Catalytic converter device for a stationary internal combustion engine

Abstract

A catalytic converter device for a stationary internal combustion engine includes at least one bracket for mounting the catalytic converter device on a carrier, and at least one catalyst substrate which can be releasably arranged in a housing of the catalytic converter device, the catalyst substrate having a cell density of at least 50 cpsi, preferably greater than 100 cpsi.

Claims

1. An arrangement comprising: a stationary internal combustion engine, a catalytic converter device for exhaust gas after-treatment of non pre-treated exhaust gases of an exhaust gas flow from the stationary internal combustion engine, an exhaust gas turbine arranged downstream of the stationary internal combustion engine in the exhaust gas flow from the stationary internal combustion engine, an injection device for injection of a reducing agent for the catalytic converter device, a muffler, and an exhaust gas conduit, wherein the injection device is arranged downstream of the exhaust gas turbine and upstream of the catalytic converter device, wherein the injection device is arranged upstream of the muffler, wherein the exhaust gas conduit is configured to guide the exhaust gas flow and the exhaust gas conduit has a conical portion which enlarges downstream, wherein the injection device is arranged in the conical portion, wherein the injection device is arranged in relation to the exhaust gas turbine such that a residual swirl imposed on the exhaust gas flow by the exhaust gas turbine promotes mixing of the exhaust gas flow and the reducing agent which has been injected, and wherein the catalytic converter device comprises: a bracket for mounting the catalytic converter device on a carrier, and a catalyst substrate which is configured to be releasably arranged in a housing of the catalytic converter device, and wherein the catalyst substrate has a cell density of at least 50 cpsi, and less than 350 cpsi.

2. The arrangement as set forth in claim 1, wherein the catalyst substrate is predominantly metallic.

3. The arrangement as set forth in claim 2, wherein the catalyst substrate is completely metallic.

4. The arrangement as set forth in claim 1, wherein the catalyst substrate comprises a plurality of substrate blocks.

5. The arrangement as set forth in claim 4, wherein the substrate blocks are releasably connected to each other and are gas-tightly sealed off relative to each other.

6. The arrangement as set forth in claim 5, wherein the substrate blocks are releasably connected to each other and are gas-tightly sealed off relative to each other by positively locking connections.

7. The arrangement as set forth in claim 6, wherein the positively locking connections are connecting bars which are configured to be hung in a frame in the housing of the catalytic converter device.

8. The arrangement as set forth in claim 4, wherein the substrate blocks are cuboidal.

9. The arrangement as set forth in claim 4, wherein each of the substrate blocks has a coupling location for coupling a lifter thereto.

10. The arrangement as set forth in claim 9, wherein the coupling location is an opening.

11. The arrangement as set forth in claim 1, wherein the catalytic converter device is an SCR catalytic converter device, an oxidation catalytic converter device or an NH3 slip catalytic converter device.

12. The arrangement as set forth in claim 1, wherein the injection device is a two-component injection device with a first component of a liquid reduction agent solution, and a second component of air.

13. The arrangement as set forth in claim 1, wherein the exhaust gas turbine is one of two exhaust gas turbines which are arranged in parallel fluidic relationship, and wherein the injection device is arranged in the exhaust gas flow of a manifold downstream of the two exhaust gas turbines.

14. The arrangement as set forth in claim 1, wherein the exhaust gas turbine is one of two exhaust gas turbines arranged in parallel fluidic relationship, and wherein either the injection device is arranged only in the exhaust gas flow of one of the two exhaust gas turbines or the injection device is one of two injection devices, a first of the two injection devices being arranged in the exhaust gas flow of a first of the two exhaust gas turbines and a second of the two injection devices being arranged in the exhaust gas flow of a second of the two exhaust gas turbines.

15. The arrangement as set forth in claim 1, wherein the exhaust gas conduit has a curved portion, and wherein the injection device is arranged upstream of the curved portion of the exhaust gas conduit.

16. The arrangement as set forth in claim 15, wherein a deflection device is arranged in the curved portion, in an injector of the injection device.

17. The arrangement as set forth in claim 16, wherein the curved portion is a baffle plate.

18. The arrangement as set forth in claim 1, wherein the conical portion is arranged immediately downstream of the exhaust gas turbine.

19. The arrangement as set forth in claim 1, wherein the housing is configured to deflect the exhaust gas flow within.

20. The arrangement as set forth in claim 19, wherein the housing is configured to deflect the exhaust gas flow within through 180°.

21. The arrangement as set forth in claim 1, wherein the injection device is arranged so as to be axially aligned inside the exhaust gas conduit.

22. The arrangement as set forth in claim 21, wherein the injection device is arranged so as to be aligned at least centrally inside the exhaust gas conduit.

23. The arrangement as set forth in claim 1, wherein the cell density is greater than 100 cpsi.

24. The arrangement as set forth in claim 1, wherein the cell density is less than 300 cpsi.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described in greater detail hereinafter with reference to the Figures in which:

(2) FIG. 1 shows a perspective view of a catalytic converter device,

(3) FIGS. 2a through 2d show structural details of the catalytic converter device,

(4) FIG. 3 is a perspective view of an arrangement including a catalytic converter device,

(5) FIG. 4 shows an arrangement according to a first embodiment,

(6) FIG. 5 shows an arrangement according to a second embodiment,

(7) FIGS. 6a through 6c show variants in the flow through the catalytic converter device,

(8) FIGS. 7a and 7b show further variants in the flow through the catalytic converter device,

(9) FIGS. 8a through 8c are diagrammatic views of the afflux flow to the catalytic converter device, and

(10) FIG. 9 shows a detail of the exhaust gas conduit.

DETAILED DESCRIPTION OF THE INVENTION

(11) FIG. 1 shows a perspective view of a catalytic converter device 5.

(12) The housing 52 is here a cuboidal sheet metal structure in which the catalyst substrate 51 is arranged as a carrier for the actual catalytic reaction. The round openings through which the exhaust gas can flow into and out of the catalytic converter unit 5 provide a view on to the structure therein.

(13) The catalyst substrate 51 is provided in the form of substrate blocks 53. The substrate blocks 53 are connected together by way of the positively locking connection 54. The positively locking connections 54 are here in the form of connecting bars. The substrate blocks 53 are held in position and sealed off relative to each other by the connecting bars. The variant is particularly advantageous, in which sealing integrity of the side surfaces of the substrate blocks is ensured without additional sealing means solely by virtue of the inherent weight of the substrate blocks and the choice of the appropriate tolerances. The catalytic converter device 5 further has a bracket 55, by way of which the catalytic converter device 5 can be mounted. In stationary applications mounting of the catalytic converter device 5 is generally in an upright position.

(14) FIG. 2a shows the detail A in FIG. 1 in a longitudinal section. The Figure shows the positively locking connection 54 which can receive the substrate blocks 53.

(15) FIG. 2b shows an exploded view of the substrate blocks 53, the positively locking connection 54, here in the form of connecting bars, and the frame 56. The Figure shows how the substrate blocks 53 are held by way of the positively locking connection 54 and then the assembly of the substrate blocks 53 with the positively locking connection 54 can be suspended in the frame 56.

(16) FIG. 2c shows a perspective view of a substrate block 53. The Figure shows the coupling locations 57 (detail B) at the side surfaces of the substrate block 53.

(17) FIG. 2d shows the coupling location 57 corresponding to the detail B from FIG. 2. The coupling location 57 allows the substrate block 53 to be securely lifted and oriented.

(18) FIG. 3 shows a perspective view of an embodiment of an arrangement according to the invention. An internal combustion engine 1 is connected to two parallel-connected exhaust gas turbines 2, 2′, downstream of which is arranged a conical portion 13 of the exhaust gas conduit 10. An injection device 3 injects reducing agent into the conical portion 13. Downstream thereof the exhaust gas conduit 10 has a curved portion 11 with integrated deflection device 12 (not visible in this view). That is followed by a manifold 14 opening into a muffler 4. The housing 52 of the catalytic converter device 5 is to be seen downstream of the muffler 4. The flow direction of the exhaust gases is symbolically indicated by bold black arrows. In this embodiment the catalytic converter device 5 causes a 180° deflection of the exhaust gases. Connected downstream thereof are two exhaust gas heat exchangers and a flue stack 8 for discharge of the treated gases.

(19) FIG. 4 shows an arrangement with a catalytic converter device 5 in a first embodiment. In this case two parallel exhaust gas turbines 2, 2′ are provided in the exhaust gas flow from the internal combustion engine 1. The exhaust gas is carried by way of the exhaust gas conduit 10. Here the injection device 3 is arranged in the exhaust gas flow of an individual exhaust gas turbine 2. The injection device 3 is controlled by way of the open-loop/closed-loop control device 9. Downstream of the exhaust gas turbines 2, 2′ there follows a first muffler 4 and the catalytic converter device 5. Provided after the catalytic converter device 5 is an exhaust gas heat exchanger 6 from which the exhaust gases are further passed through an end muffler 7 to the flue stack 8. In a variant a separate injection device 3 can be provided downstream of each of the exhaust gas turbines 2, 2′.

(20) FIG. 5 shows an arrangement of an internal combustion engine 1 with a catalytic converter device 5 according to a second embodiment. As in the previous embodiment in this case also there are two exhaust gas turbines 2, 2′ in a parallel arrangement. In this case however the injection device 3 is disposed in a manifold 14 after the individual exhaust gas conduits 10 are combined after the exhaust gas turbines 2, 2′. Otherwise the structure of the arrangement in FIG. 5 is the same as the embodiment of FIG. 4.

(21) FIGS. 6a through 6c show plan views of variants of the afflux flow of the catalytic converter device 5. The flow direction of the exhaust gas is symbolically represented by the black arrows.

(22) In the FIG. 6a variant the exhaust gas flows by way of an end into the housing 52, flows through a first substrate block 53, is deflected and issues on the intake side again through a further substrate block 53. That arrangement is suitable in particular for structural implementations in which a straight-line flow path is not possible. The external dimensions of an exhaust gas installation with a catalytic converter device in accordance with this variant can be particularly compact.

(23) In the variant shown in FIG. 6b the exhaust gas flows through a front end into the housing 52 and issues again on the rear side. The substrate block 53 is installed in a diagonally inclined position, thereby giving an increased afflux surface area for the substrate block 53, in comparison with a right-angled afflux flow. The broken-line arrows indicate that, with the same housing 52, further variations in the flow through the arrangement can be achieved. Thus in a modification of this variant, a deflection of the exhaust gas flow through 90° could be effected. The variant of FIG. 6c shows the situation with two substrate blocks 53 connected in serial succession. As already indicated the housing 52 together with frame 56 (not shown here) permits the catalytic converter device 5 to be of a modular design. As indicated by the broken lines, the individual substrate blocks 53 can also be deeper in the flow direction, as there is always still enough structural space remaining in the housing 52.

(24) If the application requires it, for example a plurality of substrate blocks 53 can be arranged in series without having to modify anything on the housing 52.

(25) FIGS. 7a and 7b show a further variant of the afflux flow for the catalytic converter device 5, FIG. 7a showing a side view and FIG. 7b showing a front view of the same embodiment. As can be seen from FIG. 7a the exhaust gas flows into the housing 52 which is here configured on edge, is deflected downwardly and through 90° and leaves the housing 52 again. The broken-line circle in FIG. 7a shows the outlet from the housing. The outlet is here on the rear side, that is to say it is not visible and is shown in broken line for that reason. FIG. 7b shows a front view of the variant. In this case also it would be possible to envisage a modification whereby the exhaust gases are deflected through 180° and flow away in the same plane as the afflux flow.

(26) FIGS. 8a through 8c diagrammatically show the above-discussed variants for the afflux flow of a catalytic converter device 5.

(27) In accordance with the view in FIG. 7a the exhaust gas flows in through the front side of the catalytic converter device 5 and away by way of the rear side.

(28) The variant in FIG. 8b shows the situation wherein the exhaust gas flows in by way of the side surface of the catalytic converter device 5 and flows away again by way of the downstream end face of the catalytic converter device 5.

(29) FIG. 8c shows the variant in which the exhaust gas flows in by way of a side surface of the catalytic converter device 5 and flows out again also by way of a side surface of the catalytic converter device 5.

(30) FIG. 9 shows a view in section of a detail of the exhaust gas conduit 10. It is possible to see here the curved portion 11 of the exhaust gas conduit 10, in which a deflection device 12, here in the form of a baffle plate, is arranged. An injection device 3 for the injection of a reducing agent is arranged in the conical portion 13 of the exhaust gas conduit 10 after the exhaust gases issue from the exhaust gas turbines (2, 2′).

(31) The deflection device 12 provides for particularly rapid vaporization of the reducing agent injected by way of the injection device 3. It is further desirable that the deflection device 12 reduces or avoids a thermal shock due to the relatively cool reducing agent impinging on the exhaust gas conduit 10 heated by the exhaust gases.

(32) It is also desirable with the illustrated arrangement that a residual swell imparted to the exhaust gas flow by the exhaust gas turbines 2, 2′ promotes mixing of the injected reducing agent and the exhaust gas flow.

LIST OF REFERENCES USED

(33) 1 internal combustion engine 2, 2′ exhaust gas turbine 3 injection device 4 muffler 5 catalytic converter device 6 exhaust gas heat exchanger 7 end muffler 8 flue stack 9 open-loop/closed-loop control device 10 exhaust gas conduit 11 curved portion of the exhaust gas conduit 12 deflection device, baffle plate 13 conical portion of the exhaust gas conduit 14 manifold 51 catalyst substrate 52 housing 53 substrate block 54 positively locking connection 55 bracket 56 frame 57 coupling location