WO2013126575A1 - Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines - Google Patents

Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines Download PDF

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Publication number
WO2013126575A1
WO2013126575A1 PCT/US2013/027142 US2013027142W WO2013126575A1 WO 2013126575 A1 WO2013126575 A1 WO 2013126575A1 US 2013027142 W US2013027142 W US 2013027142W WO 2013126575 A1 WO2013126575 A1 WO 2013126575A1
Authority
WO
WIPO (PCT)
Prior art keywords
dpf
exhaust
control module
heating mode
heater
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/US2013/027142
Other languages
English (en)
French (fr)
Inventor
Wenzhong Zhang
Mike BANGE
Scott BOEHMER
Magdi KHAIR
Tan JULIAN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Watlow Electric Manufacturing Co
Original Assignee
Watlow Electric Manufacturing Co
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 Watlow Electric Manufacturing Co filed Critical Watlow Electric Manufacturing Co
Priority to EP13714727.8A priority Critical patent/EP2834488B1/en
Priority to EP17158493.1A priority patent/EP3192991B1/en
Priority to JP2014558824A priority patent/JP6018646B2/ja
Priority to ES13714727.8T priority patent/ES2638605T3/es
Priority to CA2865165A priority patent/CA2865165C/en
Publication of WO2013126575A1 publication Critical patent/WO2013126575A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
    • 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
    • F01N3/08—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
    • F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
    • F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating 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
    • 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
    • F01N9/00—Electrical control of exhaust gas treating apparatus
    • F01N9/002—Electrical control of exhaust gas treating apparatus of filter regeneration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/16—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being an electric heater, i.e. a resistance heater
    • 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
    • F01N2590/00—Exhaust or silencing apparatus adapted to particular use, e.g. for military applications, airplanes, submarines
    • F01N2590/08—Exhaust or silencing apparatus adapted to particular use, e.g. for military applications, airplanes, submarines for heavy duty applications, e.g. trucks, buses, tractors, locomotives
    • 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

  • the present disclosure relates to exhaust aftertreatment systems for diesel engines, and more particularly to electric heating and control to provide assisted heating in the exhaust aftertreatment systems.
  • Diesel engines have been used in a variety of applications such as locomotives, marines and engine-generators.
  • exhaust aftertreatment systems have been employed and generally include a Diesel Oxidation Catalyst (DOC), a Diesel Particulate Filter (DPF), and an SCR (Selective Catalytic Reduction of NOx) to treat the exhaust gas and to control emissions to atmosphere or the outside environment.
  • DOC Diesel Oxidation Catalyst
  • DPF Diesel Particulate Filter
  • SCR Selective Catalytic Reduction of NOx
  • a method of heating an exhaust gas in an exhaust aftertreatment system including a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF) includes heating the exhaust gas to a predetermined temperature to increase N0 2 generation in the DOC when the DPF is not actively regenerated and when the engine load is low, and heating the exhaust gas to reduce an exhaust temperature gradient when the DPF is actively regenerated.
  • the increased N0 2 generation facilitates passive regeneration of the DPF.
  • the exhaust temperature gradient is reduced by providing more heat proximate a wall of an exhaust conduit and less heat proximate a center of the exhaust conduit.
  • the efficiency of the active regeneration of the DPF can be required heat for active regeneration of DPF can be increased due to more efficient burning of PM at the peripheral channels of the DPF.
  • FIG. 2 is a schematic view of a heating module constructed in accordance with the teachings of the present disclosure
  • FIG. 4 is a schematic view of an electric heater
  • FIG. 5 is a graph showing a heating strategy for operating the electric heater
  • FIG. 6 is a table showing the properties of the exhaust gas at different engine loads.
  • FIG. 7 is a schematic view of another form of an engine system including a heating module constructed in accordance with the teachings of the present disclosure.
  • the DOC 22 is disposed downstream from the electric heater 28 and serves as a catalyst to oxide carbon monoxide and any unburnt hydrocarbons in the exhaust gas.
  • the DOC 22 converts harmful nitric oxide (NO) into nitrogen dioxide (N0 2 ).
  • the DPF 24 is disposed downstream from the DOC 22 to remove diesel particulate matter (PM) or soot from the exhaust gas.
  • the SCR 26 is disposed downstream from the DPF 24 and, with the aid of a catalyst, converts nitrogen oxides (NOx) into nitrogen (N 2 ) and water.
  • a urea water solution injector 27 is disposed downstream from the DPF 24 and upstream from the SCR 26 for injecting urea water solution into the stream of the exhaust gas. When urea water solution is used as the reductant in the SCR 18, NOx is reduced into N 2 , H 2 0 and C0 2 in the following reaction:
  • the electric heater 28 provides assisted heating of the exhaust gas flowing in the exhaust conduits 32, 34, 36.
  • the generator 14 is connected to the diesel engine 12 to drive the diesel engine 12 during engine startup as an option and to supply electricity to the electric heater 34 during normal engine operation.
  • the heater control module 30 strategically controls the electric heater 28 in different heating modes to facilitate both active and passive regeneration of the DPF 24.
  • Regeneration is the process of burning and removing the accumulated particulates matters from the DPF 24. Regeneration can occur passively or actively. Passive regeneration can occur in normal engine operation when the temperature of the exhaust gas is sufficiently high. Active regeneration can occur based on a monitored DPF condition or based on a predetermined timing schedule by introducing very high heat to the exhaust aftertreatment system 10.
  • the heater control module 30 strategically controls operation of the electric heater 28 based on an engine load and a status of the DPF 24 to provide assisted heating in both active and passive regeneration of the DPF.
  • the heater control module 24 may be a part of an engine control unit (ECU) (not shown) or external to the ECU.
  • the ECU controls operation of the diesel engine 12, a fuel injection system (not shown), among others, and acquires and stores various parameters relating to engine operating conditions, including but not limited to, exhaust temperature, diesel engine load, flow conditions (air flow and air pressure etc.)
  • the heater control module 30 receives inputs from the ECU to make the proper determination how to operate the electric heater 28.
  • the control module could also receive information from stand alone after treatment control systems.
  • the heater control module 30 includes a heating mode determination module 32 and a heater operating module 33 including a passive regeneration heating module 34 and an active regeneration heating module 36.
  • the electric heater 22 can be operated in two operating modes: passive regeneration heating mode and active regeneration heating mode.
  • the heating mode determination module 32 determines a desired heating mode based on an engine load and the status of the DPF 24. When the DPF 24 is actively regenerated, the desired heating mode is the active regeneration heating mode. When the DPF 24 is not actively regenerated and the engine load is low, for example, at 10%, the desired heating mode is the passive regeneration heating mode.
  • the heating mode determination module 32 may include a heating strategy that specifies the correlation among the heating modes, duration, engine loads and the desired exhaust temperature rise. The heating mode determination module 32 also determines when the electric heater 28 should be turned on or off during normal engine operation. In response to the determination of the heating mode determination module 32, the heater operating module 33 operates the electric heater 28 accordingly.
  • the electric heater 28 is controlled to heat the exhaust gas to a predetermined temperature which allows for optimum N0 2 generation in the DOC 22.
  • N0 2 is an effective reactant for passive regeneration of DPF 24. Increasing N0 2 generation can facilitate passive regeneration of DPF 24.
  • the electric heater 28 is controlled to heat the exhaust gas differently to reduce exhaust temperature gradient across the exhaust conduits. When the temperature gradient is reduced, the active regeneration can be accomplished more efficiently.
  • the passive regeneration heating module 34 controls the electric heater 28 to heat the exhaust gas to a predetermined temperature.
  • the passive regeneration heating module 34 calculates and determines the desired temperature rise based on an exhaust temperature and the predetermined temperature.
  • the exhaust temperature may be obtained from the input from the ECU, temperature sensors.
  • the predetermined temperature depends on the properties of the catalysts in the DOC 14 and is set to allow for optimum N0 2 generation.
  • the electric heater 28 is powered by the generator 32.
  • the generator 32 drives the diesel engine 30 during engine startup. After the diesel engine 30 starts to operate on its own, the generator 30 is driven by the diesel engine 30 to generate electricity to power other electronics or electrical devices.
  • the heating strategy allows for use of available electricity generating capacity when it is not needed to power the other electrical and electronic systems during low engine load operation.
  • the heating mode determination module 32 includes a heating strategy which specifies the correlations among the heating modes, the exhaust temperature rise, the engine loads. As shown in the exemplary diagram, when the engine load is low and the DPF backpressure is in the range of medium to high, the target exhaust temperature rise (delta) would be low and the electric heater 28 is operated in the passive regeneration mode.
  • the electric heater 22 is in the passive regeneration heating mode when the diesel engine 30 is operating near low load conditions such as 10% load.
  • the electric heater 22 demands less electric power from the generator 32 because the desired temperature rise (delta) is less than that for active regeneration and because less exhaust gas is generated from the diesel engine 30 due to the low engine load.
  • the electric heater 22 is turned off. Active regeneration of DPF may be initiated when the engine load is low or according to a predetermined schedule to benefit from heating lower exhaust mass flow.
  • the electric heater is turned on and operated in the active regeneration heating mode to provide differential heating.
  • the electric heater 28 is turned off.
  • the table illustrates the exhaust contents for different load conditions.
  • the exhaust gas exhibits the lowest exhaust flow (1925 cfm) and the highest available specific NOx (6.8 g/bhp-hr) among the 5 load conditions for a gen-set type of large diesel engine.
  • the DOC downstream of the heater will generate maximum amount of N0 2 due to higher available NOx under this load engine condition.
  • N0 2 passively oxidizes the particulate matter loaded DPF downstream of the DOC at its maximum rate.
  • the electric heating strategy of the present disclosure may replace the fuel-injection-based active regeneration.
  • the heating module 20 of the present disclosure has at least the following benefits:
  • the present disclosure may include methods of heating portions of the gas flow in a more indirect matter.
  • the system could sense cooler portions within the gas flow cross section and provide heat where needed to provide a more even temperature distribution and compensate for heat losses.
  • the system may regenerate in certain sections or zones at different times.
  • These alternate forms of the present disclosure would also have a corresponding heater type that supports zone heating across the cross-section of gas flow, such as, by way of example, layered heaters or modular heat trace heaters such as those disclosed in pending U.S. application serial number 1 1/238,747 titled "Modular Layered Heater System” and in U.S. Patent No. 7,626,146 titled “Modular Heater Systems,” both of which are commonly assigned with the present application and the contents of which are incorporated by reference herein in their entirety.

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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)
  • Processes For Solid Components From Exhaust (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Control Of Vehicle Engines Or Engines For Specific Uses (AREA)
PCT/US2013/027142 2012-02-22 2013-02-21 Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines Ceased WO2013126575A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP13714727.8A EP2834488B1 (en) 2012-02-22 2013-02-21 Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines
EP17158493.1A EP3192991B1 (en) 2012-02-22 2013-02-21 Method of heating an exhaust gas in an exhaust aftertreatment system
JP2014558824A JP6018646B2 (ja) 2012-02-22 2013-02-21 ヒータ制御モジュール
ES13714727.8T ES2638605T3 (es) 2012-02-22 2013-02-21 Regeneración activa y pasiva asistida por calentamiento eléctrico para controles de emisión eficaces de motores diésel
CA2865165A CA2865165C (en) 2012-02-22 2013-02-21 Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261601923P 2012-02-22 2012-02-22
US61/601,923 2012-02-22

Publications (1)

Publication Number Publication Date
WO2013126575A1 true WO2013126575A1 (en) 2013-08-29

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2013/027142 Ceased WO2013126575A1 (en) 2012-02-22 2013-02-21 Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines

Country Status (6)

Country Link
US (4) US9115616B2 (enExample)
EP (2) EP3192991B1 (enExample)
JP (2) JP6018646B2 (enExample)
CA (1) CA2865165C (enExample)
ES (2) ES2638605T3 (enExample)
WO (1) WO2013126575A1 (enExample)

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