US20170087515A1 - System and method for regulating exhaust emissions - Google Patents
System and method for regulating exhaust emissions Download PDFInfo
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- US20170087515A1 US20170087515A1 US14/870,039 US201514870039A US2017087515A1 US 20170087515 A1 US20170087515 A1 US 20170087515A1 US 201514870039 A US201514870039 A US 201514870039A US 2017087515 A1 US2017087515 A1 US 2017087515A1
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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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- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
- B01D53/9477—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
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Definitions
- the present disclosure relates to exhaust systems and more particularly to diesel exhaust treatment systems.
- Diesel emissions include two primary components that are subject to emissions regulations: particulate matter and nitrogen oxides (NO x ).
- a variety of exhaust treatment devices have been developed to reduce these emission components.
- a diesel particulate filter (DPF) can be used to trap diesel particulate matter and oxidize soot
- SCR selective catalytic reduction
- Diesel exhaust fluid (DEF) is injected upstream of the SCR element to provide ammonia, which acts as a reducing agent and reacts with the NO x in the presence of the SCR catalyst.
- a selective catalytic reduction on filter (SCR+F) element combines SCR and DPF functionality such that NO x reduction and particulate matter filtration and oxidation can occur in a single element. This can provide a variety of advantages, including reduced size and cost. Soot oxidation, however, typically requires the presence of nitrogen dioxide (NO 2 ). Therefore, a tradeoff exists between NO x reduction and soot oxidation when an SCR+F element is used.
- NO 2 nitrogen dioxide
- an exhaust gas treatment system for an internal combustion engine includes an exhaust gas pathway configured to receive exhaust gas from the internal combustion engine, an ammonia source, and a first ammonia injector in fluid communication with the ammonia source.
- the first ammonia injector is configured to inject ammonia into the exhaust gas pathway at a first rate.
- the exhaust gas treatment system also includes a first treatment element positioned downstream of the first ammonia injector and a second ammonia injector in fluid communication with the ammonia source and positioned downstream of the first treatment element.
- the second ammonia injector is configured to inject ammonia into the exhaust gas pathway at a second rate different from the first rate.
- the exhaust gas treatment system further includes a second treatment element positioned downstream of the second ammonia injector.
- an exhaust gas treatment system for an internal combustion engine includes an exhaust gas pathway configured to receive exhaust gas from the internal combustion engine and a first ammonia injector.
- the first ammonia injector is configured to inject ammonia into the exhaust gas pathway at a first rate.
- the exhaust gas treatment system further includes a first treatment element positioned downstream of the first ammonia injector and a second ammonia injector in positioned downstream of the first treatment element.
- the second ammonia injector is configured to inject ammonia into the exhaust gas pathway at a second rate.
- the exhaust gas treatment system also includes a sensor in communication with the exhaust gas pathway.
- the exhaust gas treatment system also includes a controller configured to receive a signal from the sensor indicative of an amount of particulate present in the exhaust gas and adjust at least one of the first rate or the second rate based on the signal.
- a method of treating exhaust gas from an internal combustion engine includes injecting ammonia, at a first rate, into the exhaust gas pathway at a first location, and filtering particulate matter and converting nitrogen oxides (NO x ) from the exhaust gas in a combined selective catalytic reduction and diesel particulate filter (SCR+F) element positioned downstream of the first location.
- the method also includes injecting ammonia, at a second rate greater than the first rate, into the exhaust gas pathway at a second location downstream of the SCR+F element, and converting NO x from the exhaust gas in a selective catalytic reduction (SCR) element positioned downstream of the second location.
- SCR selective catalytic reduction
- FIG. 1 is a side view of a vehicle in which the disclosed system and method for regulating exhaust emissions may be implemented.
- FIG. 2 is a schematic diagram of an exhaust gas treatment system according to one embodiment.
- FIG. 3 is a schematic diagram of a portion of an exhaust gas treatment system according to another embodiment.
- FIG. 4 is a cross-sectional view of a portion of the exhaust gas treatment system of FIG. 2 , illustrating a flow-affecting feature according to one embodiment.
- FIG. 5 is a cross-sectional view of a portion of the exhaust gas treatment system of FIG. 2 , illustrating a flow-affecting feature according to another embodiment.
- FIG. 6 is a block diagram of an electronic control unit of the exhaust gas treatment system of FIG. 2 .
- FIG. 7 is a flow diagram of operation of the exhaust gas treatment system of FIG. 2 .
- FIG. 8 is a schematic diagram of an exhaust gas treatment system according to another embodiment.
- FIG. 1 illustrates an exemplary vehicle 10 including a diesel-powered internal combustion engine 14 and an exhaust gas treatment system 100 according to one embodiment.
- vehicle 10 is a utility tractor, but the exhaust gas treatment system 100 is not so limited in application and can be used in conjunction with any diesel-powered internal combustion engine.
- the exhaust gas treatment system 100 can be used in other work vehicles, passenger vehicles, or other equipment powered by a diesel engine (e.g., generators, compressors, pumps, and the like).
- the exhaust gas treatment system 100 includes an exhaust pathway 104 (e.g., an exhaust pipe) having an inlet or upstream side 108 and an outlet or downstream side 112 .
- a preliminary treatment element 116 , a first treatment element 120 , and a second treatment element 124 are located in series along the exhaust pathway 104 , between the inlet 108 and the outlet 112 .
- the numeric designations “first,” “second,” etc. are used herein for convenience and should not be regarded as defining order, quantity, or relative position.
- an electronic control unit (ECU 123 ) is provided to actively control various aspects of the operation of the exhaust gas treatment system 100 .
- a sensor 125 which is a pressure drop (AP) sensor in the illustrated embodiment, is disposed proximate the first treatment element 120 .
- the sensor 125 is communicatively coupled to the ECU 123 to provide feedback to the ECU 123 indicative of the performance of the exhaust gas treatment system 100 .
- one or more additional sensors may be provided to monitor various other parameters of the exhaust gas treatment system 100 .
- These sensors may monitor, for example, NO x concentrations, ammonia concentrations, temperature, exhaust flow rate, and/or ash loading at one or more points along the exhaust pathway 104 and provide feedback to the ECU 123 indicative of the performance of the exhaust gas treatment system 100 .
- the exhaust gas treatment system 100 may not be actively controlled, and the sensor 125 and/or the ECU 123 may be omitted.
- a first transition pipe 126 a interconnects the preliminary and first treatment elements 116 , 120
- a second transition pipe 126 b interconnects the first and second treatment elements 120 , 124 .
- the transition pipes 126 a , 126 b define an outer diameter that is smaller than an outer diameter of the treatment elements 116 , 120 , 124 .
- the treatment elements 116 , 120 , 124 are interconnected by transition pipes 126 c , 126 d .
- the transition pipes 126 c , 126 d define an outer diameter that is substantially the same as the outer diameter of the treatment elements 116 , 120 , 124 .
- the treatment elements 116 , 120 , 124 and the transition pipes 126 c , 126 d may collectively define a cylindrical exhaust gas treatment unit 127 .
- the transition pipes 126 c , 126 d each define an overall length that is less than their respective outer diameters. In some embodiments, the transition pipes 126 c , 126 d each define an overall length between about 30% and about 70% of their respective outer diameters.
- the illustrated preliminary treatment element 116 is a diesel oxidation catalyst (DOC) element and includes, for example, a honeycomb support coated with a catalytic material, such as a platinum group metal.
- the preliminary treatment element 116 may be used to reduce some particulate matter, carbon monoxide, and hydrocarbons from exhaust passing through the DOC element.
- the preliminary treatment element 116 may include a different exhaust treatment configuration.
- the preliminary treatment element 116 may be omitted.
- the preliminary treatment element 116 may be included as a portion of a different treatment element (e.g., the first treatment element 120 ).
- the first treatment element 120 in the illustrated embodiment is a combined selective catalytic reduction and diesel particulate filter (SCR+F) element and includes a catalytic washcoat on a porous filter substrate.
- the washcoat may include one or more base metal oxides, for example, such as Al 2 O 3 , SiO 2 , TiO 2 , CeO 2 , ZrO 2 , V 2 O 5 , La 2 O 3 .
- the washcoat may include one or more zeolites.
- the first treatment element 120 may be used to capture particulate matter, oxidize soot, and reduce NO x from exhaust gas passing through the first treatment element 120 .
- the second treatment element 124 in the illustrated embodiment includes a selective catalytic reduction (SCR) portion 128 and an ammonia oxidation catalyst (AOC) portion 132 .
- the SCR portion 128 may include, for example, a catalytic washcoat on a monolithic support material, such as ceramic.
- the SCR portion 128 and the AOC portion 132 are positioned in series, with the AOC portion 132 located downstream of the SCR portion 128 .
- the SCR portion 128 may be used to reduce NO x from exhaust gas passing through the SCR portion 128 .
- the AOC portion 132 may be used to convert excess ammonia leaving the SCR portion 128 to nitrogen and water. In some embodiments, the AOC portion 132 may be omitted. Alternatively, the AOC portion 132 may be provided as a separate treatment element positioned downstream of the second treatment element 124 .
- the exhaust gas treatment system 100 also includes an ammonia source 136 , which includes a diesel exhaust fluid (DEF) supply 140 and an ammonia producing unit 144 in the illustrated embodiment.
- the DEF supply 140 is in fluid communication with the ammonia producing unit 144 to supply DEF (e.g., a urea solution) to the ammonia producing unit 144 , which converts the DEF to ammonia gas (e.g., via thermolysis and hydrolysis).
- a pump (not shown) is provided to move DEF from the DEF supply 140 to the ammonia producing unit 144 .
- the pump may be variably controlled to vary the amount of DEF supplied to the ammonia producing unit 144 , and thus vary the amount of ammonia output by the ammonia producing unit 144 .
- the DEF may move from the DEF supply 140 to the ammonia producing unit 144 under the influence of gravity.
- one or more valves may be provided between the DEF supply 140 and the ammonia producing unit 144 to vary the flow of DEF to the ammonia producing unit 144 .
- the DEF supply 140 may be omitted, and the ammonia producing unit 144 may include an ammonia supply, such as a pressurized ammonia storage tank.
- the exhaust gas treatment system 100 further includes a first injector 148 and a second injector 152 in fluid communication with the ammonia producing unit 144 .
- the first injector 148 and the second injector 152 can be directly fluidly coupled to the ammonia producing unit 144 (e.g., by independent conduits), or the first injector 148 and the second injector 152 can be fluidly coupled to a branch line, manifold, or other structure that receives ammonia from the ammonia producing unit 144 .
- the first injector 148 is positioned to introduce ammonia into the first transition pipe 126 a , downstream of the preliminary treatment element 116 and upstream of the first treatment element 120 (i.e. between the preliminary and first treatment elements 116 , 120 ).
- the second injector 152 is positioned to introduce ammonia into the second transition pipe 126 b , downstream of the first treatment element 120 and upstream of the second treatment element 124 (i.e. between the first and second treatment elements 120 , 124 ).
- the exhaust gas treatment system 100 may further include a flow affecting feature 156 in the exhaust pathway 104 , positioned upstream of the first injector 148 .
- the flow affecting feature 156 is positioned within the first transition pipe 126 a .
- the flow affecting feature 156 can be, for example, one or more fins, vanes, projections, or other suitable means to impart turbulence or swirling into the exhaust flow proximate the first injector 148 .
- the flow affecting feature 156 may be positioned downstream of the first injector 148 .
- another flow affecting feature may be positioned in the second transition pipe 126 b upstream or downstream of the second injector 152 .
- the first injector 148 may include an elongated portion 160 that extends into the exhaust pathway 104 .
- a plurality of openings 164 in the elongated portion 160 allows ammonia to be expelled from the injector 148 at multiple locations in the exhaust pathway 104 .
- the second injector 152 may have a similar configuration.
- a first valve 168 is disposed between the ammonia producing unit 144 and the first injector 148
- a second valve 172 is disposed between the ammonia producing unit 144 and the second injector 152 .
- the first and second valves 168 , 172 can be incorporated into the respective injectors 148 , 152 or into the ammonia producing unit 144 .
- the exhaust treatment system 100 may include only one valve (i.e., the first valve 168 or the second valve 172 ).
- the valves 168 , 172 may be omitted.
- Each of the illustrated valves 168 , 172 is movable between a closed position in which the flow of ammonia through the valve 168 , 172 is substantially inhibited, and an open position in which the flow of ammonia through the valve 168 , 172 is substantially uninhibited.
- one or both of the valves 168 , 172 can also be actuated to at least one intermediate position, between the closed and open positions, in which the flow of ammonia through the valve 168 , 172 is partially restricted.
- one or both of the valves 168 , 172 can be modulated to vary the flow rate of ammonia.
- the valves 168 , 172 are controlled by the ECU 123 .
- FIG. 6 illustrates an example of the ECU 123 for control of the exhaust gas treatment system 100 .
- the ECU 123 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the ECU 123 .
- the ECU 123 includes, among other things, an electronic processor 180 (e.g., a programmable microprocessor, microcontroller, or similar device), non-transitory, machine-readable memory 184 , and an input/output interface 188 .
- the electronic processor 180 is communicatively coupled to the memory 184 and configured to retrieve from memory 184 and execute, among other things, instructions related to the control processes and methods described herein.
- the ECU 123 includes additional, fewer, or different components.
- the ECU 123 is communicatively coupled to the sensor 125 , the DEF supply 140 , the first valve 168 , and the second valve 172 .
- the ECU 123 may also be configured to communicate with external systems including, for example, engine controls and/or operator controls.
- untreated exhaust from the internal combustion engine 14 ( FIG. 1 ) is directed into the exhaust pathway 100 at the inlet 104 ( FIG. 2 ).
- the exhaust then flows through the preliminary treatment (DOC) element 116 , which reduces some particulate matter, carbon monoxide, and hydrocarbons from the exhaust.
- Ammonia is introduced into the partially-treated exhaust downstream of the preliminary treatment element 116 via the first injector 148 . Because the first injector 148 includes multiple holes 164 , the ammonia is more uniformly dispersed into the exhaust stream ( FIG. 4 ).
- turbulence or swirling movement imparted by the flow affecting feature 156 enhances mixing to create a relatively homogeneous mixture of exhaust and ammonia within a relatively short distance from the injector 148 .
- the distance between the preliminary and first elements 116 , 120 can be minimized.
- the ammonia and exhaust mixture then enters the first treatment (SCR+F) element 120 ( FIG. 2 ).
- the ammonia reacts with NO x in the presence of the catalyst to form nitrogen and water, while soot is captured and oxidized on the porous filter substrate.
- additional ammonia is introduced via the second injector 152 .
- the second injector 152 preferably includes a plurality of holes (not shown), to more uniformly disperse the ammonia into the exhaust stream, and an additional flow affecting feature (not shown) is preferably provided proximate the second injector 152 to further enhance mixing.
- the distance between the first and second treatment elements 120 , 124 can be minimized.
- the ammonia and exhaust mixture then enters the second treatment element 124 , where the ammonia reacts with any remaining NO x in the SCR portion 128 , and any unreacted ammonia is subsequently oxidized in the AOC portion 132 .
- the treated exhaust then exits the exhaust gas treatment system 100 through the outlet 108 .
- the amount of NO x converted in the first and second treatment elements 120 , 124 is dependent upon the amount of ammonia injected.
- the total amount of ammonia injected is controlled by the rate at which DEF is supplied to the ammonia producing unit 144 .
- DEF flows from the DEF supply 140 to the ammonia producing unit 144 at a rate that may be controlled by the ECU 123 , and the ammonia producing unit 144 produces ammonia gas from the DEF.
- the ammonia gas flows from the ammonia producing unit 144 , through the valves 168 , 172 , and to the injectors 148 , 152 , which inject the ammonia into the exhaust pathway 104 .
- the amount of ammonia flowing through the first injector 148 is limited so that some of the NO x remains unreacted through the first treatment element 120 .
- ammonia flows through the first injector 148 at a first rate
- ammonia flows through the second injector 152 at a second rate that is greater than the first rate.
- the ECU 123 may adjust the flow of ammonia into the exhaust pathway 104 by modulating the first valve 168 , the second valve 172 , and/or the rate at which DEF flows to the ammonia producing unit 144 .
- the ECU 123 may periodically or continuously read a value or signal from the sensor 125 at block 192 (via the input/output interface 188 ), which is indicative of the pressure drop across the first treatment element 120 .
- the ECU 123 uses the sensed value to determine whether the first treatment element 120 is properly oxidizing soot.
- the pressure drop may be correlated with the amount of soot or particulate present in the first treatment element 120 . For example, as the amount of particulate in the first treatment element 120 increases, the pressure drop increases, and as the amount of particulate in the first treatment element 120 decreases, the pressure drop decreases.
- the ECU 123 can determine an estimated particulate parameter at block 194 , which may correspond with an estimated amount of particulate in the first treatment element 120 .
- the ECU 123 may periodically or continuously read a value or signal from one or more additional or alternative sensors (e.g., NO x sensors, ammonia sensors, temperature sensors, ash loading sensors, exhaust flow rate sensors, etc.). The values or signals from these sensors may be factored into the ECU's determination of the estimated particulate parameter.
- the ECU 123 may then periodically or continuously compare the estimated particulate parameter with a threshold value or value range, stored in memory 184 , which is representative of a target soot oxidation performance level. If the estimated particulate parameter is greater than the threshold value (i.e., if the level of particulate in the first treatment element 120 is high), the ECU 123 decreases the flow of ammonia through the first injector 148 at block 200 by restricting flow through the first valve 168 . Accordingly, the amount of NO x available for soot oxidation will increase. Optionally, the ECU 123 may then increase the flow of ammonia through the second injector 152 at block 202 by opening the second valve 172 .
- the ECU 123 can increase the flow of ammonia through the first injector 148 at block 204 by opening the first valve 168 . Accordingly, the amount of NO x will be reduced.
- the ECU 123 may then decrease the flow of ammonia through the second injector 152 at block 206 by restricting flow through the second valve 172 .
- first and second injectors 148 , 152 are in fluid communication such that an increase in flow through the first injector 148 results in a proportional decrease in flow through the second injector 152 , and vice versa.
- FIG. 8 illustrates an exhaust gas treatment system 300 according to another embodiment.
- the exhaust gas treatment system 300 is similar to the exhaust gas treatment system 100 described above with reference to FIGS. 1-7 . Accordingly, like features are given identical reference numbers, and only differences between the exhaust gas treatment system 300 and the exhaust gas treatment system 100 are described in detail.
- the exhaust gas treatment system 300 includes a first ammonia passageway 304 extending between the ammonia producing unit 144 and the first ammonia injector 148 and a second ammonia passageway 308 extending between the ammonia producing unit 144 and the second ammonia injector 152 .
- the first ammonia passageway 304 defines a first diameter
- the second ammonia passageway 308 defines a second diameter that is greater than the first diameter.
- the passageways 304 , 308 may have the same outer diameter but different inner diameters.
- the passageways 304 , 308 may have the same outer and inner diameters
- the first passageway 304 may include a restriction that reduces the effective inner diameter of the first passageway 304 .
- ammonia flows from the ammonia producing unit 144 to the injectors 148 , 152 via the respective passageways 304 , 308 . Because the first passageway 304 is relatively restricted compared to the second passageway 308 , ammonia flows through the first injector 148 at a first rate and through the second injector 152 at a second rate greater than the first rate.
- the passageways 304 , 308 are sized to provide some NO x reduction in the first treatment element 120 and a greater amount of NO x reduction in the SCR portion 128 of the second treatment element 124 . This configuration may preserve enough NO x in the first treatment element 120 for effective soot oxidation.
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Abstract
Description
- The present disclosure relates to exhaust systems and more particularly to diesel exhaust treatment systems.
- Diesel emissions include two primary components that are subject to emissions regulations: particulate matter and nitrogen oxides (NOx). A variety of exhaust treatment devices have been developed to reduce these emission components. For example, a diesel particulate filter (DPF) can be used to trap diesel particulate matter and oxidize soot, and a selective catalytic reduction (SCR) element can be used to convert the NOx present in exhaust gas into other compounds, such as nitrogen and carbon dioxide. Typically, diesel exhaust fluid (DEF) is injected upstream of the SCR element to provide ammonia, which acts as a reducing agent and reacts with the NOx in the presence of the SCR catalyst.
- A selective catalytic reduction on filter (SCR+F) element combines SCR and DPF functionality such that NOx reduction and particulate matter filtration and oxidation can occur in a single element. This can provide a variety of advantages, including reduced size and cost. Soot oxidation, however, typically requires the presence of nitrogen dioxide (NO2). Therefore, a tradeoff exists between NOx reduction and soot oxidation when an SCR+F element is used.
- In one embodiment, an exhaust gas treatment system for an internal combustion engine includes an exhaust gas pathway configured to receive exhaust gas from the internal combustion engine, an ammonia source, and a first ammonia injector in fluid communication with the ammonia source. The first ammonia injector is configured to inject ammonia into the exhaust gas pathway at a first rate. The exhaust gas treatment system also includes a first treatment element positioned downstream of the first ammonia injector and a second ammonia injector in fluid communication with the ammonia source and positioned downstream of the first treatment element. The second ammonia injector is configured to inject ammonia into the exhaust gas pathway at a second rate different from the first rate. The exhaust gas treatment system further includes a second treatment element positioned downstream of the second ammonia injector.
- In another embodiment, an exhaust gas treatment system for an internal combustion engine includes an exhaust gas pathway configured to receive exhaust gas from the internal combustion engine and a first ammonia injector. The first ammonia injector is configured to inject ammonia into the exhaust gas pathway at a first rate. The exhaust gas treatment system further includes a first treatment element positioned downstream of the first ammonia injector and a second ammonia injector in positioned downstream of the first treatment element. The second ammonia injector is configured to inject ammonia into the exhaust gas pathway at a second rate. The exhaust gas treatment system also includes a sensor in communication with the exhaust gas pathway. The exhaust gas treatment system also includes a controller configured to receive a signal from the sensor indicative of an amount of particulate present in the exhaust gas and adjust at least one of the first rate or the second rate based on the signal.
- In another embodiment, a method of treating exhaust gas from an internal combustion engine, as the exhaust gas passes through an exhaust gas pathway, includes injecting ammonia, at a first rate, into the exhaust gas pathway at a first location, and filtering particulate matter and converting nitrogen oxides (NOx) from the exhaust gas in a combined selective catalytic reduction and diesel particulate filter (SCR+F) element positioned downstream of the first location. The method also includes injecting ammonia, at a second rate greater than the first rate, into the exhaust gas pathway at a second location downstream of the SCR+F element, and converting NOx from the exhaust gas in a selective catalytic reduction (SCR) element positioned downstream of the second location.
- Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.
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FIG. 1 is a side view of a vehicle in which the disclosed system and method for regulating exhaust emissions may be implemented. -
FIG. 2 is a schematic diagram of an exhaust gas treatment system according to one embodiment. -
FIG. 3 is a schematic diagram of a portion of an exhaust gas treatment system according to another embodiment. -
FIG. 4 is a cross-sectional view of a portion of the exhaust gas treatment system ofFIG. 2 , illustrating a flow-affecting feature according to one embodiment. -
FIG. 5 is a cross-sectional view of a portion of the exhaust gas treatment system ofFIG. 2 , illustrating a flow-affecting feature according to another embodiment. -
FIG. 6 is a block diagram of an electronic control unit of the exhaust gas treatment system ofFIG. 2 . -
FIG. 7 is a flow diagram of operation of the exhaust gas treatment system ofFIG. 2 . -
FIG. 8 is a schematic diagram of an exhaust gas treatment system according to another embodiment. - Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
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FIG. 1 illustrates anexemplary vehicle 10 including a diesel-poweredinternal combustion engine 14 and an exhaustgas treatment system 100 according to one embodiment. The illustratedvehicle 10 is a utility tractor, but the exhaustgas treatment system 100 is not so limited in application and can be used in conjunction with any diesel-powered internal combustion engine. For example, the exhaustgas treatment system 100 can be used in other work vehicles, passenger vehicles, or other equipment powered by a diesel engine (e.g., generators, compressors, pumps, and the like). - With reference to
FIG. 2 , the exhaustgas treatment system 100 includes an exhaust pathway 104 (e.g., an exhaust pipe) having an inlet orupstream side 108 and an outlet ordownstream side 112. Apreliminary treatment element 116, afirst treatment element 120, and asecond treatment element 124 are located in series along theexhaust pathway 104, between theinlet 108 and theoutlet 112. The numeric designations “first,” “second,” etc. are used herein for convenience and should not be regarded as defining order, quantity, or relative position. - In the illustrated embodiment, an electronic control unit (ECU 123) is provided to actively control various aspects of the operation of the exhaust
gas treatment system 100. Asensor 125, which is a pressure drop (AP) sensor in the illustrated embodiment, is disposed proximate thefirst treatment element 120. Thesensor 125 is communicatively coupled to theECU 123 to provide feedback to theECU 123 indicative of the performance of the exhaustgas treatment system 100. In some embodiments, one or more additional sensors may be provided to monitor various other parameters of the exhaustgas treatment system 100. These sensors may monitor, for example, NOx concentrations, ammonia concentrations, temperature, exhaust flow rate, and/or ash loading at one or more points along theexhaust pathway 104 and provide feedback to theECU 123 indicative of the performance of the exhaustgas treatment system 100. In other embodiments, the exhaustgas treatment system 100 may not be actively controlled, and thesensor 125 and/or the ECU 123 may be omitted. - A
first transition pipe 126 a interconnects the preliminary and 116, 120, and afirst treatment elements second transition pipe 126 b interconnects the first and 120, 124. In the illustrated embodiment, thesecond treatment elements 126 a, 126 b define an outer diameter that is smaller than an outer diameter of thetransition pipes 116, 120, 124. In an alternate embodiment illustrated intreatment elements FIG. 3 , the 116, 120, 124 are interconnected bytreatment elements 126 c, 126 d. Thetransition pipes 126 c, 126 d define an outer diameter that is substantially the same as the outer diameter of thetransition pipes 116, 120, 124. As such, thetreatment elements 116, 120, 124 and thetreatment elements 126 c, 126 d may collectively define a cylindrical exhausttransition pipes gas treatment unit 127. In the illustrated embodiment, the 126 c, 126 d each define an overall length that is less than their respective outer diameters. In some embodiments, thetransition pipes 126 c, 126 d each define an overall length between about 30% and about 70% of their respective outer diameters.transition pipes - The illustrated
preliminary treatment element 116 is a diesel oxidation catalyst (DOC) element and includes, for example, a honeycomb support coated with a catalytic material, such as a platinum group metal. Thepreliminary treatment element 116 may be used to reduce some particulate matter, carbon monoxide, and hydrocarbons from exhaust passing through the DOC element. Alternatively, thepreliminary treatment element 116 may include a different exhaust treatment configuration. In some embodiments of theexhaust treatment system 100, thepreliminary treatment element 116 may be omitted. In other embodiments, thepreliminary treatment element 116 may be included as a portion of a different treatment element (e.g., the first treatment element 120). - The
first treatment element 120 in the illustrated embodiment is a combined selective catalytic reduction and diesel particulate filter (SCR+F) element and includes a catalytic washcoat on a porous filter substrate. The washcoat may include one or more base metal oxides, for example, such as Al2O3, SiO2, TiO2, CeO2, ZrO2, V2O5, La2O3. Alternatively or additionally, the washcoat may include one or more zeolites. Thefirst treatment element 120 may be used to capture particulate matter, oxidize soot, and reduce NOx from exhaust gas passing through thefirst treatment element 120. - The
second treatment element 124 in the illustrated embodiment includes a selective catalytic reduction (SCR)portion 128 and an ammonia oxidation catalyst (AOC)portion 132. TheSCR portion 128 may include, for example, a catalytic washcoat on a monolithic support material, such as ceramic. TheSCR portion 128 and theAOC portion 132 are positioned in series, with theAOC portion 132 located downstream of theSCR portion 128. TheSCR portion 128 may be used to reduce NOx from exhaust gas passing through theSCR portion 128. TheAOC portion 132 may be used to convert excess ammonia leaving theSCR portion 128 to nitrogen and water. In some embodiments, theAOC portion 132 may be omitted. Alternatively, theAOC portion 132 may be provided as a separate treatment element positioned downstream of thesecond treatment element 124. - With reference to
FIG. 2 , the exhaustgas treatment system 100 also includes anammonia source 136, which includes a diesel exhaust fluid (DEF)supply 140 and anammonia producing unit 144 in the illustrated embodiment. TheDEF supply 140 is in fluid communication with theammonia producing unit 144 to supply DEF (e.g., a urea solution) to theammonia producing unit 144, which converts the DEF to ammonia gas (e.g., via thermolysis and hydrolysis). In some embodiments, a pump (not shown) is provided to move DEF from theDEF supply 140 to theammonia producing unit 144. The pump may be variably controlled to vary the amount of DEF supplied to theammonia producing unit 144, and thus vary the amount of ammonia output by theammonia producing unit 144. In other embodiments, the DEF may move from theDEF supply 140 to theammonia producing unit 144 under the influence of gravity. In such embodiments, one or more valves (not shown) may be provided between theDEF supply 140 and theammonia producing unit 144 to vary the flow of DEF to theammonia producing unit 144. In some embodiments, theDEF supply 140 may be omitted, and theammonia producing unit 144 may include an ammonia supply, such as a pressurized ammonia storage tank. - The exhaust
gas treatment system 100 further includes afirst injector 148 and asecond injector 152 in fluid communication with theammonia producing unit 144. Thefirst injector 148 and thesecond injector 152 can be directly fluidly coupled to the ammonia producing unit 144 (e.g., by independent conduits), or thefirst injector 148 and thesecond injector 152 can be fluidly coupled to a branch line, manifold, or other structure that receives ammonia from theammonia producing unit 144. Thefirst injector 148 is positioned to introduce ammonia into thefirst transition pipe 126 a, downstream of thepreliminary treatment element 116 and upstream of the first treatment element 120 (i.e. between the preliminary andfirst treatment elements 116, 120). Thesecond injector 152 is positioned to introduce ammonia into thesecond transition pipe 126 b, downstream of thefirst treatment element 120 and upstream of the second treatment element 124 (i.e. between the first andsecond treatment elements 120, 124). - Referring to
FIG. 4 , the exhaustgas treatment system 100 may further include aflow affecting feature 156 in theexhaust pathway 104, positioned upstream of thefirst injector 148. In the illustrated embodiment, theflow affecting feature 156 is positioned within thefirst transition pipe 126 a. Theflow affecting feature 156 can be, for example, one or more fins, vanes, projections, or other suitable means to impart turbulence or swirling into the exhaust flow proximate thefirst injector 148. With reference toFIG. 5 , in another embodiment, theflow affecting feature 156 may be positioned downstream of thefirst injector 148. Although not illustrated inFIG. 4 orFIG. 5 , another flow affecting feature may be positioned in thesecond transition pipe 126 b upstream or downstream of thesecond injector 152. - With continued reference to
FIGS. 4 and 5 , thefirst injector 148 may include anelongated portion 160 that extends into theexhaust pathway 104. A plurality ofopenings 164 in theelongated portion 160 allows ammonia to be expelled from theinjector 148 at multiple locations in theexhaust pathway 104. Although not illustrated inFIG. 3 , thesecond injector 152 may have a similar configuration. - With reference to
FIG. 2 , afirst valve 168 is disposed between theammonia producing unit 144 and thefirst injector 148, and asecond valve 172 is disposed between theammonia producing unit 144 and thesecond injector 152. In some embodiments, the first and 168, 172 can be incorporated into thesecond valves 148, 152 or into therespective injectors ammonia producing unit 144. In other embodiments, theexhaust treatment system 100 may include only one valve (i.e., thefirst valve 168 or the second valve 172). Alternatively, in some embodiments, the 168, 172 may be omitted.valves - Each of the illustrated
168, 172 is movable between a closed position in which the flow of ammonia through thevalves 168, 172 is substantially inhibited, and an open position in which the flow of ammonia through thevalve 168, 172 is substantially uninhibited. In some embodiments, one or both of thevalve 168, 172 can also be actuated to at least one intermediate position, between the closed and open positions, in which the flow of ammonia through thevalves 168, 172 is partially restricted. In some embodiments, one or both of thevalve 168, 172 can be modulated to vary the flow rate of ammonia. In the illustrated embodiment, thevalves 168, 172 are controlled by thevalves ECU 123. -
FIG. 6 illustrates an example of theECU 123 for control of the exhaustgas treatment system 100. TheECU 123 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within theECU 123. In particular, theECU 123 includes, among other things, an electronic processor 180 (e.g., a programmable microprocessor, microcontroller, or similar device), non-transitory, machine-readable memory 184, and an input/output interface 188. Theelectronic processor 180 is communicatively coupled to thememory 184 and configured to retrieve frommemory 184 and execute, among other things, instructions related to the control processes and methods described herein. In other embodiments, theECU 123 includes additional, fewer, or different components. In the illustrated embodiment, theECU 123 is communicatively coupled to thesensor 125, theDEF supply 140, thefirst valve 168, and thesecond valve 172. TheECU 123 may also be configured to communicate with external systems including, for example, engine controls and/or operator controls. - In operation, untreated exhaust from the internal combustion engine 14 (
FIG. 1 ) is directed into theexhaust pathway 100 at the inlet 104 (FIG. 2 ). The exhaust then flows through the preliminary treatment (DOC)element 116, which reduces some particulate matter, carbon monoxide, and hydrocarbons from the exhaust. Ammonia is introduced into the partially-treated exhaust downstream of thepreliminary treatment element 116 via thefirst injector 148. Because thefirst injector 148 includesmultiple holes 164, the ammonia is more uniformly dispersed into the exhaust stream (FIG. 4 ). In addition, turbulence or swirling movement imparted by theflow affecting feature 156 enhances mixing to create a relatively homogeneous mixture of exhaust and ammonia within a relatively short distance from theinjector 148. Thus, the distance between the preliminary and 116, 120 can be minimized.first elements - The ammonia and exhaust mixture then enters the first treatment (SCR+F) element 120 (
FIG. 2 ). The ammonia reacts with NOx in the presence of the catalyst to form nitrogen and water, while soot is captured and oxidized on the porous filter substrate. When the exhaust exits thefirst treatment element 120, additional ammonia is introduced via thesecond injector 152. Like thefirst injector 148, thesecond injector 152 preferably includes a plurality of holes (not shown), to more uniformly disperse the ammonia into the exhaust stream, and an additional flow affecting feature (not shown) is preferably provided proximate thesecond injector 152 to further enhance mixing. Thus, the distance between the first and 120, 124 can be minimized.second treatment elements - The ammonia and exhaust mixture then enters the
second treatment element 124, where the ammonia reacts with any remaining NOx in theSCR portion 128, and any unreacted ammonia is subsequently oxidized in theAOC portion 132. The treated exhaust then exits the exhaustgas treatment system 100 through theoutlet 108. - The amount of NOx converted in the first and
120, 124 is dependent upon the amount of ammonia injected. In the illustrated embodiment, the total amount of ammonia injected is controlled by the rate at which DEF is supplied to thesecond treatment elements ammonia producing unit 144. DEF flows from theDEF supply 140 to theammonia producing unit 144 at a rate that may be controlled by theECU 123, and theammonia producing unit 144 produces ammonia gas from the DEF. The ammonia gas flows from theammonia producing unit 144, through the 168, 172, and to thevalves 148, 152, which inject the ammonia into theinjectors exhaust pathway 104. - Because proper soot oxidation in the
first treatment element 120 requires the presence of NOx (specifically, NO2), the amount of ammonia flowing through thefirst injector 148 is limited so that some of the NOx remains unreacted through thefirst treatment element 120. In the illustrated embodiment, ammonia flows through thefirst injector 148 at a first rate, and ammonia flows through thesecond injector 152 at a second rate that is greater than the first rate. TheECU 123 may adjust the flow of ammonia into theexhaust pathway 104 by modulating thefirst valve 168, thesecond valve 172, and/or the rate at which DEF flows to theammonia producing unit 144. - With reference to
FIG. 7 , theECU 123 may periodically or continuously read a value or signal from thesensor 125 at block 192 (via the input/output interface 188), which is indicative of the pressure drop across thefirst treatment element 120. TheECU 123 uses the sensed value to determine whether thefirst treatment element 120 is properly oxidizing soot. The pressure drop may be correlated with the amount of soot or particulate present in thefirst treatment element 120. For example, as the amount of particulate in thefirst treatment element 120 increases, the pressure drop increases, and as the amount of particulate in thefirst treatment element 120 decreases, the pressure drop decreases. From this correlation, theECU 123 can determine an estimated particulate parameter atblock 194, which may correspond with an estimated amount of particulate in thefirst treatment element 120. In some embodiments, theECU 123 may periodically or continuously read a value or signal from one or more additional or alternative sensors (e.g., NOx sensors, ammonia sensors, temperature sensors, ash loading sensors, exhaust flow rate sensors, etc.). The values or signals from these sensors may be factored into the ECU's determination of the estimated particulate parameter. - At
block 196, theECU 123 may then periodically or continuously compare the estimated particulate parameter with a threshold value or value range, stored inmemory 184, which is representative of a target soot oxidation performance level. If the estimated particulate parameter is greater than the threshold value (i.e., if the level of particulate in thefirst treatment element 120 is high), theECU 123 decreases the flow of ammonia through thefirst injector 148 atblock 200 by restricting flow through thefirst valve 168. Accordingly, the amount of NOx available for soot oxidation will increase. Optionally, theECU 123 may then increase the flow of ammonia through thesecond injector 152 atblock 202 by opening thesecond valve 172. If the estimated particulate parameter is less than the threshold value (i.e., if the level of particulate in thefirst treatment element 120 is low), theECU 123 can increase the flow of ammonia through thefirst injector 148 atblock 204 by opening thefirst valve 168. Accordingly, the amount of NOx will be reduced. Optionally, theECU 123 may then decrease the flow of ammonia through thesecond injector 152 atblock 206 by restricting flow through thesecond valve 172. In embodiments where either thefirst valve 168 or thesecond valve 172 is omitted, the first and 148, 152 are in fluid communication such that an increase in flow through thesecond injectors first injector 148 results in a proportional decrease in flow through thesecond injector 152, and vice versa. -
FIG. 8 illustrates an exhaustgas treatment system 300 according to another embodiment. The exhaustgas treatment system 300 is similar to the exhaustgas treatment system 100 described above with reference toFIGS. 1-7 . Accordingly, like features are given identical reference numbers, and only differences between the exhaustgas treatment system 300 and the exhaustgas treatment system 100 are described in detail. - The exhaust
gas treatment system 300 includes afirst ammonia passageway 304 extending between theammonia producing unit 144 and thefirst ammonia injector 148 and asecond ammonia passageway 308 extending between theammonia producing unit 144 and thesecond ammonia injector 152. Thefirst ammonia passageway 304 defines a first diameter, and thesecond ammonia passageway 308 defines a second diameter that is greater than the first diameter. In some embodiments, the 304, 308 may have the same outer diameter but different inner diameters. In other embodiments, thepassageways 304, 308 may have the same outer and inner diameters, and thepassageways first passageway 304 may include a restriction that reduces the effective inner diameter of thefirst passageway 304. - In operation, ammonia flows from the
ammonia producing unit 144 to the 148, 152 via theinjectors 304, 308. Because therespective passageways first passageway 304 is relatively restricted compared to thesecond passageway 308, ammonia flows through thefirst injector 148 at a first rate and through thesecond injector 152 at a second rate greater than the first rate. The 304, 308 are sized to provide some NOx reduction in thepassageways first treatment element 120 and a greater amount of NOx reduction in theSCR portion 128 of thesecond treatment element 124. This configuration may preserve enough NOx in thefirst treatment element 120 for effective soot oxidation. - Various features of the disclosure are set forth in the following claims.
Claims (20)
Priority Applications (4)
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| US14/870,039 US9616385B1 (en) | 2015-09-30 | 2015-09-30 | System and method for regulating exhaust emissions |
| US15/472,762 US10012122B2 (en) | 2015-09-30 | 2017-03-29 | System and method for regulating exhaust emissions |
| US15/831,027 US10927740B2 (en) | 2015-09-30 | 2017-12-04 | System for regulating exhaust emissions |
| US17/150,795 US11920507B2 (en) | 2015-09-30 | 2021-01-15 | Method for regulating exhaust emissions |
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| US14/870,039 US9616385B1 (en) | 2015-09-30 | 2015-09-30 | System and method for regulating exhaust emissions |
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|---|---|
| US9616385B1 (en) | 2017-04-11 |
| US10012122B2 (en) | 2018-07-03 |
| US20170198619A1 (en) | 2017-07-13 |
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