U.S. patent application number 14/372483 was filed with the patent office on 2014-12-11 for post thermal control device for use with a nox slip catalyst.
This patent application is currently assigned to International Engine Intellectual Property Company, LLC. The applicant listed for this patent is Adam C. Lack. Invention is credited to Adam C. Lack.
Application Number | 20140360169 14/372483 |
Document ID | / |
Family ID | 48799546 |
Filed Date | 2014-12-11 |
United States Patent
Application |
20140360169 |
Kind Code |
A1 |
Lack; Adam C. |
December 11, 2014 |
POST THERMAL CONTROL DEVICE FOR USE WITH A NOx SLIP CATALYST
Abstract
A system and method for treating diesel exhaust in a diesel
exhaust system, and specifically for improved NO.sub.x conversion
efficiency during particulate filter regeneration, is disclosed.
The exhaust gas treatment system includes a diesel oxidation
catalyst (DOC); a diesel particulate filter (DPF) fluidly coupled
to the DOC; a mixer fluidly coupled to the DOC and DPF, a thermal
control device (TCD) positioned after the DPF, a NO.sub.x slip
catalyst (NSC), at least one temperature sensor (TS), wherein the
thermal control device reduces the temperature of the exhaust gas
stream. The thermal control device used in conjunction with the
NO.sub.x slip catalyst provides for improved overall exhaust system
NO.sub.x conversion efficiency during active DPF regeneration.
Inventors: |
Lack; Adam C.; (Willow
Springs, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lack; Adam C. |
Willow Springs |
IL |
US |
|
|
Assignee: |
International Engine Intellectual
Property Company, LLC
Lisle
IL
|
Family ID: |
48799546 |
Appl. No.: |
14/372483 |
Filed: |
January 19, 2012 |
PCT Filed: |
January 19, 2012 |
PCT NO: |
PCT/US12/21795 |
371 Date: |
July 16, 2014 |
Current U.S.
Class: |
60/274 ; 60/295;
60/298; 60/301 |
Current CPC
Class: |
Y02A 50/2325 20180101;
F01N 11/00 20130101; F01N 9/00 20130101; F01N 3/2066 20130101; F01N
3/103 20130101; Y02T 10/12 20130101; F01N 2610/06 20130101; F01N
3/208 20130101; Y02T 10/24 20130101; Y02T 10/47 20130101; F01N
3/0231 20130101; F01N 2610/02 20130101; Y02T 10/40 20130101 |
Class at
Publication: |
60/274 ; 60/295;
60/298; 60/301 |
International
Class: |
F01N 3/20 20060101
F01N003/20; F01N 11/00 20060101 F01N011/00; F01N 9/00 20060101
F01N009/00 |
Claims
1. A method for reducing NO.sub.x in an exhaust gas stream of a
diesel-engine vehicle, the method comprising the steps of: fluidly
coupling components of an exhaust gas treatment system package to
an engine exhaust gas system; flowing a heated exhaust stream
through the exhaust gas treatment system package; injecting gaseous
ammonia into the exhaust gas treatment system package; reducing an
outgoing temperature of engine exhaust gas after the exhaust passes
through the system package; and, reducing the NO.sub.x to an
acceptable level.
2. The method of claim 1, wherein the components of the exhaust gas
treatment system package comprise a mixing chamber for reacting the
gaseous ammonia with the exhaust gas stream to reduce NO.sub.x in
the exhaust gas.
3. The method of claim 2, wherein the components of the exhaust gas
treatment system package further comprise: a diesel oxidation
catalyst (DOC); a diesel particulate filter (DPF); a thermal
control device (TCD); a NO.sub.x slip catalyst (NSC); and, at least
one temperature sensor (TS); wherein the DOC, DPF, TCD, TS and NSC
are all fluidly coupled together and to the mixing chamber, and
wherein the TCD operates in conjunction with the NSC to effectively
reduce the amount of NO.sub.x in the exhaust stream.
4. The method of claim 3, wherein the thermal control device is
positioned before the NSC.
5. The method of claim 3, wherein at least one of the temperature
sensors is positioned after the thermal control device and before
the NSC.
6. The method of claim 3, wherein at least one of the temperature
sensors is positioned before the thermal control device.
7. The method of claim 1, wherein the step of reducing an outgoing
temperature of engine exhaust gas prior to entry into a NO.sub.x
slip catalyst (NSC) includes installation of a thermal control
device (TCD) before the NSC.
8. The method of claim 7, wherein the step of reducing an outgoing
temperature of engine exhaust gas prior to entry into a NO.sub.x
slip catalyst (NSC) includes installation of a thermal control
device (TCD) after the DPF.
9. An exhaust gas treatment system for use in reducing NO.sub.x in
an exhaust gas stream of a diesel-engine vehicle, the system
comprising: a diesel oxidation catalyst (DOC); a mixer fluidly
coupled to the DOC; a diesel particulate filter (DPF) fluidly
coupled to the mixer and DOC; a thermal control device (TCD)
positioned after the DPF; a NO.sub.x slip catalyst (NSC) positioned
downstream from the DPF; and, at least one temperature sensor (TS)
positioned in conjunction with one of the TCD and NSC, wherein the
TCD operates in conjunction with the at least one temperature
sensor to reduce the temperature of the exhaust gas stream prior to
entry into the NSC.
10. The exhaust gas treatment system of claim 9, wherein the
temperature sensor is positioned after the NSC.
11. The exhaust gas treatment system of claim 9, wherein a first
temperature sensor is positioned before the NSC, and a second
temperature sensor is located after the NSC.
12. The exhaust gas treatment system of claim 9, wherein the
thermal control device is an exhaust temperature reducing
device.
13. The exhaust gas treatment system of claim 9, wherein the
temperature sensor interacts with the thermal control device to
reduce exhaust temperatures to a desired level.
14. A method for reducing NO.sub.x in an exhaust gas stream in a
diesel-engine vehicle after particulate filter regeneration, the
method comprising: fluidly coupling components of an exhaust gas
treatment system package to an engine exhaust gas system; applying
superheated exhaust gas into the exhaust gas treatment system
package for filter regeneration; injecting gaseous ammonia into the
exhaust gas treatment system package for NO.sub.x reduction;
incorporating a NO.sub.x slip catalyst (NSC) into the exhaust gas
treatment system; reducing the temperature of the exhaust gas prior
to entry into the NSC; and, further reducing the level of NO.sub.x
to an acceptable level.
15. The method of claim 14, wherein the components of the exhaust
gas treatment system package further comprise: a diesel oxidation
catalyst (DOC); a diesel particulate filter (DPF); a thermal
control device (TCD); and, at least one temperature sensor (TS);
wherein the DOC, DPF, TCD, TS and NSC are all fluidly coupled
together and to the mixing chamber, and wherein the TCD operates to
reduce the temperature of the superheated exhaust gas.
16. The method of claim 15, wherein the TCD operates in conjunction
with the NSC to effectively reduce the amount of NO.sub.x in the
exhaust stream.
Description
TECHNICAL FIELD
[0001] The present invention relates to a system and method for
treating diesel exhaust in a diesel exhaust system. Particularly,
the present invention provides a method for improving the reduction
of nitrogen oxides (NO.sub.x) in an exhaust gas stream through
installation of a thermal control device in conjunction with a
NO.sub.x slip catalyst, which reduces exhaust gas temperature
resulting in greater NO.sub.x conversion efficiency.
BACKGROUND
[0002] Diesel engines are efficient, durable and economical. Diesel
exhaust, however, can harm both the environment and people. To
reduce this harm, governments, such as the United States and the
European Union, have proposed stricter diesel exhaust emission
regulations. These environmental regulations require diesel engines
to meet the same pollution emission standards as gasoline engines.
Typically, to meet such regulations and standards, diesel engine
systems require equipment additions and modifications.
[0003] For example, a lean burning engine provides improved fuel
efficiency by operating with an amount of oxygen in excess of the
amount necessary for complete combustion of the fuel. Such engines
are said to run "lean" or on a "lean mixture." However, the
increase in fuel efficiency is offset by the creation of
undesirable pollution emissions in the form of nitrogen oxides
(NO.sub.x). Nitrogen oxide emissions are regulated through regular
emission testing requirements. One method used to reduce NO.sub.x
emissions from lean burn internal combustion engines is known as
selective catalytic reduction. When used to reduce NO.sub.x
emissions from a diesel engine, selective catalytic reduction
involves injecting atomized urea into the exhaust stream of the
engine in relation to one or more selected engine
[0004] Another method for reducing NO.sub.x emissions is exhaust
gas recirculation (EGR), which is a technique that re-circulates a
portion of an engine's exhaust gas back to the engine cylinders.
Engines employing EGR recycle part of the engine exhaust back to
the engine air intake. The oxygen depleted exhaust gas blends into
the fresh air entering the combustion chamber. Reducing the oxygen
produces a lower temperature burn, reducing NO.sub.x emissions by
as much as 50%. The recycled exhaust gas can then be cooled. This
"cooled EGR", can create an even greater reduction in emissions by
further lowering the combustion temperatures. When used with a DPF
(diesel particle filter), emissions can be reduced up to 90%.
[0005] The DPF is made up of a diesel oxidation catalyst (DOC),
which is a ceramic material that heats up in the DPF. The filter is
used to collect particulate matter from the DPF. The DPF is cleaned
of particulate matter at periodic intervals through a regeneration
process. Regeneration is the process of removing the accumulated
soot from the filter. This is done either passively (from the
engine's exhaust heat in normal operation or by adding a catalyst
to the filter) or actively by introducing very high heat (more than
600.degree. C. to burn off the particulate matter) into the exhaust
system.
[0006] However, one potential disadvantage of the regeneration
system is the generation of higher levels of NO.sub.x. In addition,
the super heated exhaust may shorten the life of some engine
components. Therefore, it would be advantageous to provide a system
and method for improving the overall exhaust system NO.sub.x
conversion efficiency during active DPF regeneration.
SUMMARY
[0007] A method for reducing NO.sub.x in an exhaust gas stream of a
diesel-engine vehicle, is disclosed. Generally, the method
comprises the steps of fluidly coupling components of an exhaust
gas treatment system package to an engine exhaust gas system,
injecting gaseous ammonia into the exhaust gas treatment system
package, reducing an outgoing temperature of engine exhaust gas
prior to exiting the system, and, reducing the level of NO.sub.x to
an acceptable level. In a preferred embodiment, a thermal control
device (TCD) in conjunction with a NO.sub.x slip catalyst (NSC) is
incorporated into the system to reduce the temperature of the
exhaust gas.
[0008] Further, an exhaust gas treatment system for use in reducing
NO.sub.x in an exhaust gas stream of a diesel-engine vehicle, is
disclosed. The system comprises a diesel oxidation catalyst (DOC);
a mixer fluidly coupled to the DOC, a diesel particulate filter DPF
fluidly coupled to the DOC and mixer, a thermal control device
(TCD) positioned after the DPF, a NO.sub.x slip catalyst (NSC)
positioned in conjunction with the TCD, and at least one
temperature sensor (TS). In another embodiment, multiple
temperature sensors may be used in a variety of locations among the
components of the system.
[0009] In yet another embodiment, a method for reducing NO.sub.x in
an exhaust gas stream in a diesel-engine vehicle after filter
regeneration, is disclosed. The method comprises fluidly coupling
components of an exhaust gas treatment system package to an engine
exhaust gas system, superheating exhaust gas prior to entry into
the exhaust gas treatment system package, injecting gaseous ammonia
into the exhaust gas treatment system package, incorporating a
NO.sub.x slip catalyst (NSC) into the exhaust gas treatment system,
reducing the temperature of the exhaust gas prior to entry into the
NSC, and reducing the level of NO.sub.x to an acceptable level.
[0010] These and other embodiments and their advantages can be more
readily understood from a review of the following detailed
description and the corresponding appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic of an EGR system as currently
employed.
[0012] FIG. 2 is a schematic of an embodiment of an EGR system
incorporating a thermal control device and NO.sub.x slip
catalyst.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1, there is illustrated a current design
of an exhaust gas treatment system package 10. Exhaust gas is
discharged from the diesel engine 100, through conduit such as
exhaust piping to the exhaust gas treatment system 110. The exhaust
gas treatment system 10 of the present application consists of, in
order of exhaust gas flow, a pre-diesel oxidation catalyst
(pre-DOC) 112, a main diesel oxidation catalyst (main DOC) 114, a
mixing chamber 116, a diesel particulate filter (DPF) 118. The
pre-DOC 112, main DOC 114, mixing chamber 116, and DPF 118 are
exhaust gas treatment structures present in most diesel exhaust gas
treatment systems. Such structures will be generally referenced
herein and identified in the drawing figures but, as each of these
additional exhaust treatment structures is commonly understood by
those skilled in the art, a detailed discussion of the operation of
each will not be presented.
[0014] In addition, in both the current system design and in the
embodiment of the present system, the mixing chamber 116 is fluidly
connected to a gaseous ammonia (NH.sub.3) injector 116a, through
which NH.sub.3 is injected into the mixing chamber to mix with the
exhaust stream. The gaseous ammonia may be supplied through a solid
ammonia source. The NH.sub.3 reacts with the exhaust stream,
further reducing the amount of NO.sub.x in the exhaust stream.
[0015] Referring to FIG. 2, there is illustrated an improved
exhaust gas treatment system package 110 of the system package 10
described above. In the present embodiment, a thermal control
device (TCD) 120 and a NO.sub.x slip catalyst (NSC) 122 are added
to the components of the system 10 shown in FIG. 1. Incorporation
of the TCD 120 in conjunction with the NSC 122 results in an
exhaust gas treatment system 110 with enhanced overall exhaust
system NO.sub.x conversion during active DPF regeneration. It
should be understood, however, that while a specific embodiment and
sequence of components is described, the sequence of components can
be arranged in any desired fashion depending on vehicle
specifications or other requirements.
[0016] During regeneration of the DPF 118, exhaust temperatures may
be super heated to above 600.degree. C. in order to burn off the
particulate matter in the filter. However, this super heating may
lead to an increase in NO.sub.x output, during the burn off of the
particulate matter. Therefore, the present system incorporates a
thermal control device (TCD) 120 to assist in reducing the
temperature of the exhaust stream through the system 110. The TCD
120 may be positioned after the DPF 118, but before the NSC 122 in
the system 110; however, it should be understood that the TCD can
be used anywhere in the system depending on design and
specifications. In this manner, after the super heated exhaust
stream passes through and cleans the DPF of particulate matter, the
TCD 120 functions to reduce the exhaust temperature prior to entry
into the NSC 122. By positioning the NSC 122 after the DPF 118 in
the present system 110, any residual NO.sub.x generated by the DPF
regeneration may be captured in the NSC.
[0017] Thermal control devices 122 useful in the present
application may include a radiator-type device having a coolant
flowing there through for absorbing the additional heat, a series
of heat dissipating fins, having a high surface area for heat
dissipation as the exhaust travels through or any of a wide variety
of other known thermal control devices. While various thermal
control devices may be useful in the present system, the ultimate
goal is the reduction of the exhaust temperature to an acceptable
level resulting in lower NO.sub.x generation to meet current
emission standards.
[0018] In addition, the present system 110 includes at least one
temperature sensor 124. The temperature sensors 124 may be
positioned in a variety of locations among the other components of
the system 110, including after the TCD 122 and before the NSC 120,
after the NSC only, or after both the TCD and NSC. Alternatively,
the temperature sensors 124 may be positioned before the pre-DOC
112, after the main DOC 114, or anywhere else within the components
of the system 110 where it may be beneficial to monitor the
temperature of the exhaust stream.
[0019] The temperature sensors 124, which may be resistance type
temperature sensors, are useful for indicating the current
temperature of the exhaust stream temperature during and after
regeneration, as well as throughout the system 110 generally. In
addition, and depending on what type of TCD 122 are desired to be
used in the system 110, the temperature sensors 124 may send
readings back to the electronic control module (not shown) of the
system, which than activates or de-activates the TCD 122 depending
on the temperature reading of the exhaust stream in the system.
[0020] Diesel particulate filters typically require periodic
regeneration. The present method provides reducing NO.sub.x in an
exhaust gas stream in a diesel-engine vehicle after particulate
filter regeneration. The method includes fluidly coupling
components of an exhaust gas treatment system package, including a
DOC, mixer and DPF, to an engine exhaust gas system, applying
superheated exhaust gas into the exhaust gas treatment system
package for filter regeneration, injecting gaseous ammonia into the
exhaust gas treatment system package for NO.sub.x reduction,
incorporating a NO.sub.x slip catalyst (NSC) into the exhaust gas
treatment system, reducing the temperature of the exhaust gas prior
to entry into the NSC, and further reducing the level of NO.sub.x
to an acceptable level.
* * * * *