EXHAUST GAS AFTERTREATMENT SYSTEM
20220298943 · 2022-09-22
Assignee
Inventors
Cpc classification
B01D53/9418
PERFORMING OPERATIONS; TRANSPORTING
B01D53/9495
PERFORMING OPERATIONS; TRANSPORTING
F01N2900/1402
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D53/9431
PERFORMING OPERATIONS; TRANSPORTING
F01N2900/1806
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D53/9477
PERFORMING OPERATIONS; TRANSPORTING
F01N2900/0416
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/148
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2560/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2900/1602
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/008
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2560/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/146
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/208
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/009
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2900/0408
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present disclosure relates to an exhaust gas aftertreatment system and method for controlling same. The exhaust gas aftertreatment system comprises: a reductant dosing device; a selective catalytic reduction device arranged downstream of the reductant dosing device; an ammonia slip catalyst arranged downstream of the SCR device; a feedback NOx sensor arranged downstream of the SCR device and upstream of the ammonia slip catalyst; a tailpipe NOx sensor arranged downstream of the ammonia slip catalyst; and a control device configured for: providing an initial dosing of reductant from the reductant dosing device; obtaining a feedback signal from the feedback NOx sensor and a tailpipe NOx signal from the tailpipe NOx sensor; and adjusting the dosing of reductant until the feedback signal exceeds the tailpipe NOx signal by a value within a predetermined positive interval.
Claims
1. A method for controlling an exhaust gas aftertreatment system, the exhaust gas aftertreatment system comprising: a reductant dosing device; a selective catalytic reduction, SCR, device arranged downstream of the reductant dosing device; an ammonia slip catalyst arranged downstream of the SCR device; a feedback NOx sensor arranged downstream of the SCR device and upstream of the ammonia slip catalyst; and a tailpipe NOx sensor arranged downstream of the ammonia slip catalyst, wherein the method is performed by one or more control devices and comprises: providing an initial dosing of reductant from the reductant dosing device; obtaining a feedback signal from the feedback NOx sensor and a tailpipe NOx signal from the tailpipe NOx sensor; and adjusting the dosing of reductant until the feedback signal exceeds the tailpipe NOx signal by a value within a predetermined positive interval.
2. The method according to claim 1, wherein dosing of reductant comprises: determining a difference between the feedback signal and the tailpipe NOx signal; comparing the determined difference with a lower boundary difference value and an upper boundary difference value; and increasing the dosing of reductant if the determined difference is below the lower boundary difference value; or decreasing the dosing of reductant if the determined difference is above the upper boundary difference value.
3. The method according to claim 1, wherein adjusting the dosing of reductant comprises: comparing the tailpipe NOx signal with a threshold tailpipe NOx value, whereby if the tailpipe NOx signal is greater than a threshold tailpipe NOx value, then the dosing of reductant is increased in order to obtain a tailpipe NOx signal less than the threshold tailpipe NOx value; once the tailpipe NOx signal is less than the threshold tailpipe NOx value, then comparing the feedback signal with a lower boundary value and an upper boundary value; and increasing the dosing of reductant if the feedback signal is below the lower boundary value; or decreasing the dosing of reductant if the feedback signal is above the upper boundary value.
4. The method according to claim 3, wherein the threshold tailpipe NOx value is equal to a detection limit of the tailpipe NOx sensor, or does not exceed the detection limit of the tailpipe NOx sensor by more than 10%.
5. The method according to claim 1, wherein the exhaust gas aftertreatment system further comprises an initial NOx sensor arranged upstream of the reductant dosing device, and wherein the initial dosing of reductant from the reductant dosing device is provided based on an initial NOx signal from the initial NOx sensor.
6. The method according to claim 1, wherein the exhaust gas aftertreatment system further comprises a temperature sensor and wherein the method is performed at a temperature of 150° C. or greater.
7. The method according to claim 1, comprising time averaging the tailpipe NOx signal and the feedback signal.
8. An exhaust gas aftertreatment system comprising: a reductant dosing device; a selective catalytic reduction, SCR, device arranged downstream of the reductant dosing device; an ammonia slip catalyst arranged downstream of the SCR device; a feedback NOx sensor arranged downstream of the SCR device and upstream of the ammonia slip catalyst; a tailpipe NOx sensor arranged downstream of the ammonia slip catalyst; and at least one control device configured to: provide an initial dosing of reductant from the reductant dosing device; obtain a feedback signal from the feedback NOx sensor and a tailpipe NOx signal from the tailpipe NOx sensor; and adjust the dosing of reductant until the feedback signal exceeds the tailpipe NOx signal by a value within a predetermined positive interval.
9. The exhaust gas aftertreatment system according to claim 8, wherein the ammonia slip catalyst has both ammonia slip catalyst and selective catalytic reduction functionality.
10. A vehicle comprising an exhaust gas aftertreatment system comprising: a reductant dosing device; a selective catalytic reduction, SCR, device arranged downstream of the reductant dosing device; an ammonia slip catalyst arranged downstream of the SCR device; a feedback NOx sensor arranged downstream of the SCR device and upstream of the ammonia slip catalyst; a tailpipe NOx sensor arranged downstream of the ammonia slip catalyst; and at least one control device configured to: provide an initial dosing of reductant from the reductant dosing device; obtain a feedback signal from the feedback NOx sensor and a tailpipe NOx signal from the tailpipe NOx sensor; and adjust the dosing of reductant until the feedback signal exceeds the tailpipe NOx signal by a value within a predetermined positive interval.
11. The method according to claim 1, wherein the exhaust gas aftertreatment system further comprises a temperature sensor and wherein the method is performed at a temperature of 180° C. or greater.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] For a fuller understanding of the present invention and further objects and advantages of it, the detailed description set out below should be read together with the accompanying drawings, in which the same reference notations denote similar items in the various diagrams, and in which:
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
DETAILED DESCRIPTION OF THE INVENTION
[0050] The present invention concerns a method for controlling an exhaust gas aftertreatment system in order to reduce tailpipe NOx emissions below levels reliably detectable by current NOx sensors. The invention is based upon a realization by the inventors that the non-selectivity of NOx sensors could be exploited to ensure that a suitable level of over-dosing of ammonia is provided using feedback control, thus allowing tailpipe NOx emission levels to be obtained that are below the levels detectable by current NOx sensors. This is feasible as long as it is possible to determine whether a NOx sensor located downstream of the SCR catalyst is operating in a NOx-rich environment (sub-stoichiometric dosing of ammonia to SCR) or an ammonia-rich environment (over-stoichiometric dosing of ammonia to SCR). A tailpipe NOx sensor arranged downstream of the ammonia slip catalyst enables such a determination in combination with a feedback NOx sensor arranged downstream of the SCR device and upstream of the ammonia slip catalyst.
[0051] The exhaust gas aftertreatment system comprises a reductant dosing device, a selective catalytic reduction (SCR) device, an ammonia slip catalyst and a plurality of NOx sensors. The relation of aftertreatment system components to each other will in this application be defined in terms of upstream and downstream. Upstream and downstream respectively refer to positions in the exhaust aftertreatment system with reference to the typical direction of flow of exhaust gas from the engine to the tailpipe. A component is designated upstream of another if it is located in the exhaust system closer to the engine, whereas it is designated downstream if it is located in the exhaust system closer to the tailpipe.
[0052] The reductant dosing device is arranged to dose reductant to the exhaust gas aftertreatment system. To this end, the reductant dosing device may comprise or consist of at least one reductant injector. The reductant injector may be of any type known in the art, such as an air-assisted (e.g. jetspray) injector, or a liquid-only (i.e. airless) injector.
[0053] The reductant may be any SCR reductant known in the art. The reductant is preferably diesel exhaust fluid comprising a solution of urea in water, in accordance with standard AUS 32 of ISO 22241, due to its widespread commercial availability and easy handling. However, other reductants such as aqueous ammonia solution or guanidinium salt solutions may also be used where appropriate.
[0054] The SCR device is arranged downstream of the reductant dosing device. The SCR device may be of any type known in the art. By SCR device, it is meant a device comprising a catalyst capable of catalysing the reduction of NOx to N.sub.2 using the reductant. The SCR catalyst device may be a dedicated SCR catalyst, or it may be a device combining the function of an SCR catalyst with another function. For example, the SCR device may be an SCR-catalysed diesel particulate filter (SDPF). The SCR device may comprise multiple SCR catalysts arranged in parallel or series.
[0055] Selective catalytic reduction (SCR) is used to convert nitrogen oxides (NOx) to benign nitrogen gas (N.sub.2), typically using ammonia as the reductant. The dominant reactions in ammonia SCR are:
4NH.sub.3+4NO+O.sub.2.fwdarw.4N.sub.2+6H.sub.2O
4NH.sub.3+2NO.sub.2+2NO.fwdarw.4N.sub.2+6H.sub.2O
[0056] It can be seen from these reactions that the optimal stoichiometry of NH.sub.3 to NOx is approximately 1:1, i.e. an ammonia:NOx ratio (ANR) of about approximately 1. Therefore, an ANR greater than stoichiometric (over-stoichiometric) may be about 1.1 or greater, such as about 1.2 or about 1.3. An ANR less than stoichiometric (sub-stoichiometric) may be less than or equal to 1, such as less than or equal to 0.9. Sub-stoichiometric dosing of ammonia leads to incomplete conversion of NOx, i.e. NOx detectable at the outlet of the SCR device, whereas over-dosing of ammonia leads to ammonia slip, i.e. unreacted ammonia detectable at the outlet of the SCR device.
[0057] An ammonia slip catalyst is arranged downstream of the SCR device. Ammonia slip catalysts prevent tailpipe ammonia emissions by oxidation of excess ammonia to benign nitrogen gas (N.sub.2). However, this catalytic reaction is not fully selective and a proportion of ammonia slip is unavoidably converted to N.sub.2O in the catalyst. N.sub.2O is a strong greenhouse gas and its emission is highly undesirable. Therefore it is desired to limit the over-stoichiometric dosing of ammonia to a level whereby substantially all NOx is converted but no more, in order to limit production of N.sub.2O. Appropriate ANR values may for example be from about 1.05 to about 1.3, such as from about 1.1 to about 1.2. When using over-stoichiometric ammonia:NOx ratios it is advantageous if the ammonia slip catalyst also possesses SCR functionality, since in this manner it may assist in further reducing NOx emission levels or permit use of a smaller-dimensioned SCR catalyst.
[0058] The exhaust aftertreatment system comprises at least two NOx sensors, preferably three or more NOx sensors. The NOx sensors may be any type known in the art, such as the commercially available YSZ-type NOx sensors. Commercially available NOx sensors are typically not fully selective for NOX and also detect ammonia (NH.sub.3).
[0059] A NOx sensor is arranged in the exhaust aftertreatment system downstream of the ammonia slip catalyst, and is herein termed the tailpipe NOx sensor. Note however that this sensor may be located anywhere in the aftertreatment system downstream of the ASC and is not necessarily located in a tailpipe of the exhaust system.
[0060] A further NOx sensor is arranged between the SCR and the ASC, downstream of the SCR and upstream of the ASC. This NOx sensor is herein termed the feedback sensor since feedback from this sensor is used to achieve ANR values within a desired interval.
[0061] Optionally, a NOx sensor may be arranged upstream of the reductant dosing device. This sensor is herein termed the initial NOx sensor and may be used in conjunction with exhaust flow data (either virtual or measured by flow sensor) in order to determine a suitable initial dosing rate of reductant.
[0062] The exhaust aftertreatment system may comprise further components as commonly known in the art. For example, a diesel oxidation catalyst (DOC) and/or diesel particulate filter (DPF), or combined DOC/DPF may be arranged upstream of the reductant distribution arrangement. A pre-SCR unit comprising a reductant dosing device and SCR catalyst may be arranged upstream of the DOC in order to remove a proportion of exhaust NOx prior to the exhaust gas reaching the main SCR device as described herein. A mixer or evaporation plate may be arranged in conjunction with the reductant dosing device in order to improve the distribution of reductant in the exhaust stream. Further sensors, such as temperature sensors, flow sensors, and/or pressure sensors may be arranged as suitable in the aftertreatment system.
[0063] The exhaust aftertreatment system may comprise a control device configured to perform the method as described herein. Alternatively, or in addition, the exhaust aftertreatment system may in use be arranged in communication with another suitable control device for performing the method described herein.
[0064] The inventive method will now be described in more detail with reference to certain exemplifying embodiments and the drawings. However, the invention is not limited to the exemplifying embodiments discussed herein and/or shown in the drawings, but may be varied within the scope of the appended claims. Furthermore, the drawings shall not be considered drawn to scale as some features may be exaggerated in order to more clearly illustrate certain features.
[0065]
[0066]
[0067] In operation, urea solution is dosed to the prior art exhaust aftertreatment system with the aim of achieving as uniform distribution of reductant as possible at the SCR device 27. An exhaust gas temperature of approximately at least 150° C. (e.g. about at least 180° C. or about at least 200° C.) is required to be able to evaporate the dosed urea and produce NH.sub.3. The exhaust gas temperature may be measured using temperature sensor 21. Dosing is controlled by the control device 15, based on the signal from NOx sensors 13, 31, together with other inputs such as for example exhaust gas temperature and/or exhaust flow (measured or calculated). The urea decomposes to ammonia and is conveyed to the SCR device 27. The SCR device 27 catalyses the reaction of the ammonia with NOx present in the exhaust stream. At the outlet of the SCR device 27 a relatively uniform exhaust stream comprising a mixture of NOx and some ammonia slip is obtained. This exhaust stream is conveyed further to the ASC 29 where some further NOx may be removed by SCR and the remaining ammonia is oxidized to nitrogen. The exhaust stream exiting the ASC 29 comprises residual NOx and essentially no ammonia. Initial dosing of reductant is determined by the NOx concentration measured at the initial NOx sensor 13 together with exhaust flow data (either virtual or from a flow sensor). Due to limits in the measuring accuracy of NOx and exhaust flow, as well as variation in the dosing accuracy from dosing device 23, and variation in ambient conditions (ambient temperature, pressure and humidity), the initial dosing typically falls within the range of from about 0.8 to about 1.2 ANR. The tailpipe NOx sensor 31 detects residual NOx levels and is used in feedback control of urea dosing from dosing device 23 in order to obtain an ANR suitable for near-complete removal of NOx (typically from about 1.05 to about 1.1). Such prior art arrangements work satisfactorily as long as the residual NOx level is permitted to be above the limit reliably measurable by the tailpipe NOx sensor 31, which is approximately 0.1 g/kWh. However, if the permitted NOx emission is below the limit that may reliably be measurable by the tailpipe NOx sensor 31, the tailpipe sensor 31 cannot be used to control dosing of urea from dosing device 23.
[0068]
[0069]
[0070] At low ANR values (<0.95) it can be seen that significant quantities of NOx escape the SCR device (line 431), but there is essentially no ammonia slip (line 435). At these ANR values, the reading from the feedback NOx sensor (line 433) therefore essentially corresponds to the NOx concentration at the SCR device outlet. At high ANR values (ANR>1.05) it can be seen that essentially no NOx escapes the SCR device (line 431), but that significant quantities of ammonia slip are produced (line 435). As previously stated, NOx sensors are non-selective, meaning that they cannot distinguish between NOx and ammonia slip. At high ANR values, the reading from the feedback NOx sensor (line 433) therefore essentially corresponds to the ammonia slip concentration at the SCR device outlet. In a transitional ANR range (between approx. ANR 0.95-1.05) there is incomplete reaction of ammonia with NOx, meaning that both NOX emission (line 431) and ammonia slip (line 435) are detected at the SCR device outlet. In such a transitional case, the feedback NOx sensor measures the combined concentration of NOx and ammonia (line 433).
[0071] It can be seen from the chart in
[0072] Line 451 illustrates a typical detection limit for an automotive NOx sensor, and it can be seen that at high ANR values the NOx concentration is lower than the concentration measurable with an automotive NOx sensor. This means that it is not possible to control ANR at high ANR values using only a tailpipe NOx sensor.
[0073] The solution to this problem is to use a feedback NOx sensor 33 in combination with a tailpipe NOx sensor 31 in order to establish whether the exhaust aftertreatment system is operating in a low-ANR regime or a high-ANR regime and provide feedback control of the reductant dosing in order to steer ANR to the desired interval of values (ANR 1.05-1.3, preferably 1.1-1.2). Since tailpipe sensor 31 is arranged downstream of the ASC 29, it is not subjected to ammonia slip, and therefore the signal from tailpipe sensor 31 essentially corresponds to the NOx curve as illustrated in line 431 of
[0074] The first manner in which this may be done is through a simple comparison of the signals of the feedback NOx sensor 31 and the tailpipe NOx sensor 33. It can be seen from
[0075]
[0076] A second manner in which the exhaust aftertreatment system may be controlled is by first establishing that the tailpipe NOx sensor 31 has a signal lower than a threshold value. The threshold value may for example be the detection limit of the sensor (e.g. line 451 in
[0077]
[0078] It is noted that during operation within the desired ANR interval, the feedback NOx sensor 33 is primarily measuring ammonia slip, and not NOx emission. Therefore, the feedback NOx sensor could in theory be replaced by an ammonium sensor. However, since ammonium sensors are expensive, less robust than NOx sensors, and have the same issues with regard to non-selectivity, it is preferred that a feedback NOx sensor is utilized.
[0079] During operation, the temperature of the exhaust aftertreatment system may fluctuate. The SCR catalyst is capable of storing an amount of ammonia, and this storage capacity is a function of temperature. During temperature transients, the amount of ammonia stored in the SCR catalyst may rapidly increase or decrease, leading to a transient deficit or peak of ammonia slip at the feedback NOx sensor 31. In order to account for such effects the signals from the NOx sensors, such as the signals from the feedback NOx sensor 33 and tailpipe NOx sensor 31, may be time-averaged. For example, the signals may be averaged over a period of from about 1 minute to about 20 minutes.