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US20060048502A1 - Integrated system for reducing fuel consumption and emissions in an internal combustion engine - Google Patents

Integrated system for reducing fuel consumption and emissions in an internal combustion engine Download PDF

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Publication number
US20060048502A1
US20060048502A1 US11/193,930 US19393005A US2006048502A1 US 20060048502 A1 US20060048502 A1 US 20060048502A1 US 19393005 A US19393005 A US 19393005A US 2006048502 A1 US2006048502 A1 US 2006048502A1
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Prior art keywords
stream
fuel
engine
fuel processor
outlet
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US11/193,930
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English (en)
Inventor
Kirk Washington
Erik Johannes
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Nxtgen Emission Controls Inc
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Individual
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Priority to US11/193,930 priority Critical patent/US20060048502A1/en
Assigned to NXTGEN EMISSION CONTROLS INC. reassignment NXTGEN EMISSION CONTROLS INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JOHANNES, ERIK P., WASHINGTON, KIRK B.
Publication of US20060048502A1 publication Critical patent/US20060048502A1/en
Priority to US11/676,499 priority patent/US20070193254A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/54—Nitrogen compounds
    • B01D53/56—Nitrogen oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404—Removing only nitrogen compounds
    • B01D53/9409—Nitrogen oxides
    • B01D53/9431—Processes characterised by a specific device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/96—Regeneration, reactivation or recycling of reactants
    • 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
    • F01N13/011—Exhaust or silencing apparatus characterised by constructional features having two or more purifying devices arranged in parallel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0871—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents using means for controlling, e.g. purging, the absorbents or adsorbents
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0871—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents using means for controlling, e.g. purging, the absorbents or adsorbents
    • F01N3/0885—Regeneration of deteriorated absorbents or adsorbents, e.g. desulfurization of NOx traps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
    • F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F02M25/10—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture adding acetylene, non-waterborne hydrogen, non-airborne oxygen, or ozone
    • F02M25/12—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture adding acetylene, non-waterborne hydrogen, non-airborne oxygen, or ozone the apparatus having means for generating such gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
    • F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
    • F02M26/36—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with means for adding fluids other than exhaust gas to the recirculation passage; with reformers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/91—NOx-storage component incorporated in the catalyst
    • 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
    • F01N2240/30—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 a fuel reformer
    • 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
    • F01N2240/36—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 exhaust flap
    • 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
    • F01N2290/00—Movable parts or members in exhaust systems for other than for control purposes
    • F01N2290/02—Movable parts or members in exhaust systems for other than for control purposes with continuous rotary movement
    • 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
    • F01N2390/00—Arrangements for controlling or regulating exhaust apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
    • F01N2410/12—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device in case of absorption, adsorption or desorption of exhaust gas constituents
    • 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
    • F01N2470/00—Structure or shape of exhaust gas passages, pipes or tubes
    • F01N2470/16—Plurality of inlet tubes, e.g. discharging into different chambers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/03—Adding substances to exhaust gases the substance being hydrocarbons, e.g. engine fuel
    • 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
    • F01N3/025—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 fuel burner or by adding fuel to exhaust
    • F01N3/0253—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 fuel burner or by adding fuel to exhaust adding fuel to exhaust gases
    • 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
    • F01N3/029—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 by adding non-fuel substances to exhaust
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
    • F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
    • F02M26/35—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with means for cleaning or treating the recirculated gases, e.g. catalysts, condensate traps, particle filters or heaters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to the field of internal combustion engines, including diesel-fueled and gasoline-fueled internal combustion engines.
  • the present integrated system is capable of reducing fuel consumption and regulated emissions of internal combustion engines. This capability is achieved by integrating a fuel processing device with the engine system and other devices that assist in reducing regulated emissions.
  • the present integrated fuel processing system supplies a hydrogen-containing stream to one or more parts of the engine system resulting in reduced fuel consumption and reduced emissions.
  • the present system is integrated such that components of the engine provide benefits in addition to reducing fuel consumption and reduced regulated emissions.
  • the present integrated system reduces both fuel consumption and regulated emissions simultaneously, without significant adverse effect on capital costs and with the potential for improved operating costs as a result of better fuel efficiency.
  • Capital cost can be potentially reduced by eliminating certain parts, such as exhaust gas recirculation system components, and/or enabling certain parts, such as diesel particulate filters and engine displacement/total cylinder volume, to be reduced in size.
  • NOx emissions have been reduced primarily by increasing and/or cooling the exhaust gas recycle stream (EGR).
  • EGR exhaust gas recycle stream
  • Another technique employed to reduce NOx (nitrogen oxide) emissions has been to retard fuel injection timing.
  • the timing of fuel injection into the engine's combustion chamber(s) can be advanced in relation to fuel injection timing that is retarded to reduce NOx emissions.
  • Advancing fuel injection timing increases fuel economy and engine exhaust NOx emissions, which are in turn reduced downstream in the after-treatment portion of the present system.
  • the above-described and/or other shortcomings of prior techniques for reducing NOx emissions are overcome by an integrated NOx after-treatment system for an internal combustion engine.
  • the system comprises:
  • conversion of the fuel stream directed to the fuel processor to an outlet stream comprising H 2 and CO can be promoted by thermal means.
  • conversion of the fuel stream directed to the fuel processor to an outlet stream comprising H 2 and CO can also be promoted by a catalyst material.
  • a preferred catalyst material adsorbs CO, and preferably comprises platinum.
  • the platinum-containing catalyst material can be disposed on a supporting substrate.
  • a preferred supporting substrate is ceramic, preferably selected from the group consisting of zirconia and alumina.
  • the fuel processor outlet stream molar concentration of each of H 2 and CO is in the range of 5-30 percent.
  • the fuel processor outlet stream comprising H 2 and CO is passed periodically through the catalyst/adsorbent bed to evolve adsorbed NOx at a temperature lower than the NOx desorption temperature of stream compositions other than that of the fuel processor outlet stream.
  • the fuel processor outlet comprising H 2 and CO is passed periodically through the catalyst/adsorbent bed to evolve adsorbed SOx at a temperature lower than the SOx desorption temperature of stream compositions other than that of the fuel processor outlet stream.
  • a method for reducing NOx emissions and fuel consumption in an internal combustion engine comprises:
  • fuel injection timing is advanced in relation to fuel injection timing that is retarded to reduce NOx emissions.
  • conversion of the fuel stream directed to the fuel processor to an outlet stream comprising H 2 and CO can promoted by thermal means.
  • conversion of the fuel stream directed to the fuel processor to an outlet stream comprising H 2 and CO can also be promoted by a catalyst material.
  • a preferred catalyst material adsorbs CO, and preferably comprises platinum.
  • the platinum-containing catalyst material can be disposed on a supporting substrate.
  • a preferred supporting substrate is ceramic, preferably selected from the group consisting of zirconia and alumina.
  • the fuel processor outlet stream molar concentration of each of H 2 and CO is in the range of 5-30 percent.
  • the fuel processor outlet stream comprising H 2 and CO is passed periodically through the catalyst/adsorbent bed to evolve adsorbed NOx at a temperature lower than the NOx desorption temperature of stream compositions other than that of the fuel processor outlet stream.
  • the fuel processor outlet comprising H 2 and CO is passed periodically through the catalyst/adsorbent bed to evolve adsorbed SOx at a temperature lower than the SOx desorption temperature of stream compositions other than that of the fuel processor outlet stream.
  • a fuel and an engine exhaust stream are employed in the present system and method to produce a stream containing hydrogen and carbon monoxide.
  • This stream is produced substantially continually in a fuel processing device and supplied to a catalyst and adsorbent bed, which has trapped oxides of nitrogen (NOx) adsorbed to the adsorbent and/or the adsorbent/catalyst.
  • NOx trapped oxides of nitrogen
  • the stream promotes NOx desorption and reacts with the NOx and regenerates the NOx adsorption material so that it can be made available to another cycle of trapping NOx from the engine's exhaust stream.
  • the catalyst and adsorbent bed can be contained within a number of beds, including a rotating bed, that is controlled in a manner that decreases or minimizes the reducing agent required to achieve a desired reduction in NOx emissions, and/or decreases or minimizes the size and cost of the equipment involved, and/or provides some trade-off between the amount of reducing agent required and the size/cost of the equipment.
  • the adsorbent material can also be contained in a plurality of beds that are made to undergo a cycle of adsorption and regeneration. The cycle length and frequency is controlled or set so as to decrease or minimize the quantity of reducing agent required or desirable to achieve a desired reduction in NOx emissions.
  • a single material could potentially act as both a catalyst and an adsorbent.
  • a material would include platinum, which in hydrocarbon catalytic reactors (reformers) can act as a catalyst for the decomposition of the hydrocarbon feed material to hydrogen, carbon dioxide and carbon monoxide, and also acts as an adsorbent of carbon monoxide, which preferentially adsorbs on catalytic materials containing platinum.
  • adsorbent/catalyst materials are carbon nanohorns, which adsorb ethanol and, in the presence of oxygen, catalyze the oxidation reaction between ethanol and oxygen (see Nisha et al., “Adsorption and catalytic properties of single-walled carbon nanohorns”, Chemical Physics Letters 328 (2000), pp. 381-386).
  • FIG. 1 is a schematic process flow diagram illustrating a preferred embodiment of the present system for reducing emissions and fuel consumption in an internal combustion engine system.
  • FIG. 2 is a top schematic view of the rotary adsorbent bed of the system for reducing emissions and fuel consumption illustrated in FIG. 1 .
  • FIG. 3 is a cross-sectional schematic view of the rotary adsorbent bed of the system for reducing emissions and fuel consumption illustrated.
  • FIG. 4 illustrates an alternative catalyst and adsorbent bed configuration where two or more beds are cycled between an adsorption and a regeneration step.
  • intake air stream 1 is supplied to an internal combustion engine 3 .
  • the air intake system typically includes filters and flow control devices such as a throttle valve or a compressor of some type. If a compressor such as a turbo-compressor or a super charger is employed an intercooler can be included as part of the air intake stream. Sensors such as temperature and flow measuring devices are typically included to assist in optimizing the engine's operation. Most engines will also supply exhaust gas to the intake air as part of an exhaust gas recycle (EGR) system employed to reduce emissions from the engine.
  • EGR exhaust gas recycle
  • Fuel stream 2 is supplied to the internal combustion engine 3 .
  • the supply of fuel stream 2 is via fuel injectors that could have various fuel spray patterns and injection schemes controlled by the engine's control unit 14 .
  • the spray patterns and injection schemes are employed to improve or optimize the fuel consumption and exhaust emission operating parameters.
  • Fuel supply equipment is continuously being improved and thus the fuel supply equipment employed in the embodiment should be those that are deemed to be available and well-or best-suited for the desired end use.
  • Internal combustion engine 3 could be a diesel, gasoline, natural gas, liquid propane gas (LPG) or similarly fueled engine of either compression ignition of spark ignition type.
  • the engine can optionally have various after-treatment devices (not shown in FIG. 1 ) located in the exhaust system.
  • Such after-treatment devices would typically be oxidation catalysts and particulate filters that assist the total engine system to meet various emission regulations.
  • the engine exhaust stream 4 a exits engine 3 and an exhaust gas recycle stream 4 b is drawn from stream 4 a as controlled by the engine control unit 14 via the EGR valve 4 c.
  • a stream 5 that is a portion of the engine's full exhaust stream is also taken from the full exhaust stream. This can be taken at various locations in streams 4 , 4 b, 4 d and 4 e.
  • Stream 5 is directed to a fuel processing device 7 .
  • the quantity of exhaust supplied via stream 5 can optionally be controlled with a valve or other similar flow control device.
  • a passive device is an orifice that relies on the concept of sonic flow to limit the flow or flow range through the orifice.
  • the fuel processor is designed to operate as desired within the range resulting from the passive nature.
  • a fuel stream 6 is also supplied at a rate controlled by the engine control unit, 14 .
  • the fuel stream 6 is preferably composed of the same type of fuel as in stream 2 and, preferably, is supplied from the same storage device (not shown in FIG. 1 ). It is possible that the fuel type in stream 6 is different than the fuel type of stream 2 .
  • the fuel processing device 7 employs the oxygen and the water in the engine's exhaust stream to convert the fuel stream 6 into components such as hydrogen and carbon monoxide.
  • the presence of carbon dioxide in the engine exhaust stream also has beneficial effects on the reactions that produce the desired hydrogen and carbon monoxide components employed in the downstream after-treatment portion of the present system.
  • the exact composition will depend on a number of parameters such as the amount of exhaust stream supplied and the exhaust stream's composition.
  • the composition is a result of the internal design of the fuel processor.
  • Important design considerations are reactant mixing rates, temperature profiles, catalysts employed (if any) and their position in the fuel processing device as well as other considerations.
  • the design of the fuel processor and its operating parameters will be different for each different application.
  • the fuel processor 7 is preferably mechanically integrated with the exhaust stream 11 to assist with desired temperature profiles in the device and reduce equipment costs. This is envisioned to have the reactor tube be positioned within the full exhaust stream tubing but this is not required.
  • the fuel processor's product stream 8 can optionally be supplied, in part or in whole, to the engine's air intake stream 1 . If a portion of stream 8 is to be supplied to the engine's intake it can be done directly or via the EGR stream 4 d, as shown in FIG. 1 .
  • the supply of H 2 and CO to the air intake stream affects the combustion properties in a beneficial way that can be employed to reduce emissions and fuel consumption. For example in a gasoline engine the addition of H 2 and CO or such compounds will extend the lean burn limit of the combustion mixture. This allows more air to be supplied for combustion and thus reduces emissions and increases efficiency. Such performance improvements have also been reported in diesel compression ignition engines. Another benefit is that if H 2 and CO or such compounds are supplied to the engine intake air from the fuel processor the engine's power output is increased.
  • All or a portion of the fuel processor's product stream 9 is supplied to a NOx trapping device 12 that can trap NOx from the exhaust stream 11 when it is passed through the bed material made up of catalyst and/or adsorbent type materials. When the material in the bed is properly exposed to the stream from the fuel processor 9 , the NOx desorbs and reacts to form harmless emissions such as N 2 and H 2 O.
  • the fuel processor product stream 9 is also employed to remove sulfur oxide (SOx) compositions that may have adsorbed onto the adsorbent material in the same way that NOx may have adsorbed.
  • SOx sulfur oxide
  • Syngas also referred to as synthesis gas
  • This regeneration assistance could be either passive or active or a combination depending on equipment design and the application's duty cycle.
  • FIG. 2 shows some details of the adsorbent bed 12 .
  • the core 21 of bed 12 is a structure that is covered with materials that promote the ability to trap NOx and to convert NOx species into species such as N 2 , H 2 O and CO 2 .
  • the adsorption material typically includes platinum, barium oxide and rhodium. Other suitable adsorbent materials can be employed as well. The exact materials employed and their quantities depend on the specific characteristics of the application and the desired results.
  • the core's structure 21 onto which the active materials are placed can be made from various materials such as cordierite, metal meshes, wire meshes and/or fiberglass.
  • the materials can be deposited in a non-uniform way so as to more optimally meet the desired requirements of low product cost and minimal reducing agent requirements.
  • stream 11 is directed through a trapping segment 22 of the bed while the reducing agent stream 9 is directed through the regenerating segment 23 of the bed.
  • the relative sizes of the two segments depend on the specific characteristics of the application and the desired results.
  • the bed can be rotated in either a clockwise or counter clockwise direction so that all parts of the bed are alternately exposed to the exhaust stream 11 and the fuel processor's product stream 9 .
  • the speed at which the bed rotates can be controlled if desired. Adjusting the rotational speed of the bed can reduce or minimize the bed size and reduce or minimize the amount of stream 9 that is required. It may be desirable to rotate the bed at a rate between 2 and 120 revolutions per minute (1 cycle every 0.5 sec to 30 seconds). Due to the very fast adsorption, desorption and reaction rates a fast cycle rate would reduce or minimize the size of the bed.
  • the bed can also be rotated at such a rate as to keep the NOx loading at a level that is a good trade-off between the efficiency of the adsorption steps and the efficiency of the desorption/reduction steps that result in low NOx emissions.
  • the exhaust stream 11 and the stream 9 are supplied to a valve that is able to direct the flow of both stream 9 and stream 11 to the desired beds. It is possible to have any number of beds more than 1 where stream 9 is only directed to a small number, including only one, bed at a time. The most practical embodiment would include 2 to 5 beds with stream 9 being directed to one at a time while the other beds are receiving stream 11 .
  • valve 31 a is used to direct the flows of stream 9 and 11 alternatively to beds 32 and 33 .
  • Valve 31 a is repositioned at such a rate as to minimize the size of the two beds 32 and 33 and still allow desired regeneration of the beds.
  • the valve can be cycled at a rate that keeps the NOx loading on the bed fairly constant.
  • Valve 31 a can also be cycled at a rate that helps to shrink the total size and mass of the system.
  • Valve 31 b is cycled simultaneously as valve 31 a is cycled.
  • Stream 13 b from the bed that is being regenerated can then be directed to the air intake stream to avoid the wasting of fuel energy.
  • Stream 13 a is analogous to stream 10 of FIG. 1 , but has the advantage of having the recirculated stream pass over/through the catalyst and adsorbent beds to achieve a clean-up effect on the beds. As mentioned previously it also can increase engine power output due to increased fueling or provide beneficial combustion conditions.
  • exhaust stream with reduced regulated emissions is then sent to the atmosphere via stream 13 a.
  • Exhaust stream 13 a can optionally be passed through other after-treatment devices before being exhausted to the atmosphere.
  • the engine's fuel consumption can also be reduced by advancing the fuel injection timing and using the above-described after-treatment portion of the present system to reduce to acceptable levels engine exhaust stream NOx levels that result from the advanced fuel injection timing.
  • Fuel injection timing advance has the additional benefit of reducing the diesel particulate matter in the exhaust and thus reducing the size and cost of equipment required to remove diesel particulate matter.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Analytical Chemistry (AREA)
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US11/193,930 2004-07-29 2005-07-29 Integrated system for reducing fuel consumption and emissions in an internal combustion engine Abandoned US20060048502A1 (en)

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WO2011079396A1 (fr) * 2009-12-31 2011-07-07 Nxtgen Emission Controls Inc. Système de moteur avec processeur de carburant à refroidissement par gaz d'échappement
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US12152555B2 (en) 2022-12-20 2024-11-26 Saudi Arabian Oil Company Air pressure energy recovery and air/fuel/reformate storage during vehicle deceleration for active prechamber operation

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KR20150118155A (ko) 2013-02-22 2015-10-21 에이전시 포 사이언스, 테크놀로지 앤드 리서치 음성 하전된 입자들을 갖는 바이러스 제제들의 크로마토그래피 정제

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DE112005001835B4 (de) 2013-03-14
GB2431366A (en) 2007-04-25
WO2006010277A3 (fr) 2007-11-08
DE112005001835T5 (de) 2007-05-24
WO2006010277A2 (fr) 2006-02-02

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