U.S. patent application number 11/217939 was filed with the patent office on 2007-03-01 for exhaust gas aftertreatment systems.
Invention is credited to David J. Kubinski, Devesh Upadhyay.
Application Number | 20070044456 11/217939 |
Document ID | / |
Family ID | 37802143 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070044456 |
Kind Code |
A1 |
Upadhyay; Devesh ; et
al. |
March 1, 2007 |
Exhaust gas aftertreatment systems
Abstract
A method is presented for determining an amount of reductant
stored in the catalyst by intrusively desorbing a portion of
reductant and monitoring the response of an reductant sensor to the
desorbed portion. The desorbtion can be performed at vehicle
start-up to determine initial storage amount and to adjust
reductant injection accordingly to achieve optimum storage.
Additionally, a portion of reductant can be desorbed when NOx
conversion efficiency of the catalyst is reduced in order to
diagnose the component responsible for system degradation.
Inventors: |
Upadhyay; Devesh; (Canton,
MI) ; Kubinski; David J.; (Canton, MI) |
Correspondence
Address: |
FORD GLOBAL TECHNOLOGIES, LLC.
FAIRLANE PLAZA SOUTH, SUITE 800
330 TOWN CENTER DRIVE
DEARBORN
MI
48126
US
|
Family ID: |
37802143 |
Appl. No.: |
11/217939 |
Filed: |
September 1, 2005 |
Current U.S.
Class: |
60/295 ; 60/286;
60/297; 60/301 |
Current CPC
Class: |
Y02A 50/2325 20180101;
Y02A 50/20 20180101; F01N 2900/1622 20130101; F01N 2570/18
20130101; Y02T 10/12 20130101; B01D 53/9409 20130101; B01D 2258/012
20130101; F01N 13/009 20140601; F01N 2560/06 20130101; Y02T 10/47
20130101; F01N 3/0253 20130101; F01N 2560/021 20130101; F01N 3/106
20130101; F01N 13/0093 20140601; F01N 3/208 20130101; F01N 11/002
20130101; F01N 2340/00 20130101; Y02T 10/26 20130101; F01N 2610/02
20130101; F01N 2560/026 20130101; F01N 3/2026 20130101; B01D
2251/2062 20130101; F01N 2550/02 20130101; F01N 13/0097 20140603;
Y02T 10/24 20130101; B01D 53/9495 20130101; F01N 2560/14 20130101;
Y02T 10/40 20130101 |
Class at
Publication: |
060/295 ;
060/286; 060/297; 060/301 |
International
Class: |
F01N 3/00 20060101
F01N003/00; F01N 3/10 20060101 F01N003/10 |
Claims
1. A diagnostic system, comprising: an engine; a catalyst coupled
downstream of said engine, comprising: a first catalyst brick, said
brick having a heated portion; and a sensor coupled in close
proximity to said heated portion; and a controller adjusting a
temperature of said heated portion of said first catalyst brick to
desorb reductant stored on said heated portion, said controller
adjusting an amount of reductant in an exhaust gas mixture entering
said catalyst based on a response of said sensor to said desorbed
reductant; and providing an indication of catalyst degradation if
an amount of an exhaust gas component downstream of said catalyst
remains above a predetermined value for a predetermined time
following said controller adjusting said amount of reductant
entering said catalyst.
2. The system as set forth in claim 1 wherein said engine is a
diesel engine.
3. The system as set forth in claim 2 wherein said catalyst is a
NOx-reducing catalyst.
4. The system as set forth in claim 3 wherein said NOx-reducing
catalyst is a urea SCR catalyst.
5. The system as set forth in claim 4 wherein said heated portion
of said first catalyst brick is an electrically heated portion
adjusted to a predetermined temperature based on the catalyst
desorption characteristics.
6. The system as set forth in claim 5 wherein said sensor is an
ammonia sensor.
7. The system as set forth in claim 6 wherein said reductant is
ammonia.
8. The system as set forth in claim 7 wherein said controller
adjusts said temperature of said heated portion of said first
catalyst brick to desorb substantially all reductant stored on said
heated portion.
9. The system as set forth in claim 9 wherein controller adjusts an
amount of reductant in an exhaust gas mixture entering said
catalyst to cause a predetermined amount of ammonia to be stored in
said first catalyst brick.
10. The system as set forth in claim 9 wherein said catalyst
further comprises a second catalyst brick.
11. The system as set forth in claim 10 wherein said controller
provides said indication of catalyst degradation if an amount of
Nox downstream of said catalyst remains above a predetermined value
for a predetermined amount of time.
12. The system as set forth in claim 11 further comprising
regenerating said catalyst in response to said controller
generating said indication of degradation.
13. A method for controlling a NOx-reducing catalyst coupled
downstream of an internal combustion engine, the NOx-reducing
catalyst including an embedded heater and an ammonia sensor coupled
in close proximity to the embedded heater, the method comprising:
providing an indication of catalyst degradation; in response to
said indication, adjusting the heater temperature thereby causing
reductant to desorb from the catalyst; adjusting an amount of
reductant injection into the catalyst based on an amount of
reductant desorbed by said heating, said desorbed amount determined
by monitoring the ammonia sensor signal; and regenerating the
catalyst if an amount of NOx downstream of the catalyst remains
above a predetermined value for a predetermined time following said
adjusting of reductant injection into the catalyst.
14. The method as set forth in claim 13 wherein said catalyst
degradation is NOx conversion efficiency degradation.
15. The method as set forth in claim 14 further comprising
determining an amount of reductant stored in the catalyst based on
said sensor response to said reductant desorbtion.
16. A method for diagnosing a NOx-reducing catalyst having a heater
embedded therein, the catalyst further having a reductant sensor
positioned in close proximity to the embedded heater, the method
comprising: adjusting a temperature of the embedded heater to
desorb a portion of reductant stored in the NOx-reducing catalyst;
subsequently adjusting reductant injection into the catalyst based
on a response of the sensor to said desorbtion; and regenerating
the catalyst
17. A method for controlling a NOx-reducing catalyst, comprising:
intrusively desorbing a portion of reductant stored in the
catalyst; adjusting reductant injection into the catalyst based on
an amount of reductant intrusively desorbed; and regenerating the
catalyst when NOx conversion efficiency of the catalyst remains
below a predetermined value for a predetermined amount of time
following said reductant injection adjustment.
Description
FIELD OF INVENTION
[0001] The present invention relates to an emission control system
for diesel and other lean-burn vehicles, and more specifically, to
determining an amount of reductant stored in a NOx-reducing
catalyst.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] Current emission control regulations necessitate the use of
catalysts in the exhaust systems of automotive vehicles in order to
convert carbon monoxide (CO), hydrocarbons (HC), and nitrogen
oxides (NOx) produced during engine operation into unregulated
exhaust gasses. Vehicles equipped with diesel or other lean burn
engines offer the benefit of increased fuel economy, however,
catalytic reduction of NOx emissions via conventional means in such
systems is difficult due to the high content of oxygen in the
exhaust gas.
[0003] In this regard, Selective Catalytic Reduction (SCR)
catalysts, in which NOx is continuously removed through active
injection of a reductant into the exhaust gas mixture entering the
catalyst, are known to achieve high NOx conversion efficiency.
Urea-based SCR catalysts use gaseous ammonia as the active NOx
reducing agent. Typically, an aqueous solution of urea is carried
on board of a vehicle, and an injection system is used to supply it
into the exhaust gas stream entering the SCR catalyst. The aqueous
urea decomposes to hydro cyanic acid (NHCO) and gaseous ammonia
(NH.sub.3) in the exhaust gas stream. The Hydrocyanic acid is
catalytically converted to NH3 on the SCR. Ideally, most of the
ammonia will be stored in the catalyst for reaction with the
incoming NOx. NOx conversion efficiency of an SCR catalyst is
improved in the presence of adsorbed ammonia. However, if the
amount of ammonia stored in the catalyst is too high, some of it
may desorb and slip from the catalyst. Additionally, in the
presence of high temperatures, excessive ammonia storage will lead
to excessive NOx via oxidation. All of this will lead to a
reduction in the overall NO.sub.x conversion efficiency. Therefore,
in order to achieve optimal NOx reduction and minimize ammonia slip
in a urea-based SCR catalyst, it is important to control the amount
of ammonia stored in the SCR catalyst.
[0004] A typical prior art system is described in U.S. Pat. No.
6,069,013 wherein a sensor is placed downstream of an SCR catalyst
to detect NH.sub.3. The sensor is comprised of a low acidity
zeolite material of low precious metal content. The a.c. impedance
of the sensor is reduced in the presence of NH.sub.3.
[0005] The inventors herein have recognized a disadvantage with
such an approach. In particular, an ammonia sensor placed
downstream of the catalyst generates a signal only when there is
ammonia slip over the catalyst. Ammonia slip is usually a result of
temperature transients or excessive storage. Slip due to excessive
storage will be impossible to rectify expediently via any control
action. Hence it is recognized that control action based solely on
NH.sub.3 sensor feedback is at best a delayed corrective
action.
[0006] Further, the inventors have recognized that the bulk of the
ammonia introduced into the catalyst is stored or reduced on the
upstream 20-30% of a typically sized catalyst brick on the order of
1 to 2 engine swept volumes. The remaining catalyst volume acts as
a buffer to capture slip and allow some transient NOx reduction at
high space velocities. Further, inventors have recognized that in
order to achieve optimal NOx conversion in the SCR, it is not
necessary that all of the catalyst storage capacity be utilized by
ammonia. Therefore, it is desirable to either control the amount of
ammonia stored in the catalyst to some optimal level below maximum
(for a single brick configuration) or to store at higher levels
only in the front brick/s for a multi brick configuration.
[0007] The inventors herein have determined an improvement can be
achieved by splitting the catalyst brick into at least two parts,
wherein the volume of the first brick would be 20-30% of the
overall single brick equivalent catalyst volume. The first brick
would perform most of the ammonia storage/NOx conversion functions,
and the second brick would serve to catch any of the ammonia
slipping past the first brick. Thus, inventors have recognized that
by controlling the amount of ammonia stored in the first brick,
effective control of overall catalyst ammonia storage amounts can
be achieved.
[0008] Further, inventors herein have devised a method to
effectively measure and control the amount of ammonia stored in the
catalyst prior to achieving catalyst saturation levels. Namely,
inventors have recognized that it is possible to intrusively desorb
a portion of the ammonia stored in the catalyst, and to determine
the overall amount of ammonia stored based on a reading of an
NH.sub.3 sensor positioned in the vicinity of the desorbtion
area.
[0009] Additionally, the inventors have recognized that it is
possible to effectively diagnose system degradation in catalyst
performance by monitoring and controlling the amount of ammonia
stored in the catalyst. In particular, inventors have recognized
that when NOx conversion efficiency of the catalyst is degraded,
and the amount of ammonia storage is below optimal, injection of a
predetermined amount of reductant will improve NOx conversion
efficiency unless the catalyst is poisoned by hydrocarbons or
thermally aged. In other words, the inventors have recognized that
if NOx conversion efficiency of the catalyst does not improve
following injection of ammonia, the catalyst performance may be
degraded due to hydrocarbon poisoning, and it should be
regenerated.
[0010] Therefore, in accordance with the present invention, a
method is presented for controlling a NOx-reducing catalyst, the
method including: intrusively desorbing a portion of reductant
stored in the catalyst; adjusting reductant injection into the
catalyst based on an amount of reductant intrusively desorbed; and
regenerating the catalyst when NOx conversion efficiency of the
catalyst remains below a predetermined value for a predetermined
amount of time following said reductant injection adjustment.
[0011] In yet another embodiment of the present invention, a
diagnostic system includes: an engine; a catalyst coupled
downstream of said engine, including: a first catalyst brick, said
brick having a heated portion; and a sensor coupled in close
proximity to said heated portion; and a controller adjusting a
temperature of said heated portion of said first catalyst brick to
desorb reductant stored on said heated portion, said controller
adjusting an amount of reductant in an exhaust gas mixture entering
said catalyst based on a response of said sensor to said desorbed
reductant; and providing an indication of catalyst degradation if
an amount of an exhaust gas component downstream of said catalyst
remains above a predetermined value for a predetermined time
following said controller adjusting said amount of reductant
entering said catalyst.
[0012] An advantage of the present invention is improved emission
control. Another advantage of the present invention is improved
vehicle diagnostic capabilities.
[0013] The above advantages and other advantages, and features of
the present invention will be readily apparent from the following
detailed description of the preferred embodiments when taken in
connection with the accompanying drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The objects and advantages described herein will be more
fully understood by reading an example of an embodiment in which
the invention is used to advantage, referred to herein as the
Description of Preferred Embodiment, with reference to the
drawings, wherein:
[0015] FIGS. 1A and 1B are schematic diagrams of an engine wherein
the invention is used to advantage;
[0016] FIG. 2 is a schematic diagram of an emission control system,
wherein the invention is used to advantage;
[0017] FIG. 3 is a typical plot, under normal operating conditions,
of the amount of NH.sub.3 stored in a urea SCR catalyst as a
function of catalyst axial distance from front face;
[0018] FIGS. 4, and 5 are examples of a NOX-reducing catalyst in
accordance with the present invention; and
[0019] FIGS. 6 and 7 are high level flowcharts of exemplary
routines for controlling the emission control system in accordance
with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT(S)
[0020] Internal combustion engine 10, comprising a plurality of
cylinders, one cylinder of which is shown in FIG. 1, is controlled
by electronic engine controller 12. Engine 10 includes combustion
chamber 30 and cylinder walls 32 with piston 36 positioned therein
and connected to crankshaft 40. Combustion chamber 30 is shown
communicating with intake manifold 44 and exhaust manifold 48 via
respective intake valve 52 and exhaust valve 54. Intake manifold 44
is also shown having fuel injector 80 coupled thereto for
delivering liquid fuel in proportion to the pulse width of signal
FPW from controller 12. Both fuel quantity, controlled by signal
FPW and injection timing are adjustable. Fuel is delivered to fuel
injector 80 by a fuel system (not shown) including a fuel tank,
fuel pump, and fuel rail (not shown).
[0021] Controller 12 is shown in FIG. 1 as a conventional
microcomputer, including: microprocessor unit 102, input/output
ports 104, read-only memory 106, random access memory 108, and a
conventional data bus. Controller 12 is shown receiving various
signals from sensors coupled to engine 10, in addition to those
signals previously discussed, including: engine coolant temperature
(ECT) from temperature sensor 112 coupled to cooling sleeve 114; a
measurement of manifold pressure (MAP) from pressure sensor 116
coupled to intake manifold 44; a measurement (AT) of manifold
temperature from temperature sensor 117; an engine speed signal
(RPM) from engine speed sensor 118 coupled to crankshaft 40.
[0022] An emission control system 20, coupled to an exhaust
manifold 48, is described in detail in FIG. 2 below.
[0023] Referring now to FIG. 1B, an alternative embodiment is shown
where engine 10 is a direct injection engine with injector 80
located to inject fuel directly into cylinder 30.
[0024] Referring now to FIG. 2, an example of an emission control
system in accordance with the present invention is described.
Emission control system 20 is coupled downstream of an internal
combustion engine 10 described with particular reference in FIG.
1.
[0025] Catalyst 14 is a NOx-reducing catalyst wherein NOx is
continuously removed through active injection of a reductant into
the exhaust gas mixture entering the catalyst. In a preferred
embodiment, catalyst 14 is a urea based Selective Catalytic
Reduction (SCR) catalyst in which NOx is reduced through active
injection of an aqueous urea solution or other nitrogen-based
reductant into the exhaust gas entering the device. The urea
solution is converted into hydro cyanic acid (NHCO) and gaseous
ammonia (NH.sub.3) prior to entering the SCR catalyst, wherein
NH.sub.3 serves an active NOx reducing agent in the SCR.
[0026] In a preferred embodiment, the SCR catalyst is a base
metal/zeolite formulation with optimum NOx conversion performance
in the temperature range of 200-500.degree. C. Oxidation catalyst
13 is coupled upstream of the SCR catalyst and may be a precious
metal catalyst, preferably one containing Platinum for high
conversion of hydrocarbons and carbon monoxide. The oxidation
catalyst exothermically combusts hydrocarbons (HC) in the incoming
exhaust gas from the engine thus supplying heat to rapidly warm up
the SCR catalyst 14. Particulate filter 15 is coupled downstream of
the SCR catalyst for storing soot.
[0027] A reductant delivery system 16 is coupled to the exhaust gas
manifold between the oxidation catalyst and the SCR catalyst.
System 16 may be any reductant delivery system known to those
skilled in the art. In a preferred embodiment, system 16 is that
described in U.S. Pat. No. 6,834,498, assigned to the same assignee
as the present invention, the subject matter thereof being
incorporated herein by reference. In such system, air and reductant
are injected into the reductant delivery system, where they are
vaporized by the heated element and the resulting vapor is
introduced into the exhaust gas mixture entering the SCR
catalyst.
[0028] A pair of NOx sensors 17, 18 is provided upstream and
downstream of the SCR catalyst, respectively. Measurements of the
concentration of NOx in the exhaust gas mixture upstream
(C.sub.NOx.sub.--.sub.in) and downstream (C.sub.NOx.sub.--.sub.out)
of the SCR catalyst 14 provided by the NOx sensors are fed to
controller 12. Controller 12 calculates NOx conversion efficiency
of the catalyst, NOx.sub.eff. In a preferred embodiment, since a
typical NOx sensor is cross-sensitive to ammonia, sensor 17 is
coupled upstream of the reductant delivery system 16.
Alternatively, NOx sensor 17 may be eliminated and the amount of
NOx in the exhaust gas mixture entering the SCR catalyst may be
estimated based on engine speed, load, exhaust gas temperature or
any other parameter known to those skilled in the art to affect
engine NOx production.
[0029] Temperature measurements upstream (T.sub.u) and downstream
(T.sub.d) of the SCR catalyst are provided by temperature sensors
(not shown). Controller 12 calculates catalyst temperature,
T.sub.cat, based on the information provided by these sensors.
Alternatively, any other means known to those skilled in the art to
determine catalyst temperature, such as placing a temperature
sensor mid-bed of the catalyst, or estimating catalyst temperature
based on engine operating conditions, can be employed.
[0030] Referring now to FIG. 3, is a plot of the amount of NH.sub.3
stored in a urea SCR catalyst as a function of axial distance from
front face of the catalyst under normal operating conditions. The
ammonia storage behavior highlighted by this plot is that the
ammonia storage or "fill" is initiated at the front face and
progresses to the rear face over time. Hence, storage over an
extended duration would cause the plot to ultimately become a flat
line with uniform storage over the entire catalyst volume. Ammonia
storage as a function of catalyst volume can be determined by
multiplying the storage over a catalyst length by the catalyst area
up to that length, as follows:
m.sub.NH3.sup.ads(V)=A.sub.cat.intg..sub.x1.sup.x2m.sub.NH3.sup.ads(x)dx
where, A.sub.cat=cross sectional are of catalyst. X.sub.1, x.sub.2
define the catalyst length co-ordinates from the front face.
m.sub.NH3.sup.ads(x)=is defined by the storage function as in FIG.
3. m.sub.NH3.sup.ads(V)=is the cumulative storage in catalyst
volume between sections defined by x1 and x2.
[0031] As can be determined from FIG. 3, the bulk of the ammonia
introduced into the catalyst is stored or reduced on the upstream
20-30% volume of a typically sized catalyst brick on the order of 1
to 2 engine swept volumes. The remaining downstream catalyst volume
stores very little ammonia and acts primarily as a buffer to
capture slip and allow some transient NOx reduction at high space
velocities.
[0032] Referring now to FIG. 4, an example of an SCR catalyst
system according to the present invention is presented. Catalyst 14
comprises housing 120 wherein SCR catalyst bricks (121, 122) are
housed. In a preferred embodiment, brick 121 is approximately
20-30% of overall catalyst volume. Additionally, a small SCR test
catalyst brick 123 with an embedded electrical heater is coupled to
the housing 120 in close proximity to brick 121. In a preferred
embodiment, the brick 123 is approximately 5% of the volume of
brick 121. A temperature probe is used to monitor and control the
temperature of brick 123 and the rate at which it is being heated
up. The maximum heater temperature and its warm-up rate are
determined so that enough of ammonia is released from the portion
of the brick for the nearby ammonia sensor 124 to reach a
predetermined level signal. In an alternative embodiment, the
heater could be turned on for a predetermined amount of time and to
a predetermined temperature such that all of the ammonia is
presumed desorbed from the heated region. Ammonia sensor 124 may be
any conventional NH.sub.3 sensor known to those skilled in the art,
such as the one described in U.S. Pat. No. 6,240,722. When catalyst
ammonia storage amount needs to be established, the heater is
turned on to cause ammonia to desorb from brick 123. The amount of
ammonia sensed by sensor 124 may be used to infer the axial storage
profile of ammonia in brick 121, to be used to update and/or adapt
the expected axial storage profile/model via urea injection
control. The algorithm for controlling the catalyst in accordance
with the present invention is described in more detail below in
FIG. 6. In an alternative embodiment (not shown), housing 120 may
house several SCR catalyst bricks, each having a small test
catalyst and an ammonia sensor coupled in close proximity to it.
This way, ammonia storage amounts in each brick can be separately
monitored.
[0033] Referring now to FIG. 5, another example of an SCR catalyst
system according to the present invention is presented. Catalyst 14
comprises housing 125 wherein SCR catalyst bricks (126, 127) are
housed. In a preferred embodiment, brick 126 is approximately
20-30% of overall catalyst volume. SCR catalyst brick 126 has an
embedded electrical heater 128 with a temperature probe. In a
preferred embodiment, the heated portion is approximately 5% of the
volume of brick 126. The heater is located in close proximity to
the downstream edge of brick 126. The temperature probe is used to
control the maximum temperature of the heated portion of the brick
and the rate at which it is being heated up. The maximum heater
temperature and its warm-up rate are determined so that enough of
ammonia is released from the portion of the brick for the nearby
ammonia sensor 129 to reach a predetermined level signal. In an
alternative embodiment, the heater could be turned on for a
predetermined amount of time and to a predetermined temperature
such that all of the ammonia is presumed desorbed from the heated
region. Ammonia sensor 129 may be any conventional NH.sub.3 sensor
known to those skilled in the art, such as the one described in
U.S. Pat. No. 6,240,722.
[0034] Referring now to FIG. 6, a routine for achieving an optimum
amount of ammonia storage in the SCR catalyst in accordance with
the present invention is presented. In a preferred embodiment, the
routine in FIG. 6 is initiated at engine start-up to establish
initial amounts of ammonia stored in the catalyst. If the initial
ammonia storage is determined to be below optimal, reductant
injection may be initiated to achieve optimum storage amounts.
[0035] First, in step 100, the embedded heater is turned to desorb
stored ammonia from the catalyst portion above the embedded
heater.
[0036] Next, the routine proceeds to decision block 200 wherein a
determination is made whether the ammonia sensor signal
S.sub.NH.sub.3 is greater than a predetermined threshold value
S.sub.1.
[0037] The routine keeps cycling through step 200 until the answer
is YES, wherein logic proceeds to step 300. As discussed above with
particular reference for FIGS. 3 and 4, the heater may
alternatively be turned on for a predetermined time to a
predetermined temperature to presumably desorb substantially all of
the stored ammonia.
[0038] Next, in step 300, the amount of ammonia stored in the
catalyst,.theta., is established based on the response of the
NH.sub.3 sensor coupled in close proximity to the heated portion of
the catalyst. The amount of ammonia stored is determined based on
the following equations: .theta. o local = .intg. 0 t_end .times.
_TPD .times. m . NH .times. .times. 3 .times. _mes SC .function. (
T cat .function. ( o ) ) ( 1.1 ) .theta. o .function. ( x , t ) = f
1 .function. ( x , .theta. o local , T cat .function. ( t ) ) ( 1.2
) T cat .function. ( x , t ) = f 2 .function. ( T cat_upst , T
cat_dnst , x , m . exh , T amb , H ) ( 1.3 ) ##EQU1## Where:
.theta..sub.o.sup.local is the initial coverage fraction determined
for the heated catalyst portion only (determined at engine on).
.theta..sub.o(x,t) is the coverage fraction over the catalyst
length (x) at the given time (t). f1: is the function that is used
to establish the coverage over the catalyst length.
SC(T.sub.cat(o)) is the total storage capacity of the catalyst at
the temperature T.sub.cat(o) at engine on, this is established from
catalyst characterization experiments. T.sub.cat(t) is the catalyst
temperature at some time instance, evaluated from the catalyst
temperature model, defined by function "f2" in equation 1.3. {dot
over (m)}.sub.NH3.sub.--.sub.mes=mass flow rate of ammonia desorbed
as measured by the ammonia sensor. {dot over (m)}.sub.ex is the
exhaust gas flow rate. T.sub.cat.sub.--.sub.upst exhaust gas
temperature upstream of the catalyst T.sub.cat.sub.--.sub.dnst
exhaust gas temperature downstream of the catalyst T.sub.amb is the
ambient temperature. H defines the heat transfer coefficient of the
catalyst and is specific to the catalyst type.
[0039] Once ammonia storage amount is determined, the routine
proceeds to step 400 wherein the heater is turned off.
[0040] Next, logic flows to decision block 500 wherein a
determination is made whether the magnitude of the difference
between the .theta. value determined in step 300 above and
.theta..sub.threshold is within a predetermined constant, C.
[0041] If the answer to step 500 is NO, the routine proceeds to
step 600 wherein a determination is made whether catalyst
temperature, T.sub.cat is within a predetermined temperature range
(T.sub.1<T.sub.cat<T.sub.2). The method for determining
catalyst temperature is described in detail with particular
reference to FIG. 2 above. When T.sub.cat is below a T.sub.1
(170.degree. C. in a preferred embodiment), the injected urea may
decompose only partially to ammonia and hydro-cyanic acid resulting
in urea accumulation in the exhaust pipe and/or deposition on the
catalyst face. This will lead to inefficient conversion, possible
deactivation of the SCR due to polymerized deposits and excess
ammonia slip. Therefore, for temperatures below T.sub.1, there is
no reductant injection into the catalyst. When T.sub.cat is above
T.sub.1, but below a second predetermined temperature threshold,
T.sub.2 (200.degree. C. in a preferred embodiment), NOx conversion
efficiency of the SCR catalyst is very low and reductant may be
injected to allow ammonia storage in the catalyst.
.theta..sub.threshold is a desired amount of ammonia storage that
is required for improved NOx conversion once the SCR catalyst is
within the optimum NOx conversion temperature range (50% in a
preferred embodiment).
[0042] If the answer to step 600 is NO, the routine keeps cycling
until the catalyst temperature reaches the desired range.
[0043] If the answer to step 600 is YES, the routine proceeds step
700 wherein a predetermined amount of reductant, R.sub.inj, is
injected into the catalyst to presumably achieve desired ammonia
storage amount, .theta..sub.threshold. R.sub.inj may be determined
from a lookup table as a function of a plurality of operating
parameters including engine operating conditions, such as catalyst
temperature, engine speed, engine load, EGR level, start of fuel
injection (SOI), catalyst temperature, T.sub.cat, space velocity
(SV), concentration of NOx upstream (C.sub.NOx.sub.--.sub.in) and
downstream (C.sub.NOx.sub.--.sub.out) of the SCR catalyst, and the
calculated amount of ammonia stored in the catalyst,.theta.,
determined in step 300. The routine then exits.
[0044] If the answer to step 600 is YES, i.e., the desired amount
of ammonia storage is achieved, reductant injection may be
discontinued and the routine then exits.
[0045] Therefore, according to the present invention, it is
possible to establish ammonia storage amounts in the SCR catalyst
at engine startup by desorbing ammonia from a portion of the
catalyst brick (or from a small catalyst brick located in close
proximity) and monitoring the response of the ammonia sensor to the
desorbtion.
[0046] Further, when the catalyst is in the desired temperature
range, the calculated ammonia storage amount, as well as other
operating conditions, can be used to determine the quantity of
reductant to be injected in the catalyst such that optimum NOx
conversion can be achieved.
[0047] In an alternative embodiment (not shown), rather than just
at engine start up, ammonia storage amounts in the catalyst can be
periodically determined in order to adjust reductant injection
amounts such that optimum NOx conversion efficiency can be achieved
over vehicle drive cycle.
[0048] Referring now to FIG. 7, a routine for diagnosing
degradation in the SCR catalyst in accordance with the present
invention is presented. In a preferred embodiment, this routine is
performed once the SCR catalyst if fully warmed up, during normal
drive cycle of the vehicle.
[0049] First, in step 800 NOx conversion efficiency of the
catalyst, NOx.sub.eff' is calculated. The inventors herein have
recognized that since a NOx sensor is cross sensitive to any
ammonia that may slip from the catalyst, the downstream NOx sensor
reading has to be adjusted based on the ammonia sensor signal.
Therefore, NOx conversion efficiency is calculated as follows: NOx
eff = C NOx_out - .lamda. nox_nh3 .times. _fac S NH 3 C NOx_in
##EQU2## The routine then proceeds to decision block 900 wherein a
determination is made whether NOx.sub.eff is greater than or equal
to desired NOx conversion efficiency, NOx.sub.eff.sub.--.sub.des If
the answer to step 900 is YES, no degradation is detected and the
routine proceeds to step 1000 wherein efficiency degradation
counter, DC is set to zero. The routine then exits.
[0050] If the answer to step 900 is NO, the routine proceeds to
step 1100 wherein efficiency degradation counter, DC (initially set
to zero), is incremented.
[0051] The routine then proceeds to decision block 1200 wherein a
determination is made whether the value of the efficiency
degradation counter has exceeded a predetermined threshold,
DC.sub.max.
[0052] If the answer to step 1100 is NO, the routine cycles back to
step 800.
[0053] If the answer to step 1200 is YES, indicating degradation in
NOx conversion efficiency of the catalyst, the routine proceeds to
step 1300 wherein the embedded heater is turned on to desorb
ammonia from the catalyst portion above the heater. The temperature
of the heater is determined by ammonia desorbtion characteristics
of the catalyst, and is adjusted based on operating conditions,
such as engine speed, load, exhaust gas temperature, as well as
catalyst age.
[0054] Next, the routine proceeds to decision block 1400 wherein a
determination is made whether the ammonia sensor signal S.sub.NH,
is greater that a predetermined threshold value S.sub.1. The
routine keeps cycling through step 1400 until the answer is YES,
wherein logic proceeds to step 1500. As discussed above with
particular reference for FIGS. 3 and 4, the heater may
alternatively be turned on for a predetermined time to a
predetermined temperature to presumably desorb all of the stored
ammonia.
[0055] Next, in step 1500, the amount of ammonia stored in the
catalyst,.theta., is established based on the response of the
NH.sub.3 sensor coupled in close proximity to the heated portion of
the catalyst. The amount of ammonia stored is determined same as in
Equation 1 of FIG. 6 above adjusted for the catalyst temperature at
which the determination was initiated.
[0056] Once ammonia storage amount is determined, the routine
proceeds to step 1600 wherein the heater is turned off.
[0057] The routine then proceeds to step 1700 wherein a
determination is made whether the magnitude of the difference
between the .theta. value determined in step 1500 above and
.theta..sub.threshold is within a predetermined constant, C.
[0058] If the answer to step 1700 is YES, indicating that ammonia
storage amounts in the catalyst are at optimum levels, but NOx
conversion efficiency of the catalyst is degraded, the routine
proceeds to step 2100 wherein an indication of system degradation
such as, for example, NOx sensor degradation or injection system
degradation is generated. The routine then exits.
[0059] If the answer to step 1700 is NO, the routine proceeds to
step 1800 wherein a predetermined amount of reductant, R.sub.inj,
(in addition to the requisite feed-forward amount for NOx
reduction), is injected into the catalyst to presumably achieve
desired ammonia storage amount, .theta..sub.threshold. R.sub.inj is
determined in the same manner as described in step 700 FIG. 6
above.
[0060] The routine then proceeds to decision block 1900 wherein a
determination is made whether NOx.sub.eff is greater than or equal
to desired NOx conversion efficiency, NOx.sub.eff.sub.--.sub.des.
If the answer to step 1900 is YES, indicating that degradation in
NOx conversion efficiency was due to insufficient ammonia storage
in the catalyst, and has now been corrected, the routine exits.
[0061] If the answer to step 1900 is NO, indicating that
degradation in NOx conversion efficiency of the catalyst has not
been corrected by extra reductant injection, the routine proceeds
to step 2000, wherein an indication of catalyst deterioration due
to, for example, hydrocarbon poisoning, is generated. The routine
then exits.
[0062] Therefore, according to the present invention, it is
possible to improve performance of the vehicle emission control
system by monitoring and controlling ammonia storage amount in the
SCR catalyst.
[0063] If degradation in NOx conversion efficiency of the catalyst
is indicated, the present invention teaches intrusively desorbing a
portion of the ammonia stored in the catalyst to determine the
overall ammonia storage amount. If the ammonia storage amount in
the catalyst is at optimum level, but NOx conversion efficiency is
still degraded, determination can be made that one of the NOx
sensors is degraded and corrective action can be taken.
[0064] Further, using the present invention, it is also possible to
determine that catalyst performance is degraded due to hydrocarbon
poisoning. In other words, if it is not possible to increase
ammonia storage amount in the catalyst through extra reductant
injection, a determination can be made that its storage capacity is
decreased due to hydrocarbon poisoning. Therefore, catalyst
regeneration routine can be initiated.
[0065] In an alternative embodiment (not shown), upon indication of
NOx conversion efficiency degradation, the intrusive desorption can
be initiated and the difference between the actual amount of
ammonia stored and the desired storage amount determined based on
the sensor response. Based on this difference, an amount of
reductant presumably sufficient to achieve desired ammonia storage
amount can be injected into the catalyst. Catalyst degradation will
be indicated if the amount of ammonia slip past the first catalyst
brick is greater than a predetermined value as indicated by the
ammonia sensor coupled in the vicinity of the first brick.
[0066] This concludes the description of the invention. The reading
of it by those skilled in the art would bring to mind many
alterations and modifications without departing from the spirit and
the scope of the invention. Accordingly, it is intended that the
scope of the invention be defined by the following claims:
* * * * *