ZA200500085B - Mechanical power generator comprising a diesel engine and a catalytic converter. - Google Patents

Mechanical power generator comprising a diesel engine and a catalytic converter. Download PDF

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Publication number
ZA200500085B
ZA200500085B ZA200500085A ZA200500085A ZA200500085B ZA 200500085 B ZA200500085 B ZA 200500085B ZA 200500085 A ZA200500085 A ZA 200500085A ZA 200500085 A ZA200500085 A ZA 200500085A ZA 200500085 B ZA200500085 B ZA 200500085B
Authority
ZA
South Africa
Prior art keywords
channel
substrate
section
order
cross
Prior art date
Application number
ZA200500085A
Inventor
Alain Ristori
Sophie Salasc
Christian Sarda
Original Assignee
Faurecia Sys Echappement
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 Faurecia Sys Echappement filed Critical Faurecia Sys Echappement
Publication of ZA200500085B publication Critical patent/ZA200500085B/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/02—Combinations of different methods of purification filtering and catalytic conversion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • 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
    • F01N2330/34—Honeycomb supports characterised by their structural details with flow channels of polygonal cross section
    • 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
    • F01N2330/48—Honeycomb supports characterised by their structural details characterised by the number of flow passages, e.g. cell density
    • 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

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)

Description

- B%.2005/008%
Mechanical power generator comprising a diesel engine and a catalytic converter
The present invention relates to a mechanical power generator of the type comprising a diesel engine and an exhaust tract comprising a catalytic converter, which catalytic converter comprises a substrate which defines adjacent channels.
It is known, in order to carry out the depollution of exhaust gases from a diesel engine, and in particular a motor vehicle engine, to provide the ex- haust tract with a catalytic converter. This converter comprises a substrate constituted by a structure, on the surface of which a catalytic material is de- posited and is referred to by the term "washcoat". Examples of substrates are given in documents EP-0.036.052, EP-0.360.591 and EP-0.446.046.
The substrate delimits an assembly of channels which extend over the entire length thereof. These channels are adjacent and extend parallel with each other.
The cross-section of the channels is selected so as to be square in order to depollute diesel engines.
In order to improve the efficiency of the catalytic converter for a total volume of substrate under consideration, it is known to increase the channel density per unit of surface-area in accordance with a cross-section of the substrate. This channel density is referred to as “cpsi” in the technical field in question.
The increase in the channel density allows the total surface-area of the channels per unit of volume of substrate to be increased. This total sur- face-area of the channels is referred to as "GSA".
However, the increase in the channel density (cpsi) brings about a decrease in the cross-section provided for the passage of gases in each channel. Thus, with a high channel density, it is found that the presence of soots in the exhaust gases produced by the diesel engine leads to clogging of the substrate, making the catalytic converter inoperative.
The object of the invention is to provide a mechanical power genera- tor comprising a diesel engine and a catalytic converter for depolluting the exhaust gases of the diesel engine, the catalytic converter having great effi- ciency without any risk of clogging.
To this end, the invention relates to a mechanical power generator of the above-mentioned type, characterised in that each channel has a hex- agonal cross-section, and in that the hydraulic diameter of each channel is greater than 900 ym.
According to specific embodiments, the mechanical power generator comprises one or more of the following features: - the channel density over the cross-section of the substrate per unit of surface-area expressed in square inches is in the order of between 400 and 900; - the channel density over the cross-section of the substrate per unit of surface-area expressed in square inches is in the order of between 500 and 800; - the channel density over the cross-section of the substrate per unit of surface-area expressed in square inches is substantially in the order of 600; - the thickness of the porous walls, expressed in thousandths of an inch, is in the order of between 2 and 5 (50.8 um and 127 um); - the thickness of the porous walls, expressed in thousandths of an inch, is substantially in the order of 3 (76.2 um); - each channel has the cross-section of a regular hexagon; and - the substrate comprises a homogeneous and continuous structure which defines channels whose surfaces are covered with a coating of cata- lytic material.
The invention further relates to the use, in an exhaust tract of a diesel engine, of a catalytic converter which is arranged in an exhaust tract, the converter comprising a substrate which defines adjacent channels, charac- terised in that each channel has a hexagonal cross-section and the hydraulic diameter of each channel is greater than 900 um.
The invention will be better understood from a reading of the descrip- tion below which is given purely by way of example and with reference to the drawings, in which:
- Figure 1 is a schematic view of a mechanical power generator ac- cording to the invention; - Figure 2 is a schematic longitudinal section of a catalytic converter used in the invention; and - Figure 3 is a cross-section of the catalytic converter used in the in- vention.
Figure 1 illustrates a mechanical power generator according to the invention.
The generator is used, for example, for propelling a motor vehicle.
This generator comprises an engine 12 which is connected, in order to be supplied with fuel, to a storage tank 14 for diesel. The exhaust outlet of the engine 12 is connected to an exhaust tract 16 which is provided with a catalytic converter 18. A particulate filter can advantageously be arranged upstream or downstream of the catalytic converter 18.
The engine 12 is a diesel engine. According to the invention, a diesel engine is intended to refer to a high-compression internal combustion engine which brings about the self-ignition of the fuel constituted by diesel or heavy oil.
This type of engine differs from petrol engines owing to the absence of an ignition system per se.
The diesel engine is an engine of the type operating at a temperature generally higher than 200°C. This temperature is measured at the outlet of the exhaust manifold, that is to say, at the outlet of the engine. This tempera- ture is generally in the order of between 200°C and 900°C.
In this manner, this engine produces, at the outlet, a relatively large quantity of fine carbonaceous particulates which are constituted by soots resulting from combustion in the diesel engine. This quantity of soots is greater than that produced by an engine which operates at low temperature, that is to say, at a temperature of less than 200°C.
The catalytic converter 18 comprises a porous substrate 20 which is contained in a casing 21 which is connected to the exhaust tract. The sub- strate 20 defines, as illustrated in Figure 2, adjacent and parallel channels
22 which extend over the entire length of the substrate, from one end to the other thereof in the general direction F of flow of the exhaust gases.
All the channels have an identical cross-section. According to the in- vention and as illustrated in Figure 3, the cross-section of the channels is hexagonal, each channel defining a regular hexagon.
The channels are separated from each other by planar longitudinal walls 24, each forming a side of a hexagon. These walls have a total thick- ness e which is the same for all the walls.
The substrate 20 is formed by a structure 26 which is covered with a coating 28 of catalytic material referred to as "washcoat". The structure is constituted by a homogeneous and continuous block, in which the channels 22 are defined. The thickness of the walls of the structure is in the order of between 50 and 150 pm. This thickness is designated e; in the following de- scription. The structure 26 is advantageously formed by a porous honey- combed structure produced, for example, from ceramic material.
The surface of each channel is covered with a catalytic material form- ing the washcoat. Different thicknesses of washcoat are to be found over a given channel cross-section. In particular, the thickness is greater in the “corners”. The mean thickness designated e, of the coating 28 of catalytic material is in the order of between 5 um and 200 um and is preferably in the order of 50 um. Examples of catalytic material are given in documents EP- 0.601.314, EP-0.244.127 and EP-1.044.058.
Thus, the total thickness e of a wall of the substrate is equal to ey + 2 ey.
According to the invention, the dimensions of the channels 22 delim- ited in the substrate, that is to say, the structure covered with the catalytic material, are such that the hydraulic diameter HD of each channel 22 is greater than 900 ym. The hydraulic diameter HD of a channel is defined as being the diameter of the circle drawn in the hexagon which delimits the cross-section of the channel formed in the substrate covered by "washcoat".
The structure 26 covered with the catalytic material 28 and the sub- strate are characterised by their number of channels per square inch, an inch being equal to 2.54 cm. The substrate 20 is further characterised by the thickness of the walls, expressed in thousandths of an inch with a thou- sandth of an inch being equal to 25.4 ym.
In this manner, the structure of a catalytic converter can be defined by the pair X/Y, where X is the number of channels per unit of surface-area of 5 the cross-section thereof expressed in square inches and Y is the thickness er of the walls of the structure expressed in thousandths of an inch. The number X is in fact equal to the "cpsi".
Advantageously, the number X of channels per square inch is in the order of between 400 and 900, preferably between 500 and 800 and, best of all, substantially in the order of 600.
The thickness Y of each wall of the structure is advantageously in the order of between 2 and 5 thousandths of an inch (60.8 ym to 127 pm). It is preferably in the order of 3 thousandths of an inch (76.2 um).
For example, a 600/3 catalytic converter whose channel density (cpsi) is in the order of 600 channels per square inch, having a wall thickness in the order of 3 thousandths of an inch (76.2 pm) and a minimum washcoat thickness of 50 um, has, for each channel, a hydraulic diameter HD in the order of 940 pm.
It is found that, with such a catalytic converter, the channels have a sufficient cross-section to prevent clogging owing to soots conveyed by the exhaust gases. The use of hexagonal cross-sections allows the catalytic converter to have better compatibility with the presence of soots in the ex- haust gases.
The tables below show the results obtained with catalytic converters whose channels are hexagonal or square, with different channel densities.
The results below were obtained with a thickness of the catalytic ma- terial coating (washcoat, referred to as WC in the Tables) of 20 micrometres.
The load of precious metals, that is to say, platinum, of the catalytic con- verter is 40g/foot® .
GSA GSA with HD
Geometry | CPSI Wall without WC without HD with thickness WC (cm?/cm? | WC (mm) | WC (mm) (cm?/cm?®)
TEC I A CO I
TE RI CO CO A EC
Soa [S| 3 | wy | me | om | om
Feral 0 | 3 | m4 | Wz | wee | Tm (Swe wo | 8 | mex
I IC I I CN
(Fool | 6 | ® | mex
Geometry |CPSI Wall Duration Closure Soot
TT ee | | on
Square 41 Partially 23 mT ee
Square 3 20 Totally 38
ET ew
Hexagonal 3 38 Partially 35
TL Tee [7
With reference to a substrate having a cpsi of 400/6, it has been found that it is possible to obtain an increase of from 12 % to 14 % in the processing of carbon monoxide emissions using substrates having a cpsi of 600/3. Among the substrates having a cpsi of 600/3, however, those having channels of square cross-section rapidly become clogged and are even completely blocked after only 20 hours of use. On the other hand, substrates having a cpsi of 600/3 with channels of hexagonal cross-section are still op- erational after 38 hours of use.
Therefore, it has been found that these substrates have efficiency at least equal to that of substrates having a square cpsi of 600/3, whilst still having an increased service life (at least equal to substrates having a square cpsi of 400/6).
Therefore, the catalytic converter according to the invention allows both good efficiency for reducing the emission of carbon monoxide and diox- ide (14%) and delayed clogging (38 hours) to be achieved.

Claims (10)

1.- Mechanical power generator comprising a diesel engine (12) and an exhaust tract (16) comprising a catalytic converter (18), which catalytic converter (18) comprises a substrate (20) which defines adjacent channels (22), characterised in that each channel (22) has a hexagonal cross-section, the hydraulic diameter (HD) of each channel (22) is greater than 900 pm, and the channel density in the cross-section of the substrate per unit of sur- face-area expressed in square inches is in the order of between 400 and
900.
2.- Generator according to claim 1, characterised in that the channel density in the cross-section of the substrate per unit of surface-area ex- pressed in square inches is in the order of between 500 and 800.
3.- Generator according to claim 2, characterised in that the channel density in the cross-section of the substrate per unit of surface-area ex- pressed in square inches is substantially in the order of 600.
4 .- Generator according to any one of the preceding claims, charac- terised in that the thickness (e) of the porous walls (24), expressed in thou- sandths of an inch, is in the order of between 2 and 5 (50.8 um and 127 pm).
5.- Generator according to any one of the preceding claims, charac- terised in that the thickness of the porous walls (24), expressed in thou- sandths of an inch, is substantially in the order of 3 (76.2 ym).
6.- Generator according to any one of the preceding claims, charac- terised in that each channel (20) has the cross-section of a regular hexagon.
7.- Generator according to any one of the preceding claims, charac- terised in that the substrate (20) comprises a homogeneous and continuous structure (26) which defines channels whose surfaces are covered with a coating (28) of catalytic material.
8.- Generator according to any one of the preceding claims, charac- terised in that the substrate (20) comprises a structure (26) of ceramic mate- rial.
9.- Generator according to any one of the preceding claims, charac- terised in that the diesel engine has an operating temperature higher than 200°C.
10.- Use, in order to depollute exhaust gases of a diesel engine (12), of a catalytic converter (18) which is arranged in an exhaust tract (16), the converter (18) comprising a substrate (20) which defines adjacent channels (22), characterised in that each channel (22) has a hexagonal cross-section and the hydraulic diameter (HD) of each channel (20) is greater than 900 um.
ZA200500085A 2002-07-08 2005-01-05 Mechanical power generator comprising a diesel engine and a catalytic converter. ZA200500085B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0208567A FR2841937B1 (en) 2002-07-08 2002-07-08 MECHANICAL POWER GENERATOR COMPRISING A DIESEL ENGINE AND A CATALYTIC CONVERTER

Publications (1)

Publication Number Publication Date
ZA200500085B true ZA200500085B (en) 2005-10-19

Family

ID=29725280

Family Applications (1)

Application Number Title Priority Date Filing Date
ZA200500085A ZA200500085B (en) 2002-07-08 2005-01-05 Mechanical power generator comprising a diesel engine and a catalytic converter.

Country Status (6)

Country Link
EP (1) EP1546518A1 (en)
KR (1) KR20050046710A (en)
AU (1) AU2003263273A1 (en)
FR (1) FR2841937B1 (en)
WO (1) WO2004005680A1 (en)
ZA (1) ZA200500085B (en)

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS605545B2 (en) 1980-03-19 1985-02-12 日本碍子株式会社 Low expansion ceramics and their manufacturing method
EP0244127A1 (en) 1986-04-16 1987-11-04 Johnson Matthey, Inc., Method for catalytically controlling exhaust gaz from automobiles
JPH074534B2 (en) 1988-09-22 1995-01-25 日本碍子株式会社 Honeycomb structure and manufacturing method thereof
JP2736099B2 (en) * 1989-02-06 1998-04-02 株式会社日本触媒 Diesel engine exhaust gas purification catalyst
JPH03258911A (en) 1990-03-08 1991-11-19 Ngk Insulators Ltd Filter for diesel particulate
DE4239875C2 (en) 1992-11-27 1999-02-11 Degussa Exhaust gas purification system to reduce hydrocarbon emissions during the cold start of internal combustion engines
GB9800325D0 (en) 1998-01-09 1998-03-04 Johnson Matthey Plc Improvements in catalytic materials
BE1012807A3 (en) * 1998-12-21 2001-03-06 Denso Corp Catalyst for cleaning exhaust engine explosion.
DE19921263A1 (en) * 1999-05-07 2000-11-16 Emitec Emissionstechnologie Internal combustion engine with a small-volume catalyst

Also Published As

Publication number Publication date
WO2004005680A1 (en) 2004-01-15
FR2841937A1 (en) 2004-01-09
KR20050046710A (en) 2005-05-18
FR2841937B1 (en) 2006-07-14
EP1546518A1 (en) 2005-06-29
AU2003263273A1 (en) 2004-01-23

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