Exhaust gas after-treatment unit for an internal combustion engine and procedure for using a drive mechanism with such an exhaust gas after-treatment unit
10502107 ยท 2019-12-10
Assignee
Inventors
- Johannes Bleckmann (Stuttgart-Ost, DE)
- Claudia Essmann (Stuttgart, DE)
- Uwe Gaertner (Remshalden, DE)
- Alexander MASSNER (Esslingen, DE)
- Michael STILLER (Remseck, DE)
Cpc classification
B01D53/9418
PERFORMING OPERATIONS; TRANSPORTING
Y02A50/20
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
B01D2279/30
PERFORMING OPERATIONS; TRANSPORTING
B01D53/9495
PERFORMING OPERATIONS; TRANSPORTING
B01D2255/911
PERFORMING OPERATIONS; TRANSPORTING
F01N2900/1821
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D53/9431
PERFORMING OPERATIONS; TRANSPORTING
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2370/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2510/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/0093
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
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
F01N2610/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/0027
PERFORMING OPERATIONS; TRANSPORTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2370/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/208
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/009
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/03
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/00
PERFORMING OPERATIONS; TRANSPORTING
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An exhaust gas after-treatment unit for an internal combustion engine, particularly for a motor vehicle, includes a first selective catalytic reduction (SCR) catalytic converter through which the exhaust gas from the internal combustion engine can flow and at least one particle filter for retaining the soot particles from the exhaust gas. The particle filter, which is located downstream from the first SCR catalytic converter, is equipped with a heavy metal and precious metal free catalyzing coating which oxidizes the soot particles retained by the particle filter, where downstream from the particle filter there is a second SCR catalytic converter through which the exhaust gas can flow.
Claims
1. An exhaust gas after-treatment unit for an internal combustion engine, comprising: a first selective catalytic reduction (SCR) catalytic converter through which exhaust gas from the internal combustion engine is flowable, wherein the first SCR catalytic converter is a first exhaust gas after-treatment element downstream from the internal combustion engine through which the exhaust gas is flowable; a particle filter, wherein the particle filter is disposed downstream from the first SCR catalytic converter, wherein the exhaust gas is flowable through the particle filter, and wherein soot particles from the exhaust gas are retainable by the particle filter; and a second SCR catalytic converter through which the exhaust gas is flowable, wherein the second SCR catalytic converter is disposed downstream from the particle filter; wherein the particle filter has a heavy metal and precious metal free catalyzing coating, wherein soot particles retained by the particle filter are oxidizable by the heavy metal and precious metal free catalyzing coating, and wherein the particle filter is a second exhaust gas after-treatment element through which the exhaust gas is flowable after the exhaust gas has exited the internal combustion engine.
2. The exhaust gas after-treatment unit according to claim 1, wherein an oxidizing catalytic converter is not included in the exhaust gas after-treatment unit.
3. The exhaust gas after-treatment unit according to claim 1, wherein the heavy metal and precious metal free catalyzing coating has alkali and alkaline-earth compounds.
4. The exhaust gas after-treatment unit according to claim 1 further comprising a dosing unit disposed upstream from the first SCR catalytic converter, wherein a reduction agent for denoxing the exhaust gas is introducible to the exhaust gas by the dosing unit.
5. The exhaust gas after-treatment unit according to claim 4 further comprising a control and/or regulating system which, periodically and/or under given operating conditions, causes an injection or switching off of the reduction agent for a predefined time frame.
6. The exhaust gas after-treatment unit according to claim 1, wherein the first SCR catalytic converter has a smaller ammonia storage capacity than the second SCR catalytic converter.
7. The exhaust gas after-treatment unit according to claim 1, wherein the first SCR catalytic converter has a first volume through which the exhaust gas is flowable and the second SCR catalytic converter has a second volume through which the exhaust gas is flowable and wherein the first volume is smaller than the second volume.
8. The exhaust gas after-treatment unit according to claim 1 further comprising a dosing unit disposed upstream from the particle filter, wherein unconsummated hydrocarbons are introducible to the exhaust gas by the dosing unit.
9. The exhaust gas after-treatment unit according to claim 1 further comprising an ammonia slip catalyst through which the exhaust gas is flowable, wherein the ammonia slip catalyst is disposed downstream from the second SCR catalytic converter.
10. The exhaust gas after-treatment unit according to claim 9, wherein a volume of the first SCR catalytic converter has a ratio to a total volume which is comprised of a volume of the second SCR catalytic converter and a volume of the ammonia slip catalyst of approximately 0.3 to 0.8.
11. A drive mechanism for a motor vehicle, comprising: an internal combustion engine; and an exhaust gas after-treatment unit according to claim 1, wherein exhaust gas from the internal combustion engine is flowable through the exhaust gas after-treatment unit.
12. A method for operating the drive mechanism according to claim 11, wherein an exhaust gas temperature raise is effected by at least one internal measure relative to the internal combustion engine.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE DRAWINGS
(6) Identical or functionally identical elements are supplied with the same reference marks in the figures.
(7)
(8) The drive mechanism 10 further comprises an exhaust system 18 through which the exhaust gas from the cylinders 16 can flow. The exhaust system 18 is described as an exhaust tract and comprises a pipe 20 through which the exhaust gas can flow, which is described as an exhaust pipe. By means of the exhaust system 18, the internal combustion engine 12 exhaust gas is purged. The internal combustion engine 12 has a so-called outlet 24 here via which the exhaust gas from the internal combustion engine 12 flows out of and into the exhaust system 18. The outlet 24 is also described as an engine outlet or exhaust or engine exhaust and is located on an internal combustion engine 12 outlet side.
(9) The exhaust system 18 comprises an exhaust gas after-treatment unit which is referred to as a whole as 26, by means of which the internal combustion engine 12 exhaust gas is after-treated. The exhaust gas can flow through the exhaust system 18, wherein the flow of the exhaust gas through the exhaust system 18 in
(10) The exhaust system 18 comprises at least one first exhaust gas pipe 30 through which the exhaust gas can flow as well as an attached second exhaust gas pipe 32 through which the exhaust gas can flow, which includes an angle of approximately 45 degrees with the exhaust gas pipe 30. The exhaust gas pipes 30 and 32 are located downstream from the outlet 24 here, particularly downstream from the exhaust manifold 22.
(11) The exhaust gas after-treatment unit 26 comprises a first SCR catalytic converter 34 which is arranged as the first exhaust gas after-treatment element through which the exhaust gas passes after the outlet 24 and, therefore, after the exhaust gas has exited the internal combustion engine 12. This means that the first SCR catalytic converter 34 is the first exhaust gas after-treatment element through which the exhaust gas can flow downstream from the internal combustion engine 12, so that there is no exhaust gas after-treatment element through which the exhaust gas can flow and by means of which the exhaust gas can be after-treated between the first SCR catalytic converter 34 and the internal combustion engine 12, particularly the outlet 24.
(12) The exhaust gas after-treatment unit 26 further comprises a particle filter 36 which is located downstream from the first SCR catalytic converter 34 relative to the direction of exhaust gas flow through the exhaust system 18 and through the exhaust gas after-treatment unit 26. The exhaust gas can also flow through the particle filter 36 here, wherein the particle filter 36 is designed to retain soot particles from the exhaust gas. This means that the soot particles contained in the exhaust gas can be retained from the exhaust gas by means of the particle filter 36. After the exhaust gas has exited the internal combustion engine 12, there are soot particles contained within the exhaust gas which are at least partially filtered from the exhaust gas by means of the particle filter 36. The soot particles are caught in the particle filter 36, particularly in the inside, or distribute themselves on the particle filter 36, particularly on the inside, so that the particle filter 36 collects more soot particles as the operating period increases. This addition is also known as particle filter 36 loading. If the internal combustion engine 12 comprises a diesel engine, for example, the particle filter 36 is also described as a diesel particle filter (DPF).
(13) In order to realize an especially efficient operation in terms of emissions, the exhaust gas after-treatment unit 26 comprises a second SCR catalytic converter 38, through which the exhaust gas can flow, which is located downstream from the first SCR catalytic converter 34 and downstream from the particle filter 36. Furthermore, the particle filter 36 which is located downstream from the SCR catalytic converter 34 is furnished with a coating with silicates containing alkaline metals, which catalyzes the oxidation of the soot particles retained by the particle filter 36. The particle filter 36 coating catalyzes a soot oxidation, this means an oxidation of the soot particles which are retained by the particle filter 36 and are therefore found in the particle filter 36, particularly efficiently and effectively. Through this soot particle oxidation, the soot particles are removed from the particle filter 36 whereby the loading is at least reduced. This reduction in particle filter 36 loading is also known as regeneration or particle filter 36 regeneration.
(14) The relevant SCR catalytic converter 34 or 38 serves to denox the exhaust gas. Denoxing the exhaust gas is understood as the nitrogen oxide (NOx) contained within the exhaust gas being at least partially removed from the exhaust gas so that the nitrogen oxide is reduced. The relevant SCR catalytic converter 34 or 38 thereby catalyzes the so-called selective catalytic reduction (SCR), within the framework of which, the nitrogen oxide contained within the exhaust gas reacts with ammonia (NH3) to create water and nitrogen. The ammonia provided for the SCR is introduced into the exhaust gas via a reduction agent, for example. For this purpose, the exhaust gas after-treatment unit 26 comprises a dosing unit 40 upstream from the first SCR catalytic converter 34, by means of which a reduction agent for denoxing the exhaust gas can be introduced, particularly injected, into the exhaust gas. This means that the reduction agent is introduced to the exhaust gas at a specific place by means of the dosing unit 40, wherein this place is located upstream from the first SCR catalytic converter 34 relative to the direction of exhaust gas flow through the exhaust gas after-treatment unit 26. This place is also known as the supply location. A mixing unit 42 is provided downstream from the dosing unit 40 and downstream from the supply location and upstream from the first SCR catalytic converter 34, which causes and supports the mixing of the reduction agent which is introduced into the exhaust gas with the exhaust gas.
(15) The reduction agent is an aqueous urea solution (AUS) so that the NH3 which is generated from the reduction agent in the relevant SCR catalytic converter 34 or 38 can react with the nitrogen oxide contained within the exhaust gas to create water and nitrogen.
(16) It is further evident from
(17) Ultimately, there is an ammonia slip catalyst 44 located downstream from the SCR catalytic converter 38 which is also known as ASC and can also possess the function of an SCR catalytic converter so that the ammonia slip catalyst 44 is known as SCR/ASC for example.
(18) It has also proved itself to be especially beneficial if the first SCR catalytic converter 34 is smaller than the second SCR catalytic converter 38. This means that the first SCR catalytic converter 34 has a first volume through which the exhaust gas can flow and the second SCR catalytic converter 38 has a second volume through which the exhaust gas can flow, wherein the first volume is smaller than the second volume. The ASC (ammonia slip catalyst 44) also has a third volume through which the exhaust gas can flow, for example, wherein the third volume is preferably smaller than the first volume and smaller than the second volume. The ratio of the first volume to the sum of the second and third volumes lies within a range of 0.32 to 0.77, inclusive. The first volume's share of the total SCR volume then lies within a range of 20 percent to 50 percent, inclusive. The total SCR volume is understood as the sum of the volumes of the components which catalyze the SCR.
(19) By using the specified coating, two functions or active principles can be particularly used to regenerate the particle filter 36. On the one hand, a passive, NO2 based regeneration can be carried out, wherein this passive regeneration is able to be carried out with only small amounts of NO2 and with an especially high reaction rate because the reaction of the soot with the NO2 in the particle filter 36 is a solid-state reaction which is catalyzed by the coating. On the other hand, an active, O2 based regeneration, that means an O2 regeneration, can be carried out even at low temperatures. The active regeneration can, for example, be initiated in addition to passive regeneration if required. A first time period during which the passive regeneration takes place lies, for example, somewhere in the region between 5 minutes and 30 minutes, inclusive, wherein the passive regeneration is carried out, for example, cyclically during operation, for example at intervals of 10 minutes to 10 hours. A second time period during which the active regeneration takes place lies, for example, somewhere in the region between 15 minutes and 60 minutes, inclusive, and is carried out, for example, at intervals of more than 100 hours. The first time period is also known as the first regeneration period and the second time period is also known as the second regeneration period. Parameters which trigger or promote passive regeneration are named below: counter pressure>factor 1.5 compared to empty particle filter 36 (counter pressure trigger); favorable temperatures of more than 300 degrees Celsius and a minimum soot quantity of, for example, 2 grams per filter volume liter (temperature trigger); model-based NH3 storage quantities in the second SCR catalytic converter>80 percent (NH3 quantity trigger); and soot loading gradient>x grams per filter volume liter and seconds (g/L*s).
(20) Parameters which trigger or support active regeneration are named below: model-based soot loading quantities (soot quantity trigger); maximum duration without regeneration approx. 100 hours (time trigger); counter pressure>factor 2 compared to empty filter (counter pressure trigger); favorable temperatures>300 degrees Celsius and a minimum soot quantity of 5 grams per filter volume liter (temperature trigger); and model-based NH3 storage quantities in the second SCR catalytic converter>80 percent (NH3 quantity trigger).
(21) Parameters which interrupt or end a particle filter 36 regeneration are named below: Soot<1 gram per filter volume liter (w/l); Counter pressure>1.1 compared to empty filter; the SCR catalytic converter's 38 fill level is critical, meaning, for example, that the fill level is smaller than 50 percent compared to the optimum; and The NOx conversion reaches a critical threshold value which, for example, is used for on-board diagnoses (OBD).
(22) Using the particle filter 36 with the specified coating, a particularly beneficial exhaust gas denoxing can be realized even at low temperatures and particularly during real vehicle operation, so that nitrogen oxide emissions can be kept low even following an internal combustion engine 12 cold start. The particle filter 36 can also be carried out effectively at temperatures of less than 450 degrees Celsius by means of the active regeneration. Furthermore, it is possible to use a Vanadium SCR catalytic converter as the SCR catalytic converter 34 so that an exothermal to DPF regeneration can be produced using this. Furthermore, as is evident from
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(24) Furthermore, there is a further dosing unit which is not displayed in
(25) A line 58 on the diagram illustrates the HC doser status. A block 60 recorded in the line 58 illustrates a timespan during which the BC doser is activated, so that the unconsummated hydrocarbons (BC) can be introduced, particularly injected, into the exhaust gas by means of the activated BC doser during the timespan demonstrated by block 60. Furthermore, a line 62 on the diagram illustrates the internal combustion engine's 12 nitrogen oxide raw emission. Blocks 64, 66 and 68 recorded on the line 62 show nitrogen oxide reduction measures within the internal combustion engine. As the internal combustion engine 12 is also described as a combustion engine, the measures are also described as measures within the combustion engine or as CE measures. Blocks 64, 66 and 68 show the relevant timespan during which CE measures, that means measures within the internal combustion engine, are carried out to reduce nitrogen oxide. Such a CE measure concerns, for example, adjusting an injection point to later on. Furthermore, there can be an especially high exhaust gas recirculation rate for the CE measures. A further CE measure is, for example, to reduce the air-mass flow rate toward the relevant cylinder 16 which is, for example, reduced by throttling. This takes place, for example, by means of a throttle valve arranged on an intake channel through which the air can flow. A further CE measure can, for example, be that the internal combustion engine 12 is run or operated with higher loads.
(26) Block 70, which has been incorporated into the diagram illustrates an internal combustion engine 12 start, particularly a cold start. At least one CE measure, which is illustrated using block 64, is carried out during this cold start. Block 72, which has been incorporated into the diagram illustrates a heating phase, during which the dosing unit 40 is activated, as is evident on block 54. An optimal phase in terms of consumption, which is illustrated using a block 74, is attached to this. A block 76 illustrates a low load internal combustion engine 12 operation, wherein at least one CE measure, illustrated in block 66, is carried out. Furthermore, the dosing unit 40 is activated (block 56). An optimal phase in terms of consumption, which is illustrated using a block 78, is attached to this, during which, for example, the HC closer is activated (block 60). Furthermore, as illustrated by block 68, at least one CE measure is carried out. It is preferably designed so that, as is evident from
(27) A double arrow 80 in
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(29) A progression 92 illustrates the particle filter's 36 active regeneration, wherein a progression 94 shows an NO2 based regeneration for a conventional particle filter. It should be recognized that the active regeneration using the specified coating can be effectively carried out even at significantly lower temperatures, particularly at approx. 450 degrees Celsius. A difference A between progressions 92 and 94 is approx. 150 Kelvin. This means that conventional particle filters can only be actively regenerated at approx. 600 degrees Celsius. Because the particle filter 36 can be actively regenerated even at 450 degrees Celsius, thermal damage to the exhaust gas after-treatment unit 24 can be avoided.
(30) Although the passive regeneration is only carried out momentarily, or rather periodically or discontinuously, the particle filter 36 can be effectively regenerated by means of the passive regeneration because the particle filter 36 has the specified coating. A further advantage of using the coating is that the oxidation of NH3 can be avoided because the coating does not catalyze any gas-gas reactions. Because the exhaust gas does not flow through a DOC in which NH3 could oxidize, the dosing unit 40 can be located particularly close to the internal combustion engine outlet 40. Benefits include the higher temperature when the reduction agent is being introduced as well as a long reduction agent processing distance. Additionally, the exhaust gas does not cool excessively before reaching the first SCR due to its placement close to the engine, so that high NOx conversion can be achieved and, furthermore, a crystallization of the reduction agent can be omitted.
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LIST OF REFERENCE CHARACTERS
(33) 10 Drive mechanism 12 Internal combustion engine 14 Cylinder casing 16 Cylinder 18 Exhaust system 20 Pipe 22 Exhaust manifold 24 Outlet 26 Exhaust gas after-treatment unit 28 Directional arrow 30 Exhaust gas pipe 32 Exhaust gas pipe 34 First SCR catalytic converter 36 Particle filter 38 Second SCR catalytic converter 40 Dosing unit 42 Mixing equipment 44 Ammonia slip catalyst 46 Abscissa 48 Ordinate 50 Progression 52 Line 54 Block 56 Block 58 Line 60 Block 62 Line 64 Block 66 Block 68 Block 70 Block 72 Block 74 Block 76 Block 78 Block 80 Double arrow 82 Double arrow 83 Diagram 84 Abscissa 86 Ordinate 88 Progression 90 Progression 92 Progression 94 Progression 96 Exhaust gas box 98 Additional exhaust gas box close to the internal combustion engine Rsoot Regeneration rate Angle