U.S. patent application number 09/885626 was filed with the patent office on 2002-03-21 for emission control system and a method for operating an emission control system.
Invention is credited to Bruggemann, Hans, Duvinage, Frank, Nolte, Arno, Paule, Markus, Sander, Henning, Schommers, Joachim, Thiemann, Karl-Heinz, Wenninger, Gunter.
Application Number | 20020033017 09/885626 |
Document ID | / |
Family ID | 7645837 |
Filed Date | 2002-03-21 |
United States Patent
Application |
20020033017 |
Kind Code |
A1 |
Bruggemann, Hans ; et
al. |
March 21, 2002 |
Emission control system and a method for operating an emission
control system
Abstract
In an emission control system that includes a particle filter,
an arrangement is provided upstream of the particle filter, the
arrangement being configured to prevent the development of
ash-forming compounds of sulfur in the exhaust. The emission
control system may be used with a diesel engine.
Inventors: |
Bruggemann, Hans;
(Winterbach, DE) ; Duvinage, Frank; (Kirchheim,
DE) ; Nolte, Arno; (Stuttgart, DE) ; Paule,
Markus; (Remshalden, DE) ; Sander, Henning;
(Ludwigsburg, DE) ; Schommers, Joachim;
(Allmersbach i.T., DE) ; Thiemann, Karl-Heinz;
(Korb, DE) ; Wenninger, Gunter; (Stuttgart,
DE) |
Correspondence
Address: |
KENYON & KENYON
ONE BROADWAY
NEW YORK
NY
10004
US
|
Family ID: |
7645837 |
Appl. No.: |
09/885626 |
Filed: |
June 20, 2001 |
Current U.S.
Class: |
60/295 ; 60/297;
60/301 |
Current CPC
Class: |
B01D 53/94 20130101;
F01N 2570/14 20130101; F02B 37/00 20130101; Y02A 50/20 20180101;
F01N 2570/04 20130101; B01D 53/92 20130101; F01N 3/0814 20130101;
Y02A 50/2344 20180101; F01N 3/0821 20130101; F01N 13/009
20140601 |
Class at
Publication: |
60/295 ; 60/297;
60/301 |
International
Class: |
F01N 003/00; F01N
003/10 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 21, 2000 |
DE |
100 29 513.4 |
Claims
What is claimed is:
1. An emission control system, comprising: a particle filter; and
an arrangement disposed upstream from the particle filter, the
arrangement being configured to prevent development of ash-forming
compounds of sulfur contained in an exhaust gas.
2. The emission control system according to claim 1, wherein the
emission control system is configured for use with an internal
combustion engine.
3. The emission control system according to claim 1, wherein the
arrangement includes a SO.sub.x collector.
4. The emission control system according to claim 1, wherein the
arrangement includes a NO.sub.x collector.
5. The emission control system according to claim 3, wherein the
arrangement includes a NO.sub.x collector.
6. The emission control system according to claim 1, wherein the
arrangement includes an oxidation catalyst.
7. The emission control system according to claim 3, wherein the
arrangement includes an oxidation catalyst.
8. The emission control system according to claim 5, wherein the
arrangement includes an oxidation catalyst.
9. A method for operating an emission control system, the emission
control system including a particle filter and an arrangement
disposed upstream from the particle filter, the arrangement being
configured to prevent development of ash-forming compounds of
sulfur contained in an exhaust gas, the method comprising the step
of: preventing development of ash-forming compounds of sulfur
contained in the exhaust gas.
10. The method according to claim 9, further comprising the steps
of: operating the emission control system in a normal operating
phase with a lean exhaust composition to store sulfur contained in
the exhaust gas; and operating the emission control system in a
regeneration phase with a rich exhaust composition to release
stored sulfur as at least one gaseous compound.
11. The method according to claim 10, wherein the step of operating
the emission control system in the regeneration phase includes the
substep of raising an exhaust temperature to between 550.degree. C.
and 700.degree. C.
12. A method for reducing ash components in a particle filter of an
exhaust system for a diesel engine, comprising the steps of:
maintaining ash-forming exhaust components in a gaseous state in a
catalyst disposed upstream from the particle filter; storing sulfur
in the catalyst; and passing the ash-forming exhaust components in
the gaseous state through the particle filter.
13. A device for reducing ash components in a particle filter of an
exhaust system of a diesel engine, comprising: a catalyst disposed
upstream from the particle filter, the catalyst including a
sulfur-storing catalyst configured as a NO.sub.x collector, the
catalyst being further configured to change ash-forming exhaust
components to a gaseous state flowable through the particle filter.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an emission control system,
particularly for an automobile with an internal combustion engine,
having a particle filter. The present invention also relates to a
method for operating an emission control system.
BACKGROUND INFORMATION
[0002] Particle filters are used for diesel-operated vehicles to
reduce particle emissions. Particle filters are primarily used to
capture soot particles in the exhaust. Soot particles captured in
the particle filter can be combusted in special operating phases of
the internal combustion engine. However, ash residue in the filter
cannot be combusted, which clogs the filter over the life of the
vehicle.
[0003] The following ash components are generally responsible for
clogging the filter: motor oil ash residue from the oil consumed by
the internal combustion engine; fuel ash residue from fuel
consumption; additive ash residue from fuel additives to help
regenerate the particle filter; and other residue, e.g., from
intake air, motor abrasion or wear, and corrosion of the exhaust
system.
[0004] As a result, particle filters must be replaced or cleaned in
a washing procedure after a given service interval, e.g., every
80,000 km traveled.
[0005] The clogging of the filter from ash is a continuous process
over the life of the vehicle. With an average oil consumption of
0.2 1/1000 km, up to 180 grams ash or more can develop after
100,000 km. The ash residue in the filter causes increased pressure
drop in the particle filter, which increases exhaust
counterpressure, increases fuel consumption by 8% or more, and
decreases engine power. Since the ash residue cannot be decomposed
or regenerated, the particle filter must be either removed and
cleaned or replaced after a certain period or after a certain
amount of ash has collected in the filter.
[0006] In particular, Ca, Fe, Mg, Zn, P and S develop in the
exhaust from oil consumption. Sulfur develops in the exhaust from
fuel consumption. Ce, Fe, Ca and Na enter the exhaust from fuel
additives. Fe and Al enter the exhaust from abrasion and
corrosion.
[0007] Ash forms from sulfates, oxides and phosphates, e.g.,
sulfate ash in the form of CaSO.sub.4 and oxide ash in the form of
CaO.
[0008] More than 50% of the resulting ash deposits in the filter
are created by sulfate ash.
[0009] FIG. 5 schematically illustrates a conventional emission
control system with oxidation catalyst 1 and particle filter 2. The
exhaust coming from the engine contains sulfur compounds, e.g., 98%
SO.sub.2, 2% SO.sub.3 and Ca, Fe, Mg, Zn and P. At temperatures
above 350.degree. C., sulfate forms in oxidation catalyst 1, where
SO.sub.2 and SO.sub.3 are converted into SO.sub.4. Ash, such as
CaSO.sub.4, ZNSO.sub.4, MgSO.sub.4, CaO, FeO, etc., develops
downstream from oxidation catalyst 1. This ash collects in particle
filter 2 and clogs it.
SUMMARY
[0010] The present invention provides an emission control system
and a method to operate an emission control system to reduce the
clogging of the particle filter by ash residue.
[0011] According to the present invention, an emission control
system, particularly for a motor vehicle having an internal
combustion engine, is provided with a particle filter, and an
arrangement is provided upstream from the particle filter to
prevent ash-forming compounds of the sulfur in the exhaust from
developing.
[0012] The present invention is based on the principle of
preventing ash from developing in advance of the particle filter
and transforming the compounds responsible for the ash formation
into a gaseous state or keeping them in a gaseous state so that
they can flow through the particle filter without collecting. The
objective is to avoid primarily sulfates, which represent a major
component of the ash.
[0013] Accordingly, the sulfur in the exhaust, which is primarily
responsible for the formation of ash, is converted into compounds
that do not form ash in order to prevent sulfates from forming in
the exhaust.
[0014] In one example embodiment of the present invention, the
arrangement includes an SO.sub.x collector.
[0015] By using an SO.sub.x trap or SO.sub.x collector, the sulfur
contained in the exhaust may be stored to substantially reduce the
amount of ash-forming sulfur compounds in the exhaust. When the
storage capacity of the SO.sub.x trap is exhausted, it may be
regenerated in a regeneration phase. The stored sulfur is released
in the form of gaseous compounds that may pass through the particle
filter.
[0016] The arrangement may be combined with a NO.sub.x collector
and/or an oxidation catalyst.
[0017] These measures improve the quality of the exhaust.
[0018] The present invention also provides a method to operate an
emission control system so that no ash-forming compounds develop
from the sulfur contained in the exhaust.
[0019] The formation of ash may be substantially reduced in this
manner, since sulfur compounds represent a large portion of the
compounds responsible for ash formation.
[0020] In a further example embodiment of the present invention,
there are normal operating phases with a lean exhaust composition
for storing the sulfur contained in the exhaust, and there are
regeneration phases with a rich exhaust composition to release the
stored sulfur in the form of gaseous compounds.
[0021] During the normal operation phases, the formation of sulfate
in the exhaust and accordingly the formation of sulfate ash are
reduced. When the storage capacity of the sulfur collector is
exhausted, a regeneration phase with a rich exhaust composition is
initiated to regenerate the sulfur collector. The stored sulfur is
released in the form of gaseous compounds that may pass through the
particle filter.
[0022] This arrangement effectively prevents the filter from
clogging due to ash. The service interval for cleaning or replacing
a particle filter may be greatly increased with the same filter
volume. The sulfur oxides in the exhaust, such as SO.sub.2 and
SO.sub.3, are stored in the sulfur collector on a storage metal
such as barium (Ba) . Hence, BaSO.sub.4 develops in the sulfur
collector. This arrangement prevents the formation of sulfate in
the exhaust downstream from the sulfur collector. During the
regeneration phase, the BaSO.sub.4 stored in the sulfur collector
is converted to SO.sub.2, H.sub.2S and COS. There is little
formation of SO.sub.4 due to the low-oxygen or rich exhaust
composition. The released sulfur compounds are gaseous and may
therefore pass through the particle filter. After the sulfur
collector is regenerated, the engine may be operated with a lean
exhaust composition.
[0023] The exhaust temperature in the regeneration phase may be
raised to 550-700.degree. C.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic view of a first example embodiment of
the emission control system according to the present invention.
[0025] FIG. 2 is a schematic view of a second example embodiment of
the emission control system according to the present invention.
[0026] FIG. 3 is a schematic view of a third example embodiment of
the emission control system according to the present invention.
[0027] FIG. 4 is a schematic view of an exhaust system of an
automobile with an internal combustion engine having an emission
control system according to the present invention.
[0028] FIG. 5 is a schematic view of a conventional emission
control system.
DETAILED DESCRIPTION
[0029] FIG. 1 schematically illustrates an emission control system
according to the present invention with a SO.sub.x collector 10 and
particle filter 12. The exhaust passes via a pipe section 14 from
an internal combustion engine to SO.sub.x collector 10. The
direction of flow in the emission control system is indicated by
arrows. The sulfur compounds in the exhaust coming from the motor
in pipe section 14 are approximately 98% SO.sub.2 and approximately
2% SO.sub.3. Ca, Fe, Mg, Zn and P are also contained in the
exhaust.
[0030] SO.sub.x collector 10 stores the sulfur oxides SO.sub.2,
SO.sub.3 on a storage metal such as barium (Ba) when the exhaust
composition is lean, a so-called hyperstoichiometric exhaust
composition with .lambda.>1, in the form of BaSO.sub.4. The
formation of sulfate in the exhaust and subsequent formation of
sulfate ash are accordingly reduced. The ash-forming components in
the exhaust either react to form oxide ash or remain in a gaseous
state. For example, Ca, Fe, Mg, Zn and P are present in pipe
section 16 and particle filter 12 as gaseous compounds and may pass
through them, which reduces the deposition of ash in the particle
filter 12. Even when oxide ash forms instead of sulfate ash, the
amount of ash in particle filter 12 may be reduced, since oxide ash
has a lower molar mass than sulfate ash.
[0031] The internal combustion engine creating the exhaust may be
operated with fuel containing less sulfur, e.g., less than 10 ppm,
so that there will be a very small base load of sulfur in the
exhaust. Even when sulfur-free fuel is used, SO.sub.x collector 10
is useful since the exhaust in pipe section 14 contains sulfur
components from consumed motor oil.
[0032] When the storage capacity of SO.sub.x collector 10 is
exhausted, a regeneration phase according to the present invention
is started. The exhaust temperature is increased to 550-700.degree.
C. to regenerate or desulfurize the collector, and the internal
combustion engine is switched to hypostoichiometric operation or
rich operation (.lambda.<1). In the regeneration phase, SO.sub.x
collector 10 releases the sulfur, stored as BaSO.sub.4 in the form
of gaseous sulfur compounds such as SO.sub.3, SO.sub.2, H.sub.2S or
COS. There is little SO.sub.4 formation due to the low-oxygen or
rich air/fuel ratio. The released sulfur compounds may pass through
particle filter 12 in a gaseous state. Even in the regeneration
phase, sulfates do not form in pipe section 16, and Ca, Fe, Mg, Zn,
P are present as gaseous compounds and may pass through particle
filter 12 so that there is less ash deposition. After SO.sub.x
collector 10 is regenerated, the internal combustion engine may be
operated with a hyperstoichiometric or lean exhaust
composition.
[0033] FIG. 2 schematically illustrates another example embodiment
of the emission control system according to the present invention
in which, in contrast to the emission control system illustrated in
FIG. 1, SO.sub.x collector 10 is combined with NO.sub.x collector
20.
[0034] FIG. 3 illustrates a third example embodiment of the
emission control system according to the present invention in
which, in contrast to the emission control system illustrated in
FIG. 1, SO.sub.x collector 10 is combined with NO.sub.x collector
20 and an oxidation catalyst 22.
[0035] The emission control systems illustrated in FIGS. 2 and
further reduce pollutants in the exhaust. The emission control
systems illustrated in FIGS. 2 and 3 are operated in the same
manner as that illustrated in FIG. 1, i.e., with normal operation
phases having lean exhaust composition to store the sulfur in the
exhaust in the form of sulfate, and, after the storage capacity of
SO.sub.x collector 10 is exhausted, with regeneration phases having
a rich exhaust composition to release the stored sulfur in the form
of gaseous compounds.
[0036] FIG. 4 schematically illustrates a diesel engine 24 that
includes an emission purification system according to the present
invention. Diesel engine 24 is supplied with diesel fuel having a
reduced sulfur content from a fuel tank 26. The fuel is injected
with a so-called common-rail injection system 28. Diesel engine 24
is provided with an exhaust turbocharger 30 that supplies
compressed intake air via charge-air cooler 32 to intake manifold
34 of diesel engine 24.
[0037] Between exhaust manifold 36 and intake manifold 34 is an
exhaust return line 38 that may be opened and closed by
controllable exhaust return valve 40.
[0038] Proceeding from the exhaust manifold 36, the exhaust from
diesel engine 24 passes via the exhaust turbine of exhaust
turbocharger 30 to a SO.sub.x collector 42. SO.sub.x collector 42
is combined with a NO.sub.x collector and an oxidation catalyst.
Downstream from SO.sub.x collector 42 is a particle filter 44. The
particle filter 44 is followed by an underbody catalyst that
further reduces pollutant emissions. Downstream from the underbody
catalyst is a muffler to reduce noise.
[0039] Controller 50 controls common rail injection system 28 and
exhaust turbocharger 30 and may accordingly set a rich or lean
exhaust composition. Exhaust return valve 40 is also controlled by
controller 50. Sensors 52 are provided at several locations in the
exhaust system that detect the current exhaust composition and send
it to the controller 50.
[0040] By analysis of the sensor signals in controller 50, the
remaining storage capacity of SO.sub.x collector 42, for example,
may be inferred. If controller 50 determines that SO.sub.x
collector 42 is full, a regeneration phase is started. After
SO.sub.x collector 42 is regenerated, the controller 50 switches
back to storage operation.
* * * * *