[go: up one dir, main page]

WO2025080740A1 - Système de post-traitement des gaz d'échappement - Google Patents

Système de post-traitement des gaz d'échappement Download PDF

Info

Publication number
WO2025080740A1
WO2025080740A1 PCT/US2024/050621 US2024050621W WO2025080740A1 WO 2025080740 A1 WO2025080740 A1 WO 2025080740A1 US 2024050621 W US2024050621 W US 2024050621W WO 2025080740 A1 WO2025080740 A1 WO 2025080740A1
Authority
WO
WIPO (PCT)
Prior art keywords
aftertreatment device
exhaust aftertreatment
disposed
exhaust
substrate
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.)
Pending
Application number
PCT/US2024/050621
Other languages
English (en)
Inventor
Naveen Sridharan
Mariusz Pietrzyk
Francisco Silva
Bavo FOLLON
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.)
Donaldson Co Inc
Original Assignee
Donaldson Co Inc
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 Donaldson Co Inc filed Critical Donaldson Co Inc
Publication of WO2025080740A1 publication Critical patent/WO2025080740A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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
    • F01N3/08—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
    • F01N3/18—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
    • F01N3/2066—Selective catalytic reduction [SCR]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • 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
    • F01N2240/14—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 burner
    • 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
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • 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
    • 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

  • Vehicles equipped with diesel engines ty pically include exhaust systems that have aftertreatment components such as selective catalytic reduction catalyst devices, lean NOx catalyst devices, or lean NOx trap devices to reduce the amount of undesirable gases, such as nitrogen oxides (NOx) in the exhaust.
  • a doser injects reactants, such as urea, ammonia, or hydrocarbons, into the exhaust gas.
  • reactants such as urea, ammonia, or hydrocarbons
  • the exhaust gas and reactants convert the undesirable gases, such as NOx, into more acceptable gases, such as nitrogen and oxygen.
  • the efficiency' of the aftertreatment system depends upon how evenly the reactants are mixed with the exhaust gases.
  • exhaust treatment devices that are compact and that provide efficient and effective mixing of reactants.
  • the exhaust aftertreatment system includes a coated member, a heater, and a hydrocarbon injector mounting location disposed upstream from an SCR substrate.
  • the coated member includes a PGM (platinum group metals) coating that reacts with hydrocarbons carried in the exhaust stream to heat the exhaust stream.
  • the heater heats the coated member to enhance efficiency of the PGM coating to heat the exhaust more quickly.
  • the SCR substrate and an associated reactant mixer are disposed within a main conduit of the exhaust aftertreatment device.
  • the heater and the coated member are disposed in an inlet pipe leading directly to the main conduit.
  • the inlet pipe extends transverse to the main conduit.
  • the heater and the coated member are disposed within the main conduit upstream of the SCR substrate.
  • the coated member and heater may be disposed upstream of mid-stream of the reactant mixer.
  • the coated member includes a DOC (Diesel Oxidation Catalyst) substrate.
  • the coated member includes a mixer with a PGM coating.
  • the mixer includes a static mixer.
  • the mixer includes an impact mixer.
  • the mixer includes a plate spanning a crosssection of the inlet pipe and defining one or more apertures.
  • the mixer includes a louver (e g., a flat louver, a scooped louver, etc.) at each aperture.
  • the SCR substrate is a first (e.g., close-coupled) SCR substrate and the exhaust aftertreatment device also includes a second SCR substrate downstream of the first SCR substrate.
  • a second reactant mixer is disposed upstream of the second SCR substrate and downstream of the first SCR substrate.
  • inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
  • FIG. 1 is a block diagram of an example engine exhaust sy stem including an aftertreatment system including a pre-heat arrangement in accordance with the principles of the present disclosure.
  • FIG. 2 is a flow chart illustrating an example exhaust treatment process for preheating the exhaust.
  • FIG. 3 is a perspective view of an exhaust aftertreatment device suitable for use in the engine exhaust system of FIG. 1. the exhaust aftertreatment system including a first example implementation of a pre-heat arrangement.
  • FIG. 4 is an enlarged view of a portion of the first exhaust aftertreatment device of FIG. 3.
  • FIG. 5 is a perspective view of an exhaust aftertreatment device suitable for use in the engine exhaust system of FIG. 1. the exhaust aftertreatment system including a second example implementation of a pre-heat arrangement.
  • FIG. 6 is an enlarged view of a portion of the first exhaust aftertreatment device of FIG. 5.
  • FIG. 7 is a perspective view of an exhaust aftertreatment device suitable for use in the engine exhaust system of FIG. 1, the exhaust aftertreatment system including a third example implementation of a pre-heat arrangement.
  • FIG. 8 is an enlarged view of a portion of the exhaust aftertreatment device of FIG. 7.
  • FIG. 9 is a perspective view of an example coated member suitable for use in the aftertreatment device of FIGS. 1 and 7.
  • FIG. 10 is a block diagram illustrating an example implementation of a control system suitable for implementing the exhaust treatment process of FIG. 2.
  • exhaust treatment devices adapted for use in treating exhaust gas generated by engines such as diesel engines.
  • exhaust treatment devices in accordance with the principles of the present disclosure can be used to treat exhaust generated by diesel engines of vehicles such as over-the-road trucks, offroad vehicles (e.g., agricultural vehicles such as tractors, construction vehicles such as graders, bull-dozers, front end loaders, or other vehicles).
  • vehicles such as over-the-road trucks, offroad vehicles (e.g., agricultural vehicles such as tractors, construction vehicles such as graders, bull-dozers, front end loaders, or other vehicles).
  • Certain aspects of the present disclosure result in an exhaust treatment device that is relatively compact and can be readily mounted under the vehicle hood, under the vehicle cabin, adjacent the vehicle hood, adjacent the vehicle cabin or elsewhere on the vehicle.
  • a selective catalytic reduction (SCR) catalyst device is typically used in an exhaust system to remove undesirable gases such as nitrogen oxides (NO X ) from the vehicle's emissions.
  • An SCR is capable of converting NOx to nitrogen and oxygen in an oxygen rich environment with the assistance of reactants such as urea or ammonia, which are injected into the exhaust stream upstream of the SCR through a doser.
  • a lean NOx catalyst device is also capable of converting NOx to nitrogen and oxygen.
  • lean NOx catalysts use hydrocarbons as reducing agents/reactants for conversion of NO X to nitrogen and oxygen. The hydrocarbon is injected into the exhaust stream upstream of the lean NOx catalyst.
  • the NOx reacts with the injected hydrocarbons with the assistance of a catalyst to reduce the NO x to nitrogen and oxygen.
  • the exhaust treatment system is described as including an SCR, it will be understood that the scope of the present disclosure is not limited to an SCR as there are various catalyst devices, such as those described below, that can be used in accordance with the principles of the present disclosure.
  • Lean NOx traps use a material such as barium oxide to absorb NOx during lean bum operating conditions. During fuel rich operations, the NOx is desorbed and converted to nitrogen and oxygen by reaction with hydrocarbons in the presence of catalysts (precious metals) within the traps.
  • FIG. 1 is a schematic example of an engine exhaust system 500.
  • the engine exhaust system 500 includes an engine 502, a fuel tank 504 for supplying fuel (e.g., diesel fuel) to the engine 502, an air intake 506, an air filter 508, and an exhaust conduit 510 for conveying exhaust gas away from the engine 502.
  • the engine exhaust system 500 also includes an exhaust treatment device 100, 200, 300 that is in fluid communication with the exhaust conduit 510, connecting at a device inlet/inlet conduit/inlet pipe 124.
  • the exhaust treatment device 100, 200. 300 also includes a device outlet 122 which directs treated exhaust to an exhaust conduit 512.
  • the exhaust conduit 512 carries the treated exhaust to an exhaust output 518.
  • one or more types of additional exhaust treatment substrates such as a diesel particulate filter (e.g., a flow-through filter, a wall flow filter, etc.) or a diesel oxidation catalyst, can optionally be provided upstream or downstream from the exhaust treatment device 100, 200, 300.
  • a noise abatement structure such as a muffler, can be provided along the exhaust conduit 512.
  • the exhaust treatment device 100, 200, 300 is configured to reduce the concentration of NO X (or other contaminants/pollutants) present in the exhaust stream.
  • the exhaust treatment device 100, 200, 300 includes an exhaust treatment substrate 106, 130, such as an SCR substrate, a lean NOx cataly st, a lean NOx trap or other structure, an SCR coated filter (e.g.. a SCR coated DPF or flow-through filter), etc., for removing NOx (or other contaminants such as SO2. CO, VOCs. etc.) from the exhaust stream.
  • the exhaust treatment device 100, 200, 300 also includes a dispenser mounting location 108, 135 at which a doser D (e.g., an injector, a spray nozzle, or other dispensing structure) can be mounted to supply a reactant (e.g., urea (e.g., aqueous urea), ammonia, hydrocarbons, or other reducing agents) suitable for reacting with NOx (or other contaminants such as SO2, CO, VOCs, etc.) at the exhaust treatment substrate 106, 130 to reduce the overall concentration of contaminants such as NO X in the exhaust stream.
  • a doser D e.g., an injector, a spray nozzle, or other dispensing structure
  • a reactant e.g., urea (e.g., aqueous urea), ammonia, hydrocarbons, or other reducing agents) suitable for reacting with NOx (or other contaminants such as SO2, CO, VOCs, etc.
  • the exhaust treatment device 100, 200, 300 further includes a mixing arrangement 104, 132 that generates turbulence (e.g., swirling) for assisting in mixing and volatilizing the reactant from the doser D before the reactant reaches the exhaust treatment substrate 106, 130.
  • the mixing arrangement 104, 132 is disposed upstream of the doser mounting location 108, 135. In other examples, however, the mixing arrangement 104, 132 may be disposed downstream of the doser mounting location 108, 135.
  • exhaust treatment substrate can include multiple substrates 106, 130 arranged in series within the device 100, 200, 300.
  • the exhaust treatment device 100, 200, 300 also includes one or more contaminant sensors 516 (e.g., NOx sensors) and one or more temperature sensors 514.
  • one set of sensors 514, 516 is positioned at the device inlet 124 and a second set of sensors 514, 516 is positioned at the device outlet 122.
  • the various components of the exhaust treatment device 100 are relatively positioned to provide a compact configuration. While the configuration is compact, the components are configured such that the reactants from the doser D are effectively mixed and volatized prior to reaching the exhaust treatment substrate 106, 130 such that the exhaust treatment substrate 106, 130 efficiently removes NOx (or other contaminants such as SO2. CO, VOCs. etc.) from the exhaust stream.
  • the exhaust treatment device 100, 200, 300 is formed within a common housing (e.g., a single pipe, multiple pipes integrated together using welding, beading, crimping, or the like, etc.). In other implementations, the exhaust treatment device 100, 200, 300 can be formed from fluidly connecting multiple housings.
  • components (e.g.. SCR substrates) of the exhaust treatment device 100, 200, 300 are disposed along a common central longitudinal axis A.
  • the exhaust aftertreatment device 100 includes a main SCR substrate 130 and a close-coupled SCR substrate 106.
  • the close-coupled SCR substrate 106 is disposed closer to the engine than the main SCR substrate 130.
  • one of the SCR substrates 106, 130 has a corresponding reactant mixing arrangement 104, 132 and doser mounting location 108, 135, respectively. Exhaust flowing through the mixing arrangement 104, 132 is mixed with reactant dispensed from a doser D disposed at the doser mounting location before reaching the SCR substrate 106, 130.
  • the main SCR substrate 130 is larger than the close-coupled SCR substrate 106.
  • the aftertreatment device 100, 200, 300 includes a pre-heat arrangement configured to pre-heat the exhaust before the exhaust reaches the SCR substrate(s) 106, 130. Pre-heating the exhaust enhances the efficiency of the SCR substrate(s) 106, 130.
  • a first example implementation 102 of the pre-heat arrangement is discussed with respect to FIGS. 3 and 4.
  • a second example implementation 202 of the pre-heat arrangement is discussed with respect to FIGS. 5 and 6.
  • a third example implementation 302 of the pre-heat arrangement is discussed with respect to FIGS. 7-9.
  • the pre-heat arrangement 102, 202, 302 includes a heater 114, 214, 314 (e.g., an electric heater).
  • the pre-heat arrangement 102, 202, 302 includes a hydrocarbon injector H and a coated member 116. 216, 316 (e.g., a DOC substrate, a coated mixer, etc.) that includes a PGM (platinum group metals) coating or other coating configured to produce heat in response to the injected hydrocarbons.
  • a heater 114, 214, 314 e.g., an electric heater
  • the pre-heat arrangement 102, 202, 302 includes a hydrocarbon injector H and a coated member 116. 216, 316 (e.g., a DOC substrate, a coated mixer, etc.) that includes a PGM (platinum group metals) coating or other coating configured to produce heat in response to the injected hydrocarbons.
  • PGM platinum group metals
  • PGM coatings may be used to further catalytic oxidation within exhaust treatment devices.
  • the PGM coating includes platinum and palladium.
  • the PGM coating includes more platinum than palladium.
  • the PGM coating has about a 3 to 1 ratio of platinum to palladium.
  • the PGM coating may be uniform. In other instances, the PGM coating may vary across the coating surface. The total amount of PGM coating depends on various factors such as the surface area of the coating area, thickness of the coating, and density of the coating. All these factors may be modified to achieve a desired level of catalytic oxidation within a given space.
  • the amount of the PGM coating can be varied to achieve a desired level of oxidation within a given space, such as on mixer for example.
  • the PGM coating has a coating density of at least 10 grams per cubic foot. In certain implementations, the PGM coating has a coating density greater than 20 grams per cubic foot. In certain implementations, the PGM coating has a coating density greater than 100 grams per cubic foot and less than 120 grams per cubic feet. In still other implementations, the PGM coating has a coating density less than or equal to 100 grams per cubic foot. In certain implementations, the PGM coating has a varying density that ranges between 10 and 100 grams per cubic foot. In certain implementations, the PGM coating is applied upstream from an SCR catalyst device to improve NOx conversion in the SCR catalyst device.
  • the hydrocarbon doser mounting location 112 is upstream of the heater 114, 214, 314.
  • the hydrocarbon doser H is mounted at a hydrocarbon doser mounting location 112 to direct hydrocarbons towards the coated member 116, 216, 316.
  • the heater 114, 214, 314 is configured and positioned to heat the coated member 116, 216, 316 to enhance the heating efficiency of the coated member 116, 216, 316.
  • the heater 114, 214, 314 and coated member 116, 216, 316 are disposed upstream of the mixing arrangement 104, 132 and SCR substrate 106, 130.
  • a control system 550 (e.g., a microcontroller or other computing device) is configured to manage operation of the heater 114, 214. 314 and/or operation of the hydrocarbon injector H.
  • the control system 550 may send control signals to the heater 114, 214, 314 to turn on and off
  • the control system 550 may send control signals to the hydrocarbon injector H to turn the hydrocarbon injector H on and off.
  • the control system 550 also may control an injection rate of the hydrocarbons by the hydrocarbon injector H.
  • FIG. 2 illustrates an example exhaust treatment process 520 implemented by the exhaust treatment device 100, 200, 300.
  • the treatment process 520 can be used during a cold start of an engine 502.
  • the treatment process 520 can be implemented any time during operation of the engine 502.
  • the treatment process 520 begins at a receive step 521 at which the control system 550 receives a signal indicating pre-heating of the exhaust should begin.
  • the control system 550 receives a signal indicating the engine 502 has been started.
  • the control system 550 starts the heater 114, 214, 314 (e g., sends a control signal to switch the heater to ON).
  • the control system 550 monitors the temperature of one or more components (e.g., the heater 1 14, 214, 314, the coated member 116, 216, 316, and/or the SCR substrate 106, 130) within the exhaust treatment device 100, 200, 300.
  • the control system 550 tracks the temperature of the heater 114. 214, 314 (e.g., using a temperature sensor 140. 240, 340 disposed at the heater 114, 214. 314).
  • the control system 550 determines whether the temperature of the heater 114, 214, 314 has reached a first predetermined temperature T1 (e.g., at least 120 degrees Celsius, at least 130 degrees Celsius, at least 140 degrees Celsius, at least 150 degrees Celsius, or at least 160 degrees Celsius).
  • a first predetermined temperature T1 e.g., at least 120 degrees Celsius, at least 130 degrees Celsius, at least 140 degrees Celsius, at least 150 degrees Celsius, or at least 160 degrees Celsius.
  • the first predetermined temperature T1 is 150 degrees Celsius.
  • the first predetermined temperature T1 is set sufficiently high that the temperature of the exhaust reaching the coated member 116, 216, 316 is sufficient to support the chemical reaction between hydrocarbons and the PGM coating.
  • the control system 550 continues to monitor the temperature of the heater 114, 214, 314 at step 524.
  • the control system 550 determines the heater 1 14, 214, 314 has reached the first predetermined temperature Tl
  • the control system 550 starts injecting hydrocarbons into the exhaust stream at step 528.
  • the heater 114, 214, 314 increases the temperate of the exhaust and hydrocarbons passing through the coated member 116, 216, 316, which increases the efficiency of the reaction with the PGM coating.
  • the heater 114, 214, 314 is positioned sufficiently close to the coated member 116, 216, 316 so that heat generated by the heater 114, 214. 314 increases the temperature of the coated member 116. 216, 316.
  • the control system 550 sends a control signal to the hydrocarbon injector H to begin injecting hydrocarbons from a fuel source (e.g., the fuel tank of the vehicle).
  • the control signal indicates a first predetermined rate of injection (e.g.. 1.5 grams/sec, 1.8 grams/sec, 2 grams/sec. 2.2 grams/sec, 2.5 grams/sec) for the hydrocarbon.
  • the first predetermined rate is 2 grams/sec.
  • the first predetermined rate is selected to provide sufficient hydrocarbons to the coated member 116, 216, 316 to quickly increase the temperature of the coated member 116, 216, 316 through the reaction of the hydrocarbons with the PGM coating.
  • the first predetermined rate may be selected to ensure the coated mixer 1 16, 216, 316 reaches an operational temperature range within 1 minute of starting the hydrocarbon injection. In another example, the first predetermined rate may be selected to ensure the coated mixer 116, 216, 316 reaches an operational temperature range within 50 seconds of starting the hydrocarbon injection. In another example, the first predetermined rate may be selected to ensure the coated mixer 116, 216, 316 reaches an operational temperature range within 45 seconds of starting the hydrocarbon injection. In another example, the first predetermined rate may be selected to ensure the coated mixer 116, 216, 316 reaches an operational temperature range within 1 minute of starting the engine.
  • the first predetermined rate may be selected to ensure the coated mixer 116, 216, 316 reaches an operational temperature range within 50 seconds of starting the engine. In another example, the first predetermined rate may be selected to ensure the coated mixer 116, 216, 316 reaches an operational temperature range within 45 seconds of starting the engine.
  • the heated exhaust passes through the coated member 116. 216, 316 at which the hydrocarbons react with the PGM coating to generate more heat, thereby further heating the exhaust.
  • the control system 550 determines whether a temperature at the coated member 116, 216, 316 meets a second predetermined temperature threshold T2.
  • the control system 550 uses a temperature sensor 142, 242, 342 at the coated member 1 16, 216, 316 to track the temperature of the coated member 116, 216, 316 or the exhaust passing through the coated member.
  • the control system 550 is tracking the temperature at the coated member 116, 216. 316 since step 524.
  • the control system 550 may start tracking the temperature at the coated member 116, 216, 316 after starting the hydrocarbon injection at step 528.
  • the control system 550 tracks the temperature of the coated member itself.
  • the control system 550 tracks the temperature of exhaust passing through the coated member 116. 216, 316.
  • the control system 550 turns off the heater 114, 214, 314 at step 532.
  • the control system 550 may send a control signal to the heater 114, 214. 314 to switch off.
  • the second temperature threshold T2 is selected to be sufficiently high to enable continued reaction of hydrocarbons within the exhaust at the coated member 116, 216, 316 even without the presence of the heater 114, 214, 314.
  • the second threshold T2 is at least 120 degrees Celsius, at least 130 degrees Celsius, at least 140 degrees Celsius, at least 150 degrees Celsius, or at least 160 degrees Celsius.
  • the second predetermined temperature T2 is 150 degrees Celsius. In certain examples, the second predetermined temperature T2 is the same as the first predetermined temperature Tl. Switching off the heater 114, 214, 314 conserves power as the coated member 116, 216, 316 has already reached the temperature of the heater 114, 214, 314. [0038] In certain implementations, the control system 550 changes the injection rate of the hydrocarbon injector H at step 534. For example, the control system 550 may reduce the injection rate of the hydrocarbon injector H. Reducing the rate of hydrocarbon injection limits the amount of heat generated at the coated member 116. 216, 316.
  • the second injection rate may be set to inhibit the amount of reaction at the coated member 116, 216, 316 to limit the amount of heat generated.
  • the second injection rate is selected to keep the hydrocarbons and exhaust at the coated member 116, 216, 316 at or below temperatures required for regeneration (e.g., about 600 degrees Celsius).
  • the second injection rate is selected to keep the temperature of the hydrocarbons and exhaust at the coated member 116. 216, 316 significantly below regeneration temperatures (e.g...
  • the injection rate is reduced to 0.8 grams/sec, 1 gram/sec, 1.2 grams/sec, 1.4 grams/sec, 1.5 grams/sec, or 1.8 grams/sec.
  • the first injection rate is 2 grams/sec
  • the second injection rate is 1 gram/sec.
  • the first injection rate is 2 grams/sec
  • the second injection rate is 1.5 gram/sec.
  • the control system 550 determines whether a temperature at the SCR substrate meets a third predetermined temperature threshold T3 (e.g., via temperature sensor 144, 244, 344). In some implementations, the control system 550 is determining the temperature of the main SCR substrate 130. In other implementations, the control system 550 is determining the temperature of the close-coupled SCR substrate 106. In certain implementations, the third temperature threshold T3 is selected so that further preheating of the exhaust is not needed for proper functioning of the SCR substrate 130. For example, the third temperature threshold T3 may be based on a minimum operating temperature of the SCR substrate. In various examples, the third temperature threshold T3 is at least 170 degrees Celsius, at least 175 degrees Celsius, at least 180 degrees Celsius, or at least 185 degrees Celsius. In an example, the third threshold T3 is 180 degrees Celsius.
  • the hydrocarbon injector H stops injecting hydrocarbons into the exhaust at step 538.
  • the control system 550 may send a control signal to the hydrocarbon injector H to cease injection.
  • the third temperature threshold T3 is selected to be below the temperature at which regeneration would occur. Accordingly, stopping the hydrocarbon injection limits or ceases the reaction at the coated member 116, 216, 316, which limits the amount of heat generated within the aftertreatment device 100, 200, 300.
  • the SCR substrate 106 is disposed within a main conduit 118.
  • the main conduit 118 defines an annular wall 115 extending along a longitudinal axis LI between a first end wall 117 and an opposite second end wall 119.
  • the longitudinal axis LI of the conduit 118 is coaxial with the central axis A of the aftertreatment device 100, 200, 300.
  • the reactant mixer arrangement 104 also is disposed within the main conduit 118 upstream of the SCR substrate 106.
  • the doser mounting location 108 is defined at the main conduit 118 upstream of the SCR substrate 106.
  • the doser mounting location 108 is disposed at the first end wall 117 of the main conduit 1 18. It will be understood, however, that the doser mounting location 108 may be defined by the annular wall 115. In certain examples, the doser mounting location 108 is configured to mount a reactant doser D and to orient the reactant doser D to dispense reactant through the mixer arrangement 104 and towards the SCR substrate 106. [0042] In certain implementations, the outlet 122 of the main conduit 118 is defined at the second end wall 119 opposite the doser mounting location 108. In certain implementations, the inlet 120 of the main conduit 118 is defined at the annular wall 1 15.
  • the inlet 120 of the main conduit 118 radially aligns with the reactant mixer arrangement 104.
  • an inlet pipe 124 leads to the inlet 120 of the main conduit to supply exhaust from the engine to the main conduit 118.
  • the inlet pipe 124 has a longitudinal axis L2 that is not parallel with the longitudinal axis LI of the main conduit 118.
  • the longitudinal axis L2 of the inlet pipe 124 is transverse to the longitudinal axis LI of the main conduit 118.
  • the longitudinal axis L2 of the inlet pipe 124 intersects the longitudinal axis LI of the main conduit 118.
  • the hydrocarbon doser mounting location 112 is disposed within the inlet pipe 124.
  • the heater 114, 314 and coated member 116, 316 also are disposed within the inlet pipe 124.
  • the heater 214 and coated member 216 are disposed within the main conduit 118.
  • the heater 214 and coated member 216 can be disposed at the mixing arrangement 104 for the close-coupled SCR substrate 106.
  • the SCR substrate 106 and reactant mixer arrangement 104 form part of a close-coupled set up 126.
  • the main conduit 118 also can house a main set up 128 downstream of the close-coupled set up 126.
  • the main set up 128 includes a second SCR substrate 130 and a second reactant mixer arrangement 132.
  • the main set up 128 also includes a second reactant doser mounting location 135.
  • the second reactant doser mounting location 135 is defined at the annular w all 115 of the main conduit 118.
  • the second reactant doser mounting location 135 is disposed upstream of the second SCR substrate 130.
  • the second reactant doser mounting location 135 is radially aligned with the second reactant mixer arrangement 132.
  • the second reactant mixer arrangement 132 is the same as the close-coupled reactant mixer arrangement 104. In other examples, however, the second reactant mixer arrangement 132 can have a different configuration.
  • the close-coupled reactant mixer arrangement 104 includes a donut-swirl mixer and the second reactant mixer arrangement 132 includes an axial mixer.
  • donut-swirl mixers are disclosed in U.S. Patent Nos. 8.499,548 and 8,938,954, the disclosures of which are hereby incorporated herein by reference in their entireties.
  • Examples of axial mixers are disclosed in U.S. Patent Nos. 9,528,415; 10,179,315; and 11,465,105; and U.S. Publication No. 2022/0316382, the disclosures of which are hereby incorporated herein by reference in their entireties.
  • other types of mixer arrangements can be used.
  • a main set up 128 also may include a second coated member 134 upstream of the second reactant mixer arrangement 132.
  • the second coated member 134 further heats the exhaust received from the close-coupled set up 126 before the exhaust reaches the second SCR substrate 130.
  • a DPF (diesel particulate filter) 136 also can be disposed between the first SCR substrate 106 and the second reactant mixer arrangement 132.
  • the DPF 136 forms part of the main set up 128.
  • the DPF 136 is disposed between the second coated member 134 and the second reactant mixer arrangement 132.
  • FIGS. 3 and 4 illustrate a first example exhaust aftertreatment device 100 in which the heater 114 and coated member 116 are disposed within the inlet pipe 124.
  • the heater 114 is disposed upstream from the coated member 116.
  • the coated member 116 includes a DOC substrate.
  • the DOC substrate 116 is radially aligned with the first reactant mixer arrangement 104.
  • the first reactant mixer arrangement 104 includes an inner pipe 109 extending between a mixing member/mixing plate 110 and an outlet 1 11.
  • the coated member 116 radially aligns with an exterior surface of the inner pipe 109 so that heated exhaust leaving the coated member 116 first surrounds the inner pipe 109, then passes through the mixing plate 110 towards the reactant doser D, and then passes into the inner pipe 109. along an internal passage, and towards the SCR substrate 106.
  • FIGS. 5 and 6 illustrate a second example exhaust aftertreatment device 200 in which the heater 214 and coated member 216 are disposed within the main conduit 118.
  • the coated member 216 includes a DOC substrate.
  • the DOC substrate 216 is disposed upstream of the first reactant mixer arrangement 104.
  • the DOC substrate 216 has an annular shape wrapped around the inner pipe 109 of the first reactant mixer arrangement 104.
  • the heater 214 is disposed upstream of the DOC substrate 216.
  • the heater 214 also has an annular shape wrapped around the inner pipe 109 of the first reactant mixer arrangement 104.
  • the heater 214 contacts the DOC substrate 216.
  • FIGS. 7-9 illustrate a third example exhaust aftertreatment device 300 in which the heater 314 and the coated member 316 are disposed within the inlet pipe 124 downstream of the hydrocarbon doser mounting location 112.
  • the coated member 316 is not a DOC substrate. Rather, the coated member 316 includes a mixer body 360 to which the PGM coating has been applied. In some examples, the PGM coating is disposed at an upstream side 366 of the mixer 360.
  • FIG. 10 is a block diagram of an example implementation of the virtual or physical computing and control system 550 of FIG. 1 suitable for use to implement the exhaust treatment process 520 of FIG. 2.
  • the control system 550 includes one or more processors 552 and a memory 554.
  • the memory 554 stores pre-heat instructions for implementing the exhaust treatment process 520 of FIG. 2.
  • the memory 554 also stores the temperature thresholds Tl, T2, T3 utilized in the exhaust treatment process 520.
  • the control system 550 also includes a sensor communications interface 560 configured to receive data signals from the one or more sensors (e g., temperature sensors) disposed within the aftertreatment device 100, 200, 300.
  • the sensor communications interface 560 receives data signals from sensors (e.g., temperature sensors 514, NOx sensors 516, etc.) within the engine exhaust system 500. The received sensor data is compared to stored thresholds 558 in accordance with pre-heat instructions 556.
  • the control system 550 also includes a heater communications interface 562 configured to send command signals to the heater 114, 214, 314.
  • the processor 552 may instruct the heater 114, 214, 314 to turn on or off via the heater communications interface 562.
  • the control system 550 also includes an injector communications interface 564 configured to send command signals to the hydrocarbon injector H.
  • the processor 552 may instruct the hydrocarbon injector H to turn on or off via the injector communications interface 564.
  • the processor 552 may control the rate of injection at the hydrocarbon injector H via the injector communications interface 564.

Landscapes

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

Abstract

L'invention concerne un dispositif de post-traitement des gaz d'échappement qui est configuré pour préchauffer les gaz d'échappement avant qu'ils n'atteignent le substrat SCR (par exemple, pendant un démarrage à froid du moteur). L'agencement de préchauffage comprend un élément revêtu, un dispositif de chauffage et un emplacement de montage d'injecteur d'hydrocarbure disposé en amont d'un substrat SCR. L'élément revêtu comprend un revêtement de MGP (métaux du groupe platine) sur un substrat, un mélangeur ou une autre structure. Un système de commande gère le fonctionnement du dispositif de chauffage et de l'injecteur d'hydrocarbure sur la base de lectures de température à l'intérieur du dispositif de post-traitement.
PCT/US2024/050621 2023-10-10 2024-10-10 Système de post-traitement des gaz d'échappement Pending WO2025080740A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202363589118P 2023-10-10 2023-10-10
US63/589,118 2023-10-10
US202363596419P 2023-11-06 2023-11-06
US63/596,419 2023-11-06

Publications (1)

Publication Number Publication Date
WO2025080740A1 true WO2025080740A1 (fr) 2025-04-17

Family

ID=93257557

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2024/050621 Pending WO2025080740A1 (fr) 2023-10-10 2024-10-10 Système de post-traitement des gaz d'échappement

Country Status (1)

Country Link
WO (1) WO2025080740A1 (fr)

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100313547A1 (en) * 2009-06-11 2010-12-16 Gm Global Technology Operations, Inc. Apparatus and method for regenerating an exhaust filter
WO2012147205A1 (fr) * 2011-04-28 2012-11-01 トヨタ自動車株式会社 Épurateur de gaz d'échappement destiné à un moteur à combustion interne
US8499548B2 (en) 2008-12-17 2013-08-06 Donaldson Company, Inc. Flow device for an exhaust system
US8938954B2 (en) 2012-04-19 2015-01-27 Donaldson Company, Inc. Integrated exhaust treatment device having compact configuration
US9528415B2 (en) 2014-01-31 2016-12-27 Donaldson Company, Inc. Dosing and mixing arrangement for use in exhaust aftertreatment
US10179315B2 (en) 2015-06-12 2019-01-15 Donaldson Company, Inc. Exhaust treatment device
US10329985B2 (en) * 2017-06-27 2019-06-25 Tenneco Automotive Operating Company Inc. Impingement mixer for exhaust treatment
US20220025797A1 (en) * 2019-07-26 2022-01-27 J.C. Bamford Excavators Limited System for working machine
US20220316382A1 (en) 2019-07-04 2022-10-06 Donaldson Company, Inc. System for mixing a liquid spray into a gaseous flow and exhaust aftertreatment device comprising same
US11465105B2 (en) 2018-01-26 2022-10-11 Donaldson Company, Inc. Mixing device for mixing a spray from an injector into a gas and system comprising same

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8499548B2 (en) 2008-12-17 2013-08-06 Donaldson Company, Inc. Flow device for an exhaust system
US20100313547A1 (en) * 2009-06-11 2010-12-16 Gm Global Technology Operations, Inc. Apparatus and method for regenerating an exhaust filter
WO2012147205A1 (fr) * 2011-04-28 2012-11-01 トヨタ自動車株式会社 Épurateur de gaz d'échappement destiné à un moteur à combustion interne
US8938954B2 (en) 2012-04-19 2015-01-27 Donaldson Company, Inc. Integrated exhaust treatment device having compact configuration
US9528415B2 (en) 2014-01-31 2016-12-27 Donaldson Company, Inc. Dosing and mixing arrangement for use in exhaust aftertreatment
US10179315B2 (en) 2015-06-12 2019-01-15 Donaldson Company, Inc. Exhaust treatment device
US10329985B2 (en) * 2017-06-27 2019-06-25 Tenneco Automotive Operating Company Inc. Impingement mixer for exhaust treatment
US11465105B2 (en) 2018-01-26 2022-10-11 Donaldson Company, Inc. Mixing device for mixing a spray from an injector into a gas and system comprising same
US20220316382A1 (en) 2019-07-04 2022-10-06 Donaldson Company, Inc. System for mixing a liquid spray into a gaseous flow and exhaust aftertreatment device comprising same
US20220025797A1 (en) * 2019-07-26 2022-01-27 J.C. Bamford Excavators Limited System for working machine

Similar Documents

Publication Publication Date Title
US8701388B2 (en) Exhaust treatment methods and systems
CN103089380B (zh) 电加热的NOx吸附剂催化剂
US8505282B2 (en) Selective catalytic reduction (SCR) device control system
US8365517B2 (en) Apparatus and method for regenerating an exhaust filter
US8539758B2 (en) Exhaust-gas purification system for diesel engines
US8621846B2 (en) Gas/liquid mixing device for diesel exhaust aftertreatment
JP4090972B2 (ja) エンジンの排気浄化装置
US20180001279A1 (en) Dosing and mixing arrangement for use in exhaust aftertreatment
CN103321723B (zh) 具有固态氨气产生材料的排气处理系统
CN105221223B (zh) 用于内燃发动机的排气后处理装置及具有该装置的车辆
US20110107743A1 (en) Nozzle Diffuser Mixer
US8973349B2 (en) Electronically heated hydrocarbon (HC) adsorber
WO2015018971A1 (fr) Procédé, appareil et système pour post-traitement de gaz d'échappement
CN101629506B (zh) 排气净化装置
CN104061046A (zh) 用于柴油器件的紧凑废气处理系统
JP2004514829A (ja) 排ガスを後処理するための装置および方法
CN103104323B (zh) 用于内燃机的排气系统
GB2465151A (en) Engine exhaust treatment unit
US20110239624A1 (en) Apparatus and method for regenerating an exhaust filter
US20110067386A1 (en) Oxidizing Particulate Filter
US20170234188A1 (en) Scr after-treatment of engine exhaust gas
CN112576345B (zh) 用于受热定量装置的分解管
US8635862B2 (en) Control system for reducing nitrous oxide (“N2O”) after selective catalytic reduction (“SCR”) device light-off
WO2025080740A1 (fr) Système de post-traitement des gaz d'échappement
US20140041370A1 (en) Exhaust Treatment System for Internal Combustion Engine

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24795057

Country of ref document: EP

Kind code of ref document: A1