U.S. patent application number 10/325319 was filed with the patent office on 2004-06-24 for enhanced ammonia feed control for selective catalytic reduction.
Invention is credited to Gladden, John R..
Application Number | 20040118109 10/325319 |
Document ID | / |
Family ID | 32468974 |
Filed Date | 2004-06-24 |
United States Patent
Application |
20040118109 |
Kind Code |
A1 |
Gladden, John R. |
June 24, 2004 |
ENHANCED AMMONIA FEED CONTROL FOR SELECTIVE CATALYTIC REDUCTION
Abstract
A selective catalytic reduction emissions control system of a
compression ignition engine is provided with enhanced ammonia feed
control for improved emissions control performance. The reduction
agent is provided in two doses, and the reactor is provided with
two reacting beds. The second dose of reactant is provided between
the first and second reacting beds.
Inventors: |
Gladden, John R.;
(Lafayette, IN) |
Correspondence
Address: |
Todd T. Taylor
Taylor & Aust, P.C.
142 S. Main Street
P.O. Box 560
Avilla
IN
46710
US
|
Family ID: |
32468974 |
Appl. No.: |
10/325319 |
Filed: |
December 19, 2002 |
Current U.S.
Class: |
60/286 ;
60/285 |
Current CPC
Class: |
F01N 13/0093 20140601;
Y02T 10/12 20130101; F01N 2570/14 20130101; F01N 3/206 20130101;
F01N 2560/021 20130101; F01N 13/008 20130101; F01N 2900/08
20130101; F01N 13/0097 20140603; F01N 3/208 20130101; F01N 2610/146
20130101; Y02T 10/24 20130101; F01N 2560/026 20130101; F01N 2610/08
20130101; F01N 2610/02 20130101 |
Class at
Publication: |
060/286 ;
060/285 |
International
Class: |
F01N 003/00 |
Claims
What is claimed is:
1. An emissions control system for treating an exhaust gas stream
with a reduction agent in an exhaust system of an engine, the
emissions control system comprising: a first sensor for determining
at least one operating condition of the engine; a control unit
connected to the sensor for determining a calculated amount of the
reduction agent needed to treat the exhaust gas stream; a reduction
agent supply source; a first metering means for supplying a first
dose of the reduction agent to the exhaust stream, said first dose
of reduction agent being less than the calculated amount of the
reduction agent needed to treat the exhaust gas stream; a reactor
having an inlet receiving the exhaust gas stream with the first
dose of reduction agent; and a second metering means for supplying
a second dose of the reduction agent to the exhaust stream
downstream from the reactor inlet.
2. The emissions control system of claim 1, including a second
sensor for determining a characteristic of the exhaust gas stream,
and said control unit connected to said second sensor for
determining the amount of said second dose of reduction agent.
3. The emissions control system of claim 2, said reactor including
a first reacting bed and a second reacting bed, and said second
sensor and said second metering means disposed between said first
and second reacting beds.
4. The emissions control system of claim 3, said first metering
means being a flow control device to dispense said first dose in an
amount of approximately ninety percent (90%) of said calculated
amount of said reduction agent.
5. The emissions control system of claim 1, said reactor having an
outlet, and a second sensor associated with said outlet for sensing
the level of NO.sub.x emissions emitted by the reactor, said sensor
being connected to said control unit for determining the amount of
reduction agent in said second dose.
6. The emissions control system of claim 1, said first sensor being
adapted for sensing one of engine speed, fuel consumption rate,
boost and load.
7. The emissions control system of claim 1, said reactor including
a first reacting bed and a second reacting bed, and said second
metering means disposed between said first reacting bed and said
second reacting bed.
8. The emissions control system of claim 1, said first dose being
approximately ninety percent (90%) of said calculated needed amount
of said reduction agent.
9. An engine producing an exhaust gas stream to be treated by a
reduction agent which is mixed with the exhaust gas stream to
convert the exhaust gas stream, the engine comprising: a combustion
section including a plurality of combustion chambers; a combustion
air system supplying combustion air to said combustion chambers,
said combustion air system including an intake air manifold and a
combustion air conduit for supplying combustion air to said intake
manifold, an exhaust system receiving exhaust gases from said
combustion chambers, said exhaust system including an exhaust
manifold and an exhaust conduit for conducting the exhaust gases in
an exhaust gas stream from the engine; and an emissions control
system, including: a reduction agent supply source; a reactor
having first and second reacting beds in fluid flow communication
with said exhaust conduit; a first sensor and a control unit
connected to said first sensor for determining a calculated amount
of the reduction agent needed for treatment of the exhaust gas
stream; a first metering means for supplying to the exhaust stream
a first dose of reduction agent less than the calculated amount of
the reduction agent; a second metering means between said reacting
beds for supplying a second dose of the reduction agent to the
exhaust stream; and a second sensor for determining a
characteristic of the exhaust stream, and said control unit
connected to said second sensor for determining the amount of said
second dose of reduction agent.
10. The engine of claim 9, said first metering means being a flow
control device controlled for supplying said first dose in an
amount of approximately ninety percent (90%) of said calculated
amount.
11. The engine of claim 9, said second sensor disposed between said
first and second reacting beds.
12. The engine of claim 9, said second sensor disposed downstream
from said second reacting bed.
13. The engine of claim 9, said second sensor being an NO.sub.x
sensor.
14. A method for increasing the efficiency of an emissions control
system for a compression ignition engine capable of producing an
exhaust gas stream to be treated by a reduction agent which is
mixed with the exhaust gas stream to convert the exhaust gas, the
method comprising steps of: determining a needed amount of the
reduction agent to treat the exhaust gas stream; supplying a first
dose of the reduction agent to the exhaust gas stream, said first
dose being less than the needed amount; reacting the exhaust gas
stream with the first dose of reduction agent; supplying a second
dose of reduction agent to the exhaust gas stream after reacting
the exhaust gas stream with the first dose of reduction agent; and
reacting the exhaust gas stream with the second dose of reduction
agent.
15. The method of claim 14, including a step of determining an
amount of the second dose based on effectiveness of said step of
reacting the exhaust gas stream with the first dose.
16. The method of claim 14, including supplying said first dose of
the reduction agent in an amount of approximately ninety percent
(90%) of the needed amount from said step of determining the needed
amount.
17. The method of claim 16, including a step of determining an
amount of the second dose based on effectiveness of said step of
reacting the exhaust gas stream with the first dose.
18. The method of claim 17, including determining the NO.sub.x
content of the exhaust gas stream after said step of reacting the
exhaust gas stream with the second dose of reduction agent, and
determining the amount of the second dose in response to said
determining the NO.sub.x content.
19. The method of claim 17, including determining the NO.sub.x
content of the exhaust gas stream between said step of reacting the
exhaust gas stream with the first dose of reduction agent and said
step of reacting the exhaust gas stream with the second dose of
reduction agent, and determining the amount of the second dose in
response to said determining the NO.sub.x content.
20. The method of claim 14, said step of determining the needed
amount including sensing at least one engine operating condition
from the group of engine operating conditions including boost
pressure, fuel consumption rate, engine speed and engine load.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to emissions control
systems for reciprocating engines, and more particularly to an
emissions control system for increasing selective catalytic
reduction (SCR) efficiency through enhanced reactant feed
control.
BACKGROUND
[0002] Combustion engines including compression ignition and spark
ignition reciprocating engines and gas turbines provide efficient
power sources requiring low operating personnel requirements.
Combustion engines produce and emit NO.sub.x (nitrogen oxides).
Control methods to reduce the NO.sub.x often increase the fuel
consumption of the engines and require large increase in the
operating personnel required.
[0003] Compression ignition engines, such as diesel engines,
provide advantages in fuel economy, but produce and emit both
NO.sub.x and particulates during normal operation. When primary
measures (actions that affect the combustion process itself, such
as exhaust gas recirculation and engine timing adjustments) are
taken to reduce one, often the other is increased. Thus, combustion
conditions selected to reduce pollution from particulates and
obtain good fuel economy tend to increase the output of NO.sub.x.
Current and proposed regulations and legislation present
significant challenges to manufacturers to achieve good fuel
economy while at the same time reducing the emission levels of
particulates and NO.sub.x.
[0004] In order to meet such requirements or restrictions, a method
known as SCR (selective catalytic reduction) has been used for
reducing the emission of NO.sub.x. The SCR method consists of
injecting gaseous ammonia (NH.sub.3), ammonia in aqueous solution
or aqueous urea, or ammonia supplied from an ammonia generator
using a solid source of ammonia such as ammonia carbamate or
ammonia carbonate, into the exhaust gas system of the compression
ignition engine as a reduction agent. When the temperature of the
exhaust gas stream is above a reaction temperature, for example a
temperature above 160.degree. C. for aqueous urea, the reduction
agent undergoes a hydrolysis process and is decomposed into ammonia
and CO.sub.2. As the exhaust gas stream is passed through the SCR
catalyst, the gaseous ammonia reacts with the NO.sub.x to reduce
the NO.sub.x to molecular nitrogen. This reduces or limits the
NO.sub.x emissions from the compression ignition engine.
[0005] The amount of ammonia required at any given time varies as
operating conditions of the engine change, and the exhaust gas
content includes more or less NO.sub.x. It is important that a
sufficient amount of ammonia be supplied to treat NO.sub.x present
in the exhaust gas stream, so that NO.sub.x emission standards are
achieved. On the other hand, it is wasteful and inefficient to
supply ammonia in excess of the amount required to treat the
NO.sub.x present in the exhaust gas stream.
[0006] U.S. Pat. No. 4,403,473 entitled "Ammonia/Fuel Ratio Control
System For Reducing Nitrogen Oxide Emissions", issued Sep. 13,
1983, teaches a method and apparatus for efficiently reducing
NO.sub.x emissions from an engine. Ammonia is metered to the
exhaust gas conduit in a pre-selected proportion to the fuel mass
flow rate, but only in response to the temperature of the exhaust
gas stream in the reactor being within a pre-selected temperature
range.
[0007] While the aforementioned U.S. Pat. No. 4,403,473 provides a
reasonably reliable method and apparatus for reducing NO.sub.x
emissions, the method and apparatus do not provide feedback control
based on the actual effectiveness of the process. It would be
advantageous to control ammonia addition to the exhaust gas stream
based on the actual effectiveness of the treatment process.
[0008] The present invention is directed to overcoming one or more
of the problems as set forth above.
SUMMARY OF THE INVENTION
[0009] In one aspect of the present invention, an emissions control
system for treating an exhaust gas stream with a reduction agent in
an exhaust system of an engine is provided with a first sensor for
determining at least one operating condition of the engine; and a
control unit connected to the sensor for determining a calculated
amount of the reduction agent needed to treat the exhaust gas
stream. A reduction agent supply source has a first metering means
for supplying a first dose of the reduction agent to the exhaust
stream in an amount less than the calculated amount of the
reduction agent. A reactor has an inlet receiving the exhaust gas
stream with the first dose of reduction agent. A second metering
means supplies a second dose of the reduction agent to the exhaust
stream.
[0010] In another aspect of the invention, an engine is provided
with a combustion section including a plurality of combustion
chambers; a combustion air system supplying combustion air to the
combustion chambers, and an exhaust system receiving exhaust gases
from the combustion chambers. The exhaust system includes an
exhaust manifold and an exhaust conduit for conducting the exhaust
gases in an exhaust gas stream from the engine. An emissions
control system includes a reduction agent supply source and a
reactor having first and second reacting beds in fluid flow
communication with the exhaust conduit. A first sensor and a
control unit connected to the first sensor determine a calculated
amount of the reduction agent needed for treatment of the exhaust
gas stream. A first metering means supplies to the exhaust stream a
first dose of reduction agent less than the calculated amount of
the reduction agent. A second metering means between the reacting
beds supplies a second dose of the reduction agent to the exhaust
stream. A second sensor determines a characteristic of the exhaust
stream, and the control unit is connected to the second sensor for
determining the amount of the second dose of reduction agent.
[0011] In still another aspect of the invention, a method for
increasing the efficiency of an emissions control system for a
compression ignition engine capable of producing an exhaust gas
stream to be treated by a reduction agent which is mixed with the
exhaust gas stream to convert the exhaust gas, is provided with
steps of: determining a needed amount of the reduction agent to
treat the exhaust gas stream; supplying a first dose of the
reduction agent to the exhaust gas stream; reacting the exhaust gas
stream with the first dose of reduction agent; supplying a second
dose of reduction agent to the exhaust gas stream after reacting
the exhaust gas stream with the first dose of reduction agent; and
reacting the exhaust gas stream with the second dose of reduction
agent.
[0012] Other aspects and advantages of the present invention will
be apparent to those skilled in the art upon reading the following
detailed description in connection with the drawing and appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be better understood and its advantages
more apparent from the following detailed description, especially
when read in light of the accompanying drawing, wherein:
[0014] FIG. 1 is a schematic illustration of an engine having
enhanced ammonia feed control for selective catalytic reduction, in
accordance with the present invention.
DETAILED DESCRIPTION
[0015] Referring now to the drawing, FIG. 1 illustrates an
emissions control system 10 constructed and operated according to
the present invention. Emissions control system 10 is used to
control the emissions from a compression ignition engine 12, such
as a diesel engine. Engine 12 includes an exhaust system 14 in
which an exhaust gas stream, indicated by arrows 16, is conducted.
Exhaust system 14 includes one or more exhaust manifolds 18 and an
exhaust conduit 20.
[0016] Emissions control system 10 is particularly advantageous in
use for diesel engines, but can be used advantageously in all types
of reciprocating engines including spark ignited engines, diesel
engines, compression ignition and pilot ignition engines. Although
engine 12 shown and described herein is a diesel engine, it should
be understood that the term "engine" is intended to apply to all
types of reciprocating engines, and not limited to diesel engines
only. System 10 also can be adapted for use in gas turbines.
[0017] Engine 12 further includes a main combustion section 30
which includes, among other elements, an engine block and a
cylinder head forming a plurality of combustion chambers 32
therein. A fuel injector, cylinder liner, at least one intake port
and corresponding intake valves, at least one exhaust port and
corresponding exhaust valves and a reciprocating piston movable
within each chamber 32 are provided or associated with each chamber
32. A combustion air system 34, including a combustion air conduit
36 and an intake manifold 38 provide a combustion air stream,
indicated by arrows 40, to each combustion chamber 32.
[0018] While the present emissions control system 10 is shown and
described for use on a heavy duty six cylinder in-line four stroke
direct injection diesel engine, numerous other engine types may be
used, including two stroke engines. The engine configurations may
include in-line and/or v-type engines, as well as various
modifications in the number of combustion chambers 32.
[0019] Emissions control system 10 includes a reduction agent
supply source 50, such as a source for ammonia, urea, or other
acceptable reduction agent for processing exhaust gas stream 16.
Source 50 may include an ammonia generator system, storage tanks,
pumps, valves, piping and controls, as those skilled in the art
will understand readily. Supply pipes 52 and 54 from source 50
provide reduction agent to exhaust gas stream 16 in a first dose
indicated by arrows 56, and a second dose indicated by arrows 58.
First and second doses 56 and 58 are supplied to exhaust gas stream
16 in individually controllable amounts by a first metering means
60 and a second metering means 62, respectively. First metering
means 60 and second metering means 62 can be any suitable flow
control device, for reliably controlling the rate at which
reduction agent in the forms of first dose 56 and second dose 58,
respectively, are provided to exhaust gas stream 16. Some examples
of suitable devices that can be used for first metering means 60
and second metering means 62 are a controllable valve or other
orifice, a nozzle, a pump or the like.
[0020] A reactor 70 is provided in flow communication with exhaust
conduit 20, and includes a first reacting bed 72 and a second
reacting bed 74. First dose 56 of reduction agent is provided to
exhaust gas stream 16 in advance of first reacting bed 72, and
second dose 58 is supplied to exhaust gas stream 16 between first
and second reacting beds 72 and 74. Reactor 70 includes an inlet 76
receiving exhaust gas stream 16, together with first dose 56, and
an outlet 78 through which the reacted exhaust gas stream,
indicated by arrows 80, passes from reactor 70. An intermediate
zone 82 is provided in reactor 70, between first reacting bed 72
and second reacting bed 74.
[0021] Emissions control system 10 further includes an electronic
control unit 90 that is used to control and monitor various
operations and functions of emissions control system 10 and engine
12. Electronic control unit 90 is capable of monitoring various
functions of engine 12, by use of one or more sensors 92 that are
associated with engine 12. Sensors 92 are connected to electronic
control unit 40 via a signal connection 94, which may be an
electrically conductive wire. Examples of sensors 92 that may be
employed at various locations in engine 12 are an engine speed
sensor, an intake manifold air temperature sensor, an intake
manifold pressure sensor, various other load, boost and speed
sensors, all of which are known to those skilled in the art. Sensor
or sensors 92 monitor the operating status of engine 12, providing
data signals with regard thereto to control unit 90. Several such
sensors 92 can be used to concurrently monitor a number of
operating conditions of engine 12, and the various systems
associated therewith.
[0022] At least one sensor 96 connected to controller 90 by a
signal connection 98 is used to determine a condition of exhaust
gas stream 16 at some point after first reacting bed 72. Sensor 96
can be one to sense NO.sub.x present in exhaust gas stream 16, or
sensor 96 can be one to determine the presence of ammonia in
exhaust gas stream 16. Sensor 96 can be positioned in outlet 78 of
reactor 70, to provide a signal indicative of the level of ammonia
or NO.sub.x remaining in reacted exhaust gas stream 80, after
treatment in reactor 70. Sensor 96 also can be positioned in
reactor 70, between first and second reacting beds 72 and 74, to
determine the presence of ammonia or NO.sub.x between reacting beds
72 and 74. FIG. 1 illustrates two sensors 96, one in each of the
aforementioned positions; however, it is not necessary that one
sensor 96 be used in each position. A single sensor 96, in either
position shown, is adequate in many applications for emission
control system 10. Alternatively, different sensors 96 can be used
in each position. For example, an ammonia sensor 96, between first
reacting bed 72 and second reacting bed 74, can be sued to
determine the amount of ammonia still available for reacting with
exhaust gas stream 16; and an NO.sub.x sensor 96 can be used
associated with outlet 78, to determine the effectiveness of the
overall treatment in reactor 70.
[0023] Electronic control unit 90 also is connected to first
metering means 60 by a control signal connection 100, and to second
metering means 62 by a control signal connection 102, to control
the operations of first and second metering means 60 and 62.
Electronic control unit 90 further is connected to reduction agent
supply source 50 by an electrical connection or connections 104, to
control the operation of the various valves, pumps and the like
associated with reduction agent supply source 50.
[0024] Electronic control unit 90, also known as a control module
or a controller, and may take many forms, including a computer
based system, a microprocessor based system including a
microprocessor, a micro-controller, or any other control type
circuit or system. Electronic control unit 90 may include memory
for storage of a control program for operating and controlling the
emissions control system 10 of the present invention, and other
memory for temporary storage of information.
INDUSTRIAL APPLICABILITY
[0025] The operation of the emissions control system 10 is based on
electronic control unit 90 monitoring the status of the engine 12
and the effectiveness of the performance of emissions control
system 10, and controlling the supply of reduction agent to exhaust
gas stream 16 based thereon.
[0026] Combustion air stream 40 in combustion air system 34 is
provided to intake manifold 38 from combustion air conduit 36. Fuel
and combustion air from intake manifold 38 are provided to each
combustion chamber 32 of engine 12, and are combusted therein in
known manner. The combustion gases remaining after the combustion
stroke in chambers 32 are expelled from chambers 32 to exhaust
system 14, first entering exhaust manifold 18. Exhaust gas stream
16 is formed as the combustion gases flow from exhaust manifold 18
to and through exhaust conduit 20. Exhaust gas stream 16 will
contain differing amounts of NO.sub.x, depending on the operating
conditions of engine 12, therefore requiring different amounts of
reduction agent for the proper treatment of NO.sub.x contained in
exhaust gas stream 16.
[0027] Using data from one or more of engine operating condition
sensors 92, electronic control unit 90 determines a calculated
amount of the reduction agent, such as ammonia or urea, that will
be need to treat exhaust gas stream 16. Control unit 90 sends a
signal to first metering means 60 and to reduction agent supply
source 50, whereby first dose 56 of reduction agent is transported
from reduction agent supply source 50 to exhaust gas stream 16, via
supply pipe 52 and first metering means 60. First dose 56 includes
an amount of the reduction agent which is less than the calculated
amount needed to treat exhaust gas stream 16. A statistical
approach can be used for calculating first dose 56. One such
approach includes determining the accuracy of the NO.sub.x
emissions calculation from the parameters monitored, and
determining the accuracy of the dosing metering equipment. For
example, if the NO.sub.x emission calculation is accurate within
seven percent (7%) and the dosage metering equipment has a three
percent (3%) accuracy, first dose 56 may be an amount of
approximately ninety percent (90%) of the calculated amount. Other
statistical approaches to calculating first dose 56 also can be
used.
[0028] First dose 56 is supplied to exhaust gas stream 16, and
travels therewith to first reacting bed 72 in reactor 70. In known
manner, the reduction agent of first dose 56 and first reacting bed
72 cause chemical reactions to occur, decreasing the amount of
NO.sub.x present in exhaust gas stream 16.
[0029] Since first dose 56 includes an amount less than the
calculated amount of reduction agent required to treat the NO.sub.x
present in exhaust gas stream 16, it is necessary to supply
additional reduction agent to complete the treatment of exhaust gas
stream 16. Control unit 90 sends a signal to second metering means
62 and to reduction agent supply source 50, whereby second dose 58
of reduction agent is transported from reduction agent supply
source 50 to exhaust gas stream 16, via supply pipe 54 and second
metering means 62. Second dose 58 includes a remaining amount of
the reduction agent necessary to complete the treatment of exhaust
gas stream 16. Second dose 58 can be the balance of the calculated
amount needed to treat exhaust gas stream 16, not supplied in first
dose 56. For example, if first dose 56 included an amount of
approximately ninety percent (90%) of the calculated amount, second
dose 58 can include an amount of approximately ten percent (10%) of
the calculated amount. Thus, together first and second doses 56 and
58 make up one hundred percent (100%) of the calculated amount.
[0030] Advantageously, in emissions control system 10 of the
present invention, the amount of reduction agent supplied in second
dose 58 can be separately determined and varied, to thereby supply
an adequate amount of reduction agent, but not an excessive amount
of reduction agent for treating exhaust gas stream 16. Processing a
signal or signals from one or more sensors 96, control unit 90
determines an amount of reduction agent to be supplied in second
dose 58 to complete the treatment of exhaust gas stream 16. By so
calculating the amount of second dose 58, the effectiveness of the
treatment with first dose 56 in first reacting bed 72 is
considered, and if sensor 96 is provided downstream of second
reacting bed 74, feedback on the overall effectiveness of the
treatment in both reacting beds 72 and 74 is provided. Using
feedback from sensor or sensors 96, control unit 90 may determine
an amount for second dose 58 such that the combined amount of first
dose 56 and second dose 58 is more, or less, than the original
calculated amount.
[0031] Second dose 58 is supplied to exhaust gas stream 16 between
first reacting bed 72 and second reacting bed 74, as exhaust gas
stream 16 flows through intermediate zone 82. Exhaust gas stream 16
then flows to second reacting bed 74, together with second dose 58
and any residual amounts of first dose 56. The treatment of
NO.sub.x in exhaust gas stream 16 is continued in second reacting
bed 74, so that the NO.sub.x levels of reacted exhaust gas stream
80 leaving reactor 70 are at acceptable limits.
[0032] Rather than having a single reactor 70 with first reacting
bed 72 and second reacting bed 74 therein, two separate reactors,
each having a single reacting bed, also could be used. A single
reactor 70 with split reacting beds 72 and 74 is believed to be
advantageous in its simplicity and reduced space requirements
compared to using separate reactors.
[0033] The present invention provides a selective catalytic
reduction emissions control system for treating an exhaust gas
stream from an engine, which has closed feedback control, so that
an adequate amount, but not an excessive amount of the reduction
agent is provided. Reduction agent is not wasted, and the exhaust
gas stream is treated adequately. The efficiency of the process is
thereby improved.
[0034] Other aspects, objects and advantages of this invention can
be obtained from a study of the drawings, the disclosure and the
appended claims.
* * * * *