US20130312392A1 - Systems and methods to mitigate nox and hc emissions at low exhaust temperatures - Google Patents
Systems and methods to mitigate nox and hc emissions at low exhaust temperatures Download PDFInfo
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- US20130312392A1 US20130312392A1 US13/526,926 US201213526926A US2013312392A1 US 20130312392 A1 US20130312392 A1 US 20130312392A1 US 201213526926 A US201213526926 A US 201213526926A US 2013312392 A1 US2013312392 A1 US 2013312392A1
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- emissions
- reduction catalyst
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
- F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
- F01N3/208—Control of selective catalytic reduction [SCR], e.g. by adjusting the dosing of reducing agent
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
- F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
- F01N3/0835—Hydrocarbons
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
- F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
- F01N3/0842—Nitrogen oxides
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/103—Oxidation catalysts for HC and CO only
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- SCR selective catalytic reduction
- the effectiveness of a typical SCR catalyst in removing oxides of nitrogen (NO x ) emissions is sensitive to the temperature of the exhaust gas at the inlet to the SCR catalyst.
- Copper exchanged zeolite based SCR catalysts are formulated to operate satisfactorily over a fairly wide temperature range.
- current state of the art Cu-Zeolite formulations operate at peak efficiency when subjected to exhaust gas temperatures of 200-400° C.
- the emissions performance of the engine during the cold portion of the certification cycle is weighted almost equally with the emissions performance of the engine during the hot portion of the certification cycle. For this reason, improvements in preventing hydrocarbon (HC) and NO x emissions produced by the engine from slipping through the aftertreatment system at low temperature exhaust conditions, such as at temperatures less than 200° C., are desired.
- Typical diesel A/T systems include a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF) in addition to the SCR.
- the DOC is responsible for oxidation of hydrocarbons (HC), carbon monoxide (CO), and nitric oxide (NO). Similar to the SCR catalyst, the DOC is not able to effectively and efficiently oxidize these molecules at cold exhaust temperatures.
- NO x and HC emissions levels for example, 0.02 and 0.01 g/mile, respectively for Tier 2 Bin 2 federal certification
- improvements in aftertreatment designs are required to mitigate the slip of these criteria pollutants through the exhaust flowpath during low temperature operation. Accordingly, further technological developments in this area are desirable.
- One embodiment is a unique method and system for managing low temperature NO x and HC emissions to improve the NO x conversion efficiency of diesel aftertreatment systems under low exhaust temperature conditions.
- a multiple component aftertreatment system that includes passively operated HC and NO x storage devices for improved low temperature mitigation of NO x and HC emissions to achieve desired emissions levels for light duty vehicles, although applications with other vehicles are not precluded.
- the systems and methods reduce the need for external devices intended to artificially increase the exhaust gas temperature for cold start cycles, which is beneficial since such external devices tend to increase fuel consumption and greenhouse gas emissions, although the use of such external devices are not precluded.
- the systems and methods disclosed herein provide reductions in cost and fuel consumption over current thermal management strategies to mitigate low temperature NO x and HC emissions. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.
- FIG. 1 is an exemplary system for reducing emissions of HC and NO x of an internal combustion engine during low exhaust temperature operating conditions.
- FIG. 2 is a schematic of a controller comprising a portion of the system of FIG. 1 .
- FIG. 3 is a graph showing an estimated impact of a hydrocarbon storage device on HC slip flow over time during low temperature exhaust operating conditions.
- the systems and methods reduce criteria pollutants at least during low exhaust temperature conditions.
- the disclosed systems and methods are configured so that the vehicles equipped therewith are operable to meet emissions standards during low exhaust temperature operating conditions without the need for external aftertreatment heating systems, which increase fuel consumption and greenhouse gas emissions from the vehicle, although the use of such external systems is not precluded.
- the systems and methods have application for light duty certified chassis vehicles, although applications with other vehicle types are not precluded.
- the systems and methods include an aftertreatment system architecture configured to temporarily store HC emissions and NO x emissions during periods of low exhaust temperature operation, and then passively release the stored NO x and HC emissions for aftertreatment as the exhaust temperature increases.
- the systems and methods are configured so that at temperatures where HC and NOx emissions are released, the diesel oxidation catalyst (DOC) and SCR catalysts are effective at mitigating the released HC and NO x emissions from the storage devices before exiting the tailpipe.
- DOC diesel oxidation catalyst
- the aftertreatment system includes a close coupled HC storage device (HCSD) located directly downstream of the turbocharger, with a close coupled NO x storage device (NSD) located directly downstream of the HCSD.
- HCSD close coupled HC storage device
- NSD close coupled NO x storage device
- the HCSD readily adsorbs and stores HC.
- the HCSD includes a catalyst, such as a zeolite-based catalyst, for storing and adsorbing HC. As the exhaust temperature increases, the HCSD effectively oxidizes HC in the gas phase that are stored on the surface of the HCSD to form H 2 O and CO 2 .
- the NSD is any suitable component, such as a NO x adsorber, capable of passively storing NO x at low exhaust temperature, and then releasing the stored NO x as the exhaust temperature increases.
- the NSD may also have an oxidation function, primarily for NO oxidation to NO 2 , but under normal operating conditions is not capable of effectively reducing NO x to N 2 and H 2 O.
- the NSD relies on a downstream selective catalytic reduction (SCR) catalyst or other NO x reduction catalyst to chemically reduce the NO x to N 2 and H 2 O.
- SCR selective catalytic reduction
- an exemplary aftertreatment system 10 includes a close coupled HCSD 12 and NSD 14 followed by a standard SCR or NAC-type NO x reduction catalyst 16 to receive exhaust gas produced by an internal combustion engine 20 into exhaust flowpath 18 .
- the HCSD 12 and NSD 14 are passively operated devices, which require little or no active control strategies, although the use of active control strategies is not precluded.
- the HCSD 12 readily adsorbs and stores HC on the surface of a catalyst until the HCSD 12 reaches a surface temperature where it can effectively oxidize the stored HC to form CO 2 and H 2 O.
- the NSD 14 readily adsorbs and stores NO x on the surface of its catalyst under low exhaust temperature conditions, and then begins to desorb this NO as the exhaust temperature and therefore the NSD catalyst temperature increases.
- the NSD 14 is configured to release the stored NO x at an exhaust temperature where the reduction catalyst 16 is highly effective for reducing NO x to N 2 and H 2 O.
- either or both of the catalysts of the HCSD 12 and the NSD 14 may operate as DOC catalysts, and together are responsible for the oxidation of HC, CO and NO.
- System 10 may include a controller 100 and other aftertreatment components in addition to those shown in FIG. 1 .
- system 10 typically includes a reductant doser 17 operationally coupled to the exhaust conduit at a position upstream of the reduction catalyst 16 .
- the reductant injected into exhaust flowpath 18 is any type of reductant utilized in a NO x reduction system.
- the reductant can include at least ammonia (gaseous or aqueous) and urea.
- System 10 may also include a diesel particulate filter (DPF) forming, with the HCSD 12 and NSD 14 , a DOC/DPF system positioned upstream of reduction catalyst 16 during engine operation where exhaust temperatures are effective for NO x reduction with reduction catalyst 16 .
- DPF diesel particulate filter
- the system 10 may include an ammonia oxidation catalyst (AMOX) downstream of the reduction catalyst 16 .
- AMOX ammonia oxidation catalyst
- the AMOX may not be present, or the AMOX may be commingled with the reduction catalyst 16 (or the last SCR catalyst, where multiple SCR catalysts are present), for example with a washcoat applied toward the rear portion of the reduction catalyst 16 that is responsive to at least partially oxidize ammonia.
- any of these components may be present or missing, catalyzed or not catalyzed, and may be arranged in alternate order. Further, certain components or all components may be provided in the same or separate housings.
- controller 100 can include a number of modules structured to functionally execute operations for controlling the SCR system.
- the controller forms a portion of a processing subsystem including one or more computing devices having memory, processing, and communication hardware.
- the controller 100 may be a single device or a distributed device, and the functions of the controller may be performed by hardware or software.
- the controller 100 may be in communication with any sensor, actuator, datalink, and/or network in the system.
- the controller 100 includes a NO x determination module 102 , a temperature determination module 104 , and a dosing control module 106 .
- the description herein including modules emphasizes the structural independence of the aspects of the controller 100 , and illustrates one grouping of operations and responsibilities of the controller 100 . Other groupings that execute similar overall operations are understood within the scope of the present application. Modules may be implemented in hardware and/or software on computer readable medium, and modules may be distributed across various hardware or software components. More specific descriptions of certain embodiments of controller operations are included in the section referencing FIG. 2 .
- the exemplary system 10 further includes various sensors.
- the illustrated sensors in FIG. 1 include a first NO x sensor 22 positioned upstream of the HCSD 12 and a second NO x sensor 24 positioned downstream of the reduction catalyst 16 .
- a NO x sensor 38 can be provided at the outlet of NSD 14 , or between the inlet to reduction catalyst 16 and the outlet of NSD 14 .
- System 10 also includes a first temperature sensor 26 at the inlet of HCSD 12 , a second temperature 28 between HCSD 12 and NSD 14 , a third temperature sensor 30 at the outlet of NSD 14 , and a fourth temperature sensor 32 at the outlet of reduction catalyst 16 .
- Other sensors can be provided to measure or determine the mass flow through the exhaust system, the temperature of any component of the aftertreatment system, the amount of ammonia stored in reduction catalyst 16 or outlet therefrom, etc.
- sensors are exemplary only, and may be re-positioned, removed, substituted, and other sensors may be present that are not illustrated in FIG. 1 . Further, certain sensors may instead be virtual sensors that are calculated from other parameters available to the system 10 , or values that would be indicated by sensors may instead be supplied to a computer readable memory location, via a datalink or network communication, or otherwise be made available to the system 10 where the sensor providing the sensed parameter is not a part of the defined system 10 .
- the exemplary controller 100 in FIGS. 1-2 is configured for executing operations to provide a reductant doser command for the effective removal of NO x emissions with reduction catalyst 16 .
- the controller operations of the controller 100 in FIG. 2 include operations that adjust nominal control operations for a NO x aftertreatment system utilizing a reductant. Nominal control operations for a NO x aftertreatment system, including an SCR aftertreatment system, are understood in the art and are not described further herein. Any nominal NO x aftertreatment control operations may be utilized by system 10 disclosed herein.
- the controller 100 includes a NO x determination module 102 that receives NO x parameters 108 from NO x sensors 22 , 24 , 38 and determines an amount of NO x emitted from engine 20 and from reduction catalyst 16 , respectively. Controller 100 can also be configured to determine or calculate and amount of NO x at the outlet of NSD 14 . Controller 100 also includes a temperature determination module 104 that receives temperature signals from temperature sensors 26 , 28 , 30 , 32 to determine a temperature of the exhaust gas in flowpath 18 and/or of the various catalysts of the aftertreatment components in flowpath 18 . Controller 100 further includes a dosing control module 106 that determines an appropriate dosing command for reductant to be injected in flowpath 18 to provide a desired emissions level for NO x at the outlet of reduction catalyst 16 and ultimately to the tailpipe.
- a NO x determination module 102 that receives NO x parameters 108 from NO x sensors 22 , 24 , 38 and determines an amount of NO x emitted from engine 20 and from reduction catalyst 16
- reduction catalyst 16 is ineffective in treating emissions of NO x to meet desired emissions level targets. Furthermore, traditional oxidation catalysts upstream of reduction catalyst 16 are ineffective in removing HC to meet criteria emissions levels at low temperature operating conditions. Therefore, HCSD 12 is configured to store HC, and NSD 14 is configured to store NO x during low exhaust temperature operating conditions until the aftertreatment components of system 10 are raised to a temperature effective to remove the criteria pollutants from the emissions of engine 20 .
- the amount of accumulation during low exhaust temperature operating conditions of NO x in NSD 14 can be determined by the difference between the amount of NO x detected by upstream NO x sensor 22 and the corresponding amount detected by downstream NO x sensor 24 and converted by oxidation catalyst 16 during low temperature operation.
- Dosing control module 106 is configured to determine a dosing command that delays reductant dosing during low temperature operating conditions since NO x sensor 24 senses NO x levels that are reduced or lower than the levels determined by NO x sensor 22 due to the NO x storage at NSD 14 .
- dosing control module 106 is configured to increase reductant dosing to treat the NO x emissions released from NSD 14 as determined by one or both of NO x sensor 38 and NO x sensor 24 , or by a calculated or sensed NO x amount at the outlet of NSD 14 . Furthermore, in certain embodiments, dosing control module 106 can be configured to anticipate a future NO x emissions load and timing of the release of the stored NO x emissions by monitoring temperature parameters 110 . The amount of reductant dosing can be increased prior to release of NO x emissions to provide a sufficient amount of reductant on reduction catalyst 16 to meet the expected increased in NO x emissions.
- the dosing control module 106 provides a reductant doser command 114 to reductant doser 17 in response to a threshold deviation value 116 .
- the threshold deviation value 116 includes a determination that NO x emissions at NO x sensor 24 is approaching or meeting a threshold deviation from an emissions level target value which requires reductant to be supplied to reduction catalyst 16 .
- the reductant doser command 114 provided by the dosing control module 106 may include a reductant amount to be supplied to reduction catalyst 16 .
- the dosing control module 106 provides the reductant doser command 114 in response to the threshold deviation value 116 indicating that the present NO x emissions level deviates more than a threshold amount from a NO x emissions level target.
- the reductant doser command 114 may be provided under any control scheme understood in the art, and/or under specific control schemes described herein.
- the reductant doser command 114 may include an actuator command value, a voltage or other electrical signal, and/or a datalink or network command.
- a reductant doser in a system including the controller 100 is responsive to the reductant doser command 114 to provide reductant to an exhaust stream at the position of the reductant doser 17 upstream of the reduction catalyst 16 .
- Dosing control module 106 can further be configured to provide a reductant doser command 114 that can be delayed to account for the amount of NO x stored by NSD 14 during low temperature exhaust conditions.
- a delayed reductant doser command includes decreasing the rate at which reductant is injected and/or decreasing the range of engine operating conditions in which reduction catalyst 16 is utilized for treatment of NO x emissions, including those conditions which otherwise would have resulted in treatment of emissions of NOx from engine 20 by supplying reductant to reduction catalyst 16 without NO x storage by NSD 14 upstream of reduction catalyst 16 .
- injection of reductant for storage on reduction catalyst 16 during low temperature operation is not precluded.
- An exemplary HCSD 12 is operable to store HC over a range of operating temperatures below an effective operating temperature. For example, at temperatures below 200° C., HCSD 12 is effective at storing HC emissions typically seen in operation of a diesel engine. As the exhaust temperatures approach and exceed 200° C., the lightoff of the HC emissions stored in HCSD 12 is effective to oxidize the HC to form CO 2 and H 2 O.
- the catalyst of HCSD 12 is a zeolite catalyst with an oxidation catalyst thereon.
- line 302 indicates the cumulative HC received at the inlet to HCSD 12 over time at the start of a low temperature operating condition.
- Lines 304 , 306 indicate the minimal outlet of HC from HCSD 12 over time during the low temperature operating condition.
- the stored HC stored until a sufficiently high catalyst temperature for HCSD 12 is attained to oxidize HC.
- An exemplary set of embodiments is a method including storing in an exhaust flowpath, upstream of a NO x reduction catalyst, hydrocarbon and NO x emissions from an internal combustion engine during low exhaust temperature operation; releasing the stored hydrocarbons and NO x emissions into the exhaust flowpath as the exhaust temperature increases toward an effective operating temperature; and treating the released hydrocarbons and NO x emissions with the NO x reduction catalyst.
- the NO x reduction catalyst is a selective catalytic reduction catalyst.
- the method includes storing hydrocarbon emissions on the surface of a hydrocarbon storage device catalyst.
- the method includes storing NO x emissions includes storing NO x emissions on the surface of a NO x storage device catalyst.
- the NO x storage device is a NO x adsorber.
- the effective operating temperature is around 200° Celsius.
- the method further includes delaying reductant dosing during the low exhaust temperature operation so that a reductant amount dosed into the exhaust flowpath during low exhaust temperature operation is insufficient for the NO x reduction catalyst to treat the NO x emissions from the internal combustion engine.
- Another set of exemplary embodiments is a method comprising: operating an internal combustion engine to produce hydrocarbon and NO x emissions into an exhaust flowpath during low exhaust temperature operation; storing, upstream of a NO x reduction catalyst, HC and NO x emissions from the internal combustion engine during low exhaust temperature operation; and providing a reductant dosing command that treats the NO x emissions with the NO x reduction catalyst when the exhaust temperature reaches an effective operating temperature that releases the stored HC and NO x emissions.
- the method further comprises delaying reductant dosing during the low exhaust temperature operation so that a reductant amount dosed into the exhaust flowpath during low exhaust temperature operation is insufficient for a NO x reduction catalyst to treat the NO x emissions from the internal combustion engine.
- storing hydrocarbon emissions includes storing hydrocarbon emissions on the surface of a hydrocarbon storage device catalyst and releasing the stored hydrocarbons includes oxidizing the hydrocarbons as the exhaust temperature increases toward the effective operating temperature.
- storing NO x emissions includes storing NO x emissions on the surface of a NO x storage device catalyst.
- the NO x storage device is a NO x adsorber.
- the effective operating temperature is around 200° Celsius.
- the NO x reduction catalyst is a selective catalytic reduction catalyst.
- Another exemplary set of embodiments is a system including an internal combustion engine; an exhaust conduit fluidly coupled to the internal combustion engine; a hydrocarbon storage device fluidly coupled to the exhaust conduit; a NO x adsorber fluidly coupled to the exhaust conduit; a NO x reduction catalyst downstream of the NO x adsorber; and a reductant doser operationally coupled to the exhaust conduit upstream of the NO x reduction catalyst and downstream of the NO x adsorber.
- the system includes the NO x reduction catalyst downstream of the hydrocarbon storage device.
- the reductant doser is operationally coupled to the exhaust conduit downstream of the hydrocarbon storage device and the NO x adsorber.
- the reductant doser is operationally coupled to the exhaust conduit downstream of the hydrocarbon storage device and the NO x adsorber.
- the system includes a controller comprising a NO x ratio determination module structured to determine a NO x amount at an outlet of the NO x reduction catalyst; a temperature determination module structured to determine a present operating temperature of the exhaust gas in the exhaust flowpath; and a dosing control module structured to determine a reductant doser command in response to the NO x amount to achieve a desired NO x emissions from the NO x reduction catalyst.
- a controller comprising a NO x ratio determination module structured to determine a NO x amount at an outlet of the NO x reduction catalyst; a temperature determination module structured to determine a present operating temperature of the exhaust gas in the exhaust flowpath; and a dosing control module structured to determine a reductant doser command in response to the NO x amount to achieve a desired NO x emissions from the NO x reduction catalyst.
- the controller is configured to provide a delayed reductant doser command during low exhaust temperature operating conditions.
- the hydrocarbon storage device includes a catalyst configured to store hydrocarbon emissions thereon during low exhaust temperature operating conditions and to oxidize the stored hydrocarbons when the exhaust temperature reaches an effective temperature.
- the NO x adsorber is structured to adsorb NO x emissions during low exhaust temperature operating conditions and release and oxidize NO x emissions when the exhaust temperature reached an effective temperature.
- the system includes a first NO x sensor at an inlet of the hydrocarbon storage device and a second NO x sensor at an outlet of the nitrous oxide reduction catalyst.
- the system includes a NO x sensor at an outlet of the NO x storage device.
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Abstract
Description
- The present application claims the benefit of the filing date of Provisional Application No. 61/650,722 filed on May 23, 2012, which is incorporated herein by reference.
- Control of selective catalytic reduction (SCR) catalysts is of increasing interest to meet modern internal combustion engine emissions standards. The effectiveness of a typical SCR catalyst in removing oxides of nitrogen (NOx) emissions is sensitive to the temperature of the exhaust gas at the inlet to the SCR catalyst. Copper exchanged zeolite based SCR catalysts are formulated to operate satisfactorily over a fairly wide temperature range. However, current state of the art Cu-Zeolite formulations operate at peak efficiency when subjected to exhaust gas temperatures of 200-400° C. For certification of certain diesel engines, the emissions performance of the engine during the cold portion of the certification cycle is weighted almost equally with the emissions performance of the engine during the hot portion of the certification cycle. For this reason, improvements in preventing hydrocarbon (HC) and NOx emissions produced by the engine from slipping through the aftertreatment system at low temperature exhaust conditions, such as at temperatures less than 200° C., are desired.
- Typical diesel A/T systems include a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF) in addition to the SCR. The DOC is responsible for oxidation of hydrocarbons (HC), carbon monoxide (CO), and nitric oxide (NO). Similar to the SCR catalyst, the DOC is not able to effectively and efficiently oxidize these molecules at cold exhaust temperatures. In order to meet NOx and HC emissions levels (for example, 0.02 and 0.01 g/mile, respectively for Tier 2 Bin 2 federal certification) at low temperature conditions, improvements in aftertreatment designs are required to mitigate the slip of these criteria pollutants through the exhaust flowpath during low temperature operation. Accordingly, further technological developments in this area are desirable.
- One embodiment is a unique method and system for managing low temperature NOx and HC emissions to improve the NOx conversion efficiency of diesel aftertreatment systems under low exhaust temperature conditions. In one embodiment, there is provided a multiple component aftertreatment system that includes passively operated HC and NOx storage devices for improved low temperature mitigation of NOx and HC emissions to achieve desired emissions levels for light duty vehicles, although applications with other vehicles are not precluded. The systems and methods reduce the need for external devices intended to artificially increase the exhaust gas temperature for cold start cycles, which is beneficial since such external devices tend to increase fuel consumption and greenhouse gas emissions, although the use of such external devices are not precluded. The systems and methods disclosed herein provide reductions in cost and fuel consumption over current thermal management strategies to mitigate low temperature NOx and HC emissions. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.
-
FIG. 1 is an exemplary system for reducing emissions of HC and NOx of an internal combustion engine during low exhaust temperature operating conditions. -
FIG. 2 is a schematic of a controller comprising a portion of the system ofFIG. 1 . -
FIG. 3 is a graph showing an estimated impact of a hydrocarbon storage device on HC slip flow over time during low temperature exhaust operating conditions. - For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated herein.
- There is disclosed systems and methods for reduction in HC and NOx emissions at low exhaust temperature operating conditions for an internal combustion engine. The systems and methods reduce criteria pollutants at least during low exhaust temperature conditions. The disclosed systems and methods are configured so that the vehicles equipped therewith are operable to meet emissions standards during low exhaust temperature operating conditions without the need for external aftertreatment heating systems, which increase fuel consumption and greenhouse gas emissions from the vehicle, although the use of such external systems is not precluded. In one embodiment, the systems and methods have application for light duty certified chassis vehicles, although applications with other vehicle types are not precluded.
- The systems and methods include an aftertreatment system architecture configured to temporarily store HC emissions and NOx emissions during periods of low exhaust temperature operation, and then passively release the stored NOx and HC emissions for aftertreatment as the exhaust temperature increases. The systems and methods are configured so that at temperatures where HC and NOx emissions are released, the diesel oxidation catalyst (DOC) and SCR catalysts are effective at mitigating the released HC and NOx emissions from the storage devices before exiting the tailpipe.
- In one embodiment, the aftertreatment system includes a close coupled HC storage device (HCSD) located directly downstream of the turbocharger, with a close coupled NOx storage device (NSD) located directly downstream of the HCSD. At low exhaust temperatures, the HCSD readily adsorbs and stores HC. In one specific embodiment, the HCSD includes a catalyst, such as a zeolite-based catalyst, for storing and adsorbing HC. As the exhaust temperature increases, the HCSD effectively oxidizes HC in the gas phase that are stored on the surface of the HCSD to form H2O and CO2. The NSD is any suitable component, such as a NOx adsorber, capable of passively storing NOx at low exhaust temperature, and then releasing the stored NOx as the exhaust temperature increases. The NSD may also have an oxidation function, primarily for NO oxidation to NO2, but under normal operating conditions is not capable of effectively reducing NOx to N2 and H2O. The NSD relies on a downstream selective catalytic reduction (SCR) catalyst or other NOx reduction catalyst to chemically reduce the NOx to N2 and H2O.
- In a further embodiment, systems and methods for reducing the emission of HC and NOx from lean burn internal combustion engines for low exhaust temperature operating conditions are disclosed. As shown in
FIG. 1 , anexemplary aftertreatment system 10 includes a close coupledHCSD 12 and NSD 14 followed by a standard SCR or NAC-type NOx reduction catalyst 16 to receive exhaust gas produced by aninternal combustion engine 20 intoexhaust flowpath 18. The HCSD 12 and NSD 14 are passively operated devices, which require little or no active control strategies, although the use of active control strategies is not precluded. - At low exhaust gas temperatures which result in low catalyst temperatures, the HCSD 12 readily adsorbs and stores HC on the surface of a catalyst until the HCSD 12 reaches a surface temperature where it can effectively oxidize the stored HC to form CO2 and H2O. The
NSD 14 readily adsorbs and stores NOx on the surface of its catalyst under low exhaust temperature conditions, and then begins to desorb this NO as the exhaust temperature and therefore the NSD catalyst temperature increases. TheNSD 14 is configured to release the stored NOx at an exhaust temperature where thereduction catalyst 16 is highly effective for reducing NOx to N2 and H2O. Once theaftertreatment system 10 reaches operating temperature, either or both of the catalysts of theHCSD 12 and theNSD 14 may operate as DOC catalysts, and together are responsible for the oxidation of HC, CO and NO. -
System 10 may include acontroller 100 and other aftertreatment components in addition to those shown inFIG. 1 . For example,system 10 typically includes areductant doser 17 operationally coupled to the exhaust conduit at a position upstream of thereduction catalyst 16. The reductant injected intoexhaust flowpath 18 is any type of reductant utilized in a NOx reduction system. For example, the reductant can include at least ammonia (gaseous or aqueous) and urea.System 10 may also include a diesel particulate filter (DPF) forming, with the HCSD 12 andNSD 14, a DOC/DPF system positioned upstream ofreduction catalyst 16 during engine operation where exhaust temperatures are effective for NOx reduction withreduction catalyst 16. Thesystem 10 may include an ammonia oxidation catalyst (AMOX) downstream of thereduction catalyst 16. In certain embodiments, the AMOX may not be present, or the AMOX may be commingled with the reduction catalyst 16 (or the last SCR catalyst, where multiple SCR catalysts are present), for example with a washcoat applied toward the rear portion of thereduction catalyst 16 that is responsive to at least partially oxidize ammonia. In other embodiments, any of these components may be present or missing, catalyzed or not catalyzed, and may be arranged in alternate order. Further, certain components or all components may be provided in the same or separate housings. - For
system 10 includingcontroller 100,controller 100 can include a number of modules structured to functionally execute operations for controlling the SCR system. In certain embodiments, the controller forms a portion of a processing subsystem including one or more computing devices having memory, processing, and communication hardware. Thecontroller 100 may be a single device or a distributed device, and the functions of the controller may be performed by hardware or software. Thecontroller 100 may be in communication with any sensor, actuator, datalink, and/or network in the system. - In certain embodiments, such as shown in
FIG. 2 , thecontroller 100 includes a NOx determination module 102, atemperature determination module 104, and adosing control module 106. The description herein including modules emphasizes the structural independence of the aspects of thecontroller 100, and illustrates one grouping of operations and responsibilities of thecontroller 100. Other groupings that execute similar overall operations are understood within the scope of the present application. Modules may be implemented in hardware and/or software on computer readable medium, and modules may be distributed across various hardware or software components. More specific descriptions of certain embodiments of controller operations are included in the section referencingFIG. 2 . - The
exemplary system 10 further includes various sensors. The illustrated sensors inFIG. 1 include a first NOx sensor 22 positioned upstream of theHCSD 12 and a second NOx sensor 24 positioned downstream of thereduction catalyst 16. Alternatively or additionally, a NOx sensor 38 can be provided at the outlet ofNSD 14, or between the inlet toreduction catalyst 16 and the outlet ofNSD 14.System 10 also includes afirst temperature sensor 26 at the inlet ofHCSD 12, a second temperature 28 betweenHCSD 12 andNSD 14, a third temperature sensor 30 at the outlet ofNSD 14, and afourth temperature sensor 32 at the outlet ofreduction catalyst 16. Other sensors can be provided to measure or determine the mass flow through the exhaust system, the temperature of any component of the aftertreatment system, the amount of ammonia stored inreduction catalyst 16 or outlet therefrom, etc. - The illustrated sensors are exemplary only, and may be re-positioned, removed, substituted, and other sensors may be present that are not illustrated in
FIG. 1 . Further, certain sensors may instead be virtual sensors that are calculated from other parameters available to thesystem 10, or values that would be indicated by sensors may instead be supplied to a computer readable memory location, via a datalink or network communication, or otherwise be made available to thesystem 10 where the sensor providing the sensed parameter is not a part of the definedsystem 10. - The
exemplary controller 100 inFIGS. 1-2 is configured for executing operations to provide a reductant doser command for the effective removal of NOx emissions withreduction catalyst 16. The controller operations of thecontroller 100 inFIG. 2 include operations that adjust nominal control operations for a NOx aftertreatment system utilizing a reductant. Nominal control operations for a NOx aftertreatment system, including an SCR aftertreatment system, are understood in the art and are not described further herein. Any nominal NOx aftertreatment control operations may be utilized bysystem 10 disclosed herein. - The
controller 100 includes a NOxdetermination module 102 that receives NOxparameters 108 from NOx 22, 24, 38 and determines an amount of NOx emitted fromsensors engine 20 and fromreduction catalyst 16, respectively.Controller 100 can also be configured to determine or calculate and amount of NOx at the outlet ofNSD 14.Controller 100 also includes atemperature determination module 104 that receives temperature signals from 26, 28, 30, 32 to determine a temperature of the exhaust gas intemperature sensors flowpath 18 and/or of the various catalysts of the aftertreatment components inflowpath 18.Controller 100 further includes adosing control module 106 that determines an appropriate dosing command for reductant to be injected inflowpath 18 to provide a desired emissions level for NOx at the outlet ofreduction catalyst 16 and ultimately to the tailpipe. - During low temperature operating conditions for
engine 20 and for exhaust gas and/or aftertreatment components inflowpath 18,reduction catalyst 16 is ineffective in treating emissions of NOx to meet desired emissions level targets. Furthermore, traditional oxidation catalysts upstream ofreduction catalyst 16 are ineffective in removing HC to meet criteria emissions levels at low temperature operating conditions. Therefore,HCSD 12 is configured to store HC, andNSD 14 is configured to store NOx during low exhaust temperature operating conditions until the aftertreatment components ofsystem 10 are raised to a temperature effective to remove the criteria pollutants from the emissions ofengine 20. - The amount of accumulation during low exhaust temperature operating conditions of NOx in
NSD 14 can be determined by the difference between the amount of NOx detected by upstream NOx sensor 22 and the corresponding amount detected by downstream NOx sensor 24 and converted byoxidation catalyst 16 during low temperature operation.Dosing control module 106 is configured to determine a dosing command that delays reductant dosing during low temperature operating conditions since NOxsensor 24 senses NOx levels that are reduced or lower than the levels determined by NOxsensor 22 due to the NOx storage atNSD 14. As the exhaust gas temperature increases to and above an effective temperature,dosing control module 106 is configured to increase reductant dosing to treat the NOx emissions released fromNSD 14 as determined by one or both of NOxsensor 38 and NOxsensor 24, or by a calculated or sensed NOx amount at the outlet ofNSD 14. Furthermore, in certain embodiments,dosing control module 106 can be configured to anticipate a future NOx emissions load and timing of the release of the stored NOx emissions by monitoringtemperature parameters 110. The amount of reductant dosing can be increased prior to release of NOx emissions to provide a sufficient amount of reductant onreduction catalyst 16 to meet the expected increased in NOx emissions. - The
dosing control module 106 provides areductant doser command 114 toreductant doser 17 in response to athreshold deviation value 116. Thethreshold deviation value 116 includes a determination that NOx emissions at NOxsensor 24 is approaching or meeting a threshold deviation from an emissions level target value which requires reductant to be supplied toreduction catalyst 16. The reductant doser command 114 provided by thedosing control module 106 may include a reductant amount to be supplied toreduction catalyst 16. Thedosing control module 106 provides thereductant doser command 114 in response to thethreshold deviation value 116 indicating that the present NOx emissions level deviates more than a threshold amount from a NOx emissions level target. The reductant doser command 114 may be provided under any control scheme understood in the art, and/or under specific control schemes described herein. The reductant doser command 114 may include an actuator command value, a voltage or other electrical signal, and/or a datalink or network command. In certain embodiments, a reductant doser in a system including thecontroller 100 is responsive to thereductant doser command 114 to provide reductant to an exhaust stream at the position of thereductant doser 17 upstream of thereduction catalyst 16. -
Dosing control module 106 can further be configured to provide areductant doser command 114 that can be delayed to account for the amount of NOx stored byNSD 14 during low temperature exhaust conditions. As used herein, a delayed reductant doser command includes decreasing the rate at which reductant is injected and/or decreasing the range of engine operating conditions in whichreduction catalyst 16 is utilized for treatment of NOx emissions, including those conditions which otherwise would have resulted in treatment of emissions of NOx fromengine 20 by supplying reductant toreduction catalyst 16 without NOx storage byNSD 14 upstream ofreduction catalyst 16. However, injection of reductant for storage onreduction catalyst 16 during low temperature operation is not precluded. - The descriptions here provide illustrative embodiments of performing procedures for controlling an aftertreatment system for low temperature operating conditions. Operations illustrated are understood to be exemplary only, and operations may be combined or divided, and added or removed, as well as re-ordered in whole or part, unless stated explicitly to the contrary herein. Certain operations illustrated may be implemented by a computer executing a computer program product on a computer readable medium, where the computer program product comprises instructions causing the computer to execute one or more of the operations, or to issue commands to other devices to execute one or more of the operations.
- An
exemplary HCSD 12 is operable to store HC over a range of operating temperatures below an effective operating temperature. For example, at temperatures below 200° C.,HCSD 12 is effective at storing HC emissions typically seen in operation of a diesel engine. As the exhaust temperatures approach and exceed 200° C., the lightoff of the HC emissions stored inHCSD 12 is effective to oxidize the HC to form CO2 and H2O. In one embodiment, the catalyst ofHCSD 12 is a zeolite catalyst with an oxidation catalyst thereon. - As shown in
graph 300 ofFIG. 3 ,line 302 indicates the cumulative HC received at the inlet toHCSD 12 over time at the start of a low temperature operating condition. 304, 306 indicate the minimal outlet of HC fromLines HCSD 12 over time during the low temperature operating condition. As the operating temperature increases over time, as indicated byline 308, the stored HC stored until a sufficiently high catalyst temperature forHCSD 12 is attained to oxidize HC. - As is evident from the figures and text presented above, a variety of embodiments according to the present invention are contemplated.
- An exemplary set of embodiments is a method including storing in an exhaust flowpath, upstream of a NOx reduction catalyst, hydrocarbon and NOx emissions from an internal combustion engine during low exhaust temperature operation; releasing the stored hydrocarbons and NOx emissions into the exhaust flowpath as the exhaust temperature increases toward an effective operating temperature; and treating the released hydrocarbons and NOx emissions with the NOx reduction catalyst.
- In certain embodiments of the method, the NOx reduction catalyst is a selective catalytic reduction catalyst. In other embodiments, the method includes storing hydrocarbon emissions on the surface of a hydrocarbon storage device catalyst. In other embodiments, the method includes storing NOx emissions includes storing NOx emissions on the surface of a NOx storage device catalyst. In other embodiments, the NOx storage device is a NOx adsorber. In certain embodiments, the effective operating temperature is around 200° Celsius. In other embodiments, the method further includes delaying reductant dosing during the low exhaust temperature operation so that a reductant amount dosed into the exhaust flowpath during low exhaust temperature operation is insufficient for the NOx reduction catalyst to treat the NOx emissions from the internal combustion engine.
- Another set of exemplary embodiments is a method comprising: operating an internal combustion engine to produce hydrocarbon and NOx emissions into an exhaust flowpath during low exhaust temperature operation; storing, upstream of a NOx reduction catalyst, HC and NOx emissions from the internal combustion engine during low exhaust temperature operation; and providing a reductant dosing command that treats the NOx emissions with the NOx reduction catalyst when the exhaust temperature reaches an effective operating temperature that releases the stored HC and NOx emissions.
- In yet other embodiments, the method further comprises delaying reductant dosing during the low exhaust temperature operation so that a reductant amount dosed into the exhaust flowpath during low exhaust temperature operation is insufficient for a NOx reduction catalyst to treat the NOx emissions from the internal combustion engine. In another embodiment, storing hydrocarbon emissions includes storing hydrocarbon emissions on the surface of a hydrocarbon storage device catalyst and releasing the stored hydrocarbons includes oxidizing the hydrocarbons as the exhaust temperature increases toward the effective operating temperature. In one refinement of this embodiment, storing NOx emissions includes storing NOx emissions on the surface of a NOx storage device catalyst. In yet another refinement, the NOx storage device is a NOx adsorber. In additional embodiments, the effective operating temperature is around 200° Celsius. In other embodiments, the NOx reduction catalyst is a selective catalytic reduction catalyst.
- Another exemplary set of embodiments is a system including an internal combustion engine; an exhaust conduit fluidly coupled to the internal combustion engine; a hydrocarbon storage device fluidly coupled to the exhaust conduit; a NOx adsorber fluidly coupled to the exhaust conduit; a NOx reduction catalyst downstream of the NOx adsorber; and a reductant doser operationally coupled to the exhaust conduit upstream of the NOx reduction catalyst and downstream of the NOx adsorber.
- In certain embodiments, the system includes the NOx reduction catalyst downstream of the hydrocarbon storage device. In one refinement of this embodiment, the reductant doser is operationally coupled to the exhaust conduit downstream of the hydrocarbon storage device and the NOx adsorber. In another embodiment, the reductant doser is operationally coupled to the exhaust conduit downstream of the hydrocarbon storage device and the NOx adsorber.
- In certain embodiments, the system includes a controller comprising a NOx ratio determination module structured to determine a NOx amount at an outlet of the NOx reduction catalyst; a temperature determination module structured to determine a present operating temperature of the exhaust gas in the exhaust flowpath; and a dosing control module structured to determine a reductant doser command in response to the NOx amount to achieve a desired NOx emissions from the NOx reduction catalyst.
- In another exemplary embodiment of the system, the controller is configured to provide a delayed reductant doser command during low exhaust temperature operating conditions. In another embodiment, the hydrocarbon storage device includes a catalyst configured to store hydrocarbon emissions thereon during low exhaust temperature operating conditions and to oxidize the stored hydrocarbons when the exhaust temperature reaches an effective temperature. In a refinement of this embodiment, the NOx adsorber is structured to adsorb NOx emissions during low exhaust temperature operating conditions and release and oxidize NOx emissions when the exhaust temperature reached an effective temperature. In another embodiment, the system includes a first NOx sensor at an inlet of the hydrocarbon storage device and a second NOx sensor at an outlet of the nitrous oxide reduction catalyst. In another embodiment, the system includes a NOx sensor at an outlet of the NOx storage device.
- While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
Claims (26)
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| Application Number | Priority Date | Filing Date | Title |
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| US13/526,926 US20130312392A1 (en) | 2012-05-23 | 2012-06-19 | Systems and methods to mitigate nox and hc emissions at low exhaust temperatures |
| DE201310008534 DE102013008534A1 (en) | 2012-05-23 | 2013-05-17 | Method for reducing e.g. hydrocarbon emissions from diesel engine of light duty vehicle during low exhaust gas temperature operation, involves treating released emissions with oxidation catalyst and nitrogen oxide reduction catalyst |
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| US201261650722P | 2012-05-23 | 2012-05-23 | |
| US13/526,926 US20130312392A1 (en) | 2012-05-23 | 2012-06-19 | Systems and methods to mitigate nox and hc emissions at low exhaust temperatures |
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| US13/526,926 Abandoned US20130312392A1 (en) | 2012-05-23 | 2012-06-19 | Systems and methods to mitigate nox and hc emissions at low exhaust temperatures |
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