US20140250865A1 - Exhaust gas aftertreatment bypass system and methods - Google Patents

Exhaust gas aftertreatment bypass system and methods Download PDF

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Publication number
US20140250865A1
US20140250865A1 US13/789,345 US201313789345A US2014250865A1 US 20140250865 A1 US20140250865 A1 US 20140250865A1 US 201313789345 A US201313789345 A US 201313789345A US 2014250865 A1 US2014250865 A1 US 2014250865A1
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Prior art keywords
component
exhaust
internal combustion
operating condition
exhaust gasses
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US13/789,345
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English (en)
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Gregory Bentley
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Cummins Intellectual Property Inc
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Cummins Intellectual Property Inc
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Priority to US13/789,345 priority Critical patent/US20140250865A1/en
Assigned to CUMMINS IP, INC. reassignment CUMMINS IP, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BENTLEY, GREGORY
Priority to DE112014001142.8T priority patent/DE112014001142T5/de
Priority to GB1515728.2A priority patent/GB2525813B/en
Priority to PCT/US2014/014538 priority patent/WO2014137518A1/fr
Publication of US20140250865A1 publication Critical patent/US20140250865A1/en
Priority to US14/602,748 priority patent/US20150128571A1/en
Priority to US15/241,560 priority patent/US9964013B2/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
    • F01N3/18—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]
    • F01N3/208—Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
    • 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
    • F01N9/00—Electrical control of exhaust gas treating apparatus
    • 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
    • F01N3/2053—By-passing catalytic reactors, e.g. to prevent overheating
    • 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
    • F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
    • F01N11/002—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus
    • 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
    • F01N13/011—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 purifying devices arranged in parallel
    • F01N13/017—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 purifying devices arranged in parallel 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
    • F01N3/10—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
    • F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other 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
    • F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
    • F01N2410/02—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device in case of high temperature, e.g. overheating of catalytic 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
    • F01N2550/00—Monitoring or diagnosing the deterioration of exhaust systems
    • F01N2550/02—Catalytic activity of catalytic converters
    • 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
    • F01N2550/00—Monitoring or diagnosing the deterioration of exhaust systems
    • F01N2550/06—By-pass systems
    • F01N2550/10—By-pass systems of catalytic converters
    • 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
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/08—Parameters used for exhaust control or diagnosing said parameters being related to the engine
    • 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
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/14—Parameters used for exhaust control or diagnosing said parameters being related to the exhaust gas
    • F01N2900/1404—Exhaust gas temperature
    • 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

  • This disclosure relates generally to exhaust aftertreatment systems for internal combustion engines, and more particularly to a bypass system and method for protecting exhaust aftertreatment devices from harmful environmental or operating conditions.
  • Exhaust aftertreatment systems include components used to process exhaust gasses produced by an internal combustion engine for the purpose of reducing harmful exhaust emissions.
  • Some aftertreatment system components such as diesel oxidation catalysts (DOC) and selective catalytic reduction (SCR) catalysts, use catalytic materials to chemically convert potentially harmful exhaust emissions into other less harmful emission products.
  • DOC diesel oxidation catalysts
  • SCR selective catalytic reduction
  • Such catalyst-based exhaust aftertreatment system components are desirable for their ability to efficiently control emissions.
  • some catalyst-based exhaust aftertreatment system components are also susceptible to damage from adverse operational and environmental conditions
  • catalyst-based exhaust aftertreatment system components Another potential hazard to catalyst-based exhaust aftertreatment system components is the use of high sulfur-content fuels.
  • Many of the catalysts used in exhaust aftertreatment systems include catalytic materials capable of oxidizing sulfur. Consequently, due to sulfur poisoning, fuels having high sulfur content can overwhelm and deactivate a catalyst configured to oxidize other emissions components.
  • Engine failures are yet another hazard to the components of exhaust aftertreatment systems.
  • a bearing seal failure might release oil into the exhaust line that could damage the components of an exhaust aftertreatment system.
  • the subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems and needs in exhaust aftertreatment art that have not yet been fully solved by currently available exhaust aftertreatment systems.
  • the inventors of the subject matter of the present application have recognized that, given the high costs of exhaust aftertreatment systems, it would be advantageous to have a bypass system that would protect the aftertreatment components from operational and environmental hazards that might cause damage to the components.
  • a control system and methodology for bypassing one or more components of an exhaust aftertreatment system would extend the service life of the components when operational or environmental hazards threaten the components.
  • the subject matter of the present application has been developed to provide a method for protecting an exhaust aftertreatment system of an internal combustion engine from deterioration by selectively diverting exhaust gasses from the engine away from a component of the exhaust aftertreatment system.
  • the method includes assessing a status of an operating condition associated with a physical condition of the component of the internal combustion engine.
  • the status of the operating condition is compared with a threshold value that corresponds with deterioration of the physical condition of the component.
  • a valve upstream of the component is moved to a first position to open a bypass fluid path directing exhaust gasses around the component when the status of the operating condition meets the threshold value to reduce deterioration of the component.
  • the valve is moved to a second position to close the bypass fluid path thereby directing exhaust gasses to the component when the status of the operating condition does not meet the threshold value.
  • assessing the status of the operating condition includes assessing a temperature of the exhaust gasses and comparing the temperature to a lower temperature threshold value below which the exhaust gasses include a predetermined level of unburned hydrocarbons.
  • assessing the status of the operating condition includes assessing a temperature of the exhaust gasses and comparing the temperature to an upper temperature threshold value above which the component degrades and produces harmful byproducts, such as pentoxide.
  • assessing the status of the operating condition includes assessing a geographical location of the internal combustion engine and comparing the geographical location to a threshold value includes comparing the geographical location of the engine to geographical locations that do not require emissions controls for internal combustion engines
  • assessing the status of the operating condition includes assessing a chemical formulation of fuel used by the internal combustion engine and comparing fuel chemistry to a threshold value includes comparing the fuel chemistry to chemicals that deteriorate the component, such as sulfur.
  • the step of moving the valve to the first position based on the threshold comparison can also be overridden by a user by manually moving the valve to the second position to close the first fluid path and open the second fluid path to bypass the exhaust aftertreatment device.
  • the subject matter of the present application has been developed to provide an apparatus for bypassing an exhaust aftertreatment device of an internal combustion engine to protect a selective catalytic reducer or reduction (SCR) component of the exhaust aftertreatment device from deterioration.
  • the apparatus includes a flow control valve operable to open and close a bypass fluid path wherein exhaust gasses from the engine bypass the exhaust after treatment device when the valve is in the open position and the exhaust gasses flow through the exhaust aftertreatment device when the valve is in the closed position.
  • a sampling module samples an operating condition of the internal combustion engine that is associated with a physical condition of the SCR component.
  • a comparison module compares the operating condition with a threshold value that corresponds with deterioration of the physical condition of the SCR component.
  • a control module operates the flow control valve to open the bypass fluid path if the operating condition does not meet the threshold condition and to close the bypass fluid path if the operating condition meets the threshold condition.
  • a user interface is associated with the control module.
  • the user interface is configured to accept user input to override the control module control of the flow control valve and manually open the valve to the bypass fluid path to bypass the exhaust aftertreatment device.
  • the engine includes an exhaust aftertreatment system including a SCR component in exhaust receiving communication with the internal combustion engine.
  • a bypass system is operatively associated with the exhaust aftertreatment system and operates to bypass the SCR component when an operating condition of the internal combustion engine that corresponds with deterioration of a physical condition of the SCR component is detected.
  • the bypass system includes a flow control valve operable to open and close a bypass fluid path with exhaust gasses from the engine bypassing the exhaust after treatment device when the valve is in the open position and the exhaust gasses flow through the exhaust aftertreatment device when the valve is in the closed position.
  • the bypass system also includes a controller that determines whether the flow control valve is open to the bypass fluid path by sampling the operating condition of the internal combustion engine that is associated with the physical condition of the SCR component. The controller compares the sampling of the operating condition with a threshold value that corresponds with deterioration of the physical condition of the SCR component.
  • FIG. 1 is schematic representation of an internal combustion engine according to one embodiment of the present invention shown with an exhaust aftertreatment bypass system coupled to an exhaust system of the engine;
  • FIG. 2 is a schematic representation of an exhaust aftertreatment bypass system according to one embodiment of the present application, shown with a flow control valve directing flow into a first fluid flow pathway;
  • FIG. 3 is a schematic representation of the bypass system of FIG. 1 shown with the flow control valve directing flow into a second fluid flow pathway;
  • FIG. 4 is a schematic block diagram of a controller of the engine system of FIG. 1 in accordance with one representative embodiment
  • FIG. 5 is a schematic representation of an exhaust aftertreatment bypass system according to another embodiment shown with a flow control valve directing flow into a first fluid flow pathway;
  • FIG. 6 is a schematic representation of the bypass system of FIG. 3 shown with the flow control valve directing flow into a second fluid flow pathway;
  • FIG. 7 is a schematic representation of an exhaust aftertreatment bypass system according to another embodiment shown with a flow control valve directing flow into a first fluid flow pathway;
  • FIG. 8 is a schematic representation of the bypass device of FIG. 5 shown with the flow control valve directing flow to a second fluid flow pathway;
  • FIG. 9 is a flow chart of a method for protecting an exhaust aftertreatment device of an internal combustion engine system using a bypass device in accordance with another embodiment of the present application.
  • an internal combustion engine 10 is shown with a bypass system 100 operatively associated with an exhaust aftertreatment system 20 that is in exhaust receiving communication with an exhaust manifold 12 of the internal combustion engine.
  • the bypass system 100 is configured to protect an exhaust aftertreatment component 22 from potentially harmful operational and environmental conditions.
  • the bypass system 100 forms part of the exhaust aftertreatment system 20 , which is configured to reduce harmful emissions in exhaust gasses generated by the internal combustion engine 10 .
  • the exhaust aftertreatment system 20 includes one or more components (e.g., the exhaust aftertreatment component 22 ) configured to treat the exhaust gas in a particular way.
  • the exhaust aftertreatment system 20 also includes a main exhaust line 24 that provides exhaust gas to the one or more components prior to being treated and directs exhaust gas away from the one or more components after being treated. Accordingly, the main exhaust line 24 includes an upstream section 26 (e.g., upstream of the components) and a downstream section 28 (e.g., downstream of the components).
  • the components 22 that treat the exhaust gas include a catalyst based treatment device that has a finite useful life based on a catalytic chemical reaction with the exhaust gasses that remove undesirable emissions from the exhaust gasses.
  • a catalyst based treatment device that has a finite useful life based on a catalytic chemical reaction with the exhaust gasses that remove undesirable emissions from the exhaust gasses.
  • the more exposure the component 22 has to exhaust gasses the more the component will deteriorate and the shorter the component's useful life will be. For this reason, it is desirable to control exposure of the catalyst component 22 to the exhaust gasses to maximize the useful life of the component.
  • the component 22 can include a selective catalytic reducer (SCR), a selective catalytic reducer coated filter, a diesel oxidation catalyst (DOC), a diesel particulate filter (DPF) with a selective catalytic reducer, and the like.
  • SCR selective catalytic reducer
  • DOC diesel oxidation catalyst
  • DPF diesel particulate filter
  • the bypass system 100 includes a bypass line 110 with an inlet 112 fluidly coupleable to the upstream section 26 of the main exhaust line 24 and an outlet 114 fluidly coupleable to the downstream section 28 of the main exhaust line.
  • the bypass system 100 also includes a flow control valve 120 that is operable to divert exhaust gas flow around the exhaust aftertreatment component 22 via the bypass line 110 .
  • the bypass system 100 is shown with the flow control valve 120 disposed in the upstream section 26 of the main exhaust line 24 proximate the inlet 112 to the bypass line 110 .
  • the flow control valve 120 is actuatable between at least first and second positions. As shown in FIG. 2 , in the first position (e.g., closed position), the flow control valve 120 defines a first fluid pathway extending from the upstream section 26 of the main exhaust line 24 , through the flow control valve 120 , and into the aftertreatment component 22 . In other words, the flow control valve 120 in the closed position fluidly couples the upstream section 26 of the main exhaust line 24 with the aftertreatment component 22 such that exhaust gas, indicated by directional arrow 32 , flows from the upstream section 26 into the aftertreatment component 22 .
  • the flow control valve 120 in the second position (e.g., open position), at least partially blocks the first fluid pathway 32 to the aftertreatment component 22 and defines a second fluid pathway extending from the upstream section 26 of the main exhaust line 24 , through the flow control valve 120 , around the aftertreatment component 22 , and into the downstream section 28 of the main exhaust line.
  • the flow control valve 120 in the open position fluidly couples the upstream section 26 with the downstream section 28 while bypassing the component 22 such that exhaust gas, indicated by directional arrow 34 , flows from the upstream section 26 directly into the downstream section 28 .
  • the downstream section 28 of the main exhaust line may be coupled to a tailpipe of the aftertreatment system.
  • the flow control valve 120 can be a gate valve 122 , a ball valve, a check valve a globe valve, a butterfly valve or other similar type valve configured to direct the flow of gas based fluids as known in the art. Additionally, the flow control valve 120 can have an actuator 124 that can move the valve between the first position and the second position. The actuator 124 can receive power from an electronic, pneumatic, or vacuum source.
  • a controller 130 may be designed to provide a performance status to an on-board diagnostic system 150 , or OBD 150 .
  • the OBD 150 may convey the status to a user such as a driver of the vehicle containing the engine system 10 ( FIG. 1 ), for example, with a light or LED, an auditory signal or alarm, an analog gauge, a digital readout, or the like.
  • the controller 130 is in electronic communication with the flow control valve 120 to control movement of the flow control valve 120 between the first position and the second position.
  • the controller 130 may include various modules for controlling the operation of the exhaust aftertreatment system 20 .
  • the controller 130 may include one or more modules for controlling the operation of the bypass system 100 .
  • the controller 130 includes a sampling module 132 , a comparison module 134 , and a control module 136 .
  • the control module 136 may control the ordinary operation of the bypass system 100 and the more particularly the flow control valve 120 by providing instruction to move the valve to either the first position (e.g., closed position) 138 or the second position (e.g., open position) 140 .
  • the sampling module 132 may, at desired times, sample an operating condition of the internal combustion engine and the aftertreatment component 22 that is associated with a physical condition of the component 22 .
  • the sampling module can be a physical sensor 52 ( FIGS. 2 and 3 ), such as a thermocouple, a virtual sensor, and the like.
  • the sampling module 132 sends data regarding the sampled condition to the comparison module 134 for analysis.
  • the comparison module 134 may include a processor with logic and instructions for comparing data from the sampling module 132 with a threshold value of the operating condition being sampled. When the data from the sampling module 132 exceeds the threshold value, the comparison module 134 informs the control module 136 which sends instructions 140 to the bypass system 100 to move the valve 120 to the second position to bypass the aftertreatment component 22 . When the data from the sampling module 132 meets the threshold value, the comparison module 134 informs the control module 136 which sends instructions 138 to the bypass system 100 to move the flow control valve 120 to the first position to allow the exhaust gasses to flow through the aftertreatment component 22 .
  • the controller 130 and its various modular components may comprise processor, memory, and interface modules that may be fabricated of semiconductor gates on one or more semiconductor substrates. Each semiconductor substrate may be packaged in one or more semiconductor devices mounted on circuit cards. Connections between the modules may be through semiconductor metal layers, substrate-to-substrate wiring, or circuit card traces or wires connecting the semiconductor devices.
  • the controller 130 can include additional modules for conducting other control system functions.
  • the controller can include a calculation module 142 and a reporting module 144 .
  • the reporting module 144 can report the performance status of the various modules in the controller 130 to a user via an output device 146 .
  • the sampling module 132 can receive data from multiple sources such as additional sensors 148 that sample other operating conditions of the internal combustion engine that can have a deteriorating effect on the aftertreatment component 22 .
  • the additional sensors 148 can sample an upper temperature of the exhaust gasses, a lower temperature of the exhaust gasses, a sulfur content of the fuel and exhaust gasses, and a global positioning sensor (GPS) location of the engine during operation as described below.
  • GPS global positioning sensor
  • sensors located throughout the engine can be used to detect engine performance problems that may adversely affect the SCR device, such as a bearing seal failure that releases engine oil into the exhaust system and the aftertreatment system.
  • the controller can receive data from the engine sensors and turn the exhaust stream to the bypass pathway in order to prevent damage to the catalyst due to the engine performance problems.
  • the physical properties of the exhaust gasses can have a deteriorating effect on the exhaust aftertreatment component 22 that can shorten the service life of the aftertreatment component.
  • temperature of the exhaust gasses can result in undesirable and even dangerous operating conditions for the SCR. If the temperature of the exhaust gasses is too high, the catalyst in the SCR device can produce undesirable oxides, such as pentoxide from a vanadia based catalyst, which are produced at an unacceptable rate at temperatures of around 550 degrees C. Moreover, if the temperature exceeds an even higher threshold, a vanadia based catalyst may be rendered useless.
  • Other materials used as catalysts in SCR devices, as known in the art may also degrade, produce harmful byproducts, or be rendered useless at relatively high temperatures.
  • the controller 132 includes a sensor 52 , real or virtual, that samples an upper temperature of the exhaust gasses and a sampling module 132 that receives the sensor data.
  • the sampling module 132 sends the sampled temperature data to the comparison module 134 where the data is compared to a high temperature threshold.
  • the high temperature threshold is set at a temperature that is below the temperature (e.g., 550 degrees C.) at which harmful byproducts, such as pentoxides, may be produced at an unacceptable rate.
  • the high temperature threshold is set at a temperature that is below the temperature at which the catalyst is rendered useless by overheating.
  • the comparison module 134 sends the comparison results to the control module 136 to move the flow control valve 120 to the second position to bypass the exhaust aftertreatment device 20 if the temperature exceeds the high temperature threshold, thereby protecting the aftertreatment component 22 from an undesirable production of harmful byproducts, such as pentoxides, or damage from heat that may render the catalyst useless.
  • the exhaust gasses may contain an unacceptably high amount of unburned hydrocarbons.
  • Large quantities of unburned hydrocarbons can overwhelm the catalyst such that the catalyst leaves residual unburned hydrocarbons in the exhaust aftertreatment device 20 .
  • Unburned hydrocarbons affect the efficiency of the catalyst and can create an undesirable thermal event if enough accumulate within the aftertreatment device 20 . Therefore, a high unburned hydrocarbon rate in the exhaust gas can result in a high unburned hydrocarbon adsorption rate on the aftertreatment device 20 .
  • the unburned hydrocarbon production rate may be, but is not necessarily, equal to or proportional to the unburned hydrocarbon device adsorption rate. Accordingly, in some implementations, the sensed or estimated rate of accumulation or adsorption of unburned hydrocarbons on the device 20 relative to a threshold can be another factor controlling the operation of the exhaust bypass valve.
  • the controller 130 includes a virtual or physical sensor 52 to detect a low temperature of the exhaust gasses which would indicate the presence of unburned hydrocarbons, a virtual or physical sensor that samples for unburned hydrocarbon, a virtual or physical sensor that samples for both low temperature and for unburned hydrocarbons, or a virtual or physical that determines an accumulation or adsorption rate of unburned hydrocarbons on a catalyst or other aftertreatment device.
  • the controller also includes a sampling module 132 that receives the data from the sensor. The sampling module 132 sends the sampled temperature or unburned hydrocarbon data to the comparison module 134 where the data is compared to a low temperature threshold or an unburned hydrocarbon threshold respectively.
  • the low temperature threshold is set at temperature at which hydrocarbons are known to accumulate in the exhaust aftertreatment devices at an unacceptable rate.
  • the unburned hydrocarbon threshold is set at a level at which unburned hydrocarbons are known to interfere with the catalyst material in the SCR.
  • the comparison module 134 sends the comparison results to the control module 136 to move the flow control valve 120 to the second position to bypass the exhaust aftertreatment device 20 if the temperature falls below the low temperature threshold or the unburned hydrocarbon rate exceeds the unburned hydrocarbon threshold level, thereby protecting the aftertreatment component 22 from an undesirable buildup of unburned hydrocarbons.
  • Another physical property of the exhaust gasses that can have a deteriorating effect on the exhaust aftertreatment component 22 is the presence of sulfur in the exhaust gasses.
  • Some petroleum based fuels have a high sulfur content.
  • exhaust from high sulfur content fuels is also high in sulfur.
  • Sulfur is also oxidized by catalyst based exhaust aftertreatment devices and can overwhelm the catalyst causing “sulfur poisoning” of the catalyst wherein the catalyst is rendered useless.
  • the controller 130 includes a sensor 148 that samples the sulfur content of the exhaust gasses or the fuel and a sampling module 132 that receives the sensor data.
  • the sampling module 132 sends the sampled sulfur content data to the comparison module 134 where the data is compared to a sulfur content threshold value.
  • the comparison module 134 sends the comparison results to the control module 136 to move the flow control valve 120 to the second position to bypass the exhaust aftertreatment device 20 if the sulfur content is above the sulfur content threshold, thereby protecting the aftertreatment component 22 from an undesirable buildup of sulfur within the aftertreatment device.
  • Yet another operating parameter that can have a deteriorating effect on the exhaust aftertreatment component 22 is operation of the exhaust aftertreatment device when control of emissions is not needed. For example, some geographical areas of the world do not have emissions regulations and being able to bypass the exhaust aftertreatment device 20 when traveling in these areas can extend the service life of the aftertreatment device.
  • the controller 130 includes a sensor 148 that samples the geographic location of the internal combustion engine from a global positioning sensor (GPS).
  • the sampling module 132 sends the GPS data to the comparison module 134 where the data is compared to a GPS threshold value.
  • the comparison module 134 sends the comparison results to the control module 136 to move the flow control valve 120 . If the GPS location is found within a geographical area that requires exhaust emission controls, then the control module 136 sends a signal to the actuator 124 to move or maintain the flow control valve 120 in the first position opening the first fluid path 32 which directs flow through the after treatment device 20 . If the GPS location is in a geographical area that does not require exhaust emissions control, the control module 136 sends a signal to move the flow control valve 120 to the second position directing flow to the second flow path that bypasses the exhaust aftertreatment device 20 .
  • GPS global positioning sensor
  • the flow control valve 120 can also be manually opened or closed thereby overriding the controller 130 .
  • the actuator 124 on the flow control valve can be manually adjusted to override the controller 130 and move the flow control valve 120 between the first position and the second position.
  • the controller 130 can receive input data directly from a user through a user interface 56 ( FIGS. 2 and 3 ).
  • the user interface 56 can be a physical interface, such as a keypad, or a virtual interface, as known in the art. Through the user interface 56 , the user can override the controller 130 and direct the controller 130 to move the flow control valve 120 to the first or second position as desired.
  • the bypass system 100 described herein provides a bypass pathway 110 that can be selectively opened or closed by the user in order to protect and preserve the life of the exhaust aftertreatment component 22 .
  • a bypass system indicated generally at 300 , is shown in accordance with another embodiment for use in protecting an exhaust aftertreatment system 220 that is in exhaust receiving communication with an exhaust manifold of an internal combustion engine (not shown).
  • the bypass system is similar in many respects to the bypass system 100 described above and shown in FIGS. 1-4 .
  • the bypass system 300 is configured to protect the exhaust aftertreatment component 22 from potentially harmful operational and environmental conditions.
  • the bypass system 300 forms part of the exhaust aftertreatment system 220 .
  • the exhaust aftertreatment system 220 includes one or more components (e.g. the exhaust aftertreatment component 22 ) configured to treat the exhaust gas in a particular way.
  • the components 22 that treat the exhaust gas include a catalyst based treatment device, such as an SCR, SCR coated filter, and the like, that have a finite useful life based on a catalytic chemical reaction with the exhaust gasses that remove undesirable emissions from the exhaust gasses.
  • the bypass system 300 includes a housing 302 with an inlet 304 and an outlet 306 .
  • the aftertreatment component 22 is disposed within the housing 302 and is configured to receive exhaust gasses from the inlet 304 and to direct treated gasses to the outlet 306 .
  • a partition 308 is disposed within the housing 302 and separates the housing into an inlet side 310 and an outlet side 312 .
  • the partition 308 restricts flow from the inlet side 310 to the outlet side 312 such that flow of exhaust gasses passes through the aftertreatment component 22 and to the outlet 306 .
  • a flow control valve 320 is disposed in the housing 302 adjacent the inlet 304 upstream from the aftertreatment component 22 .
  • the flow control valve 320 is actuatable between at least first and second positions. As shown in FIG. 5 , in the first position (e.g. closed position) the flow control valve 320 defines a first fluid pathway extending from the inlet, through the flow control valve and into the aftertreatment component 22 . In other words, when the flow control valve 320 is in the closed position, exhaust gasses, indicated by directional arrow 332 , flow through the valve 320 to the inlet side 310 of the housing 302 , and into the aftertreatment component 22 .
  • the flow control valve 320 in the second position (e.g. open position) at least partially blocks the first fluid pathway 332 to the aftertreatment component 22 and defines a second fluid pathway extending from the inlet side 304 of the housing 302 , around the aftertreatment component 22 , and into the outlet side 306 of the housing 302 .
  • the flow control valve 320 in the open position fluidly couples the inlet side 304 of the housing 302 with the outlet side 306 of the housing 302 while bypassing the component 22 such that exhaust gas, indicated by directional arrow 334 , flows through the housing 302 without flowing through the aftertreatment component 22 .
  • the bypass system 300 also includes the controller 130 described above and shown in detail in FIG. 4 .
  • the controller 130 is electronically coupled to the flow control valve 320 to control movement of the flow control valve 320 between the first position and the second position. In the embodiment shown in FIGS. 5 and 6 , the controller sends a signal to the actuator 124 to move the flow control valve 320 to the desired position.
  • a bypass system indicated generally at 500 , is shown in accordance with another embodiment for use in protecting an exhaust aftertreatment system 220 that is in exhaust receiving communication with an exhaust manifold of an internal combustion engine (not shown).
  • the bypass system is similar in many respects to the bypass systems 100 and 300 described above and shown in FIGS. 1-6 .
  • the bypass system 500 is configured to protect the exhaust aftertreatment component 22 from potentially harmful operational and environmental conditions.
  • the bypass system 500 forms part of the exhaust aftertreatment system 220 .
  • the exhaust aftertreatment system 220 includes one or more components (e.g. the exhaust aftertreatment component 22 ) configured to treat the exhaust gas in a particular way.
  • the components 22 that treat the exhaust gas include a catalyst based treatment device, such as an SCR, SCR coated filter, and the like, that have a finite useful life based on a catalytic chemical reaction with the exhaust gasses that remove undesirable emissions from the exhaust gasses.
  • the bypass system 500 includes a housing 502 with an inlet 504 , a bypass outlet 506 and an aftertreatment outlet 508 .
  • the aftertreatment component 22 is disposed within the housing 502 and is configured to receive exhaust gasses from the inlet 504 and to direct treated gasses to the aftertreatment outlet 508 .
  • a partition 510 is disposed within the housing 502 and separates the housing into an inlet side 512 and an outlet side 514 .
  • the partition 510 restricts flow from the inlet side 512 to the outlet side 514 such that flow of exhaust gasses passes through the aftertreatment component 22 to the aftertreatment outlet 508 when the bypass outlet 506 is closed by the flow control valve 520 .
  • the flow control valve 520 is disposed in the housing 502 adjacent the bypass outlet 506 upstream from the aftertreatment component 22 .
  • the flow control valve 520 is actuatable between at least first and second positions. As shown in FIG. 7 , in the first position (e.g. closed position) the flow control valve 520 closes the bypass outlet 506 and defines a first fluid pathway extending from the inlet 504 through the aftertreatment component 22 to the aftertreatment outlet 508 . In other words, when the flow control valve 520 is in the closed position, exhaust gasses, indicated by the directional arrow at 532 , flow through into the inlet side of the housing and into the aftertreatment component 22 .
  • the flow control valve 520 in the second position (e.g. open position) opens a bypass exhaust pipe 550 that is downstream of the aftertreatment component 22 and defines a second fluid pathway extending from the inlet side 512 of the housing 502 , past the aftertreatment component 22 , through the flow control valve 520 and into bypass exhaust pipe 550 .
  • the flow control valve 520 in the open position the flow control valve 520 fluidly couples the inlet side 512 of the housing 502 with the bypass exhaust pipe 550 such that exhaust gas, indicated by directional arrow 534 , flows through the housing 302 without flowing through the aftertreatment component 22 .
  • the bypass system 500 also includes the controller 130 described above and shown in detail in FIG. 4 .
  • the controller 130 is electronically coupled to the flow control valve 520 to control movement of the flow control valve 520 between the first position and the second position. In the embodiment shown in FIGS. 7 and 8 , the controller 130 sends a signal to the actuator 124 to move the flow control valve 520 to the desired position.
  • a method for protecting an exhaust aftertreatment system of an internal combustion engine is shown in accordance with another embodiment of the present invention.
  • the method for protecting the exhaust aftertreatment system 700 selectively diverts exhaust gasses from the engine away from an aftertreatment component, such as a Selective Catalyst Reducer, susceptible to deterioration from potentially harmful operational and environmental conditions which an internal combustion engine may encounter.
  • the method includes assessing a status of an operating condition associated with a physical condition of the aftertreatment component of the internal combustion engine, as shown at 702 .
  • the status of the operating condition is compared with a threshold value that corresponds with deterioration of the physical condition of the aftertreatment component, shown at 704 .
  • a valve upstream of the aftertreatment component is moved to a first position to open a bypass fluid path that directs exhaust gasses around the component to reduce deterioration of the component, shown at 706 . If the operating condition does not exceed the threshold, then the valve is moved to a second position to close the bypass fluid path thereby directing exhaust gasses to the aftertreatment component, shown at 708 .
  • the operating condition is a temperature of the exhaust gasses which is compared to a lower temperature threshold below which an unacceptable amount of unburned hydrocarbons remains in the exhaust gasses.
  • the operating condition is a flow rate of unburned hydrocarbons in the exhaust gasses which is compared to an upper threshold of an unacceptable amount of unburned hydrocarbons in the exhaust gasses.
  • the operating is a temperature of the exhaust gasses which is compared to a higher temperature threshold of the exhaust gasses above which the Selective Catalyst Reducer component produces harmful byproducts, such as pentoxides from a vanadia based catalyst, or may otherwise be rendered useless by overheating.
  • the operating condition is a chemical formulation of the fuel used by the internal combustion engine which is compared to an upper threshold limit of sulfur content above which the sulfur deteriorates the aftertreatment component.
  • the operational condition is a geographical location of the internal combustion engine which is compared to geographical locations that do not require emissions controls for internal combustion engines.
  • a valve upstream of the aftertreatment component is moved to a first position to open a bypass fluid path that directs exhaust gasses around the component to reduce deterioration of the component. If the operating condition does not exceed the threshold, then the valve is moved to a second position to close the bypass fluid path thereby directing exhaust gasses to the aftertreatment component.
  • the step of moving a valve to a first position includes receiving a signal from a controller that directs an actuator associated with the valve to move the valve to the first position.
  • the step of moving the valve to the second position 716 includes receiving a signal from the controller directing the actuator to move the valve to the second position.
  • the step of moving the valve to the first position based on the threshold comparison can be overridden by manually moving the valve to the second position to close the first fluid path and open the second fluid path to bypass the exhaust aftertreatment device.
  • instances in this specification where one element is “coupled” to another element can include direct and indirect coupling.
  • Direct coupling can be defined as one element coupled to and in some contact with another element.
  • Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements.
  • securing one element to another element can include direct securing and indirect securing.
  • adjacent does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

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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)
  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Processes For Solid Components From Exhaust (AREA)
US13/789,345 2013-03-07 2013-03-07 Exhaust gas aftertreatment bypass system and methods Abandoned US20140250865A1 (en)

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US13/789,345 US20140250865A1 (en) 2013-03-07 2013-03-07 Exhaust gas aftertreatment bypass system and methods
DE112014001142.8T DE112014001142T5 (de) 2013-03-07 2014-02-04 Abgasnachbehandlungs-Umleitungssystem und -Verfahren
GB1515728.2A GB2525813B (en) 2013-03-07 2014-02-04 Exhaust gas aftertreatment bypass system and methods
PCT/US2014/014538 WO2014137518A1 (fr) 2013-03-07 2014-02-04 Système et procédés de dérivation de post-traitement de gaz d'échappement
US14/602,748 US20150128571A1 (en) 2013-03-07 2015-01-22 Exhaust gas aftertreatment bypass system and methods
US15/241,560 US9964013B2 (en) 2013-03-07 2016-08-19 Exhaust gas aftertreatment bypass system and methods

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US20150128571A1 (en) 2015-05-14
US20170138238A1 (en) 2017-05-18
GB2525813A (en) 2015-11-04
GB2525813B (en) 2017-11-22
WO2014137518A1 (fr) 2014-09-12
DE112014001142T5 (de) 2015-11-19
GB201515728D0 (en) 2015-10-21
US9964013B2 (en) 2018-05-08

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