WO2012123618A1 - Dispositif de purification - Google Patents

Dispositif de purification Download PDF

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Publication number
WO2012123618A1
WO2012123618A1 PCT/FI2011/050225 FI2011050225W WO2012123618A1 WO 2012123618 A1 WO2012123618 A1 WO 2012123618A1 FI 2011050225 W FI2011050225 W FI 2011050225W WO 2012123618 A1 WO2012123618 A1 WO 2012123618A1
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WO
WIPO (PCT)
Prior art keywords
ops
purification device
pcu
open
regeneration
Prior art date
Application number
PCT/FI2011/050225
Other languages
English (en)
Inventor
Teuvo Maunula
Matti Härkönen
Erkki NÄRHI
Juha-Matti ÅSENBRYGG
Keijo Torkkell
Toni Kinnunen
Pekka Matilainen
Original Assignee
Ecocat Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ecocat Oy filed Critical Ecocat Oy
Priority to PCT/FI2011/050225 priority Critical patent/WO2012123618A1/fr
Priority to PCT/FI2012/050247 priority patent/WO2012123643A1/fr
Priority to RU2013142196/06U priority patent/RU151051U1/ru
Priority to CN201290000368.2U priority patent/CN203867667U/zh
Publication of WO2012123618A1 publication Critical patent/WO2012123618A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
    • B01D46/525—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material which comprises flutes
    • B01D46/526—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material which comprises flutes in stacked arrangement
    • 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
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/0231—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using special exhaust apparatus upstream of the filter for producing nitrogen dioxide, e.g. for continuous filter regeneration systems [CRT]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/027—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/027—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means
    • F01N3/0275—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means using electric discharge means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • F01N3/103—Oxidation catalysts for HC and CO only
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/32—Honeycomb supports characterised by their structural details characterised by the shape, form or number of corrugations of plates, sheets or foils
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/38—Honeycomb supports characterised by their structural details flow channels with means to enhance flow mixing,(e.g. protrusions or projections)

Definitions

  • the invention relates to a purification device for removing impurities, such as carbon containing particles and hydrocarbons, from exhaust and waste gas.
  • the invention also relates to a method for manufacturing and to a method to use and regenerate such a purification device.
  • diesel vehicles the hardest to reach are particulate-matter (PM) and NO x emission limits, but carbon monoxide and hydrocarbon emissions can be effectively eliminated by oxidation catalysts.
  • EGR exhaust gas recirculation
  • Diesel particulate filters (DPF) are particularly utilised in vehicle targets to decrease the quantity of particles detrimental to health with conversions of over 90%.
  • partial filters are maintenance-free as unburned ashes and the excess of particles are able to exit the assembly without using external energy, unlike conventional filters, where the main fraction of ashes and unburned material will remain on the surface of a filter. Therefore, the pressure drop of full-filters aims to increase during the use, although soot/carbon is removed completely in regenerations.
  • the deep filters are prepared usually by ceramic or metallic fibers or foams or sintered metal. Fibers can be as a bed or folded mat in the filter.
  • the ratio of efficiency and pressure drop can be optimized by maximizing the filtration surface area (thin mats folded like in oil and air filters). Nets, fiber mats and perforated plates/foils are commonly used in partial filters and particles are accumulating on these structures due to pressure differences and turbulence.
  • the reaction mechanism and design are different between deep and partial filters, even if the namely the same materials are used.
  • the fiber mat can act as a cell structure by the assembly, where fluid is forced to flow through the mat (deep filtration) or as a cell structure, where the main stream flows between the flow channel formed from straight and corrugated fiber mats and a part of particles remains however on the surface of walls (partial filtration).
  • the filtration on fiber-based filters is based on the appropriate diameter of fibers.
  • the void fraction is usually very high (>90%) in fiber layer or mat but the void fraction or porosity on typical skin-type filters (e.g. cordierite, SiC, Al titanate) is typically 40-50% and in particular high-porous skin filters even up to 60-70%. Also in deep filtration, particles start to accumulate more on the front part of by the flow direction, by the similar way like on skin filtration.
  • filtered carbon fraction (soot) in PM is thermally combusted by means of extra heat. Soot can be oxidised by an intensive combustion reaction with oxygen at a temperature higher than 550 °C or slowly at lower temperatures (250-350 °C) by means of N0 2 . N0 2 being formed in the oxidation catalyst oxidises soot in reasonably low temperatures (>250-300 °C) when the oxidation catalyst is efficient enough.
  • VOF volatile organic fraction
  • SOF soluble organic fraction
  • the VOF fraction is usually 1 0-40%, but with some engines and in some driving conditions the VOF of particles can be even 70-90%. Such conditions are provided in urban traffic, with old engines and/or specific fuels.
  • the separating efficiency of filters in which particles accumulate within the filter phase and not on the channel surfaces is dependent strongly on flow and linear speed.
  • a known continuous regenerating trap (CRT) method includes a Pt containing oxidation catalyst and following it an uncoated or catalyst-coated DPF (EP341832). Problems in the passive method with the conventional full filter are related to situations where the formation of N0 2 is not sufficient e.g.
  • structures are also known made of steel wool, of ceramic foam, as a tapered structure, as a pipe structure coated with fibre, using electrostatic separation or wet scrubbers.
  • known filter structures on top of perforated pipe structures is wrapped fibre matting or metal wool and one or more of these structures can be installed in the whole filter assembly. It is typical that the fibre structure is uniform without intermediate spaces and the flow is controlled in the structure randomly avoiding fibre threads, the average main direction being radial. This is typical for filters based on deep filtration in which particles partially accumulate within the filter material.
  • exhaust gas flows in these filters in the radial direction towards the inside of the pipe, whereby particles have sufficient room to accumulate within, on the surface of and in the open space of the assembly before the filter.
  • metallic full-filters they have made e.g. of sintered metal or metal foams.
  • the assembly of partial filters has been modified of the oxidation catalyst such that the separation of particles is promoted by using, instead of a ceramic or metal cell, assemblies which include various pass-through openings, claws or projections on the walls as well as throttles or filtering elements in the flow channels of the cell.
  • the pass-through openings or filtering elements have been provided by employing ceramic or metal meshes, wools or porous materials instead of the normal metal or ceramic walls.
  • Partial filters usually have a cellular structure which includes axial open channels in the main flow direction.
  • the main flow is similar to the one of normal catalyst assemblies, but particle separation has been enhanced by forcing the flow to partially travel in the radial direction via meshes, fibres or holes in the wall controlled by a pressure difference.
  • the radial flow is usually random in different directions, whereby a vector in the direction of the main flow is on average axial.
  • the basic principle is also that the flow enters from one end and exits on the opposite side from the other end of the cell which is usually circular or rectangular.
  • particulate filters has been conducted by combined engine throttling (air/fuel ratio adjusted near to stoichiometric values) and additional fuel injection, in addition electrical, plasma (SAE Paper 1 999-01 -3638) or burners, which create additional heat and soot will burn (EP 007061 9-1982 and Emissionminderung, Autobilabgase, Dieselmotoren, Nurnberg 1 5-1 7 Oct 1985, Kurz chargeden, VDI 1 985).
  • Additional fuel can be injected into cylinders (post- injection) or into exhaust gas before an oxidation catalyst and/or catalyzed particulate filter. Combustion can be enhanced with the agents injected into exhaust gas. These compounds consist of e.g.
  • the system consisted of one or more glow plugs assembled directly to the contact to the front face of a wall-flow filter which initiates soot combustion.
  • control of active regeneration is an own technical field, where exist a lot of patents and publications.
  • the control is usually based on the responses of temperature, pressure or engine map variables, which are correlated to the accumulated particulate loading and appropriate regeneration conditions.
  • the catalytic coating of particulate filter promotes the catalytic combustion of soot (SAE Paper 850001 5, 1 985), NO 2 formation and the oxidation of hydrocarbons injected to get temperature to rise.
  • soot SAE Paper 850001 5, 1 985
  • the most efficient and durable catalysts for HC (originating from fuel), carbon monoxide (CO) and NO oxidation are based on the use of platinum (Pt).
  • Pt platinum
  • the high NO 2 formation rate requires the presence of Pt but in HC and CO oxidation also palladium (Pd) is active.
  • Different kind of coated catalysts have been utilized to catalytic soot combustion and they consist of for example vanadium, copper, potassium, molybdenum and compounds based on similar elements. Their catalytic reactions are typically based on their high mobility on soot surface or they form mobile oxygen species.
  • the regeneration of partial filters is based mainly on passive regeneration by NO 2 .
  • Partial filters have been used without blocking also with fuels containing more sulphur and ashes, because unburned impurities and sulphates are emitted immediately or later out of open filter.
  • the requirement for regeneration is that temperature and NO x /C ratio are high enough in average, when it is possible to form enough NO 2 and NO 2 +C reaction is fast enough to prevent the cumulative accumulation of carbonaceous particulates.
  • the structure and the filtration of particulates differs from those of full-filters, therefore the regeneration conditions are different.
  • the object of this invention is to provide a purification device (PD), system and regeneration method operating in diesel or equivalent waste gases which substantially minimises the quantity of emission components, particularly particulate emissions and hydrocarbons.
  • PD purification device
  • the purification device comprises at least one open particle separator (OPS) comprising permeable/semipermeable sheets and/or mats and having open channels (CHA) for gas with impurities to flow between said sheets/mats/foils, and that said purification device (PD) additionally comprises at least one ignition element (IE) for (periodically) igniting collected and flowing gas impurities.
  • OPS open particle separator
  • CHA open channels
  • IE ignition element
  • the novel type of a purification device and regeneration method/system provides service-free operation, regeneration in all use conditions and a low energy consumption.
  • the purification device according to the invention remains unblocked over the life-time causing a low pressure loss and it additionally has low manufacturing and operation costs.
  • purification device can utilize catalytic coating.
  • the purification device can employ coatings which comprise catalytically active components active for the oxidation of carbon monoxide, hydrocarbons, nitrogen monoxide (NO), particles and the reduction of nitrogen oxides by any reductants.
  • the oxidation of particles can be promoted directly or indirectly by means of NO 2 and parallel periodically and/or continuously with the ignition element to guarantee the regeneration.
  • Possible fields of usage of the invention are e.g. exhaust, flue gas and waste gas applications in mobile or stationary targets.
  • the gas mixture comprises an excess of oxygen, either continuously or on average.
  • gaseous fuel e.g. methane, propane, biogas
  • liquid fuel e.g. light or heavy fuel oil, diesel, petrol or biofuels
  • the device according to the invention can thus be used in completely lean conditions (excess of oxygen) or in conditions where the mixture ratio is adjusted from time to time to stoichiometric or rich for a short time.
  • the adjustment of the mixture ratio and the possible rise in temperature are carried out in order to regenerate the device or its units either completely or partially from adsorbents, accumulated poisons and/or particles.
  • the mixture can be adjusted if the complete system consists also, in addition to the device in this invention, of other catalysts/units (like NO x adsorption catalyst or full-filters) which require periodically stoichiometric or rich conditions or higher temperature for regeneration.
  • Partial filters and OPS have usually thin walls and structures (e.g. fibers, low heat capacity -> lower external energy needed for heating compared to full-filters like cordierite or silicon carbate) and metallic structures have a good thermal conductivity, when the local temperature peaks are created less during carbon combustion.
  • the active regeneration can be divided into categories by the magnitude and effect of additional heating: 1 ) Heating of whole exhaust or waste gas and filter up to the combustion temperature of soot (high energy/power requirement), 2) Heating parallel filter segments by controlled phases at the different times up to the combustion temperature of soot or 3) Igniting the accumulated carbon containing particles or injected fuel/HCs to burn with an ignition impulse (the lowest energy/power requirements). That third regeneration can be conducted also segment by segment locally in separate positions in the filter. In the regeneration by the invention, this third method is applied with the purification device and open particle separator, which differs essentially from those two other known methods used with full-filters.
  • At least one metallic or ceramic particle collection unit locating near said ignition element (IE) for collecting carbon containing particulates and/or hydrocarbons near said ignition element (IE) thus enhancing the ignition and combustion of impurities.
  • at least one ignition element (IE) is located at least partly in said particle collection unit (PCU) or in contact with said particle collection unit (PCU).
  • said particle collection unit (PCU) is located inside the channels of open particle separator (OPS), advantageously in the front part of open particle separator (OPS) by flow direction.
  • Fluid (1 , 2, 3) (usually exhaust gas) flows into a reactor (4), where an open particle separator (5) (OPS) is located with one or more ignition elements (6) (IE).
  • OPS open particle separator
  • IE ignition elements
  • Front of this reactor can be also a separate purification catalyst (7), which is advantageously an oxidation catalyst.
  • the ignition element can be connected with the particle collection unit (8) (PCU), which collects particles efficiently near to the ignition element.
  • PCU particle collection unit
  • the reactor is for example a conventional mantled catalyst converter, where the substrate can be non-insulated or wrapped in insulation/assembly mat and/or heat shields.
  • the reactor can be integrated into muffler, where is possibly also other functional units (oxidation or deNO x catalysts (SCR, LNT), full-filters and other additional unit related to the use of previous ones).
  • the open particle separator is a structure, which has, instead of tight pore or fiber structures of full-filters, open channels, where the detachment of particles on flow channels has been enhanced by using tortuous, in places throttling and expanding channel shapes, where exist passing paths through channel walls, which balance the pressure differences between parallel channels.
  • the essential difference between full filters and the open particle separator is the fact, that fluid is enforced completely through filtering/collecting layer in full filters but it exist also free, open route through the OPS.
  • the open channels through OPS is corresponding a hydraulic diameter, or distance from wall to wall, above 50 ⁇ , which pores or mean distance between filtration walls are smaller with full-filters.
  • Ceramic are inorganic non-metallic materials like metal oxides (alumina, silica and their mixtures; cordierite and other materials used a porous fibers or sheets).
  • These wall materials in OPS are permeable or semipermeable and allow the fluid to pass through.
  • the semipermeable walls allow gaseous compounds to penetrate it but solid or liquid particles are attached on the surface of that wall. Even if the wall was completely full of particles, it will remain permeable in respect of gas flow. Typical filtration efficiency is between 40-80%, which is clearly lower than with wall-flow filters.
  • the walls of OPS can be flexible or frigid, advantageously metallic and ceramic sheets/fiber mats are made from flexible materials which are easy to roll for the final structure.
  • the metallic structures are made from typical oxidation resistant steel or alloy materials, which can be used in normal use conditions without excessive oxidation. The presence of aluminium in alloy is preferred to form protecting alumina (AI 2 O 3 ) layer in preparation or in use conditions.
  • said open particle separator comprises permeable/semipermeable corrugated sheets/mats/foils forming an open particle separator (OPS) structure with open channels (CHA) having corrugation height between 0.2-200 mm, advantageously between 0.35-25 mm, such as 0.5-3 mm.
  • said open particle separator (OPS) comprises permeable/semipermeable metal wire meshes/sheets/mats having wire diameter between 0.01-5 mm, advantageously between 0.05-1 mm, and/or the holes in metal wire sheets which apparent diameter is between 0.02-10 mm, advantageously between 0.05-0.6 mm.
  • said open particle separator comprises (semi)permeable ceramic fiber sheet/mats.
  • said open particle separator comprises permeable/semipermeable metallic fiber sheet/mats.
  • said (semi)permeable sheets/mats are corrugated forming an open particle separator (OPS) structure with channels having corrugation angle in relation to the main flow in either direction between 1 -89 degree, advantageously between 10-80 degree, such as 20-60 degree.
  • said particle collection unit comprises fibres or/and wire mesh having wire diameter of 1 to 20 % compared to the wire diameters of the open particle separator (OPS).
  • OPS open particle separator
  • the ratio of fiber/wire diameters is in the range of 5-100 (diameter of OPS wires /diameter of CPU fibers).
  • an open particle separator is built from corrugated mesh (net, screen), where the corrugation shapes channels, which orientation differs from the main flow direction and parallel nets are mutually in a different angle compared to the main flow direction (Fig. 2 and 3).
  • the corrugation height (hi and h2) in the mesh structure can be selected suitable for the target as regards the assembly, back pressure and emission limits.
  • the corrugation height can be the same or different in various meshes/screens.
  • the height can be varied between 0.2-200 mm, advantageously between 0.35-25 mm, such as 0.5-3 mm.
  • the corrugation angle in relation to the main flow in either direction is at least in one mesh 1 - 89 degrees, such as 10 - 80 degrees, such as advantageously between 20 - 60 degrees.
  • the corrugation angle can also be varied between -89 - +89 degrees, advantageously it is between -60 - -20 and +20 - +60 degrees.
  • the minus and plus angles mean angles in the opposite directions in relation to the main flow direction. It is practical to use the same slant corrugated mesh material, make a mesh pair of them by turning one of the meshes inside out such that the corrugation peaks are in different directions and carrying against each other. Then, an OPS according to the invention is provided of the same mesh. It is also possible to prepare special structures, where the corrugation angle is between 89- 90 degrees.
  • the ratio of the height and width of the corrugation can be varied at a very large range, using either low and wide corrugations or high and narrow corrugation peaks.
  • These slant meshes are prepared by driving a flat mesh through obliquely toothed wheels, which form the corrugation structure used for open particle separators in the invention.
  • Between two corrugated meshes can be also flat mesh, fiber mat or perforated wall, when the decreased channel size improves mass transfer and particle accumulation capacity. It is also possible that between permeable/semipermeable sheets is non-permeable a foil or wall, which divides OPS for sectors which have not connection paths.
  • the non- permeable wall can substitute every, every second or every fourth flat sheets in the previous structure (flat sheet between two slant corrugated sheets).
  • This structure has few advantages: non-permeable wall acts as a fire-wall during fast combustion of particles, the regeneration can be restricted in each sectors and it acts as mechanical support for the structure.
  • it is possible to optimize the peak heights by the targets: very dirty targets -> high peak height, very clean targets -> low peak height.
  • the mesh/sheet structure in OPS comprises threads (wires) the thickness of which is 0.01 -5 mm, advantageously between 0.05-1 mm, and holes the size of which (apparent diameter/hydraulic diameter from mesh to mesh at the middle of the meshwork) is 0.02-10 mm, advantageously 0.05-0.6 mm.
  • the mesh (sheet) can be a woven structure or a mesh matting or otherwise cohering. The great variation is due to the fact that there are very different targets of usage or intended uses. In very dirty targets, the mesh is coarser, e.g. thickness 0.2-0.5 mm and holes 0.1 -2 mm, and the corrugation height is high, e.g.
  • the mesh is denser, e.g. thickness 0.05-0.2 mm and holes 0.05-0.1 mm, and the corrugation height low, e.g. 0.5-2 mm.
  • metallic or ceramic fibre mats/sheets, membranes or perforated foils of which an equivalent structure is made and they partially allow fluid through instead of or together with the mesh, it is also possible to use above-mentioned metallic or ceramic fibre mats/sheets, membranes or perforated foils of which an equivalent structure is made and they partially allow fluid through.
  • the structure shown in Fig. 2 and 3 can have additional or alternatively flow barriers, throttling/expanding shapes/elements, dead ends and blades, which still improve the mass transfer and collection efficiency and create open particle separator structure.
  • the ignition element has a function to create local additional heat, energy or impulse, which initiate the combustion of collected particles on OPS.
  • Particles consist mainly of carbon and hydrocarbons, which are potential to ignite by this kind of additional energy or spark.
  • Hydrocarbons can locally ignite when temperature rises over 150-300°C and carbon, when temperature rises locally over 400-600 °C depending on soot structure and possible catalytic effect on carbon oxidation. Simultaneous high N0 2 concentration may also enhance this ignition.
  • the target is thus not to warm up the whole separator but only ignite combustion, while the energy to regenerate the whole separator is created in situ by the combustion of ignited carbon, not by external heat.
  • the ignition element is an ignition glow plug, a lighter and/or spark generator.
  • the ignition element is typically a glow plug, lighter, burner, primer firing, ignitor, other spark source or electrical resistance, which power can be significantly lower compared to known external heating elements heating wholly or a segment in a filter.
  • the number of ignition elements can be one or more parallel and/or in sequences depending on regeneration strategy.
  • the power for ignition element is originating from an energy source (ES), which releases electrical power or fuel. In mobile applications, this source is usually a battery and/or fuel. A battery is able to release the required power for the ignition element, which needs not to heat the whole exhaust gas but only locally for a moment.
  • the bottle neck of many known regeneration methods based on electricity is the power of batteries.
  • This problem has been solved in the invention because the main energy for particle regeneration is created by the combustion of carbon and/or hydrocarbons on open particle separator or in this device, not from that external energy source.
  • the particle collection unit PCU
  • PCU particle collection unit
  • OPS is not a closed filter, particles are not naturally on its inlet part or on face.
  • the particle collection unit is able to promote the regeneration and ignition of OPS for example in the conditions, when the loading degree of OPS is not yet very high.
  • the material of particle collection unit can be inorganic (silica, alumina or their mixture or corresponding material) or organic fiber selected in the way that it stands the use conditions.
  • Metallic PCU is advantageous in some embodiments because it is mechanically strong and conducts heat better than ceramic structures.
  • the particle collection unit PCU is for example metallic or ceramic fiber mat or layer, which is behind of the ignition element in flow direction. This unit is advantageously inside OPS wholly or partly.
  • PCU can be also a separate unit directly front of OPS (Fig. 4).
  • the PCU can have also a supporting mantle or cover, which protects PCU mechanically and prevents an excessive cooling effect by exhaust gas.
  • the same particle collection material can be applied also in other positions than near to the ignition element in purpose to enhance the particle collection and balance pressure drop over the OPS.
  • the local collection efficiency of particulates is clearly higher in positions where the PCU material is present (e.g. inside OPS). Depending on the total amount of PCU material, this can have a small or significant effect on the PM efficiency of whole OPS, which can be utilized to also to improve OPS. If the PCU is not covering wholly the face of OPS, it is a risk that flow distribution in uneven. Filling PCU material about as the same amount in the separate radial sectors by flow direction, will the pressure drop over different radial positions be the same and no uneven accumulation of particles will happen (Fig. 5).
  • PCU The function of PCU is also to bring carbonaceous particles near enough to each others in the way, that combustion zone will propagate in PCU.
  • PCU is made of fiber or wire mesh, the distance between threads of PCU material is essentially smaller than the distance between the channel walls in OPS.
  • said in particle collection unit PCU the thickness of fibers/threads in PCU is between 1 -1000 ⁇ , advantageously 5-100 ⁇ , which size differs essentially from the wire diameters of OPS screens (about 1/10 or less).
  • the thinner fiber is used, the higher is the fiber surface area and thinner fibers are able to collect more and more efficiently particles per fiber weight than thicker fibers. Too thin fibers result in the limiting factor of mechanical strength and too thin fibers have negative health effects.
  • the use of thin-fiber mat between the channel walls will result in a high PM efficiency with a low amount of additional material combined with OPS.
  • the void fraction (porosity) of particle collection unit (PCU) is between 50-99.9 %, advantageously between 85-98 %.
  • OPS/CU -ratio (w/w) is between 2-1000, advantageously between 5-100, such as between 10-50. This differs clearly from the properties of wall-flow filter walls (40-50%), which is the corresponding filtration layer.
  • the weight ratio between OPS and CU components is between 2-1000, more typically between 5-100.
  • a thin fiber mat in the inlet of OPS will not add the weight of OPS made e.g. from metallic screens.
  • the other reason to use low void fraction and relative amount is to keep pressure drop and blocking tendency as low in this purification device. If the PCU is too dense, it will be blocked too fast and most of particles are on outer surface of PCU.
  • OPS contains wires arranged to a sheet (wires in line, 2D sheet) but PCU contains wires as a mesh bed having 3D structure between OPS channels.
  • PCU can be also full-filter or a part of it, while it collects carbon containing particles, which can be ignited with IE.
  • IE can be adjusted inside blocked end of cellular wall-flow filter and the other structure around is OPS.
  • PCU can be integrated into IE and can be installed and changed during IE service. If IE is e.g. a glow plug, the ash accumulated in PCU can be removed in service.
  • the pressure and temperature sensors can be also integrated into IE, which is possible with the modern technology. This is a way to have direct information about the operation and ignition conditions of IE.
  • PCU can form also one, another or several of the channel walls in OPS, when a corrugated structure is metallic screen and another is fiber mat equipped with IE at the edge.
  • An application is a design, where PCU is located front of or inside purification catalyst, which application differs from the basic definition (Fig. 6). Then IE ignite HCs or other burning compounds, which are naturally in waste fluid or which are added in purpose during ignition moments, before it flows into purification catalyst.
  • This design enables to ignite HCs in a HC-rich exhaust gas in any conditions if the light-off is otherwise too slow, e.g. low temperatures ( ⁇ 200°C), small purification catalyst, it is not possible to use too active purification catalysts due to high- sulphur fuel.
  • the ignition element in this design could be used thus advantageously with high-S fuels possibly together with fuel injection and temperature increase with engine management.
  • the possible locations of PCU between OPS screens are shown Fig. 7.
  • OPS structure contains angle corrugated screens which lock the PCU (e.g. fiber mat) between channels.
  • the OPS structure also locks fibers in small spaces where the flow is not able to break a fiber mat as easily than as thick loose mats. It is important to observe the direction of flow through the structure. It exist certain structures with metallic nets and fibers (deep filters) but they have the flow forced completely though that structure.
  • fluid flows in open channels between screens where PCU can locate in selected parts. The fluid may be partly forced on the surface of OPS and through OPS by mass transfer and pressure drop forces but it remains still that open channel through PD. An easy way to keep a part of channels free even from PCU is shown by Fig. 7C.
  • the mesh of OPS is fastened by welding, soldering or metal nails or pins pushed through meshes.
  • IE can be integrated into these mechanical fitting elements (e.g. nails/pins with an option for IE).
  • said particle collection unit is coated with catalytic coatings active for CO, HC, NO and particulate oxidation and/or NO x reduction.
  • front of the said purification device (PD) is installed a purification catalyst (CAT), for catalyzing the oxidation of carbon monoxide, hydrocarbons, NO to NO 2 and /or reduction of NO x by any reductants.
  • the OPS can be coated with porous support material which operates as a base for active compounds which oxidise CO, hydrocarbons, NO, hydrogen, ammonia or carbon.
  • the hydrocarbons can also include functional groups containing oxygen, nitrogen or halogens.
  • said open particle separator is coated with catalytic coatings active for CO, HC, NO and particulate oxidation and/or NO x reduction.
  • the coating is made such that the mesh holes remain at least partially open at least in one mesh/screen.
  • holes in meshes are substantially open (30-99.9% of holes in OPS), advantageously 70-99%. This provides the advantage that in the open channel the fluid is able to go through the mesh at every point, whereby particles remain on the surface of the mesh with great filtering efficiency.
  • the fluid is driven to change to the other channel by the pressure difference between the channels, which provides efficient mass transport to the catalyst surface on the surface of the mesh.
  • An assembly according to an object of the invention does not have a coating at all, whereby it only operates as a open particle separator and sound damper.
  • the catalyst can catalyse the reduction of NO x with hydrocarbons or ammonia, adsorb nitrogen oxides (reduction in rich conditions) or oxidize ammonia.
  • the catalyst comprises in the support material aluminium, silicon, titanium oxides and/or zeolites.
  • the thickness of the coating is between 1 -500 micrometres, advantageously between 5-40 micrometres.
  • the area of the coating is determined by used materials and is between 1 -700 m 2 /g, usually between 20-300 m 2 /g.
  • the coating can be added on OPS device using various slurries, sols and/or solutions by dipping, pumping, sucking and/or spraying methods.
  • the meshes of OPS can be coated open when loose of its pair by spraying and, after that, wind the mesh and OPS structure. Consequently, it is possible to ensure that the eyes of the mesh remain open.
  • the coating can also be made totally or partially by means of volatile starting materials (CVD, ALE techniques).
  • At least part of the mesh structure is coated with support material in which is added catalytically active compounds.
  • the catalytically active compounds in OPS include platinum (Pt), palladium (Pd), rhodium (Rh), iridium and/or ruthenium to catalyze the oxidation and/or reduction reaction of exhaust and waste gases.
  • the active components can be added in the coated catalyst structure by impregnation (dry, wet or chemisorption) or among coating slurry, solution or sol.
  • the active components can be pre-matched in the particles of materials before coating.
  • the coatings and/or absorptions employ water or other solvents or their mixtures usually in the liquid phase.
  • active metal e.g. noble metal
  • the first can include active metal advantageously for 0.8-3 g/dm 3 and the latter 0-0.8 g/dm 3 .
  • the aim is to add to the same structure e.g. Pt more on the inlet side in the direction of the flow where it is possible to make more NO 2 .
  • Pt cannot catalyse the oxidation of NO as much for passive regeneration, whereby there the loading is lower.
  • active components such as Pd, which is active for HC oxidation but not for NO oxidation.
  • This structure and described loading distribution can be used together with the purification (oxidation) catalyst being upstream.
  • the active component is selected according to the use.
  • Platinum-bearing catalyst coatings can enhance the formation of NO 2 , which promotes the combustion of particles and the regeneration of the device e.g. in diesel targets. Decreasing the formation of NO 2 is an object in targets in which the regeneration is done totally actively (fuel injection and/or engine throttling) and when wishing to minimise NO 2 emissions.
  • the presence of Pt is not automatically catalyzing high NO 2 formation, e.g. if vanadium is added with Pt on catalyst, NO 2 formation will be very low.
  • Pd can be employed as an active component when the object of the catalyst coating is to catalyse the oxidation of CO and HCs and the temperatures are high in the operating or regeneration conditions.
  • promoters in the support material can be used e.g. vanadium (V), wolfram (W), iron (Fe), zirconium (Zr), cerium (Ce), lanthanum (La), manganese (Mn), cobalt (Co), barium (Ba), strontium (Sr) and/or nickel (Ni).
  • the support material can also mainly consist of the compounds of these promoters.
  • typical NO x adsorption compounds e.g. by impregnation, whereby nitrogen oxides can be adsorbed in lean mixture and reduced during rich mixture.
  • PCU by invention it is possible to use similar coatings as on OPS or optimally a coating added as sol, which coat PCU's fibers and pores with thin coating without blocking the open spaces which blocking increases pressure drop in that position.
  • Sol means a liquid where are dispersed small particles, which mean diameter is in the range of 5-1000 nm, advantageously between 15-100 nm, which particle size allows to coat evenly even the smallest pores and thin fibers.
  • the particle in sol can be for example Al, Si Ti, Zr, Ce Mn, V, Cr, Co, Sr, La, Y and/or Pr compounds (oxides).
  • the amount of coating is typically 0.1 -30% of the weight of PCU and the active component is typically noble metal like Pt, Pd, Rh or their mixture.
  • PCU compounds V, Cr, Mn, Co, Sr
  • soot oxidation and thermally stable oxides La, Y, Zr
  • An application by the invention is design, where PCU is coated with sol based coating (small particle size) and OPS with normal catalyst slurry, where also larger particles can be present (»100 ⁇ ). Slurry coating of thin screens/mats leaves the eyes open in OPS. But a coating slurry having large particles blocks e.g.
  • the purification catalyst differs from typical OPS by the properties in the way that the typical coating amount is higher i.e. about 50-500 g/L and the amount of active compound is also higher, typically 1 -5 g/L.
  • the substrate is ceramic or metallic one which cell density is between 1 -2000 cpsi (cells per square inch), advantageously 50-600 cpsi.
  • the substrate structure may be conventional with negligible filtration properties compared to the structures used for OPS or it can have also certain structures defined for OPS.
  • the operation target is to oxidize efficiently CO, HCs and NO to water, CO 2 and NO 2 , which can be utilized in situ or on OPS. Typically, this catalyst is also active in NO x reduction, which property is needed in addition to PM removal in common diesel applications.
  • An example about different coatings for the purification catalyst (CAT) and OPS/PCU is a case, where OPS/PCU is coated with a catalyst coatings active preferably for particle/carbon oxidation and purification catalyst has preferably a coating active for oxidation of CO, HCs and NO as well as the reduction of NO x with any known reductants. If OPS/PCU contains Pt and e.g. V as promoter, it has negligible oxidation activity for NO and SO 2 , opposite to other Pt containing oxidation catalysts. In this case, a lot of NO 2 is formed in CAT but not in OPS/PCU.
  • OPS, PCU and/or purification catalyst coated with catalysts according to the invention can be treated during manufacture in static or dynamic conditions with oxidising and/or reducing gas mixtures which can include air, oxygen, hydrogen, carbon monoxide, ammonia, exhaust gas, hydrocarbons, water or inert gas. With the treatments, it is also possible to form various mixed oxides between the coating compounds by employing suitable starting materials, particle sizes and finishing conditions.
  • the device according to the invention is thus able to purify waste gases particularly in respect of particles. By utilising sufficiently dense mesh, low corrugation height and several layers of the mesh or an equivalent structure in OPS, good particle separating efficiency is also provided.
  • the device includes a novel kind of an open particle separator structure for diesel targets (among others), where accumulated particles are regenerated in addition of passive regeneration with the periodical ignitions, when the condition are not appropriate for passive carbon oxidation.
  • This device is particularly well suited for the purification of the exhaust gases with very low temperatures where regeneration can not be guaranteed with passive ways.
  • passive methods are utilized as much as possible to optimize fuel economy.
  • the device or its components may also replace normal elements used in sound damping. At its best, the units can be located in the same original sound damper/mufflers. The particles accumulated in OPS are regenerated therefore passively and/or active regeneration is initiated using IE.
  • a purification catalyst e.g. DOC
  • DOC purification catalyst
  • the DOC can be located in the same container or it is separate in front of an OPS according to the invention.
  • the DOC can also be within the inlet or outlet pipe.
  • the temperature of the catalyst can also be increased externally by combusting hydrocarbons or by utilising other exothermic (heat-forming) reactions. Additional heat is provided by feeding fuel among the exhaust gas and/or by post- injection in the engine. At the same time, it is possible to decrease the volume of combustion air (by decreasing A/F ratio).
  • the accumulation of particles can be promoted with electrostatic methods, by using mesh pairs as charged collection meshes and by insulating the meshes from the other structure and each other.
  • FBC fuel-born catalyst
  • the regeneration control of device by the invention is conducted using timing, where the low-energy ignition is activated e.g. with the periods of 0.1 -900 sec, advantageously 2-300 sec, punctually, which intervals are usually about 0.2-100 hours, advantageously 1 -10 hours. This timing is decided by the amount of accumulating particles.
  • An appropriate time to make an ignition is when the amount of carbonaceous particles is e.g about 2-20 g/dm 3 , advantageously about 4-10 g/dm 3 , when it is a suitably burning carbon amount to heat OPS up to regeneration conditions.
  • the needed heat amount corresponds to energy, which is enough to heat OPS up to 500-600 °C, which is enough for thermal PM oxidation and which can be assisted of the catalysts; -> lower PM oxidation temperatures; present on OPS or added into exhaust gas.
  • it is essential that particles are collected up to the loading, which is enough to heat and keep combustion for so long time that the OPS is regenerated fully or partly.
  • glow plugs When glow plugs are used as IE, ignition of plug is kept on e.g. for mentioned 10- 500 s continuously or by on/off cycling.
  • the target is to ignite the burning material in vicinity and/or increase the temperature in vicinity up to so high values that carbon and/or hydrocarbons start to burn.
  • the power of plug (IE) in power-on conditions can be about 10-2000 W, advantageously about 50 ⁇ 100 W.
  • the powers can be scaled up or down by the size of units in device. For example, if the vehicle has a battery of 12 V and a plug of 15 A is used, the nominal power is 180 W.
  • the carbon fraction in PCU will be ignited by the additional energy or sparks from a plug (IE).
  • the top of plug (IE) can be in contact to the mesh of OPS or it can be faced to the open channel of OPS, where also is PCU material (e.g. fiber wool or mesh) between OPS's meshes.
  • IE can be connected to either. On insulator, IE creates a point high temperature, where soot is ignited. On heat conductive metal surface, the heat propagated wider. IE can locate also in the middle or at the end of OPS, when the combustion zone will proceed against flow direction. This is possible and device can have one or more IE to guarantee the regeneration of end parts of OPS.
  • the ignition can start as well from the rear as from front part of OPS. When initiating from rear part the thermal stress on OPS is lower but the thermal stress of IE and PCU higher than when starting from the front part.
  • the initiation of ignition can be focused on the moments, when exhaust gas or fluid is naturally warm enough (exhaust above 300 °C) but the gas flow of exhaust gas is decreasing. This is a case e.g. when it is first driven on roads about 100 km/h and then the speed is decreased (a foot taken away from gas pedal). Then OPS is warm and it s quite easy to ignite soot present and due to decreasing speed, a low amount of cooling exhaust gas is coming from engine.
  • the regeneration strategy can be created based on timings and the known engine map. Primary ignitions will thus be focused on these moments, when OPS contains enough burning particles. Secondary, ignition will be focused on some other driving conditions, if the primary condition will be never reached during the defined regeneration (time) window.
  • the ignitions can be varied by the type, power and timings. Short ignitions (e.g. 100-200 s) can be made periodically and more seldom a longer ignition (e.g 500 s), which is able regenerate OPS also in boundary conditions or if regenerations tend otherwise to stay insufficient.
  • the power of IE can be varied or the device can have in different positions varying lEs by power or type. These control actions are done to optimize regeneration with the same power usage.
  • the ignitions of several ignition elements can be timed to happen at the same or different times. If many lEs are ignited at the same time, it gives a possibility to heat more widely the surface of OPS/PCU and burning zone may propagate widely but causes also a higher peak of energy consumption.
  • the timings can be at different times, when the burning zone can spread also to the vicinity of other lEs but the energy consumption peaks are lower.
  • a device can be designed to have two or several OPS units in sequence, which system is not applicable with full-filters (Fig. 8).
  • the filtration capacity of OPS can be added by increasing axially the length of total OPS system with several units based on the same particle separation mechanism which is different than with skin type filters.
  • ignition elements it is possible to install ignition elements also after 1 st OPS unit and before and/or after 2 nd OPS unit. Therefore, the particles in each unit can be ignited independently.
  • PCU can be added in each units by the same principles shown earlier.
  • the device described in invention is designed for conditions, where exist solely low temperatures for long times and the passive regeneration of OPS is insufficient.
  • a OPS with a right design will not be blocked even without ignition elements but the accumulation capacity is decreased and more particles may pass through. This is a condition e.g. with a vehicle in continuous city driving or other drivings with low speeds.
  • the regeneration can be initiated periodically even if speeds and/or loads are continuously low.
  • the passive regeneration of OPS or full-filters requires quite high Pt loadings on the oxidation catalyst located front of filters or on filters itself.
  • the amount of expensive Pt can be dropped significantly.
  • the main fraction of Pt in current passively regenerating systems is needed to increase NO 2 concentration between 200-300 °C.
  • OPS can be regenerated passively above 300 °C when IE guarantee regeneration over the use conditions. This results also in lower NO 2 emissions and a smaller oxidation catalyst (purification catalyst) creates lower pressure drop, which has a positive effect on fuel economy.
  • a target in the invention is to combine the benefits of the passive method and the use of IE with or without PCU in particle regeneration (of OPS).
  • the system consists of pressure and temperature sensors, even if the control is not based on them. These sensors can be applied with the system of invention for OBD purposes, to detect e.g. when device and OPS is blocking or overheated and requires service.
  • the enrichments and fuel injections for PD regeneration can be made at the same time with ignitions (the use of ignition elements).
  • ignitions the use of ignition elements.
  • the use of ignition principle enables the use of active regeneration at lower temperatures.
  • the functional properties deNO x , particulate removal, oxidation reactions
  • the purification device Before the purification device, it is possible to feed in addition to hydrocarbons and known fuels also other oxidising or reducing compounds such as ammonia, urea, ozone, hydrogen peroxide, air, oxygen and/or water as clean or in mixtures. These can promote the reaction of NO x and/or particles and the maintenance of the purifier and adjust the stoichiometry of reactions.
  • oxidising or reducing compounds such as ammonia, urea, ozone, hydrogen peroxide, air, oxygen and/or water as clean or in mixtures.
  • the screen was coated with slurry coating including also larger catalyst raw material particles (alumina and zeolite and a mixed oxide of ZrCe, (d 5 o > 1 ⁇ ) together with small (d 50 « 1 ⁇ ) Ti and Al sol particles, 10 g/m 2 of GSA, 0.07 g/dm 3 Pt).
  • the slant screens were rolled to the OPS in a way that the tops of corrugation support the next corrugated screen (angles +34 and -34 degrees in relation to main flow direction).
  • Silica fiber (d 5 o ⁇ 9 ⁇ ) mat (PCU) was added between these metallic screens for the first 30 mm from the inlet of OPS. Radial, all the spaces between screens were filled.
  • the void fraction in that fiber layer was about 96- 97%.
  • the fibers were coated by Pt containing sol coatings consisting of alumina and titania as small particles ( ⁇ 100 nm) which did not block the spaces between fibers and coat fiber mats evenly, which properties are advantages for filtering and regeneration.
  • the amount of coating in fiber layer (PCU) as dry basis was about 2.5 g in fiber layer and Pt loading was about 1 .2 g (3.9 g/dm 3 ).
  • Pt loading was higher on that fibrous PCU unit than on whole OPS.
  • the length of OPS was 180 mm and the diameter was 1 15 mm.
  • the addition of PCU layer inside OPS structure did not change the total volume of OPS without the fibre mats.
  • the device without ignition element can be used as in the applications where temperatures are high enough to passive regeneration and/or the design does not need ignitions and/or active regeneration are in use (Fig. 9).
  • the use of PCU enhances the particulate efficiency without increasing unnecessarily the volume or weight of the system.
  • Metallic PCU is advantageous in some embodiments because it is mechanically strong and conducts heat better than ceramic structures.

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Abstract

L'invention concerne un dispositif de purification (PD) destiné à éliminer des impuretés, par exemple des particules contenant du carbone et des hydrocarbures des gaz d'échappement et de combustion. L'invention concerne également un procédé de fabrication et un procédé d'utilisation et de régénération d'un tel dispositif de purification. Le dispositif de purification (PD) comprend au moins un séparateur particulaire ouvert (OPS) comprenant des feuilles perméables/semi-perméables, des nappes et/ou des plaques et ayant des canaux ouverts (CHA) destinés à l'écoulement des gaz avec des impuretés entre lesdites feuilles/nappes/plaques, et ledit dispositif de purification (PD) comprend en outre au moins un élément d'allumage (IE) pour allumer (périodiquement) des impuretés des gaz recueillis et en écoulement.
PCT/FI2011/050225 2011-03-16 2011-03-16 Dispositif de purification WO2012123618A1 (fr)

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PCT/FI2011/050225 WO2012123618A1 (fr) 2011-03-16 2011-03-16 Dispositif de purification
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RU2013142196/06U RU151051U1 (ru) 2011-03-16 2012-03-16 Очистительное устройство
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CN105371287A (zh) * 2015-12-15 2016-03-02 苏州韵蓝环保科技有限公司 一种废气净化燃烧装置
WO2019194881A1 (fr) * 2018-04-05 2019-10-10 Catalytic Combustion Corporation Catalyseur en feuille métallique pour la commande d'émissions provenant de moteurs diesel
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DE102017130314A1 (de) * 2016-12-19 2018-06-21 Johnson Matthey Public Limited Company Erhöhte NOx-Umwandlung durch Einführung von Ozon
DE102018221575A1 (de) * 2018-12-12 2020-06-18 Eos Gmbh Electro Optical Systems Verfahren und Vorrichtung zur Nachbehandlung von in einem Prozessgas mitgeführten Partikeln sowie Filter hierfür
CN112195349B (zh) * 2020-10-10 2022-06-24 江西邦展建筑模板科技有限公司 一种建筑固体废弃物的铝合金回收利用装置
CN112879124A (zh) * 2021-01-26 2021-06-01 东风汽车集团股份有限公司 汽车尾气颗粒物吸附装置

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CN105298592A (zh) * 2015-11-18 2016-02-03 苏州韵蓝环保科技有限公司 一种汽车尾气处理装置
CN105371287A (zh) * 2015-12-15 2016-03-02 苏州韵蓝环保科技有限公司 一种废气净化燃烧装置
WO2019194881A1 (fr) * 2018-04-05 2019-10-10 Catalytic Combustion Corporation Catalyseur en feuille métallique pour la commande d'émissions provenant de moteurs diesel
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CN114425207B (zh) * 2020-09-17 2023-01-10 中国石油化工股份有限公司 气体除尘装置及其除尘填料

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RU151051U1 (ru) 2015-03-20
CN203867667U (zh) 2014-10-08
WO2012123643A1 (fr) 2012-09-20

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