust system 14 comprising a diesel oxidation catalyst (DOC) 16 located downstream of the turbo (turbo not shown) followed in turn in the flow direction (indicated by arrows) by a NO x adsorber catalyst ((NAC) 18 , and a catalysed soot filter (CSF), 20 , wherein the filter substrate is a partial filter as described in EP 1276549.
  • a washcoat comprising nickel (under rich conditions, the nickel may be present as nickel metal and possibly the carbonate under lean running conditions. Therefore, by “comprising nickel” we mean a nickel compound) for adsorbing hydrogen sulfide in rich exhaust gas.
  • Each of the DOC and NAC are coated on a flow-through ceramic substrate monolith.
  • engine control unit 24 comprising a microprocessor controls the engine's fuel injection regime intermittently (e.g. 2-3 minutes) to enrich the exhaust gas in the exhaust system momentarily (e.g. up to a few seconds) during normal lean running operation when it is determined that the capacity of NAC 18 to adsorb NO x is reduced and requires regeneration.
  • the engine control unit instigates a desulfation regime, e.g. of up to 10 minutes duration, wherein the engine fuel injection is controlled to make the exhaust gas rich (lambda ⁇ 1).
  • a desulfation regime e.g. of up to 10 minutes duration
  • lean exhaust gas composition is controlled during the desulfation regime to return briefly to the lean side (lambda>1).
  • lean exhaust gas composition is obtained by controlling the engine air-to-fuel ratio by means of engine control unit 24 .
  • lean exhaust gas can also be obtained by providing an injector for injecting air into the exhaust gas downstream of the engine controlled by engine control unit 24 .
  • FIG. 2 shows an alternative embodiment of an apparatus according to the invention, wherein like numbered components refer to identical components as disclosed in connection with FIG. 1 .
  • Apparatus 30 comprises exhaust system 32 , wherein 34 is a flow-through ceramic substrate monolith coated from an inlet end to less than half way of the entire length “L” thereof with an oxidation catalyst composition in zone 36 and with a NAC composition in a zone 38 defined at an upstream end by zone 36 and at a downstream end by an outlet end of the monolith substrate.
  • Downstream of substrate monolith 34 is a separate, relatively short flow-through substrate monolith 40 coated with a calcium oxide-based hydrogen sulfide adsorber composition.
  • Downstream of substrate monolith 40 is a CSF comprising a ceramic wall-flow filter substrate.
  • Reference numeral 44 refers to a fuel injector arranged to inject a supply of hydrocarbon reductant from reservoir 46 into exhaust gas flowing in the exhaust system 30 between engine 12 and substrate monolith 34 .
  • Flow of reductant to an injector nozzle is controlled by actuator 48 , which is in turn controlled by engine control unit 24 .
  • Air injector 28 is provided to inject air into exhaust gas flowing in the exhaust system 30 between substrate monolith 34 and the hydrogen sulfide adsorber-coated monolith substrate 40 .
  • Air injection is actuated by air pump 52 , which is controlled by the engine control unit 24 .
  • FIG. 2 The use of the embodiment shown in FIG. 2 is very similar to that described hereinabove in relation to the first embodiment (shown in FIG. 1 ) except in that exhaust gas enrichment for the purposes of NAC regeneration and NAC desulfation is done using fuel injector 44 and the redox composition of the exhaust gas for preventing the NAC overheating and for regenerating the hydrogen sulfide adsorber is done by controlling the interaction of actuator 48 and air pump 52 and thereby the ingress of reducing components and air into the exhaust gas. No further specific description is deemed necessary.
  • FIG. 3 shows the detected SO 2 and H 2 5 content of gas downstream of the catalyst over a repeat cycle at 450° C.
US13/263,652 2006-12-21 2007-12-21 Apparatus comprising lean burn ic engine and an exhaust system therefor Abandoned US20120233985A1 (en)

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RU2455503C2 (ru) 2012-07-10

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