U.S. patent application number 15/588110 was filed with the patent office on 2017-08-24 for reducing agent injection device, exhaust gas treatment device and exhaust gas treatment method.
This patent application is currently assigned to NGK Insulators, Ltd.. The applicant listed for this patent is NGK Insulators, Ltd.. Invention is credited to Yoshiyuki KASAI, Kazumi MASE, Katsumi SAIKI.
Application Number | 20170241318 15/588110 |
Document ID | / |
Family ID | 51580183 |
Filed Date | 2017-08-24 |
United States Patent
Application |
20170241318 |
Kind Code |
A1 |
KASAI; Yoshiyuki ; et
al. |
August 24, 2017 |
REDUCING AGENT INJECTION DEVICE, EXHAUST GAS TREATMENT DEVICE AND
EXHAUST GAS TREATMENT METHOD
Abstract
A reducing agent injection device includes a honeycomb structure
having a honeycomb structure body and a pair of electrode members
arranged in a side surface of the honeycomb structure body and a
urea spraying device spraying a urea water solution in mist form.
The urea water solution sprayed from the urea spraying device is
supplied inside cells from a first end face of the honeycomb
structure body, and urea in the urea water solution supplied in the
cells is heated and hydrolyzed inside the electrically heated
honeycomb structure body to generate ammonia. The ammonia is
discharged outside the honeycomb structure body from a second end
face and injected outside. There is provided a reducing agent
injection device that can generate and inject ammonia from a urea
solution with less energy.
Inventors: |
KASAI; Yoshiyuki;
(Nagoya-City, JP) ; MASE; Kazumi; (Nagoya-City,
JP) ; SAIKI; Katsumi; (Nagoya-City, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NGK Insulators, Ltd. |
Nagoya-City |
|
JP |
|
|
Assignee: |
NGK Insulators, Ltd.
Nagoya-City
JP
|
Family ID: |
51580183 |
Appl. No.: |
15/588110 |
Filed: |
May 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14856659 |
Sep 17, 2015 |
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15588110 |
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PCT/JP2014/057385 |
Mar 18, 2014 |
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14856659 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F01N 2610/02 20130101;
B01D 53/9431 20130101; B01D 2257/502 20130101; B01D 53/90 20130101;
F01N 2240/40 20130101; F01N 2330/30 20130101; F01N 2610/1453
20130101; B01J 35/04 20130101; B01J 27/224 20130101; F01N 2610/10
20130101; B01D 2255/1021 20130101; F01N 3/0222 20130101; B01D
2255/20723 20130101; B01D 2255/50 20130101; F01N 2610/146 20130101;
Y02T 10/24 20130101; B01D 2257/406 20130101; F01N 3/2842 20130101;
B01D 53/9477 20130101; F01N 3/208 20130101; Y02T 10/12 20130101;
B01D 2255/1023 20130101; B01D 2255/1025 20130101; B01D 2257/404
20130101; F01N 2240/16 20130101; F01N 2610/105 20130101; B01D
2251/2067 20130101; B01D 2257/702 20130101; F01N 3/2026 20130101;
F01N 3/2066 20130101 |
International
Class: |
F01N 3/28 20060101
F01N003/28; B01D 53/94 20060101 B01D053/94; B01J 27/224 20060101
B01J027/224; F01N 3/20 20060101 F01N003/20; B01J 35/04 20060101
B01J035/04 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 22, 2013 |
JP |
2013-060923 |
Claims
1. A reducing agent injection device, comprising: a honeycomb
structure that has an electrically heated honeycomb structure body
with a pillar shape having partition walls defining and forming a
plurality of cells which are through channels of a fluid and extend
from a first end face being an end face on an inflow side of the
fluid to a second end face being an end face on an outflow side of
the fluid, and that has a pair of electrode members arranged in a
side surface of the honeycomb structure body; and a urea spraying
device that sprays a urea water solution in mist form, wherein each
of the pair of electrode members is formed in a band shape
extending to a cell extending direction of the honeycomb structure
body, and one electrode member of the pair of electrode members is
arranged on an opposite side of the other electrode member of the
pair of electrode members with respect to a center of the honeycomb
structure body sandwiched by the pair of electrode members, in a
cross section perpendicular to the cell extending direction, and
the urea water solution sprayed from the urea spraying device is
supplied inside the cells from the first end face of the honeycomb
structure body, and urea in the urea water solution supplied in the
cells is heated and hydrolyzed inside the electrically heated
honeycomb structure body to generate ammonia, and the ammonia is
discharged outside the honeycomb structure body from the second end
face and is injected outside.
2. The reducing agent injection device according to claim 1,
wherein a urea spraying space is formed between the first end face
of the honeycomb structure body and the urea spraying device.
3. The reducing agent injection device according to claim 1,
wherein an electrical resistivity of the honeycomb structure body
is 0.01 .OMEGA.cm to 500 .OMEGA.cm.
4. The reducing agent injection device according to claim 1,
wherein the honeycomb structure body contains a silicon-silicon
carbide composite material or silicon carbide as a main
component.
5. The reducing agent injection device according to claim 1,
wherein a urea hydrolysis catalyst is loaded onto the honeycomb
structure.
6. The reducing agent injection device according to claim 1,
wherein the urea water solution is sprayed toward the first end
face of the honeycomb structure body from the urea spraying device
and an angle between a spraying direction of the urea water
solution from the urea spraying device and a direction parallel to
the cell extending direction of the honeycomb structure body and
heading to the first end face of the honeycomb structure body from
the urea spraying device is from 5.degree. to 60.degree..
7. The reducing agent injection device according to claim 1,
wherein the honeycomb structure body has a plugging portion at an
end portion of the first end face side in a part of the cells
thereof.
8. The reducing agent injection device according to claim 1,
wherein the urea spraying is a solenoid type, a piezoelectric
actuator type, an ultrasonic type, or an atomizer type.
9. An exhaust gas treatment device, comprising: an exhaust pipe
that flows an exhaust gas containing NO.sub.x; the reducing agent
injection device according to claim 1 that injects ammonia inside
the exhaust pipe; and an SCR catalyst arranged on a downstream side
of the exhaust pipe with respect to a position where the ammonia is
injected.
10. An exhaust gas treatment method comprising flowing exhaust gas
containing NO.sub.x in an exhaust pipe, injecting ammonia inside
the exhaust pipe to the exhaust gas by the reducing agent injection
device according to claim 1, and performing a reduction treatment
to the exhaust gas mixed with the ammonia by an SCR catalyst
arranged on a downstream side of the exhaust pipe with respect to a
position where the ammonia is injected.
11. The exhaust gas treatment method according to claim 10, wherein
a temperature of the honeycomb structure is equal to or more than
160.degree. C.
12. The exhaust gas treatment method according to claim 10,
comprising intermittently performing, under a temperature of the
honeycomb structure equal to or more than 360.degree. C., a
reducing agent injection device cleaning operation which removes a
sulfur compound adhered to the reducing agent injection device.
13. The exhaust gas treatment method according to claim 10,
calculating a temperature of the honeycomb structure body from a
resistance value of the honeycomb structure body, and controlling
the temperature of the honeycomb structure body such that the
calculated temperature becomes a desired temperature.
14. The reducing agent injection device according to claim 2,
wherein an electrical resistivity of the honeycomb structure body
is 0.01 .OMEGA.cm to 500 .OMEGA.cm.
15. The reducing agent injection device according to claim 14,
wherein the honeycomb structure body contains a silicon-silicon
carbide composite material or silicon carbide as a main
component.
16. The reducing agent injection device according to claim 15,
wherein a urea hydrolysis catalyst is loaded onto the honeycomb
structure.
17. The reducing agent injection device according to claim 16,
wherein the urea water solution is sprayed toward the first end
face of the honeycomb structure from the urea spraying device, and
an angle between a spraying direction of the urea water solution
from the urea spraying device and a direction parallel to the cell
extending direction of the honeycomb structure body and heading to
the first end face of the honeycomb structure from the urea
spraying device is from 5.degree. to 60.degree..
18. The reducing agent injection device according to claim 17,
wherein a surface area per unit volume of the honeycomb structure
body is equal to or more than 5 cm.sup.2/cm.sup.3.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. application Ser.
No. 14/856,659, filed Sep. 17, 2015, which is a Continuation of
International Application No. PCT/JP2014/057385, filed Mar. 18,
2014, the entireties of which are incorporated herein by reference,
and claims the benefit under 35 U.S.C. .sctn.119(a)-(d) of Japanese
Patent Application No. 2013-060923 filed Mar. 22, 2013.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention relates to a reducing agent injection
device, an exhaust gas treatment device, and an exhaust gas
treatment method. More specifically, the present invention relates
to the reducing agent injection device that can generate and inject
ammonia from a urea solution with less energy. Further, the present
invention relates to the exhaust gas treatment device that includes
this reducing agent injection device, and that can treat NO.sub.x
in an exhaust gas with less energy even when the exhaust gas is at
low temperature. Furthermore, the present invention relates to the
exhaust gas treatment method that can treat NO.sub.x in the exhaust
gas with less energy by use of this exhaust gas treatment device,
even when the exhaust gas is at low temperature.
[0004] Description of Related Art
[0005] Conventionally, a selective catalytic reduction type
NO.sub.x catalyst (an SCR catalyst) has been used to purify
nitrogen oxides (NO.sub.x) in the exhaust gas discharged from
various kinds of engines and the like (for example, see Patent
Documents 1 to 3).
[0006] The exhaust gas purifying device disclosed in Patent
Document 1 has a catalyst (an SCR catalyst) mounted on an exhaust
pipe of an engine and means for injecting a urea water into the
exhaust pipe between the engine and the catalyst. Further, in the
exhaust gas purifying device, a plurality of urea water injection
means, which mixes the urea water and the exhaust gas, and mixes
the urea water with the exhaust gas while causing the urea water to
react with a specific component in the exhaust gas by the catalyst,
are provided in a plurality of places.
[0007] The device disclosed in Patent Document 2 is the device for
reducing nitrogen oxides in the exhaust gas in an internal
combustion engine. Further, the device includes a thermal
decomposition reactor to generate ammonia from a solid urea, a
heating device, and an SCR catalyst, and cause the ammonia
generated from the solid urea to flow in the SCR catalyst.
[0008] The device disclosed in Patent Document 3 is the device for
evaporating at least one of a reducing agent precursor (urea)
solution and a reducing agent precursor (urea). The evaporated
substance (urea) is to undergo hydrolysis by a hydrolysis catalytic
converter arranged on a downstream side. This device includes a
heating zone and a heating element arranged in the heating zone,
and evaporates at least one of the reducing agent precursor
solution and the reducing agent precursor by the heating element.
The hydrolyzed substance (ammonia) by the hydrolysis catalytic
converter is used for a reduction treatment in the SCR catalytic
converter.
CITATION LIST
Patent Documents
[0009] [Patent Document 1] JP-A-2007-327377
[0010] [Patent Document 2] JP-T-2009-524765
[0011] [Patent Document 3] JP-A-2010-506077
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
[0012] Because the exhaust gas purifying device disclosed in Patent
Document 1 decomposes the urea water by heat of the exhaust gas,
there has been a problem that urea is less likely to react when the
temperature of the exhaust gas lowers due to improvement of fuel
consumption of the engine and the like.
[0013] Though the device disclosed in Patent Document 2 uses a
solid urea, there is the problem that it is difficult to convey the
solid urea to a reaction device and conveyance becomes further
difficult due to absorption of moisture unless moisture is
completely cut off during storage.
[0014] In the device disclosed in Patent Document 3, the heating
element does not have an appropriate shape to evaporate at least
one of the reducing agent precursor solution and reducing agent
precursor with less energy, and thus there has been a problem that
thermal decomposition is less likely to occur with less energy.
[0015] The present invention has been developed in view of such
problems of the conventional techniques. The present invention
provides a reducing agent injection device that can generate and
inject ammonia (reducing agent) from a urea solution with less
energy. The present invention provides an exhaust gas treatment
device that includes this reducing agent injection device and that
can treat NO.sub.x in exhaust gas with less energy even when the
exhaust gas is at low temperature. The present invention provides
an exhaust gas treatment method that can treat NO.sub.x in the
exhaust gas with less energy by using this exhaust gas treatment
device, even when the exhaust gas is at low temperature.
Means for Solving the Problem
[0016] The present invention provides the following reducing agent
injection device, exhaust gas treatment device, and exhaust gas
treatment method.
[0017] According to a first aspect of the present invention, a
reducing agent injection device is provided, including: a honeycomb
structure that has a honeycomb structure body with a pillar shape
having a partition wall defining and forming a plurality of cells
which are through channels of a fluid and extend from a first end
face being an end face on an inflow side of the fluid to a second
end face being an end face on an outflow side of the fluid, and
that has a pair of electrode members arranged in a side surface of
the honeycomb structure body; and a urea spraying device that
sprays a urea water solution in mist form, wherein each of the pair
of electrode members is formed in a band shape extending to a cell
extending direction of the honeycomb structure body, and one
electrode member of the pair of electrode members is arranged on an
opposite side of the other electrode member of the pair of
electrode members with respect to a center of the honeycomb
structure body sandwiched by the pair of electrode members, in a
cross section perpendicular to the cell extending direction, and
the urea water solution sprayed from the urea spraying device is
supplied inside the cells from the first end face of the honeycomb
structure body, and urea in the urea water solution supplied in the
cells is heated and hydrolyzed inside the electrically heated
honeycomb structure body to generate ammonia, and the ammonia is
discharged outside the honeycomb structure body from the second end
face and is injected outside.
[0018] According to a second aspect of the present invention, the
reducing agent injection device according to the first aspect is
provided, wherein a urea spraying space is formed between the first
end face of the honeycomb structure body and the urea spraying
device.
[0019] According to a third aspect of the present invention, the
reducing agent injection device according to the first or second
aspects is provided, wherein an electrical resistivity of the
honeycomb structure body is 0.01 .OMEGA.cm to 500 .OMEGA.cm.
[0020] According to a fourth aspect of the present invention, the
reducing agent injection device according to any one of the first
to third aspects is provided, wherein the honeycomb structure body
contains a silicon-silicon carbide composite material or silicon
carbide as a main component.
[0021] According to a fifth aspect of the present invention, the
reducing agent injection device according to any one of the first
to fourth aspects is provided, wherein a urea hydrolysis catalyst
is loaded onto the honeycomb structure.
[0022] According to a sixth aspect of the present invention, the
reducing agent injection device according to any one of the first
to fifth aspects is provided, wherein the urea water solution is
sprayed toward the first end face of the honeycomb structure body
from the urea spraying device and an angle between a spraying
direction of the urea water solution from the urea spraying device
and a direction parallel to the cell extending direction of the
honeycomb structure body and heading to the first end face of the
honeycomb structure body from the urea spraying device is from
5.degree. to 60.degree..
[0023] According to a seventh aspect of the present invention, the
reducing agent injection device according to any one of the first
to sixth aspects is provided, wherein a surface area per unit
volume of the honeycomb structure body is equal to or more than 5
cm.sup.2/cm.sup.3.
[0024] According to an eighth aspect of the present invention, the
reducing agent injection device according to any one of the first
to seventh aspects is provided, wherein the honeycomb structure
body has a plugging portion at an end portion of the first end face
side in a part of the cells thereof.
[0025] According to a ninth aspect of the present invention, the
reducing agent injection device according to any one of the first
to eighth aspects is provided, wherein the urea spraying device is
a solenoid type, a piezoelectric actuator type, an ultrasonic type,
or an atomizer type.
[0026] According to a tenth aspect of the present invention, an
exhaust gas treatment device is provided, including: an exhaust
pipe that flows an exhaust gas containing NO.sub.x; the reducing
agent injection device according to any one of the first to ninth
aspects is provided, that injects ammonia inside the exhaust pipe;
and an SCR catalyst arranged on a downstream side of the exhaust
pipe with respect to a position where the ammonia is injected.
[0027] According to an eleventh aspect of the present invention, an
exhaust gas treatment method is provided, including flowing the
exhaust gas containing NO.sub.x in the exhaust pipe, injecting
ammonia in the exhaust gas, and performing a reduction treatment to
the exhaust gas mixed with the ammonia by the SCR catalyst, by
using the exhaust gas treatment device according to the tenth
aspect of the present invention.
[0028] According to a twelfth aspect of the present invention, the
exhaust gas treatment method according to the eleventh aspect is
provided, wherein temperature of the honeycomb structure is equal
to or more than 160.degree. C.
[0029] According to a thirteenth aspect of the present invention,
the exhaust gas treatment method according to the eleventh or
twelfth aspects is provided, including intermittently performing,
under temperature of the honeycomb structure equal to or more than
360.degree. C., a reducing agent injection device cleaning
operation which removes a sulfur compound adhered to the reducing
agent injection device.
[0030] According to a fourteenth aspect of the present invention,
the exhaust gas treatment method according to any one of the
eleventh to thirteenth aspects is provided, calculating temperature
of the honeycomb structure body from a resistance value of the
honeycomb structure body, and controlling the temperature of the
honeycomb structure body such that the calculated temperature
becomes desired temperature.
Effect of the Invention
[0031] According to the reducing agent injection device of the
present invention, the urea water solution sprayed by the urea
spraying device is supplied inside the cell of the honeycomb
structure. Then, the urea in the urea water solution is heated and
hydrolyzed inside the electrically heated honeycomb structure to
generate ammonia. Then, the generated ammonia is injected outside.
Because "the honeycomb structure has a larger surface area and a
smaller pressure loss," the ammonia can be generated from the urea
solution with less energy.
[0032] According to the exhaust gas treatment device of the present
invention, because the exhaust gas treatment device of the
above-described present invention is included, the ammonia can be
generated from the urea water solution with less energy even when
the exhaust gas is at low temperature. Then, NO.sub.x in the
exhaust gas can be treated with less energy.
[0033] According to the exhaust gas treatment method of the present
invention, because the exhaust gas is treated by use of the exhaust
gas treatment device of the above-described present invention,
NO.sub.x in the exhaust gas can be treated with less energy even
when the exhaust gas is at low temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a schematic diagram showing a cross section of one
embodiment of a reducing agent injection device of the present
invention.
[0035] FIG. 2 is a schematic diagram showing a cross section of an
ammonia injection system using the one embodiment of the reducing
agent injection device of the present invention.
[0036] FIG. 3 is a plan view schematically showing an end face of a
honeycomb structure constituting of the one embodiment of the
reducing agent injection device of the present invention.
[0037] FIG. 4 is a plan view schematically showing the end face of
the honeycomb structure constituting of other embodiment of the
reducing agent injection device of the present invention.
[0038] FIG. 5 is a schematic diagram showing a cross section of a
yet another embodiment of the reducing agent injection device of
the present invention.
[0039] FIG. 6 is a schematic diagram showing a cross section of one
embodiment of an exhaust gas treatment device of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The following specifically describes a mode for carrying out
the present invention. It should be understood that the present
invention is not limited to the following embodiments and that
design change, improvement, and the like may be suitably added on
the basis of ordinary knowledge of a person skilled in the art
without departing from the gist of the present invention.
[0041] (1) Reducing Agent Injection Device:
[0042] As shown in FIG. 1, one embodiment of a reducing agent
injection device 100 includes a honeycomb structure 1 and a urea
spraying device 2 spraying a urea water solution in mist form. The
honeycomb structure 1 has a pillar-shaped honeycomb structure body
11 and a pair of electrode members 12 and 12 arranged in a side
surface of the honeycomb structure body 11. The honeycomb structure
body 11 has "partition walls 15 defining and forming" a plurality
of cells 16 which are through channels of a fluid and extend from a
first end face 13 being an end face on an inflow side of the fluid
to a second end face 14 being an end face on an outflow side of the
fluid.`" Each of the pair of electrode members 12 and 12 is formed
in a band shape extending in cells 16 extending direction of the
honeycomb structure body 11. In a cross section perpendicular to
the cells 16 extending direction, one electrode member 12 of the
pair of electrode members 12 and 12 is arranged on an opposite side
of the other electrode member 12 of the pair of electrode members
12 and 12 sandwiching a center of the honeycomb structure body 11.
In the reducing agent injection device 100 of the embodiment, a
urea water solution a2 sprayed from the urea spraying device 2 is
supplied inside the cell 16 from the first end face 13 of the
honeycomb structure body 11. Then, urea in the urea water solution
supplied inside the cell 16 is heated and hydrolyzed inside the
electrically heated honeycomb structure body 11 to generate ammonia
(reducing agent). Then, an ammonia b is discharged outside the
honeycomb structure body 11 from the second end face 14, and this
ammonia b is injected outside. FIG. 1 is a schematic diagram
showing a cross section (a cross section parallel to the cell 16
extending direction of the honeycomb structure body 11) of the one
embodiment of the reducing agent injection device 100 of the
present invention.
[0043] In consequence, according to the reducing agent injection
device 100 of the embodiment, the urea water solution a2 sprayed
from the urea spraying device 2 is supplied inside the cell 16 of
the honeycomb structure 1. Then, the urea in the urea water
solution is heated and hydrolyzed inside the electrically heated
honeycomb structure 1 to generate ammonia. Then, the generated
ammonia b is injected outside. Because the honeycomb structure 1
has a larger surface area and a smaller pressure loss, the ammonia
can be generated from a urea solution with less energy. In the
reducing agent injection device 100 of the embodiment, a raw
material for generation of the ammonia is the urea water solution.
Therefore, a urea water solution distributed on the market (for
example, AdBlue (a urea water solution of 32.5 mass %: a registered
trademark of the German Automotive Industry Association (VDA)) is
available. Accordingly, it is highly convenient in terms of
procurement of a urea water solution as a raw material for
generation of ammonia.
[0044] Here, a case that the urea water solution is heated by the
honeycomb structure and another case that the urea water solution
is heated by a nichrome wire are compared below. For example, when
the honeycomb structure with a partition wall thickness of 0.1524
mm and a cell density of 62 cells/cm.sup.2 is used, the surface
area per 1 cm.sup.3 becomes approximately 27.73 cm.sup.2. When
attempting to make the surface area to be 27.73 cm.sup.2 by use of
the nichrome wire with a diameter of, for example, 0.5 mm, the
nichrome wire with a length of 1.76 m is necessary. It is difficult
to house the nichrome wire of this length in 1 cm.sup.3 while "a
passage, such as the cell of the honeycomb structure, where the
urea water solution flows" is ensured. When the urea water solution
is heated, a heat transfer area and temperature of a heating member
(the honeycomb structure, a nichrome wire and the like) become
dominant factors. Therefore, during heating a predetermined amount
of the urea water solution, when the area of this heating member is
smaller, higher temperature is necessary, and thus higher energy
becomes necessary. As described above, the method of electrical
heating by use of the honeycomb structure, compared to the method
in which a linear heating member such as a nichrome wire is used,
can heat the urea water solution with less energy and generate
ammonia with less energy.
[0045] In the reducing agent injection device 100 of the
embodiment, the honeycomb structure 1 and the urea spraying device
2 are housed inside a tubular outer cylinder 4. The honeycomb
structure 1 is secured inside the outer cylinder 4 by an insulation
supporting portion 5. As shown in FIG. 3, in the honeycomb
structure 1, a shape of the first end face 13 of the honeycomb
structure body 11 is preferably a square shape. The shape of the
first end face 13 is not limited to a square shape, and may be a
rectangular shape, other polygonal shape, a circular shape, an oval
shape and the like. The shape of the first end face 13 is the same
as that of the second end face 14, and further preferably also the
same as that of a cross section, which is perpendicular to the cell
16 extending direction of the honeycomb structure body 11. The
shape (the shape of the outer cylinder) of "the cross section
perpendicular to a direction heading from an inlet side end portion
21 to an outlet side end portion 22," of the outer cylinder 4 is
preferably a similar shape to "the shape (the shape of the
honeycomb structure body) of the cross section perpendicular to the
cell 16 extending direction" of the honeycomb structure body 11.
Here, "the similar shape" means that when "the shape of the outer
cylinder" is a square shape, "the shape of the honeycomb structure
body" is the square shape, and when "the shape of the outer
cylinder" is a rectangular shape, "the shape of the honeycomb
structure body" is the rectangular shape. Here, for example, when
"the shape of the outer cylinder" and "the shape of the honeycomb
structure body" are "the similar shape", and the shapes are the
rectangular shapes, even ratios between longitudinal lengths and
lateral lengths are not necessary to be the same. The size of "the
cross section perpendicular to the cell 16 extending direction," of
the honeycomb structure body 11 is smaller than that of "the cross
section perpendicular to a central axis," of the outer cylinder
4.
[0046] A urea spraying space 3 is preferably formed between the
first end face 13 of the honeycomb structure body 11 and the urea
spraying device 2. Further, "the urea spraying space 3 between the
first end face 13 of the honeycomb structure body 11 and the urea
spraying device 2" is preferably formed inside the outer cylinder
4. The urea spraying space 3 is a space formed by the first end
face 13 of the honeycomb structure body 11, the urea spraying
device 2, and the outer cylinder 4. A substance (droplets in mist
form, gas and the like) inside the urea spraying space 3 cannot
move outside except when "it flows inside the honeycomb structure
body 11 from the first end face 13 of the honeycomb structure body
11 and then is discharged outside." Each wall of the first end face
13 of the honeycomb structure body 11, the urea spraying device 2,
and the outer cylinder 4, which form the urea spraying space 3, has
pressure resistance able to endure a pressurized state when ammonia
is generated by heating (hydrolysis of the urea). In the reducing
agent injection device 100 of the embodiment, when the urea
spraying space 3 is formed, the urea water solution a2 sprayed from
the urea spraying device 2 is supplied inside the cell 16 from the
first end face 13 of the honeycomb structure body 11 through the
urea spraying space 3.
[0047] In the urea spraying space 3, the urea water solution
sprayed from the urea spraying device 2 evaporates by contact with
"the first end face 13 of the electrically heated honeycomb
structure body 11 and its proximity" and raises pressure. When
ammonia is generated by the urea in the urea water solution
hydrolyzed inside the honeycomb structure 1, this pressure rise
becomes a propulsive force to inject the generated ammonia outside
from an injection port 23.
[0048] A distance between the inlet side end portion 21 and the
urea spraying device 2 is preferably from 5 mm to 50 mm. When the
distance is closer than 5 mm, it is likely to cause an operation
failure due to a high temperature of the urea spraying device. When
the distance is longer than 50 mm, an operating time from the
injection of the urea to introduction of ammonia into an exhaust
pipe may be longer.
[0049] The outer cylinder 4 has a tubular shape having the inlet
side end portion 21 as one end portion and the outlet side end
portion 22 as the other end portion. At a distal end of the outlet
side end portion 22, the injection port 23 as an open end for
injection of the ammonia is formed. Inside the inlet side end
portion 21 of the outer cylinder 4, the urea spraying device 2 is
mounted. In the inlet side end portion 21 of the outer cylinder 4,
there is not formed any open end except a portion where the urea
spraying device 2 is inserted. A material of the outer cylinder 4
is preferably stainless steel and the like.
[0050] The honeycomb structure 1 is secured (held) inside the outer
cylinder 4 by the insulation supporting portion 5. This ensures
insulation between the honeycomb structure 1 and the outer cylinder
4. A material of the insulation supporting portion 5 is preferably
alumina. There may be a portion (space), where the insulation
supporting portion 5 is not arranged, between the honeycomb
structure 1 and the outer cylinder 4. The whole outer circumference
of the honeycomb structure 1 may be covered by the insulation
supporting portion 5 (in this case, an insulating member is not
arranged).
[0051] The reducing agent injection device 100 of the embodiment is
configured such that the ammonia discharged from the second end
face 14 of the honeycomb structure 1 is injected from the injection
port 23 through the inside of the outlet side end portion 22 of the
outer cylinder 4. In the reducing agent injection device of the
present invention, the second end face 14 of the honeycomb
structure 1 may be arranged on the same surface as a surface on
which an open end portion of the injection port 23 of the outer
cylinder 4 is positioned. In this case, the ammonia discharged from
the second end face 14 of the honeycomb structure 1 comes to be
discharged from the injection port 23 of the outer cylinder 4
simultaneously with the discharge from the second end face 14.
[0052] As shown in FIG. 2, the reducing agent injection device 100
of the embodiment preferably performs controls of electrical
heating of the honeycomb structure 1 and spraying of the urea water
solution, by an electronic control device 31. The electronic
control device 31 is preferably connected to a power source (not
shown). Voltages of the power source are preferably from 12 V to
200 V. The urea water solution is preferably supplied to the
reducing agent injection device 100 from a urea water solution
reservoir 32. The urea water solution reservoir 32 and a urea water
solution inlet 8 of the reducing agent injection device 100 are
preferably connected by a pipe 33 where the urea water solution
passes. Further, the pipe 33 preferably has a heating function (not
shown) in order to be able to heat the urea water solution. The
heating function of the pipe 33 includes a structure for
circulation of a heating medium in a jacket, an electric heating
device and the like. In the outer cylinder 4, two connectors 6 for
connection with wiring from the electronic control device 31 (power
source) are preferably arranged.
[0053] The following further describes the reducing agent injection
device 100 of the embodiment by respective constituent
components.
[0054] (1-1) Honeycomb Structure;
[0055] In the reducing agent injection device 100 of the
embodiment, as described above, the honeycomb structure 1 includes
the honeycomb structure body 11 and the pair of electrodes 12 and
12.
[0056] In the honeycomb structure body 11, an outer circumferential
wall 17 is arranged outside the partition wall 15. In the honeycomb
structure body 11, the materials of the partition wall 15 and the
outer circumferential wall 17 are preferably ceramic. Especially,
the materials of the partition wall 15 and the outer
circumferential wall 17 preferably contain a "silicon-silicon
carbide composite material", "silicon carbide" and the like as a
main component. Among these, the material containing the
"silicon-silicon carbide composite material" is further preferable
as the main component. By using such materials, it becomes easier
to adjust electrical resistivity of the honeycomb structure body to
any value by change of a ratio between silicon carbide and silicon.
Here, the silicon-silicon carbide composite material contains
silicon carbide particles as aggregates and metal silicon as a
bonding material combining the silicon carbide particles. In the
silicon-silicon carbide composite material, a plurality of silicon
carbide particles are preferably bonded by the metal silicon. The
above-described "silicon carbide" is formed by the silicon carbide
particles sintered together. In this description, the "main
component" means the component occupying equal to or more than 90
mass %.
[0057] The electrical resistivity of the honeycomb structure body
11 is preferably from 0.01 .OMEGA.cm to 500 .OMEGA.cm, and is
further preferably from 0.1 .OMEGA.cm to 200 .OMEGA.cm. This allows
causing the honeycomb structure (honeycomb structure body) to
effectively generate heat by application of voltage to the pair of
electrode members 12 and 12. Especially, the above-described
electrical resistivity preferably causes the honeycomb structure 1
(honeycomb structure body 11) to generate heat in a range of
160.degree. C. to 600.degree. C. by use of a power source with
voltages of 12 V to 200 V. The electrical resistivity of the
honeycomb structure body is a value at 25.degree. C. The electrical
resistivity of the honeycomb structure body is the value measured
by a four-terminal method.
[0058] In the honeycomb structure body 11, the surface area per
unit volume is preferably equal to or more than 5
cm.sup.2/cm.sup.3, and is further preferably from 8
cm.sup.2/cm.sup.3 to 45 cm.sup.2/cm.sup.3, and is especially
preferably from 20 cm.sup.2/cm.sup.3 to 40 cm.sup.2/cm.sup.3. When
the surface area per unit volume is smaller than 5
cm.sup.2/cm.sup.3, a contact area with the urea water solution
becomes smaller, so that a treatment rate of the urea water
solution, namely a generation amount (generation rate) of ammonia
may decrease. The surface area of the honeycomb structure body is
the area of the surface of the partition wall of the honeycomb
structure body.
[0059] In the honeycomb structure 1 (honeycomb structure body 11),
a thickness of the partition wall 15 is preferably from 0.06 mm to
1.5 mm, and is further preferably from 0.10 mm to 0.80 mm. When the
thickness of the partition wall 15 is thicker than 1.5 mm, the
pressure loss becomes larger, and the treatment rate of the urea
water solution, namely the generation amount (generation rate) of
ammonia may decrease. When the thickness of the partition wall 15
is thinner than 0.06 mm, it may be broken by thermal shock by
energization. When the shape of the cell 16 (the shape
perpendicular to the cell extending direction) is a circular shape,
the thickness of the partition wall means the thickness of the
partition wall for "a portion where the distance between the cells
is shortest (the portion where the partition wall is thinnest)."
The cell density is preferably from 7 cells/cm.sup.2 to 140
cells/cm.sup.2, and further preferably from 15 cells/cm.sup.2 to
120 cells/cm.sup.2. When the cell density is smaller than 7
cells/cm.sup.2, the contact area with the urea water solution
becomes smaller, so that the treatment rate of the urea water
solution, namely the generation amount (generation rate) of the
ammonia may decrease. When the cell density is larger than 140
cells/cm.sup.2, the pressure loss becomes larger, and the treatment
rate of the urea water solution, namely the generation amount
(generation rate) of ammonia may decrease.
[0060] As shown in FIG. 4, the reducing agent injection device of
the present invention preferably has a plugging portion 43 in "an
end portion on the first end face 13 side of each of a part of the
cells 16 of the honeycomb structure body 42". FIG. 4 is a plan view
schematically showing the end face (the first end face 13) of a
honeycomb structure 41 constituting another embodiment of the
reducing agent injection device of the present invention. The
material of the plugging portion 43 is preferably the same as the
material of the partition wall, and may be other material.
[0061] As to the size of the honeycomb structure 1, the area of the
first end face 13 (the second end face 14) is preferably from 50
mm.sup.2 to 10000 mm.sup.2, and is further preferably 100 mm.sup.2
to 8000 mm.sup.2.
[0062] In the honeycomb structure 1, the shape of the cells 16 in
the cross section perpendicular to the cell 16 extending direction
is preferably a circular shape, an oval shape, a quadrilateral
shape, a hexagonal shape, an octagonal shape, or a combination of
these shapes. Forming the shape of the cell in this way decreases
the pressure loss when flowing the exhaust gas in the honeycomb
structure and makes it possible to efficiently hydrolyze the urea.
In the honeycomb structure 1 shown in FIG. 3, the shape of the
cells 16 in the cross section (the first end face) perpendicular to
the cell 16 extending direction is the circular shape.
[0063] Each of the pair of electrode members 12 and 12 is formed in
a band shape extending in the cell 16 extending direction of the
honeycomb structure body 11. Further, the electrode member 12 is
preferably formed in a wider width expanding also in a
circumferential direction of the honeycomb structure body 11. In
the cross section perpendicular to the cell 16 extending direction,
one electrode member 12 of the pair of electrode members 12 and 12
is arranged in the opposite side with respect to the other
electrode member 12 of the pair of electrode members 12 and 12 with
a center of the honeycomb structure body 11 sandwiched by the pair
of electrode members 12 and 12. This can reduce variations of a
current flowing inside the honeycomb structure body 11 when a
voltage is applied between the pair of electrode members 12 and 12.
Then, this can reduce variations of heat generation inside the
honeycomb structure body 11.
[0064] In the honeycomb structure 1, the main component of the
electrode member 12 is preferably the same as the main component of
the partition walls 15 and the outer circumferential wall 17. The
material of the electrode member 12 is further preferably the
material where the electrical resistivity is adjusted to a desired
value.
[0065] The electrical resistivity of the electrode member 12 is
preferably from 0.0001 .OMEGA.cm to 100 .OMEGA.cm, and further
preferably from 0.001 .OMEGA.cm to 50 .OMEGA.cm. By setting a range
of the electrical resistivity of the electrode member 12 as just
described, the pair of electrode members 12 and 12 effectively
performs a function as electrodes inside the pipe where the high
temperature exhaust gas flows. In the honeycomb structure 1, the
electrical resistivity of the electrode member 12 is preferably
lower than the electrical resistivity of the honeycomb structure
body 11. The electrical resistivity of the electrode member is the
value at 400.degree. C. The electrical resistivity of the electrode
member is the value measured by a four-terminal method.
[0066] A porosity and an average pore diameter of the electrode
member 12 can be appropriately determined so as to obtain a desired
electrical resistivity corresponding to an application.
[0067] In each of the electrode members 12 and 12, an electrode
terminal projecting portion 18 for connection with the electrical
wiring from outside may be arranged, respectively. The material of
the electrode terminal projecting portion 18 may be a conductive
ceramic material or metal. The material of the electrode terminal
projecting portion 18 is preferably the same as that of the
electrode member 12. The electrode terminal projecting portion 18
and the connector 6 of the outer cylinder 4 are preferably
connected by an electrical wiring 7.
[0068] In the reducing agent injection device 100 of the
embodiment, a urea hydrolysis catalyst is preferably loaded onto
the honeycomb structure 1. This efficiently generates the ammonia
from the urea. As the urea hydrolysis catalyst, an aluminum oxide
and the like can be included.
[0069] (1-2) Urea Spraying Device;
[0070] The urea spraying device 2 is preferably a solenoid type, an
ultrasonic type, a piezoelectric actuator type, or an atomizer
type, and is further preferably the solenoid type, the ultrasonic
type, or the piezoelectric actuator type. By using these types, the
urea water solution can be sprayed in mist form. Among these types,
use of the solenoid type, the ultrasonic type, or the piezoelectric
actuator type makes it possible to spray the urea water solution in
mist form without use of air. Accordingly, the honeycomb structure
does not need to heat even the air used for the urea injection and
can reduce an energy amount for heating. A reduction of an
injection volume due to no injection air allows decreasing a speed
at which "the urea water solution in mist form" passes through the
honeycomb structure, and thus this ensures having a longer reaction
time necessary for hydrolysis. A size (diameter) of droplets of the
urea water solution sprayed from the urea spraying device is
preferably equal to or less than 0.3 mm. When the size of droplets
is larger than 0.3 mm, the droplets may be less likely to evaporate
when they received heat from the honeycomb structure 1.
[0071] The urea water solution inlet 8 is preferably formed for
introduction of the urea water solution inside the urea spraying
device 2.
[0072] A urea spraying device of a solenoid type is a device that
sprays urea water solution in mist form by "vibration of a
solenoid" or "forward and backward movement of a piston due to an
electric field when a solenoid is used".
[0073] A urea spraying device of an ultrasonic type is a device
that sprays urea water solution in mist form by an ultrasonic
vibration.
[0074] A urea spraying device of a piezoelectric actuator type is a
device that sprays urea water solution in mist form by a vibration
of a piezoelectric element.
[0075] A urea spraying device of an atomizer type is, for example,
a device that, while drawing up a fluid by a tube, blows off "the
fluid drawn up in an open end at a distal end of this tube" in mist
form by air, and sprays this fluid. A urea spraying device of an
atomizer type may be even a device that sprays a fluid in mist form
from a plurality of small open ends formed at a distal end of a
nozzle of the device.
[0076] In the reducing agent injection device of the embodiment,
the urea water solution is preferably sprayed toward the first end
face 13 of the honeycomb structure body 11 from the urea spraying
device 2. That is, in the urea spraying device 2, a spraying
direction (ejected direction of droplets) of the urea water
solution preferably faces to the first end face 13 of the honeycomb
structure body 11. Here, "the spraying direction of the urea water
solution from the urea spraying device" is referred by "a spraying
direction .alpha. (see FIG. 5)" and "a direction where the ammonia
passes through the inside of the cell in the honeycomb structure
body" is referred by "a cell direction .beta. (see FIG. 5)." Then,
an angle .theta. (see FIG. 5) between "the spraying direction
.alpha." and "the cell direction .beta." is preferably equal to or
less than 60.degree., and is further preferably from 5.degree. to
60.degree., and especially preferably from 30.degree. to
50.degree.. The above-described angle .theta. equal to or less than
60.degree. can efficiently introduce the urea water solution inside
the cells 16 from the first end face 13 of the honeycomb structure
body 11. Furthermore, the above-described angle .theta. from
5.degree. to 60.degree. allows the urea water solution sprayed from
the urea spraying device 2 entering inside the cells 16 from the
first end face 13 of the honeycomb structure body 11 and easily
colliding to the surface of the partition walls 15. This allows the
urea water solution to easily contact to the partition walls 15 and
thus allows the partition walls 15 to efficiently heat the urea
water solution. FIG. 5 is a schematic diagram showing a cross
section of further another embodiment (a reducing agent injection
device 200) of the reducing agent injection device of the present
invention.
[0077] In the reducing agent injection device 200 shown in FIG. 5,
the first end face 13 of the honeycomb structure body 11 is formed
oblique with respect to the cell direction .beta. so as to be
perpendicular to the spraying direction .alpha.. This allows the
urea water solution sprayed from the urea spraying device 2 to
contact with the partition wall inside the cell more easily.
[0078] (2) Manufacturing Method of Reducing Agent Injection
Device:
[0079] (2-1) Manufacturing of Honeycomb Structure;
[0080] When the honeycomb structure is made of ceramic, the
manufacturing method of the honeycomb structure is preferably the
manufacturing method described as follows. The manufacturing method
of the honeycomb structure preferably includes a honeycomb formed
body forming process, a dried honeycomb body forming process, an
unfired electrode provided honeycomb body forming process, and a
honeycomb structure forming process. The honeycomb formed body
forming process is preferably the process to form the honeycomb
formed body having partition walls defining and forming "a
plurality of cells which are through channels of a fluid and extend
from one end face to the other end face", by extrusion of forming
raw material. The forming raw material preferably contains a
ceramic raw material and an organic binder. The dried honeycomb
body forming process is preferably the process to form the dried
honeycomb body by drying the honeycomb formed body. The unfired
electrode provided honeycomb body forming process is preferably the
process to form the unfired electrode provided honeycomb body by
forming the unfired electrode by applying slurry for electrode
formation containing a ceramic raw material and water over a side
surface of the dried honeycomb body and drying it. The honeycomb
structure forming process is preferably the process to form the
honeycomb structure by firing of the unfired electrode provided
honeycomb body.
[0081] (2-1-1) Honeycomb Formed Body Forming Process:
[0082] In the honeycomb formed body forming process, the honeycomb
formed body is preferably formed by extrusion of the forming raw
material. The forming raw material is preferably a raw material
containing a ceramic raw material and an organic binder. In the
forming raw material, a surfactant, a sintering additive, a pore
former, water and the like besides a ceramic raw material and an
organic binder are preferably contained. The forming raw material
can be prepared by mixture of these raw materials.
[0083] The ceramic raw material in the forming raw material is
"ceramic" or "a raw material which becomes ceramic by firing." The
ceramic raw material becomes ceramic after firing in both cases.
The ceramic raw material in the forming raw material preferably
contains metal silicon and silicon carbide particles (silicon
carbide powder) as main components or silicon carbide particles
(silicon carbide powder) as a main component. Accordingly, the
obtained honeycomb structure exhibits electrical conductivity.
Metal silicon is also preferably metal silicon particles (metal
silicon powder). "Containing metal silicon and the silicon carbide
particles as main components" means that a total mass of the metal
silicon and silicon carbide particles is equal to or more than 90
mass % of the whole material (ceramic raw material). As components
contained in the ceramic raw material other than main component,
SiO.sub.2, SrCO.sub.3, Al.sub.2O.sub.3, MgCO.sub.3, cordierite and
the like can be included.
[0084] When silicon carbide is used as the main component of the
ceramic raw material, the silicon carbide is sintered by firing.
When metal silicon and silicon carbide particles are used as the
main component of the ceramic raw material, the silicon carbide as
aggregates can be bonded together by firing with metal silicon used
as a bonding material.
[0085] When silicon carbide particles (silicon carbide powder) and
metal silicon particles (metal silicon powder) are used as the
ceramic raw material, the mass of the metal silicon particles is
preferably from 10 mass % to 40 mass % with respect to the total of
the mass of the silicon carbide particles and the mass of the metal
silicon particles. An average particle diameter of the silicon
carbide particles is preferably from 10 .mu.m to 50 .mu.m, and
further preferably from 15 .mu.m to 35 .mu.m. The average particle
diameter of the metal silicon particles is preferably from 0.1
.mu.m to 20 .mu.m, and further preferably from 1 .mu.m to 10 .mu.m.
The average particle diameters of the silicon carbide particles and
metal silicon particles are values measured by a laser diffraction
method.
[0086] As the organic binder, methyl cellulose, glycerin,
hydroxypropyl methyl cellulose and the like can be included. As the
organic binder, one kind of organic binder may be used, and plural
kinds of organic binder may be used. A content of the organic
binder is preferably from 5 parts by mass to 10 parts by mass when
the total mass of the ceramic raw material is 100 parts by
mass.
[0087] As the surfactant, ethylene glycol, dextrin and the like can
be used. As the surfactant, one kind of surfactant may be used, and
plural kinds of surfactant may be used. The content of the
surfactant is preferably from 0.1 parts by mass to 2.0 parts by
mass when the total mass of the ceramic raw material is 100 parts
by mass.
[0088] As the sintering additive, SiO.sub.2, SrCO.sub.3,
Al.sub.2O.sub.3, MgCO.sub.3, cordierite and the like can be used.
As the sintering additive, one kind of sintering additive may be
used, and plural kinds of sintering additive may be used. The
content of the sintering additive is preferably from 0.1 parts by
mass to 3 parts by mass when the total mass of the ceramic raw
material is 100 parts by mass.
[0089] The pore former is not especially limited as long as it
forms pores after firing, and, for example, graphite, starch, a
foamable resin, a water absorbable resin, silica gel and the like
are included as the pore former. As pore former, one kind of pore
former may be used, and plural kinds of pore former may be used.
The content of the pore former is preferably from 0.5 parts by mass
to 10 parts by mass when the total mass of the ceramic raw material
is 100 parts by mass.
[0090] The content of water is preferably 20 parts by mass to 60
parts by mass when the total mass of the ceramic raw material is
100 parts by mass.
[0091] when extruding the forming raw material, first, the forming
raw material is preferably kneaded to form a kneaded material. The
method for forming the kneaded material by kneading the forming raw
material is not especially restricted, and, for example, the method
using a kneader, a vacuum pugmill and the like can be included.
Here, the kneaded material is also one aspect of the forming raw
material.
[0092] Next, the kneaded material is preferably extruded to form
the honeycomb formed body. In the extrusion, a die having a
desirable whole shape, cell shape, partition wall thickness, cell
density and the like is preferably used. The honeycomb formed body
has porous partition walls defining and forming "a plurality of
cells which are through channels of a fluid and extend from a first
end face being an end face on an inflow side of the fluid to a
second end face being an end face on an outflow side of the fluid".
The honeycomb formed body formed to have a circumferential wall
positioned in an outermost circumference is also a preferable
aspect. The partition wall of the honeycomb formed body is an
undried and unfired partition wall.
[0093] (2-1-2) Dried Honeycomb Body Forming Process:
[0094] The dried honeycomb body forming process is preferably the
process to dry the obtained honeycomb formed body and form the
dried honeycomb body. A drying condition is not especially limited,
and a known condition can be used. It is preferable, for example,
to dry for 0.5 hours to 5 hours at 80.degree. C. to 120.degree. C.
The honeycomb formed body can be dried by use of an electric
furnace, a gas furnace, a microwave heating furnace, a high
frequency dielectric heating furnace and the like.
[0095] (2-1-3) Unfired Electrode Provided Honeycomb Body Forming
Process:
[0096] In the unfired electrode provided honeycomb body forming
process, slurry for electrode formation containing the ceramic raw
material and water is preferably applied over the side surface of
the dried honeycomb body. After that, the slurry for electrode
formation is preferably dried to form an unfired electrode and form
the unfired electrode provided honeycomb body.
[0097] In the unfired electrode provided honeycomb body, the
unfired electrode having rectangular shape with a wider width,
which extends to the cell extending direction in a band shape and
expands also in a circumferential direction, is preferably formed
to the dried honeycomb body. The circumferential direction is a
direction along the side surface of the dried honeycomb body in a
cross section perpendicular to the cell extending direction.
[0098] The slurry for electrode formation used in the unfired
electrode provided honeycomb body forming process contains the
ceramic raw material and water, and, besides these materials,
preferably contains the surfactant, the pore former, water and the
like.
[0099] As the ceramic raw material, it is preferable to use the
ceramic raw material used when the honeycomb formed body is formed.
For example, when the main components of the ceramic raw material
used when the honeycomb formed body is formed are silicon carbide
particles and metal silicon, the silicon carbide particles and
metal silicon are preferably used also as the ceramic raw material
of the slurry for electrode formation.
[0100] When silicon carbide particles (silicon carbide powder) and
metal silicon particles (metal silicon powder) are used as the main
components of the ceramic raw material, the mass of the metal
silicon particles is preferably from 20 mass % to 50 mass % with
respect to the total of the mass of the silicon carbide particles
and the mass of the metal silicon particles. The average particle
diameter of the silicon carbide particles is preferably from 10
.mu.m to 100 .mu.m, and further preferably from 15 .mu.m to 75
.mu.m. The average particle diameter of the metal silicon particles
is preferably from 0.1 .mu.m to 20 .mu.m, and further preferably
from 1 .mu.m to 10 .mu.m.
[0101] As the organic binder, methyl cellulose, glycerin,
hydroxypropyl methyl cellulose and the like can be included. As the
organic binder, one kind of organic binder may be used, and plural
kinds of organic binder may be used. The content of the organic
binder is preferably 0.1 parts by mass to 2 parts by mass when the
total mass of the ceramic raw material is 100 parts by mass.
[0102] As the surfactant, ethylene glycol, dextrin and the like can
be used. As the surfactant, one kind of surfactant may be used, and
plural kinds of surfactant may be used. The content of the
surfactant is preferably 5 parts by mass to 15 parts by mass when
the total mass of the ceramic raw material is 100 parts by
mass.
[0103] The pore former is not especially limited as long as pores
are formed after firing, and, for example, graphite, starch, a
foamable resin, a water absorbable resin, silica gel and the like
can be included as the pore former. As the pore former, one kind of
pore former may be used, and plural kinds of pore former may be
used. The content of the pore former is preferably 0.5 parts by
mass to 10 parts by mass when the total mass of the ceramic raw
material is 100 parts by mass.
[0104] The content of water is preferably 25 parts by mass to 65
parts by mass when the total mass of the ceramic raw material is
100 parts by mass.
[0105] The method to apply the slurry for electrode formation over
the side surface of the dried honeycomb body is not especially
limited. For example, the method to apply by use of a brush or a
printing technique can be employed.
[0106] Viscosity of the slurry for electrode formation is
preferably equal to or less than 500 Pas, and further preferably 10
Pas to 200 Pas, at 20.degree. C. The viscosity exceeding 500 Pas
may make it difficult to apply the slurry for electrode formation
over the side surface of the dried honeycomb body.
[0107] After application of the slurry for electrode formation to
the dried honeycomb body, the slurry for electrode formation is
preferably dried to form the unfired electrode (unfired electrode
provided honeycomb body). A drying temperature is preferably
80.degree. C. to 120.degree. C. A drying time is preferably 0.1
hours to 5 hours.
[0108] (2-1-4) Honeycomb Structure Forming Process:
[0109] The honeycomb structure forming process is a process to form
the honeycomb structure by firing the unfired electrode provided
honeycomb body.
[0110] A firing condition can be appropriately determined based on
the ceramic raw material used for manufacturing of the honeycomb
formed body and the kind of the ceramic raw material used for the
slurry for electrode formation. When silicon carbide is used as the
main component of the ceramic raw material used for manufacturing
of the honeycomb formed body and is used as the main component of
the ceramic raw material used for the slurry for electrode
formation, the firing condition is preferably determined as
follows. That is, firing is preferably performed by heating for 0.5
hours to 5 hours at 2,300.degree. C. to 2,700.degree. C. under an
inert atmosphere such as argon. When silicon carbide and metal
silicon are used as the main components of the ceramic raw material
used for manufacturing of the honeycomb formed body and is used as
the main component of the ceramic raw material used for the slurry
for electrode formation, the firing condition is preferably
determined as follows. That is, firing is preferably performed by
heating for 0.5 hours to 5 hours at 1,425.degree. C. to
1,500.degree. C. under an inert atmosphere such as argon. The
method of firing is not especially limited, and firing can be
performed by use of an electric furnace, a gas furnace and the
like.
[0111] After firing, for improvement of durability, an oxidation
treatment is preferably performed by leaving 1 hour to 10 hours at
1,200.degree. C. to 1,350.degree. C. under an air atmosphere.
[0112] After the unfired electrode provided honeycomb formed body
is dried, before firing, calcination is preferably performed for
reducing the binder and the like. The calcination is preferably
performed for 0.5 hours to 20 hours at 400.degree. C. to
500.degree. C. under the air atmosphere.
[0113] The methods of calcination and firing are not especially
limited, and firing and calcination can be performed by use of an
electric furnace, a gas furnace and the like.
[0114] (2-2) Manufacturing of Reducing Agent Injection Device;
[0115] The reducing agent injection device is preferably
manufactured as follows: a connector connecting the electrical
wiring from outside is mounted on the outer cylinder, and then the
honeycomb structure and the urea spraying device are housed in and
secured to the outer cylinder.
[0116] The outer cylinder is preferably formed by forming a
material, such as stainless steel, in a tubular shape. The
honeycomb structure is preferably secured inside the outer cylinder
by the insulation supporting portion. When there is a portion
(space) where the insulation supporting portion between the
honeycomb structure and the outer cylinder is not arranged, it is
preferable to fill it with an insulating member.
[0117] As a urea spraying device, a urea spraying device of a
solenoid type, an ultrasonic type, a piezoelectric actuator type,
or an atomizer type is preferably used. As a urea spraying device
of a solenoid type, an ultrasonic type, a piezoelectric actuator
type, or an atomizer type, a known urea spraying device can be
used.
[0118] (3) Method for Using Reducing Agent Injection Device:
[0119] The following describes a method for using the reducing
agent injection device 100 (see FIG. 1) of the embodiment.
[0120] The reducing agent injection device 100, when a urea water
solution a1 is supplied, can hydrolyze urea in the supplied urea
water solution a1, and inject ammonia. The urea water solution is
the raw material for generation of ammonia. Further, specifically,
after energizing the honeycomb structure 1 to raise its temperature
(heating) and supplying the urea water solution a1 to the urea
spraying device 2, the urea water solution in mist form is
preferably sprayed inside the urea spraying space 3 from the urea
spraying device 2. When the urea water solution is sprayed from the
urea spraying device 2, the urea water solution is preferably
sprayed toward the first end face 13 of the honeycomb structure
body 11. Then, the urea water solution in mist form (the urea water
solution a2 sprayed from the urea spraying device 2) sprayed inside
the urea spraying space 3 is heated by the honeycomb structure 1
and evaporates. Because the pressure inside the urea spraying space
3 increases due to evaporation of the urea water solution, urea and
water enter inside the cell 16 of the honeycomb structure 1 from
the first end face 13. The urea supplied inside the cell 16 is
hydrolyzed by the temperature of the heated honeycomb structure 1,
and the ammonia b is generated. Then, the reducing agent injection
device 100 injects the ammonia b by injecting the generated ammonia
b from the injection port 23 of the outer cylinder 4. The increased
pressure inside the urea spraying space 3 accelerates the injection
of ammonia from the injection port.
[0121] A supply amount of the urea water solution is preferably 1.0
to 2.0 in terms of an equivalence ratio with respect to the amount
of nitrogen oxides contained in the exhaust gas. When the supply
amount of the urea water solution is equal to or less than 1.0 in
terms of the equivalence ratio, the amount of nitrogen oxides
discharged without being purified may increase. When the supply
amount of the urea water solution exceeds 2.0 in terms of the
equivalence ratio, it may be more likely that the exhaust gas is
discharged with ammonia mixed in the exhaust gas.
[0122] The urea water solution is preferably the urea water
solution of 10 mass % to 40 mass %. When the value is lower than 10
mass %, because a large amount of urea water is required to be
injected for NO.sub.x reduction, electric energy used in honeycomb
heater may increase. When the value is higher than 40 mass %, there
is a concern that urea solidifies in cold region. In the most
preferable example, AdBlue (32.5 mass % urea water solution) widely
distributed on the market is used.
[0123] The temperature of the honeycomb structure 1 is preferably
equal to or more than 160.degree. C., further preferably
160.degree. C. to 600.degree. C., and especially preferably
160.degree. C. to 400.degree. C. When the temperature is lower than
160.degree. C., it may be difficult to hydrolyze urea. When the
temperature is higher than 600.degree. C., ammonia is burnt and
ammonia may not be supplied to the exhaust pipe. It is preferable
to set the temperature of the honeycomb structure 1 equal to or
more than 360.degree. C. in that a sulfur compound, such as
ammonium hydrogen sulfate, ammonium sulfate and the like, that
deposits in the reducing agent injection device 100 can be
removed.
[0124] The maximum voltage to be applied to the honeycomb structure
1 is preferably 12 V to 200 V, further preferably 12 V to 100 V,
and especially preferably 12 V to 48 V. When the maximum voltage is
lower than 12 V, it may be difficult to raise the temperature of
the honeycomb structure 1. The maximum voltage higher than 200 V
requires a more expensive voltage booster and is not
preferable.
[0125] A spraying amount of the urea water solution and the
temperature (applied voltage) of the honeycomb structure 1 are
preferably controlled (adjusted to proper value) by the electronic
control device 31 (see FIG. 2). Preferably, temperature of the
honeycomb structure is calculated from a resistance value of the
honeycomb structure and is controlled such that the calculated
temperature becomes desired temperature.
[0126] (4) Exhaust Gas Treatment Device:
[0127] One embodiment (an exhaust gas treatment device 300) of the
exhaust gas treatment device of the present invention includes an
exhaust pipe 51, the reducing agent injection device 100, an SCR
catalyst 52 arranged on "the downstream side of the exhaust pipe 51
with respect to the position where ammonia is injected." The
reducing agent injection device 100 injects ammonia inside the
exhaust pipe 51. The exhaust pipe 51 is the pipe that flows "an
exhaust gas c containing NO.sub.x."
[0128] The exhaust pipe 51 is a pipe passing the exhaust gas (the
exhaust gas c containing NO.sub.x) discharged from various kinds of
engines, and the exhaust gas and ammonia are mixed in the exhaust
pipe 51. The size of the exhaust pipe 51 is not especially limited
and can be appropriately determined in accordance with an exhaust
system of an engine and the like where the exhaust gas treatment
device 300 of the embodiment is mounted. Though the length in the
exhaust gas flowing direction in the exhaust pipe 51 is not
especially limited, it is preferable for the length to make a
distance between the reducing agent injection device 100 and the
SCR catalyst 52 an appropriate distance. It is preferable for the
length in the exhaust gas flowing direction of the exhaust pipe 51
to be a length which allows the exhaust pipe 51 to be mounted in a
narrow space of the automobile and the like. The distance between
the reducing agent injection device 100 and the SCR catalyst 52 can
be shorter than "a conventional injector (urea injection device)
where droplets of urea are directly added to an exhaust pipe"
because gaseous ammonia is supplied to realize better mixing with
the exhaust gas.
[0129] Though the material of the exhaust pipe 51 is not especially
limited, a material where corrosion by the exhaust gas is less
likely to occur is preferable. As the material of the exhaust pipe
51, for example, stainless steel and the like are preferable.
[0130] The reducing agent injection device 100 is a reducing agent
injection device of the present invention. The reducing agent
injection device 100 is mounted to the exhaust pipe 51 and injects
ammonia inside the exhaust pipe 51. By injection of ammonia inside
the exhaust pipe 51 from the reducing agent injection device 100, a
mixed gas d of ammonia and the exhaust gas is generated inside the
exhaust pipe 51.
[0131] The exhaust gas treatment device 300 of the embodiment
includes the SCR catalyst 52 arranged on "the downstream side of
the exhaust pipe 51 with respect to the position where ammonia is
injected." The SCR catalyst is preferably arranged on the
downstream side of the exhaust pipe 51 in a state of catalyzer (SCR
catalyst loaded onto the ceramic honeycomb structure).
[0132] As the SCR catalyst, specifically, a vanadium-based
catalyst, a zeolite-based catalyst and the like can be
included.
[0133] When the SCR catalyst 52 is used as a catalyzer 53 loaded
onto the honeycomb structure, this catalyzer 53 is housed in a
storing container 54, and this storing container 54 is preferably
installed on the downstream side of the exhaust pipe 51.
[0134] The honeycomb structure loading the SCR catalyst is not
especially limited, and a known honeycomb structure as "a ceramic
honeycomb structure loading an SCR catalyst" can be used.
[0135] In an upstream side of the exhaust pipe 51, a filter for
trapping particulate matter in the exhaust gas is preferably
arranged. As the filter for trapping a particulate matter, for
example, a honeycomb-shaped ceramic diesel particulate filter (DPF)
is included. In the upstream side of the exhaust pipe 51, an
oxidation catalyst for removing hydrocarbon and carbon monoxide in
the exhaust gas is preferably arranged. The oxidation catalyst is
preferably in a state of being loaded onto the ceramic honeycomb
structure. As the oxidation catalyst, noble metals, such as
platinum (Pt), palladium (Pd), rhodium (Rh) and the like are
suitably used.
[0136] On the downstream side of the SCR catalyst, an ammonia
removal catalyst (oxidation catalyst) for removing ammonia is
preferably arranged. This prevents ammonia from being discharged
outside when extra ammonia not used for removal of NO.sub.x in the
exhaust gas flows on the downstream side. As the oxidation
catalyst, noble metals, such as platinum (Pt), palladium (Pd),
rhodium (Rh) and the like are suitably used.
[0137] (5) Exhaust Gas Treatment Method:
[0138] One embodiment of an exhaust gas treatment method of the
present invention is a method that flows the exhaust gas c in the
exhaust pipe 51, injects the ammonia b to the exhaust gas c, and
performs a reduction treatment of the mixed gas by the SCR
catalyst, by using the one embodiment (the exhaust gas treatment
device 300) of the present invention shown in FIG. 6. This allows
an exhaust gas e after NO.sub.x removal to be obtained. The
above-described exhaust gas c contains NO.sub.x. The
above-described mixed gas is "the exhaust gas with ammonia being
mixed," and is the mixed gas d of ammonia and the exhaust gas. The
ammonia b is injected by the reducing agent injection device
100.
[0139] Temperature of the honeycomb structure constituting the
reducing agent injection device 100 is preferably equal to or more
than 160.degree. C., further preferably 160.degree. C. to
600.degree. C., and especially preferably 160.degree. C. to
400.degree. C. When the temperature is lower than 160.degree. C.,
urea may be less likely to be hydrolyzed. When the temperature is
higher than 600.degree. C., ammonia is burnt and may not be
supplied to the exhaust pipe. Under the temperature of the
honeycomb structure equal to or more than 360.degree. C., a
reducing agent injection device purification operation that removes
the sulfur compound adhered to the reducing agent injection device
is preferably performed intermittently.
[0140] The voltage to be applied to the honeycomb structure 1 is
preferably 12 V to 200 V, further preferably 12 V to 100 V, and
especially preferably 12 V to 48 V. When the voltage is lower than
12 V, it may be difficult to raise the temperature of the honeycomb
structure 1. The voltage higher than 200 V requires a more
expensive voltage booster and is not preferable.
[0141] The spraying amount of the urea water solution and the
temperature (applied voltage) of the honeycomb structure 1 are
preferably controlled by the electronic control device 31 (see FIG.
2). Preferably, temperature of the honeycomb structure is
calculated from the resistance value of the honeycomb structure and
is controlled such that the calculated temperature becomes desired
temperature.
[0142] An injection amount of ammonia injected from the reducing
agent injection device 100 is preferably 1.0 to 2.0 in terms of the
equivalence ratio with respect to the amount of nitrogen oxides
contained in the exhaust gas. When the injection amount of ammonia
is equal to or less than 1.0 in terms of the equivalence ratio, the
amount of nitrogen oxides discharged without being purified may
increase. When the injection amount of ammonia exceeds 2.0 in terms
of the equivalence ratio, it may be more likely that the exhaust
gas is discharged with ammonia mixed in the exhaust gas.
EXAMPLES
[0143] The following describes the present invention more
specifically with example, but the present invention is not limited
to these examples.
Example 1
[0144] A reducing agent injection device was formed as shown in
FIG. 1. The reducing agent injection device is specifically
described as follows.
[0145] The silicon carbide (SiC) powder and metal silicon (Si)
powder were mixed at a mass ratio of 70:30 to prepare ceramic raw
material. Then, hydroxypropyl methyl cellulose as a binder and a
water absorbable resin as a pore former were added to this ceramic
raw material, and water was added together to prepare a forming raw
material. Then, the forming raw material was kneaded by a vacuum
pugmill to form a round pillar-shaped kneaded material. The content
of the binder was 7 parts by mass when the ceramic raw material was
100 parts by mass. The content of the pore former was 3 parts by
mass when the ceramic raw material was 100 parts by mass. The
content of water was 42 parts by mass when the ceramic raw material
was 100 parts by mass. The average particle diameter of the silicon
carbide powder was 20 .mu.m, and the average particle diameter of
the metal silicon powder was 6 .mu.m. The average particle diameter
of the pore former was 20 .mu.m. The average particle diameters of
the silicon carbide, the metal silicon, and the pore former were
the values measured by the laser diffraction method.
[0146] The obtained round pillar-shaped kneaded material was formed
by an extruder, and a square pillar-shaped (a cross section
perpendicular to the cell extending direction is square-pillar
shape) honeycomb formed body was obtained. After the obtained
honeycomb formed body was dried by high frequency dielectric
heating, the obtained honeycomb formed body was dried for 2 hours
at 120.degree. C. by use of a hot-air drying machine, and then both
end faces were cut as much as predetermined amounts.
[0147] Next, the silicon carbide (SiC) powder and metal silicon
(Si) powder were mixed at the mass ratio of 60:40 to prepare the
ceramic raw material for the electrode member. Then, hydroxypropyl
methyl cellulose as the binder, glycerin as a moisturizing agent,
and a surfactant as a dispersing agent were add to the ceramic raw
material for the electrode member, and water was added together to
mix. The mixture was kneaded to prepare an electrode member forming
raw material. The content of the binder was 0.5 parts by mass when
the ceramic raw material for the electrode member was 100 parts by
mass. The content of glycerin was 10 parts by mass when the ceramic
raw material for the electrode member was 100 parts by mass. The
content of the surfactant was 0.3 parts by mass when the ceramic
raw material for the electrode member was 100 parts by mass. The
content of water was 42 parts by mass when the ceramic raw material
for the electrode member was 100 parts by mass. The average
particle diameter of the silicon carbide powder was 52 .mu.m, and
the average particle diameter of the metal silicon powder was 6
.mu.m. The average particle diameters of the silicon carbide and
metal silicon were the values measured by the laser diffraction
method. Kneading was performed by a vertical stirrer.
[0148] Next, the electrode member forming raw material were applied
in a band shape over two parallel surfaces in the side surfaces of
the dried honeycomb formed body. The electrode member forming raw
material was applied in a band shape over one side surface among
"the side surfaces (four side surfaces) having four planes" of the
dried honeycomb formed body, and was also applied in a band shape
over one side surface parallel to this "applied side surface." The
shape (circumference shape) of the electrode member forming raw
material applied over the side surface of the honeycomb formed body
was a rectangular shape.
[0149] Next, the electrode member forming raw material applied to
the honeycomb formed body was dried. The drying condition was
70.degree. C.
[0150] Next, by using the same material as an electrode forming
material, an electrode terminal projecting portion forming member
was obtained. The shape of the electrode terminal projecting
portion forming member was a round pillar body with "8 mm (.phi.:
diameter).times.10 mm (length)." Two electrode terminal projecting
portion forming members were formed.
[0151] Next, each of two electrode terminal projecting portion
forming members was laminated to the respective portions, where the
electrode member forming raw material was applied, of two places of
the honeycomb formed body, respectively. The electrode terminal
projecting portion forming member was laminated to the portion
where the electrode member forming raw material of the honeycomb
formed body was applied, by using the electrode member forming raw
material. Afterwards, "the honeycomb formed body, where the
electrode member forming raw material was applied and the electrode
terminal projecting portion forming member was laminated," was
degreased, fired, and further underwent oxidation treatment to
obtain the honeycomb structure. The degreasing condition was 3
hours at 550.degree. C. The firing condition was 2 hours at
1,450.degree. C. under the argon atmosphere. The oxidation
treatment condition was 1 hour at 1,300.degree. C.
[0152] The thickness of the partition walls of the obtained
honeycomb structure was 0.152 mm, and a cell pitch was 1.11 mm. The
surface area per unit volume of the honeycomb structure body was
31.1 cm.sup.2/cm.sup.3. The shape of the honeycomb structure was
round pillar shape with a square bottom surface. One side of the
bottom surface of the honeycomb structure was 30 mm. The length in
the cell extending direction of the honeycomb structure was 45 mm.
The electrical resistivity of the electrode member was 0.1
.OMEGA.cm, and the electrical resistivity of the honeycomb
structure body was 1.4 .OMEGA.cm.
[0153] An outer cylinder was formed with a stainless steel. The
outer cylinder was formed in a tubular shape with an inlet side end
portion as one end portion and an outlet side end portion as the
other end portion. An injection port, which is an open end to
inject an ammonia gas, was formed at a distal end of the outlet
side end portion of the outer cylinder. In the inlet side end
portion of the outer cylinder, a hole for passing a pipe
introducing the urea water solution was formed.
[0154] In the outer circumference of the outer cylinder, two
connectors for the electrical wiring were mounted.
[0155] The honeycomb structure was inserted inside the outer
cylinder and secured by the insulation supporting portion. Then,
the electrode terminal projecting portions of the honeycomb
structure were connected to the connectors in the outer cylinder by
the electrical wiring. A urea spraying device of a solenoid type
was mounted inside the inlet side end portion of the outer cylinder
to obtain the reducing agent injection device. The material of the
insulation supporting portion was alumina. An angle between a
spraying direction of the urea spraying device and a cell direction
of the honeycomb structure was 0.degree..
[0156] An SCR catalyst was loaded onto the honeycomb structure
containing cordierite as a main component to form a catalyzer. As
the SCR catalyst, a catalyst where a noble metal was loaded onto
zeolite was used. The volume of the catalyzer was 4.0 liters. The
thickness of the partition wall of the catalyzer was 0.15 mm, and
the cell pitch of the catalyzer was 1.27 mm.
[0157] By mounting the obtained reducing agent injection device to
an exhaust pipe, inserting the catalyzer in a storing container,
and connecting the exhaust pipe to the storing container, the
exhaust gas treatment device as shown in FIG. 6 was obtained.
[0158] By using the obtained exhaust gas treatment device,
following a method described below, "an exhaust gas treatment test"
was performed, and a purification efficiency of NO.sub.x was
measured. The result is shown in Table 1. When performing the "the
exhaust gas treatment test," a urea water solution inlet of the
reducing agent injection device was connected to a urea water
solution reservoir with a pipe so that the urea water solution was
supplied to the reducing agent injection device. The wiring from an
electronic control device was connected to the connectors of the
reducing agent injection device and the urea spraying device.
[0159] (Exhaust Gas Treatment Test)
[0160] An exhaust gas of a diesel engine with a displacement of 3.0
liters is introduced to the exhaust pipe of the exhaust gas
treatment device to perform treatment of the exhaust gas by the
exhaust gas treatment device. Then, an NOx concentration in the gas
discharged from the catalyzer where the SCR catalyst is loaded is
measured. The NO.sub.x concentration of the exhaust gas introduced
in the exhaust pipe of the exhaust gas treatment device is 400 ppm.
The amount of the urea water solution supplied to the reducing
agent injection device is adjusted so that an NOx amount (mole) in
the exhaust gas and an amount (mole) of the injected ammonia become
the same. When the test is performed while changing temperature of
exhaust gas as shown in Table 1, the NO.sub.x concentration in the
gas discharged from the catalyzer at the respective temperature is
measured. The NO.sub.x concentration in the discharged gas is a
concentration when this NO.sub.x concentration becomes constant.
Then, NO.sub.x purification efficiency is obtained from the
NO.sub.x concentration in the exhaust gas introduced to the exhaust
pipe of the exhaust gas treatment device and the NO.sub.x
concentration in the gas discharged from the catalyzer. At the time
of the measurement, the temperature of 360.degree. C. is maintained
by applying a voltage of maximum 48 V to the honeycomb
structure.
TABLE-US-00001 TABLE 1 NO.sub.x Purification Efficiency(%)
Temperature of Exhaust Gas(.degree. C.) Example 1 Comparative
Example 1 140 26 5 160 49 21 180 78 38 200 89 55 250 93 85 300 95
91
Comparative Example 1
[0161] An exhaust gas treatment device was formed similarly to
Example 1 except that the honeycomb structure was not included in
the reducing agent injection device. Similarly to the case of
Example 1, "an exhaust gas treatment test" was performed. The
result is shown in Table 1.
[0162] From Table 1, it is possible to confirm that the exhaust gas
purifying device of Example 1 exhibits higher NO.sub.x purification
efficiencies compared to the exhaust gas purifying device of
Comparative Example 1. Especially, in a lower temperature region of
the exhaust gas, the differences are larger. The higher
purification efficiency requires, in addition to ensuring activity
of the SCR catalyst, acceleration of hydrolysis from urea to
ammonia and introduction of ammonia as a reducing agent are
necessary. However, in the exhaust gas purifying device of
Comparative Example 1, because the hydrolysis to ammonia is not
accelerated in the lower temperature and the reducing agent becomes
insufficient, the NO.sub.x purification efficiency becomes lower.
In contrast to this, in the exhaust gas purifying device of Example
1, because urea spraying space, where the urea water solution is
injected, is heated by the honeycomb structure in the reducing
agent injection device, the hydrolysis of urea is accelerated, and
ammonia is introduced in the exhaust pipe, the NO.sub.x
purification efficiency is improved. The exhaust gas purifying
device of Example 1 was able to generate ammonia from the urea
solution and inject the ammonia with less energy.
INDUSTRIAL APPLICABILITY
[0163] The reducing agent injection device of the present invention
can be suitably used to purify nitrogen oxides (NO.sub.x) in an
exhaust gas discharged from various kinds of engines and the
like.
DESCRIPTION OF REFERENCE NUMERALS
[0164] 1: honeycomb structure
[0165] 2: urea spraying device
[0166] 3: urea spraying space
[0167] 4: outer cylinder
[0168] 5: insulation supporting portion
[0169] 6: connector
[0170] 7: electrical wiring
[0171] 8: urea water solution inlet
[0172] 11: honeycomb structure body
[0173] 12: electrode member
[0174] 13: first end face
[0175] 14: second end face
[0176] 15: partition wall
[0177] 16: cell
[0178] 17: outer circumferential wall
[0179] 18: electrode terminal projecting portion
[0180] 21: inlet side end portion (of outer cylinder)
[0181] 22: outlet side end portion (of outer cylinder)
[0182] 23: injection port
[0183] 31: electronic control device
[0184] 32: urea water solution reservoir
[0185] 33: pipe
[0186] 41: honeycomb structure
[0187] 42: honeycomb structure body
[0188] 43: plugging portion
[0189] 51: exhaust pipe
[0190] 52: SCR catalyst
[0191] 53: catalyzer
[0192] 54: storing container
[0193] 100, 200: reducing agent injection device
[0194] 300: exhaust gas treatment device
[0195] a1: urea water solution
[0196] a2: urea water solution sprayed from urea spraying
device
[0197] b: ammonia
[0198] c: exhaust gas
[0199] d: mixed gas of ammonia and exhaust gas
[0200] e: exhaust gas after removal of NO.sub.x
[0201] .theta.: angle
[0202] .alpha.: spraying direction
[0203] .beta.: cell direction
* * * * *