U.S. patent application number 12/286001 was filed with the patent office on 2009-07-16 for egr catalyzation with reduced egr heating.
This patent application is currently assigned to Cummins Inc.. Invention is credited to Haiying Chen, Neal W. Currier, Howard Hess, Mahesh Konduru, Bradlee J. Stroia, Aleksey Yezerets.
Application Number | 20090178396 12/286001 |
Document ID | / |
Family ID | 40849477 |
Filed Date | 2009-07-16 |
United States Patent
Application |
20090178396 |
Kind Code |
A1 |
Yezerets; Aleksey ; et
al. |
July 16, 2009 |
EGR catalyzation with reduced EGR heating
Abstract
One embodiment is a unique system of EGR catalyzation with
reduced EGR heating. Further embodiments, forms, objects, features,
advantages, aspects, and benefits shall become apparent from the
following description and drawings.
Inventors: |
Yezerets; Aleksey;
(Columbus, IN) ; Currier; Neal W.; (Columbus,
IN) ; Stroia; Bradlee J.; (Columbus, IN) ;
Chen; Haiying; (Gulph Mills, PA) ; Hess; Howard;
(Schwenksville, PA) ; Konduru; Mahesh;
(Philadelphia, PA) |
Correspondence
Address: |
KRIEG DEVAULT LLP
ONE INDIANA SQUARE, SUITE 2800
INDIANAPOLIS
IN
46204-2079
US
|
Assignee: |
Cummins Inc.
|
Family ID: |
40849477 |
Appl. No.: |
12/286001 |
Filed: |
September 26, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61010733 |
Jan 11, 2008 |
|
|
|
Current U.S.
Class: |
60/299 ;
60/320 |
Current CPC
Class: |
F02M 26/28 20160201;
F01N 3/08 20130101; F01N 2370/04 20130101; F01N 2570/12 20130101;
F02M 26/05 20160201; F02B 37/00 20130101; F02M 26/35 20160201; F02B
29/0406 20130101 |
Class at
Publication: |
60/299 ;
60/320 |
International
Class: |
F01N 3/10 20060101
F01N003/10 |
Claims
1. A system comprising: an EGR cooler operable to receive EGR gas
at a first temperature and output EGR gas at a second temperature,
the first temperature being greater than the second temperature;
and a substantially non-oxidizing catalyst unit configured to
intake EGR gas at an intake and output EGR gas at an output;
wherein the EGR cooler and the substantially non-oxidizing catalyst
unit are flow coupled and the substantially non-oxidizing catalyst
unit is positioned upstream of the EGR cooler.
2. A system according to claim 1 wherein the substantially
non-oxidizing catalyst unit is operable to catalyze hydrocarbon
cracking.
3. A system according to claim 1 wherein the substantially
non-oxidizing catalyst unit includes a solid acid catalyst.
4. A system according to claim 1 wherein the substantially
non-oxidizing catalyst unit includes a zeolite catalyst
composition.
5. A system according to claim 1 wherein the substantially
non-oxidizing catalyst unit is operable to catalyze a reaction of
hydrocarbons without increasing the temperature of EGR gas within
the substantially non-oxidizing catalyst unit.
6. A system according to claim 1 wherein the substantially
non-oxidizing catalyst unit is operable to catalyze a reaction of
hydrocarbons while increasing the temperature of EGR gas within the
substantially non-oxidizing catalyst unit by less than about 10
degrees centigrade.
7. A system according to claim 1 further comprising an internal
combustion engine and an exhaust manifold, the exhaust manifold
being in fluid communication with the intake of the substantially
non-oxidizing catalyst unit.
8. A system comprising: an engine; an EGR conduit flow coupled to
the engine to receive exhaust gas therefrom; means for reducing
molecular weight of hydrocarbon molecules in exhaust gas flow
coupled to the EGR conduit; and means for cooling the EGR flow
coupled to the means for reducing molecular weight of hydrocarbon
molecules in exhaust gas.
9. A system according to claim 8 wherein the means for cooling the
EGR includes an engine coolant cooled EGR cooler.
10. A system according to claim 8 wherein the means for reducing
molecular weight of hydrocarbon molecules in exhaust gas includes a
zeolite catalyst
11. A system according to claim 8 wherein the means for reducing
molecular weight of hydrocarbon molecules in exhaust gas includes a
hydrocarbon cracking catalyst.
12. A system according to claim 8 wherein the means for reducing
molecular weight of hydrocarbon molecules in exhaust gas includes a
solid acid catalyst.
13. A system according to claim 8 wherein the engine is a diesel
engine.
14. A system according to claim 8 further comprising a vehicle
wherein the diesel engine is configured to be the prime mover of
the vehicle.
15. A method comprising: operating an internal combustion engine to
produce exhaust including one or more hydrocarbon compounds;
treating a portion of the exhaust with a substantially
non-oxidizing catalyst effective to reduce the molecular weight of
the one or more hydrocarbon compounds; cooling the portion of the
exhaust; and providing the portion of the exhaust to an intake of
the internal combustion engine.
16. A method according to claim 15 wherein the treating a portion
of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes a hydrocarbon cracking reaction.
17. A method according to claim 15 wherein the treating a portion
of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes exposing the one or more hydrocarbon
compounds to a hydrocarbon cracking catalyst.
18. A method according to claim 15 wherein the treating a portion
of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes exposing the one or more hydrocarbon
compounds to a solid acid catalyst.
19. A method according to claim 15 wherein the treating a portion
of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes exposing the one or more hydrocarbon
compounds to a zeolite catalyst.
20. A method according to claim 15 wherein the treating a portion
of the exhaust with a substantially non-oxidizing catalyst occurs
in a single catalyst unit positioned upstream from an EGR cooler.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS:
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 61/010,733 filed Jan. 11, 2008, which is
incorporated herein by reference in its entirety.
BACKGROUND
[0002] Exhaust gas recirculation ("EGR") may be used in connection
with internal combustion engines to reduce emissions or for other
purposes. Present approaches to EGR suffer from a variety of
drawbacks, limitations, disadvantages and problems including, for
example, those respecting reduction or prevention of deposits such
as carbonaceous deposits, reducing or avoiding heating of EGR, and
others. There is a need for the unique and inventive apparatuses,
systems, and methods disclosed herein.
SUMMARY
[0003] One embodiment is a unique system of EGR catalyzation with
reduced EGR heating. Further embodiments, forms, objects, features,
advantages, aspects, and benefits shall become apparent from the
following description and drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0004] FIG. 1 is a schematic of a system including an internal
combustion engine.
[0005] FIG. 2 is a schematic of a cooled EGR system.
[0006] FIG. 3 is a schematic of a cooled EGR system.
[0007] FIG. 4 is a schematic of a cooled EGR system.
[0008] FIG. 5 is a schematic of a vehicle including an engine and a
cooled EGR system.
DETAILED DESCRIPTION
[0009] For purposes of promoting an understanding of the principles
of the invention, reference will now be made to the embodiments
illustrated in the figures and specific language will be used to
describe the same. It will nevertheless be understood that no
limitation of the scope of the invention is thereby created, and
that the invention includes and protects such alterations and
modifications to the illustrated embodiments, and such further
applications of the principles of the invention illustrated therein
as would occur to one skilled in the art to which the invention
relates.
[0010] With reference to FIG. 1, there is illustrated a system 10
including an internal combustion engine 12 having an intake
manifold 14 with an intake conduit 20 coupled thereto. The intake
conduit 20 is coupled to an intake 22 which supplies ambient air to
intake conduit 20. Preferably, the intake conduit 20 is coupled to
an outlet of compressor 16 of turbocharger 18 or of another type of
supercharger. Compressor 16 receives fresh air from intake 22 and
outputs compressed air. System 10 may include an air throttle 66
disposed between the intake manifold 14 and the intake conduit 22.
System 10 preferably includes a charge air cooler 24 disposed
downstream from compressor 16 and which cools compressed air
received from compressor 16.
[0011] Engine 12 further includes an exhaust manifold 30 having an
exhaust conduit 32 coupled thereto. Exhaust flow from conduit 32
drives a turbine 26 of turbocharger 18 which is mechanically
coupled to compressor 16 via drive shaft 28. Turbine 26 preferably
outlets to an aftertreatment system or to ambient via the exhaust
conduit 34. A portion of the exhaust from conduit 32 may be
recirculated via EGR conduit 38. The rate of exhaust gas
recirculation or EGR may be controlled by EGR valve 36 which is
illustrated as being upstream of EGR cooler 40, but could also be
positioned downstream from EGR cooler 40, or intermediate EGR
cooler 40 and catalyst unit 90. Regardless of the location or
presence of EGR valve 36, catalyst unit 90 is preferably positioned
at a location upstream of EGR cooler 40. Catalyst unit 90
preferably includes a non-oxidizing catalyst or a mildly oxidizing
catalyst which are referred to herein as a substantially
non-oxidizing catalyst. Substantially non-oxidizing catalysts are
catalysts which are operable to catalyze one or more chemical
reactions which decrease the molecular weight of hydrocarbon
compounds present in exhaust gas without increasing the temperature
of the exhaust gas or with a reduced temperature increase relative
to that which would occur with an oxidizing catalyst. Examples of
substantially non-oxidizing catalysts include solid acid catalysts
and zeolite catalysts. Hydrocarbon cracking is an exemplary
reaction which is catalyzed by substantially non-oxidizing
catalysts.
[0012] System 10 also preferably includes a control circuit 42 that
is microprocessor-based and operable to control and manage the
operation of engine 12, for example, an engine control module
(ECM), engine control unit (ECU). Control circuit 42 includes a
number of inputs for receiving signals from various sensors or
sensing systems associated with system 10. For example, system 10
preferably includes an engine speed sensor 44 electrically
connected to an engine speed input, ES, of control circuit 42 via
signal path 46. Engine speed sensor 44 is operable to sense
rotational speed of the engine 12 and produce an engine speed
signal on signal path 46 indicative of engine rotational speed.
System 10 also preferably includes a mass air flow sensor 48
disposed in fluid communication with the intake conduit 20 of
engine 12, and electrically connected to a mass flow of air input
(MFA) of control circuit 42 via signal path 50. Mass air flow
sensor 48 is operable to produce a mass flow rate signal on signal
path 50 indicative of the mass flow rate of fresh air flowing into
the intake conduit 20. System 10 also preferably includes a lambda
sensor 80 disposed in fluid communication with exhaust conduit 34
and electrically connected to a lambda input of control circuit 42
via signal path 82, as shown in FIG. 1. Control circuit 42 also
preferably includes a number of outputs for controlling one or more
fluid handling mechanisms associated with system 10. For example,
EGR valve 36 includes an EGR valve actuator 62 electrically
connected to an EGR valve control output (EGRC) of control circuit
42 via signal path 63. Control circuit 42 is operable to produce an
EGR valve control signal on signal path 63, and EGR valve actuator
62 is responsive to the EGR valve control signal on signal path 63
to control the position of EGR valve 36 relative to a reference
position. In addition, air throttle 66 includes an air throttle
actuator 68 electrically connected to an air throttle control
output (ATC) of control circuit 42 via signal path 70. Control
circuit 42 is operable to produce an air throttle control signal on
signal path 70, and air throttle actuator 68 is responsive to the
air throttle control signal on signal path 70 to control the
position of air throttle 66 relative to a reference position.
System 10 also preferably includes a fueling system 72 electrically
connected to a fuel command output (FC) of control computer 42 via
signal path 74. Fueling system 72 is responsive to fueling control
signals produced by control circuit 42 on signal path 74 to supply
fuel to engine 12, and control circuit 42 is operable to produce
such fueling control signals.
[0013] With reference to FIG. 2 there is illustrated an exemplary
cooled EGR system 200 which includes an EGR valve 236 which is flow
coupled to a substantially non-oxidizing catalyst unit 290 which is
flow coupled to an EGR cooler 240. During operation exhaust flows
from an engine, exhaust manifold, exhaust conduit or other exhaust
source to EGR valve 236 which is preferably operable to control the
amount or rate of exhaust flow but could also simply be an on/off
valve. Exhaust next flows to substantially non-oxidizing catalyst
unit 290 which includes one or more substantially non-oxidizing
catalysts operable to catalyze one or more reactions of
hydrocarbons in the exhaust in order to convert higher molecular
weight hydrocarbons into lower molecular weight hydrocarbons while
avoiding, minimizing, controlling or reducing any temperature
increase of the exhaust owing to the catalyzed reaction(s). Exhaust
then flows to EGR cooler 240 which cools the exhaust. From EGR
cooler 240, exhaust may optionally flow through one or more
additional coolers, and may be mixed with intake or charge air
before being provided to an intake manifold or directly to one or
more engine cylinders.
[0014] With reference to FIG. 3 there is illustrated an exemplary
cooled EGR system 300 which includes a substantially non-oxidizing
catalyst unit 390 which is flow coupled to an EGR cooler 340 which
is flow coupled to an EGR valve 336. During operation exhaust flows
from an engine, exhaust manifold, exhaust conduit or other exhaust
source to substantially non-oxidizing catalyst unit 290 which
includes one or more substantially non-oxidizing catalysts operable
to catalyze one or more reactions of hydrocarbons in the exhaust in
order to convert higher molecular weight hydrocarbons into lower
molecular weight hydrocarbons while avoiding, minimizing,
controlling or reducing any temperature increase of the exhaust
owing to the catalyzed reaction(s). Exhaust next flows to EGR
cooler 340 which cools the exhaust. Exhaust then flows to EGR valve
336 which is preferably operable to control the amount or rate of
exhaust flow but could also simply be an on/off valve. From EGR
valve 336, exhaust may optionally flow through one or more
additional coolers and may be mixed with intake or charge air
before being provided to an intake manifold or directly to one or
more engine cylinders.
[0015] With reference to FIG. 4 there is illustrated an exemplary
cooled EGR system 400 which includes a substantially non-oxidizing
catalyst unit 490 which is flow coupled to an EGR valve 436 which
is flow coupled to an EGR cooler 440. During operation exhaust
flows from an engine, exhaust manifold, exhaust conduit or other
exhaust source to substantially non-oxidizing catalyst unit 490
which includes one or more substantially non-oxidizing catalysts
operable to catalyze one or more reactions of hydrocarbons in the
exhaust in order to convert higher molecular weight hydrocarbons
into lower molecular weight hydrocarbons while avoiding,
minimizing, controlling or reducing any temperature increase of the
exhaust owing to the catalyzed reaction(s). Exhaust next flows to
EGR valve 436 which is preferably operable to selectably control
the amount or rate of exhaust flow but could also simply be an
on/off valve. Exhaust then flows to EGR cooler 440 which cools the
exhaust. From EGR cooler 440 exhaust may optionally flow through
one or more additional coolers and may be mixed with intake or
charge air before being provided to an intake manifold or directly
to one or more engine cylinders.
[0016] With reference to FIG. 5, there is illustrated a vehicle
500. Vehicle 500 is shown as a semi tractor, but could also be a
variety of types of vehicles, for example, light duty trucks,
medium duty trucks, heavy duty trucks, buses, cars, motorhomes,
fire and emergency vehicles, construction vehicles, boats and other
marine vehicles, and rail vehicles such as locomotives. Vehicle 500
includes an engine 540, which is preferably a diesel engine but
could be a spark ignition or other type of internal combustion
engine, and a cooled EGR system 530 which preferably includes one
or more EGR coolers operable to cool EGR to provided to engine 440,
one or more substantially non-oxidizing catalyst units which could
be the same as or similar to those described above, and one or more
valves, pumps or other EGR controls. Further embodiments
contemplate that engine 540 could be used in other applications
including, for example, in generator sets, or industrial, mining,
or oil and gas equipment.
[0017] As is evident from the figures and text presented above, a
variety of embodiments according to the present invention are
contemplated. Certain exemplary embodiments include a system
comprising an EGR cooler operable to receive EGR gas at a first
temperature and output EGR gas at a second temperature, the first
temperature being greater than the second temperature; and a
substantially non-oxidizing catalyst unit configured to intake EGR
gas at an intake and output EGR gas at an output; wherein the EGR
cooler and the substantially non-oxidizing catalyst unit are flow
coupled and the substantially non-oxidizing catalyst unit is
positioned upstream of the EGR cooler. In further exemplary
embodiments the substantially non-oxidizing catalyst unit is
operable to catalyze hydrocarbon cracking; the substantially
non-oxidizing catalyst unit includes a solid acid catalyst; the
substantially non-oxidizing catalyst unit includes a zeolite
catalyst composition; the substantially non-oxidizing catalyst unit
is operable to catalyze a reaction of hydrocarbons without
increasing the temperature of EGR gas within the substantially
non-oxidizing catalyst unit; and/or the substantially non-oxidizing
catalyst unit is operable to catalyze a reaction of hydrocarbons
while increasing the temperature of EGR gas within the
substantially non-oxidizing catalyst unit by less than about 10
degrees centigrade. Further exemplary embodiments include an
internal combustion engine and an exhaust manifold, the exhaust
manifold being in fluid communication with the intake of the
substantially non-oxidizing catalyst unit.
[0018] Certain exemplary embodiments include a system comprising an
engine; an EGR conduit flow coupled the engine to receive exhaust
gas therefrom; means for reducing molecular weight of hydrocarbon
molecules in exhaust gas flow coupled to the EGR conduit; and means
for cooling the EGR flow coupled to the means for reducing
molecular weight of hydrocarbon molecules in exhaust gas. In
further exemplary embodiments the means for cooling the EGR
includes an engine coolant cooled EGR cooler; the means for
reducing molecular weight of hydrocarbon molecules in exhaust gas
includes a zeolite catalyst; the means for reducing molecular
weight of hydrocarbon molecules in exhaust gas includes a
hydrocarbon cracking catalyst; and/or the means for reducing
molecular weight of hydrocarbon molecules in exhaust gas includes a
solid acid catalyst. In further exemplary embodiments the engine is
a diesel engine; and/or the diesel engine is configured to be the
prime mover of a vehicle.
[0019] Certain exemplary embodiments include a method comprising
operating an internal combustion engine to produce exhaust
including one or more hydrocarbon compounds; treating a portion of
the exhaust with a substantially non-oxidizing catalyst effective
to reduce the molecular weight of the one or more hydrocarbon
compounds; cooling the portion of the exhaust; and providing the
portion of the exhaust to an intake of the internal combustion
engine. In further exemplary embodiments the treating a portion of
the exhaust with a substantially non-oxidizing catalyst effective
to reduce the molecular weight of the one or more hydrocarbon
compounds includes a hydrocarbon cracking reaction; the treating a
portion of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes exposing the one or more hydrocarbon
compounds to a hydrocarbon cracking catalyst; the treating a
portion of the exhaust with a substantially non-oxidizing catalyst
effective to reduce the molecular weight of the one or more
hydrocarbon compounds includes exposing the one or more hydrocarbon
compounds to a solid acid catalyst; the treating a portion of the
exhaust with a substantially non-oxidizing catalyst effective to
reduce the molecular weight of the one or more hydrocarbon
compounds includes exposing the one or more hydrocarbon compounds
to a zeolite catalyst; and/or the treating a portion of the exhaust
with a substantially non-oxidizing catalyst occurs in a single
catalyst unit positioned upstream from an EGR cooler.
[0020] While exemplary embodiments of the invention have been
illustrated and described in detail in the drawings and foregoing
description, the same is to be considered as illustrative and not
restrictive in character, it being understood that only the
preferred embodiments have been shown and described and that all
changes and modifications that come within the spirit of the
invention are desired to be protected. It should be understood that
while the use of words such as preferable, preferably, preferred or
more preferred utilized in the description above indicate that the
feature so described may be more desirable, it nonetheless may not
be necessary and embodiments lacking the same may be contemplated
as within the scope of the invention, the scope being defined by
the claims that follow. In reading the claims, it is intended that
when words such as "a," "an," "at least one," or "at least one
portion" are used there is no intention to limit the claim to only
one item unless specifically stated to the contrary in the claim.
When the language "at least a portion" and/or "a portion" is used
the item can include a portion and/or the entire item unless
specifically stated to the contrary.
* * * * *