Exhaust gas after-treatment unit for an internal combustion engine
10287939 ยท 2019-05-14
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
B01D2279/30
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
F01N3/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2892
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2510/0684
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
F01N3/103
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2510/0682
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/00
PERFORMING OPERATIONS; TRANSPORTING
F01N3/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An exhaust gas after-treatment unit includes a first catalytic converter, a particle filter arranged downstream of the first catalytic converter, and a second catalytic converter arranged downstream of the particle filter and which is a selective catalytic reduction (SCR) catalytic converter. The first catalytic converter is a combination catalytic converter including a first catalytic converter part which is an SCR catalytic converter, a second catalytic converter part arranged downstream of the first catalytic converter part which is an ammonia slip catalytic converter and has a noble metal layer with a first noble metal content, a third catalytic converter part arranged downstream of the second catalytic converter part which is an oxidation catalytic converter and has a noble metal layer with a second noble metal content, and an SCR layer arranged on the noble metal layers and extending over the entire length of the second and third catalytic converter parts.
Claims
1. An exhaust gas after-treatment unit for an internal combustion engine of a motor vehicle, comprising: a first catalytic converter through which exhaust gas from the internal combustion engine is flowable; a particle filter through which the exhaust gas is flowable and which is disposed downstream of the first catalytic converter, wherein soot particles from the exhaust gas are retainable by the particle filter; and a second catalytic converter through which the exhaust gas is flowable and which is disposed downstream of the particle filter and is configured as a selective catalytic reduction (SCR) catalytic converter; wherein the first catalytic converter is a combination catalytic converter and includes: a first catalytic converter part which is configured as an SCR catalytic converter; a second catalytic converter part which is disposed downstream of the first catalytic converter part, is configured as an ammonia slip catalytic converter, and has a first layer of noble metals with a first noble metal content; a third catalytic converter part which is disposed downstream of the second catalytic converter part, is configured as an oxidation catalytic converter, and has a second layer of noble metals with a second noble metal content; and an SCR layer which is disposed on the first and the second layers of noble metals and extends over an entire length of the second and the third catalytic converter parts.
2. The exhaust gas after-treatment unit according to claim 1, wherein the first and the second layers of noble metals are formed from platinum or mixtures of platinum and palladium and wherein the second noble metal content is higher than the first noble metal content.
3. The exhaust gas after-treatment unit according to claim 2, wherein the second layer of noble metals of the third catalytic converter part has a platinum content of at least 50 percent in a mixture of platinum and palladium.
4. The exhaust gas after-treatment unit according to claim 1, wherein the first noble metal content is in a range from approximately 1/28316.8 grams per cubic centimeter to approximately 5/28316.8 grams per cubic centimeter, inclusive.
5. The exhaust gas after-treatment unit according to claim 1, wherein the second noble metal content is in a range from approximately 5/28316.8 grams per cubic centimeter to approximately 20/28316.8 grams per cubic centimeter, inclusive.
6. The exhaust gas after-treatment unit according to claim 1, wherein the particle filter includes a catalyzing coating that is free of heavy metals and precious metals and that oxidizes the soot particles retained by the particle filter.
7. The exhaust gas after-treatment unit according to claim 6, wherein the catalyzing coating contains alkaline and alkaline-earth compounds.
8. The exhaust gas after-treatment unit according to claim 1 further comprising a first metering device via which a first reduction agent is introducible into the exhaust gas in a first location upstream of the first catalytic converter.
9. The exhaust gas after-treatment unit according to claim 8 further comprising a second metering device via which a second reduction agent is introducible into the exhaust gas in a second location downstream of the first catalytic converter and upstream of the second catalytic converter.
10. The exhaust gas after-treatment unit according to claim 1, wherein the first catalytic converter part of the first catalytic converter is a first exhaust gas after-treatment element through which the exhaust gas is flowable downstream of the internal combustion engine.
11. The exhaust gas after-treatment unit according to claim 1, wherein the second catalytic converter part and the third catalytic converter part form a hybrid catalytic converter, wherein a volume of the second catalytic converter part through which the exhaust gas is flowable is approximately twice as large as a volume of the third catalytic converter part.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
DETAILED DESCRIPTION OF THE DRAWINGS
(5) Identical or functionally identical elements are provided with the same reference signs in the figures.
(6)
(7) The drive mechanism 10 further comprises an exhaust system 20, which is identified as an exhaust channel. The exhaust gas from the cylinders 16 can flow through the exhaust system 20. The exhaust gas from internal combustion engine 12 is purged by means of the exhaust system 20. The internal combustion engine 12 has a so-called outlet 22, via which the exhaust gas from the internal combustion engine 12 flows out of and into the exhaust system 20. The outlet 22 is also described as an engine outlet or exhaust or an engine exhaust and is located on an outlet side of the internal combustion engine 12.
(8) The exhaust system 20 comprises an exhaust gas after-treatment unit, which as a whole is designated 24 and is shown according to a first embodiment in
(9) The exhaust gas after-treatment unit 24 comprises at least one first catalytic converter 32, through which the exhaust gas from the internal combustion engine 12 can flow and which is configured as a combination catalytic converter, with at least one particle filter 30, through which the exhaust gas flows and which is arranged downstream of the first catalytic converter 32, for retaining soot particles from the exhaust gas, and comprises a second catalytic converter 28, through which the exhaust gas can flow and which is located downstream of the particle filter 30 and is configured as an SCR catalytic converter. The combination catalytic converter 32 is the first exhaust gas after-treatment element through which the exhaust gas passes downstream of the outlet 22 and is therefore after the exhaust gas has exited the internal combustion engine 12. This means that the first combination catalytic converter 32 is the first exhaust gas after-treatment element through which the exhaust gas can flow downstream of the internal combustion engine 12, and so 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 combination catalytic converter 32 and the internal combustion engine 12, in particular the outlet 22.
(10) The drive mechanism 10 further comprises an exhaust gas turbocharger, also called a turbocharger, which is not shown in its entirety in
(11) Furthermore, the exhaust gas turbocharger comprises a turbine 34, which is arranged in the exhaust system 20, and the exhaust gas flowing through the exhaust system 20 can accordingly flow through the turbine. Relative to the direction of exhaust gas flow through the exhaust system 20, the turbine 34 is downstream of the combination catalytic converter 32. The turbine 34 comprises, for example, a turbine housing 36 and a turbine wheel 38, which is arranged in the turbine housing 36 and which can be driven by the exhaust gas flowing through the turbine 34 and which can be rotated about a rotary axis relative to the turbine housing 36. The compressor comprises a compressor wheel, for example, by means of which the air flowing through the intake channel can be compressed. The compressor wheel can be arranged, for example, coaxially to the turbine wheel 38 and can thus rotated about the aforementioned rotary axis. The exhaust gas turbocharger further comprises a shaft, not shown in
(12) The retaining of soot particles from the exhaust gas by the particle filter 30 should be understood to mean that the soot particles in the exhaust gas which are held back by the particle filter 30 can be filtered out of the exhaust gas and thereby retained. 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 out of the exhaust gas by means of the particle filter 30. The soot particles are caught in the particle filter 30, particularly in its interior, or are distributed over the particle filter 30, particularly in its interior, so that the particle filter 30 collects more soot particles as its operational life increases. This accumulation is also known as the loading or load of the particle filter 30. If the internal combustion engine 12 is configured as a diesel engine, for example, the particle filter 30 is also described as a diesel particle filter (DPF).
(13) In order to implement operations with particularly favorable emissions, the combination catalytic converter 32as can be seen especially well in conjunction with
(14) This first SCR catalytic converter is configured as a vanadium-based SCR catalytic converter, wherein vanadium is also denominated with Va. Therefore and because an SCR catalytic converter is generally simply also called an SCR, the first catalytic converter part 40 in
(15) The combination catalytic converter 32 additionally comprises a second catalytic converter part 42, which is downstream of the first catalytic converter part 40in the flow direction of the exhaust gas through the combination catalytic converter 32and which is configured as an ammonia slip catalytic converter (ASC) and has a noble metal layer 44, which is formed exclusively of platinum and has a first platinum content. The layer of noble metal 44 in the second catalytic converter part 42 can also be formed with a noble metal mixture of platinum and palladium, wherein the platinum content of the platinum-palladium mixture is at least 80 percent. The combination catalytic converter 32 additionally comprises a third catalytic converter part 46, which is downstream of the second catalytic converter part 42in the flow direction of the exhaust gas through the combination catalytic converter 32and which is configured as an oxidation catalytic converter and has a noble metal layer 48, which is likewise formed exclusively of platinum and has a second platinum content. The layer of noble metal 48 in the third catalytic converter part 42 can also be formed with a noble metal mixture of platinum and palladium rather than with pure platinum, wherein the platinum content of the platinum-palladium mixture is at least 50 percent. Since the present internal combustion engine 12 is configured as a diesel engine, for example, the oxidation catalytic converter is also referred to as a diesel oxidation catalytic converter (DOC). Moreover, the combination catalytic converter 32 comprises an SCR layer 50, which is disposed on the respective platinum layers 44 and 48 and comprises copper (Cu) and zeolite (Z) and is thus also called the CuZ layer.
(16) The respective platinum layers 44 and 48 are layers containing platinum (Pt). In the combination catalytic converter 32 shown in
(17) It can be discerned from
(18) The partial length t and total length L add up to the length of the combination catalytic converter 32. For instance, it is provided that the partial length t is in a range from 50 percent to 90 percent, inclusive, of the length G, wherein the total length L lies in a range, for example, from 10 percent to 50 percent, inclusive, of the length C.
(19) The SCR layer disposed on the platinum layers 44 and 48 is identified with reference sign 50 and is configured as a copper-zeolite layer (CuZ layer), for example. The SCR layer 50 should be understood such that the SCR layer 50 has an SCR effect. This means that the SCR layer 50 catalyzes, i.e., brings about and/or supports, a selective catalytic reduction (SCR), within the scope of which the nitrogen oxides contained in the exhaust gas are converted into nitrogen and water.
(20) It can be discerned from
(21) In particular, it is possible that partial length l1 lies in a range from 0 percent to 80 percent, inclusive, of the total length L. Furthermore, it is possible that partial length l2 lies in a range from 20 percent to 100 percent, inclusive, of the total length L.
(22) The drive mechanism 10, in particular the exhaust gas after treatment unit 24, comprises a first metering device 54, by means of which a reduction agent can be introduced into the exhaust gas in at least one first location S1 upstream of the combination catalytic converter 32 in order to denitrify the exhaust gas. The reduction agent is an aqueous urea solution, for instance, from which ammonia is produced, which can react with the nitrogen oxides in the exhaust gas within the scope of the aforementioned SCR to yield water and nitrogen.
(23) Additionally, a second metering device 56 is provided, by means of which a reduction agent can be introduced into the exhaust gas in at least one second location S2 downstream of the combination catalytic converter 32 and upstream of the SCR catalytic converter 28 in order to denitrify the exhaust gas. As a result of the conversion of nitrogen oxides in the exhaust gas into water and nitrogen, as was described earlier, at least a part of the nitrogen oxide is removed from the exhaust gas. This removal of the nitrogen oxides is also referred to as the denitrification of the exhaust gas, whichas describedoccurs with the aid of the reduction agent. In the first embodiment shown in
(24) Downstream of the second location 82 and of the second metering device 56 and upstream of the SCR catalytic converter 28 is a mixing device 58, by means of which the metered reduction agent is mixed and/or blended with the exhaust gas. In the first embodiment, the mixing device 58 is arranged upstream of the particle filter 30. Furthermore, the exhaust gas after-treatment unit 24 comprises a catalytic converter 60 that is arranged downstream of the SCR catalytic converter 28 and is configured as an SCR catalytic converter and/or ammonia slip catalytic converter.
(25) In order to make it possible to operate with partially favorable emissions, the particle filter 30 is provided with a catalyzing coating on the basis of alkaline metal-silicate structures, which is free of heavy metals and precious metals and which oxidizes the soot particles retained by the particle filter 30, and so the coating is a coating with alkaline metal-containing silicates. This coating performs a particularly efficient and effective catalysis of a soot oxidation, i.e., the oxidation of the soot particles that are retained by the particle filter 30 and are therefore found in the particle filter 30. As a result of this soot particle oxidation, the soot particles are removed from the particle filter 30, whereby the loading is at least reduced. This reduction in the loading of the particle filter 30 is also known as regeneration or particle filter 30 regeneration.
(26)
(27) An HC doser, not shown in the Figures, can additionally be provided and used to introduce uncombusted hydrocarbons into the exhaust has at a metering location D. It can be discerned from
(28) The catalytic converter volumes of the combination catalytic converter 32 as well as the volumes of the catalytic converter parts 40, 42 and 46 and those of the catalytic converters 28 and 60 are determined by the swept volume of the internal combustion engine 12. The first catalytic converter part 40 in
(29) Hereafter, a start condition for the passive, NO2-based regeneration of the particle filter 30, for example, will be illustrated: For instance, if the SCR catalytic converter 28 has a sufficient temperature, e.g., in a range from 200 to 250 degrees Celsius, then the first metering device 54 is deactivated so that NO2 formed within the engine is not converted at the first SCR, and NO2 is additionally formed via the hybrid catalytic converter 52. Hereafter, stop conditions for passive regeneration will be illustrated: For example, if the temperature of the SCR catalytic converter 28 falls below a prescribable threshold value, e.g., in a range from 180 to 220 degrees Celsius, then the first metering device 54 is activated so that a nitrogen oxide conversion occurs at lower exhaust temperatures by means of the first catalytic converter part 40, which functions as an SCR catalytic converter. Alternatively or additionally, the stop condition includes the stipulation that the space velocity of the SCR catalytic converter 28 must exceed a prescribable threshold value, e.g., in a range from 40,000 to 60,000, and/or that a storage rate must exceed a threshold value and/or that the nitrogen oxide content must exceed a prescribable threshold value.
(30) The duration of the active regeneration falls in a range, for example, of between 15 minutes and 60 minutes, inclusive, and is carried out, for example, at intervals of more than 100 hours. The proportion of the first catalytic converter part 40 in the entire SCR volume of the exhaust gas after-treatment unit 24 lies within a range of 20 percent to 50 percent, inclusive, for example. Parameters which trigger passive NO2-based regeneration are described below: For instance, the state of the first metering device 54 is the value that triggers passive regeneration.
(31) Parameters which trigger active O2-based regeneration are described below:
(32) model-based soot loading limit (soot quantity trigger);
(33) maximum duration without regeneration approx. 100 hours (time trigger);
(34) counter-pressure>factor 2 compared to empty filter (counter-pressure trigger); and
(35) favorable temperatures>300 degrees Celsius+minimum soot quantity (5 grams per liter) (temperature trigger).
(36) Parameters which interrupt or end a regeneration are explained below:
(37) soot quantity<1 gram per liter; and
(38) counter-pressure<1.1 compared to empty filter.
(39)
(40) A line 74 illustrates a status of the second metering device 56, wherein the second metering device 56 is activated at blocks 76 and 78, which are included in line 74. Therefore, blocks 76 and 78 illustrate the respective timespans during which the reduction agent is introduced, particularly injected, into the exhaust gas by the activated second metering device 56. A line 80 illustrates the status of the HC doser or an activation of engine-internal measures to increase the exhaust gas temperature. A block 82 included in line 80 illustrates a timespan during which the HC doser is activated, and so the uncombusted hydrocarbons (HC) can be introduced, especially injected, into the exhaust gas by the activated HC doser at metering location D during the timespan illustrated by block 82. Furthermore, a line 84 on the diagram illustrates the raw nitrogen oxide emissions of the internal combustion engine 12. Blocks 86, 88 and 90, which are included in line 84, 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 taken within the internal combustion engine are also described as combustion engine-internal measures or as CE measures.
(41) Blocks 86, 88 and 90 show the respective timespans during which combustion engine measures, i.e., measures within the internal combustion engine, are carried out to reduce nitrogen oxide, i.e., for denitrification. Adjusting an injection time to a later point is an example of a CE measure such as this. Furthermore, the internal combustion engine measure can be an especially high exhaust gas recirculation rate. A further CE measure is, for example, to reduce the air mass flow rate to the relevant cylinder 16, such as 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 internal combustion engine measure can be, for example, that the internal combustion engine is run or operated with higher loads.
(42) A block 92, which has been incorporated into the diagram, illustrates the start, particularly a cold start, of an internal combustion engine 12. At least one internal combustion engine measure, which is illustrated using block 86, is carried out during this cold start. A block 94, which has been incorporated into the diagram, illustrates a heating phase, during which the metering device 54 is activatedas is evident at block 70. This is followed by an optimal consumption phase, which is illustrated by a block 96. A block 98 illustrates a low load operation of the internal combustion engine 12, wherein at least one internal combustion engine measure, illustrated by block 88, is carried out.
(43) Furthermore, the metering device 54 is activated (block 72), or engine-internal measures are triggered. An optimal consumption phase follows, which is illustrated by a block 100, during which the HC doser is activated, for example (block 82). Furthermoreas is illustrated by block 90at least one internal combustion engine measure is carried out. It is preferable for the HC doser to be activated only when the first metering device 54 is deactivated, meaning when the introduction of reduction agent to the exhaust gas by the metering device 54 has stopped. If the respective metering device 54 or 56 is deactivated, then the introduction of reduction agent into the exhaust gas by the respective metering device 54 or 56 has stopped. If the HC doser is activated, then uncombusted hydrocarbons (HC) are introduced into the exhaust gas by the HC closer. If the HC doser is deactivated, the introduction of HC into the exhaust gas by the HC closer has stopped.
(44) Furthermore, a double arrow 102 in