Exhaust purification system for internal combustion engine
09719394 ยท 2017-08-01
Assignee
Inventors
- Kazuhiro Umemoto (Ebina, JP)
- Toshihiro Mori (Gotenba, JP)
- Hiroshi Kobayashi (Susono, JP)
- Shigeki Nakayama (Gotenba, JP)
Cpc classification
F01N13/0097
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2560/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2430/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/108
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2570/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/0842
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2570/18
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
F01N2570/145
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2900/1602
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/008
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/40
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
Y02C20/10
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
F01N2900/1621
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/009
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/03
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2073
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N9/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N3/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N9/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
In an engine exhaust passage, in order from an exhaust upstream side, an NO.sub.x storage and reduction catalyst, NO oxidation catalyst, NO.sub.2 reduction catalyst, and selective reduction catalyst may be arranged. An air-fuel ratio of an exhaust gas which flows into the NO.sub.x storage and reduction catalyst may be temporarily switched to a rich air-fuel ratio which may be adapted for generating ammonia from NO.sub.x which may be stored in the NO.sub.x storage and reduction catalyst. The ammonia, which may be generated by the NO.sub.x storage and reduction catalyst, may be held at the selective reduction catalyst. The NO.sub.x which flows into the selective reduction catalyst may be reduced by the ammonia. The NO oxidation catalyst and NO.sub.2 reduction catalyst may be used to make an NO ratio of the exhaust gas which flows into the selective reduction catalyst approach an optimum ratio of the selective reduction catalyst.
Claims
1. An exhaust purification system for an internal combustion engine where combustion is performed under an excess of air, the exhaust purification system comprising: an NO.sub.x storage and reduction catalyst which is arranged in an engine exhaust passage, the NO.sub.x storage and reduction catalyst being configured to: store NO.sub.x when an air-fuel ratio of exhaust gas which flows into said NO.sub.x storage and reduction catalyst is lean, and release stored NO.sub.x and reduce the released NO.sub.x to N.sub.2 or ammonia when the air-fuel ratio of the exhaust gas which flows into said NO.sub.x storage and reduction catalyst becomes rich; an NO oxidation catalyst which is arranged downstream of said NO.sub.x storage and reduction catalyst in the engine exhaust passage, the NO oxidation catalyst being configured to oxidize part of NO in the exhaust gas which flows into said NO oxidation catalyst to NO.sub.2; an NO.sub.2 reduction catalyst which is arranged downstream of said NO oxidation catalyst in the engine exhaust passage, the NO.sub.2 reduction catalyst being configured to reduce part of the NO.sub.2 in the exhaust gas which flows into said NO.sub.2 reduction catalyst to NO under an oxidizing atmosphere; a selective reduction catalyst which is arranged downstream of said NO.sub.2 reduction catalyst in the engine exhaust passage, the selective reduction catalyst being configured to: hold ammonia in the exhaust gas which flows into said selective reduction catalyst, and selectively reduce NO.sub.x in the exhaust gas which flows into said selective reduction catalyst by said ammonia under an oxidizing atmosphere; and a controller which is configured to temporarily switch the air-fuel ratio of the exhaust gas which flows into said NO.sub.x storage and reduction catalyst to a rich air-fuel ratio which is adapted for producing ammonia from NO.sub.x which is stored in said NO.sub.x storage and reduction catalyst, wherein the ammonia which is produced by said NO.sub.x storage and reduction catalyst is held by said selective reduction catalyst, and the NO.sub.x in the exhaust gas which flows into said selective reduction catalyst is reduced by said ammonia after the air-fuel ratio of the exhaust gas which flows into said NO.sub.x storage and reduction catalyst is returned to lean.
2. The exhaust purification system for an internal combustion engine according to claim 1, wherein an NO oxidizing ability of said NO oxidation catalyst and an NO.sub.2 reducing ability of said NO.sub.2 reduction catalyst are respectively set so that an NO ratio difference of exhaust gas which flows into said selective reduction catalyst is equal to or smaller than an NO ratio difference of exhaust gas which flows into said NO oxidation catalyst, the NO ratio difference of exhaust gas which flows into said selective reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said selective reduction catalyst to an optimum ratio of said selective reduction catalyst, and the NO ratio difference of exhaust gas which flows into said NO oxidation catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said NO oxidation catalyst to said optimum ratio.
3. The exhaust purification system for an internal combustion engine according to claim 1, wherein an NO.sub.2 reducing ability of said NO.sub.2 reduction catalyst is set so that an NO ratio difference of exhaust gas which flows into said selective reduction catalyst is equal to or smaller than an NO ratio difference of exhaust gas which flows into said NO.sub.2 reduction catalyst, the NO ratio difference of exhaust gas which flows into said selective reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said selective reduction catalyst to an optimum ratio of said selective reduction catalyst, and the NO ratio difference of exhaust gas which flows into said NO.sub.2 reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said NO.sub.2 reduction catalyst to said optimum ratio.
4. The exhaust purification system for an internal combustion engine according to claim 1, wherein said controller is configured to temporarily switch the air-fuel ratio of exhaust gas which flows into said NO.sub.x storage and reduction catalyst to the rich air-fuel ratio which is adapted for producing ammonia from the NO.sub.x which is stored in said NO.sub.x storage and reduction catalyst when a temperature of said NO.sub.x storage and reduction catalyst exceeds a predetermined set temperature, whereby the NO.sub.x in the exhaust gas which flows into said selective reduction catalyst is reduced by said ammonia when the temperature of said NO.sub.x storage and reduction catalyst is higher than said set temperature.
5. The exhaust purification system for an internal combustion engine according to claim 4, wherein an NO oxidizing ability of said NO oxidation catalyst and an NO.sub.2 reducing ability of said NO.sub.2 reduction catalyst are respectively set so that an NO ratio difference of exhaust gas which flows into said selective reduction catalyst is equal to or smaller than an NO ratio difference of exhaust gas which flows into said NO oxidation catalyst when the temperature of said NO.sub.x storage and reduction catalyst is higher than said set temperature, the NO ratio difference of exhaust gas which flows into said selective reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said selective reduction catalyst to an optimum ratio of said selective reduction catalyst, and the NO ratio difference of exhaust gas which flows into said NO oxidation catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said NO oxidation catalyst to said optimum ratio.
6. The exhaust purification system for an internal combustion engine according to claim 4, wherein an NO.sub.2 reducing ability of said NO.sub.2 reduction catalyst is set so that an NO ratio difference of exhaust gas which flows into said selective reduction catalyst is equal to or smaller than an NO ratio difference of exhaust gas which flows into said NO.sub.2 reduction catalyst when the temperature of said NO.sub.x storage and reduction catalyst is higher than said set temperature, the NO ratio difference of exhaust gas which flows into said selective reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said selective reduction catalyst to an optimum ratio of said selective reduction catalyst, and the NO ratio difference of exhaust gas which flows into said NO.sub.2 reduction catalyst being an absolute value of a difference of NO ratio of exhaust gas which flows into said NO.sub.2 reduction catalyst to said optimum ratio.
7. The exhaust purification system for an internal combustion engine according to claim 4, wherein said controller is configured to maintain the air-fuel ratio of exhaust gas which flows into said NO.sub.x storage and reduction catalyst lean after temporarily switching the air-fuel ratio of exhaust gas which flows into said NO.sub.x storage and reduction catalyst to the rich air-fuel ratio which is adapted for generating ammonia from the NO.sub.x which is stored in said NO.sub.x storage and reduction catalyst until the temperature of said NO.sub.x storage and reduction catalyst becomes lower than said set temperature.
8. The exhaust purification system for an internal combustion engine according to claim 4, wherein said controller is configured to temporarily switch the air-fuel ratio of the exhaust gas which flows into said NO.sub.x storage and reduction catalyst to a rich air-fuel ratio which is adapted for reducing the NO.sub.x which is stored in said NO.sub.x storage and reduction catalyst to N.sub.2 when the temperature of said NO.sub.x storage and reduction catalyst is lower than said set temperature.
9. The exhaust purification system for an internal combustion engine according to claim 4, wherein said NO.sub.x storage and reduction catalyst is configured to have an NO.sub.x purification rate rises, reaches a peak value, and then falls, along with the temperature of said NO.sub.x storage and reduction catalyst becoming higher when the air-fuel ratio of exhaust gas which flows into said NO.sub.x storage and reduction catalyst is temporarily switched to the rich air-fuel ratio which is adapted for reducing the NO.sub.x which is stored in said NO.sub.x storage and reduction catalyst to N.sub.2, and wherein said set temperature is set to a temperature higher than the temperature at which the NO.sub.x purification rate of said NO.sub.x storage and reduction catalyst reaches said peak value.
10. The exhaust purification system for an internal combustion engine according to claim 1, wherein an NO.sub.2 reducing ability of said NO.sub.2 reduction catalyst is set so that an NO.sub.2 reduction rate of said NO.sub.2 reduction catalyst is higher than a predetermined set NO.sub.2 reduction rate in a temperature range where an NO ratio of the exhaust gas which flows into said NO.sub.2 reduction catalyst is lower than a predetermined threshold NO rate.
11. The exhaust purification system for an internal combustion engine according to claim 1, wherein said NO.sub.2 reduction catalyst contains potassium or lithium.
12. The exhaust purification system for an internal combustion engine according to claim 1, wherein said NO oxidation catalyst and said NO.sub.2 reduction catalyst are carried on a common substrate.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1)
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(11)
(12)
(13)
(14)
DESCRIPTION OF EMBODIMENTS
(15)
(16) Referring to
(17) Each fuel injector 3 is connected through a fuel feed tube 13 to a common rail 14. This common rail 14 is connected through an electrical control type of variable discharge fuel pump 15 to a fuel tank 16. The fuel inside the fuel tank 16 is fed by the fuel pump 15 to a common rail 14. The fuel which is fed to an inside of the common rail 14 is fed through each fuel feed tube 13 to the fuel injector 3. Note that, the common rail 14 has a fuel pressure sensor (not shown) which detects a fuel pressure inside the common rail 14 attached to it. An amount of fuel discharge of the fuel pump 15 is controlled based on a signal from the fuel pressure sensor so that the fuel pressure inside the common rail 14 matches a target pressure.
(18) The exhaust manifold 5 and the intake manifold 4 are connected with each other through an exhaust gas recirculation (below, referred to as EGR) passage 17. Inside the EGR passage 17, an electrical control type EGR control valve 18 is arranged. Further, around the EGR passage 17, a cooling device 19 is arranged for cooling an EGR gas which flows through an inside of the EGR passage 17.
(19) The exhaust post-treatment device 20 comprises an exhaust pipe 21 which is connected to the outlet of the exhaust turbine 7t. This exhaust pipe 21 is connected to an inlet of an NO.sub.x storage and reduction catalyst 22a. An outlet of the NO.sub.x storage and reduction catalyst 22a is connected through an exhaust pipe 21a to an inlet of an NO oxidation catalyst 22b. An outlet of the NO oxidation catalyst 22b is connected through an exhaust pipe 21b to an inlet of an NO.sub.2 reduction catalyst 22c. An outlet of the NO.sub.2 reduction catalyst 22c is connected through an exhaust pipe 21c to a selective reduction catalyst 22d. An outlet of the selective reduction catalyst 22d is connected to an exhaust pipe 21d.
(20) Controller 30 (e.g., an electronic control unit (ECU)) is comprised of a digital computer provided with components which are connected with each other by a bidirectional bus 31 such as a ROM (read only memory) 32, a RAM (random access memory) 33, a CPU (microprocessor) 34, an input port 35, and an output port 36. Controller 30 may be programmed to perform disclosed functions. At the exhaust pipe 21a, a temperature sensor 23 for detecting a temperature of an exhaust gas which flows out from the NO.sub.x storage and reduction catalyst 22a is attached. The temperature of the exhaust gas which flows out from the NO.sub.x storage and reduction catalyst 22a expresses a temperature of the NO.sub.x storage and reduction catalyst 22a. Output voltages of the air flow meter 9 and temperature sensor 23 are input through respectively corresponding AD converters 37 to the input port 35. Further, at an accelerator pedal 39, a load sensor 40 is connected which generates an output voltage which is proportional to an amount of depression of the accelerator pedal 39. An output voltage of the load sensor 40 is input through a corresponding AD converter 37 to the input port 35. Further, a crank angle sensor 41 which generates an output pulse each time a crankshaft rotates for example 30 degrees is connected to the input port 35. In the CPU 34, the output pulses from the crank angle sensor 41 are used as the basis to calculate the engine speed. Furthermore, an output pulse which expresses turning on or off of an ignition switch 42 is connected to the input port 35. The ignition switch 42 is operated by a vehicle operator. On the other hand, the output port 36 is connected through corresponding drive circuits 38 to the fuel injectors 3, drive device of the throttle valve 11, fuel pump 15, and EGR control valve 18.
(21) The NO.sub.x storage and reduction catalyst 22a forms a honeycomb structure and is provided with a plurality of exhaust flow passages which are separated from each other by thin substrates. The substrates of the NO.sub.x storage and reduction catalyst 22a carry catalyst carriers 55 comprised of, for example, alumina.
(22) In this embodiment according to the present disclosure, as the precious metal catalyst 56, at least one element selected from platinum Pt, rhodium Rh, and palladium Pd is used. As the ingredient which forms the basicity layer 57, for example, at least one selected from potassium K, sodium Na, and cesium Cs or other such alkali metals, barium Ba and calcium Ca and other such alkali earths, lanthanoids and other rare earths, and silver Ag, copper Cu, iron Fe, and iridium Ir and other such metals which can donate electrons to NO.sub.x is used.
(23) If referring to a ratio of an air and fuel which are supplied to an intake passage, combustion chamber 2, and exhaust passage upstream from a certain position in the exhaust passage as an air-fuel ratio of the exhaust gas at that position and using the term storage as a term including both absorption and adsorption, the basicity layer 57 performs an NO.sub.x storage and release action in which it stores NO.sub.x when the air-fuel ratio of an inflowing exhaust gas is lean and releases the stored NO.sub.x when a concentration of oxygen in the inflowing exhaust gas falls.
(24) That is, explaining this taking as an example a case of using platinum Pt as the precious metal catalyst 56 and of using barium Ba as the ingredient forming the basicity layer 57, when the air-fuel ratio of the inflowing exhaust gas is lean, that is, when the concentration of oxygen of the inflowing exhaust gas is high, NO which is contained in the inflowing exhaust gas, as shown in
(25) On the other hand, when NO.sub.x is absorbed in the basicity layer 57 in the form of nitrates, if the air-fuel ratio of the inflowing exhaust gas becomes rich, the concentration of oxygen of the inflowing exhaust gas falls, so the reaction proceeds in the opposite direction (NO.sub.3.sup..fwdarw.NO.sub.2) and therefore, as shown in
(26) In this case, the NO.sub.x which is released from the basicity layer 57 is reduced to nitrogen N.sub.2 or ammonia NH.sub.3 in accordance with a rich degree of the air-fuel ratio of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a.
(27) That is, if the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is made a rich air-fuel ratio AFRN with a relatively small rich degree, the NH.sub.3 generation rate RGAMN becomes lower and, therefore, almost all of the NO.sub.x which is released from the basicity layer 57 is reduced to N.sub.2. Therefore, the rich air-fuel ratio AFRN can be said to be a rich air-fuel ratio which is adapted for reducing the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a to N.sub.2. This rich air-fuel ratio AFRN is for example 13.0 or so. As opposed to this, if the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is made a rich air-fuel ratio AFRA with a relatively large rich degree, the NH.sub.3 generation rate RGAMN becomes higher and, therefore, almost all of the NO.sub.x which is released from the basicity layer 57 is reduced to NH.sub.3. Therefore, the rich air-fuel ratio AFRA can be said to be a rich air-fuel ratio AFRA which is adapted for generating ammonia from the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. This rich air-fuel ratio AFRA is for example 12.0 or so. In this way, the NO.sub.x storage and reduction catalyst 22a is configured to store NO.sub.x when the air-fuel ratio of the inflowing exhaust gas is lean and to release the stored NO.sub.x and to reduce the released NO.sub.x to N.sub.2 or ammonia when the air-fuel ratio of the inflowing exhaust gas becomes rich.
(28) On the other hand, the NO oxidation catalyst 22b is configured to oxidize part of an NO in the exhaust gas which flows into the NO oxidation catalyst 22b to NO.sub.2. The NO oxidation catalyst 22b also forms a honeycomb structure and is provided with exhaust flow passages which are separated from each other by thin substrates. The substrates of the NO oxidation catalyst 22b carry catalyst carriers comprised of, for example, alumina. On the catalyst carrier, a precious metal catalyst which is comprised of at least one element selected from platinum Pt, rhodium Rh, and palladium Pd is carried. Note that the NO oxidation catalyst 22b is not provided with almost any NO.sub.2 reducing ability.
(29) Further, the NO.sub.2 reduction catalyst 22c is configured to reduce part of the NO.sub.2 in the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c to NO under an oxidizing atmosphere. The NO.sub.2 reduction catalyst 22c also forms a honeycomb structure and is provided with a plurality of exhaust flow passages which are separated from each other by thin substrates. The substrates of the NO.sub.2 reduction catalyst 22c carry catalyst carriers comprised of, for example, alumina, and the catalyst carriers carry a basic catalyst which is comprised of at least one element selected from potassium K and lithium Li. Note that the NO.sub.2 reduction catalyst 22c is not provided with almost any NO oxidizing ability at all.
(30) The selective reduction catalyst 22d is configured to hold an ammonia NH.sub.3 in the exhaust gas which flows into the selective reduction catalyst 22d and selectively reduce an NO.sub.x in the exhaust gas which flows into the selective reduction catalyst 22d by the ammonia NH.sub.3 under an oxidizing atmosphere. In this case, it is believed that the ammonia is held at the selective reduction catalyst 22d by adsorption. The selective reduction catalyst 22d also forms a honeycomb structure and is provided with a plurality of exhaust flow passages which are separated from each other by thin substrates. The substrates of the selective reduction catalyst 22d carry catalyst carriers which are comprised of, for example, titania TiO.sub.2, and the catalyst carriers carry vanadium oxide V.sub.2O.sub.5. Alternatively, the substrates of the selective reduction catalyst 22d carry a catalyst carriers which are comprised of, for example, zeolite, and the catalyst carriers carry copper Cu.
(31) Now, in this embodiment according to the present disclosure, usually combustion is performed under an excess of air. In this case, the air-fuel ratio of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is lean, so at this time, an NO.sub.x in the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is stored in the NO.sub.x storage and reduction catalyst 22a. However, if the engine operation continues, an NO.sub.x storage amount of the NO.sub.x storage and reduction catalyst 22a becomes greater. Finally, the NO.sub.x storage and reduction catalyst 22a ends up no longer able to store NO.sub.x. Therefore, in this embodiment according to the present disclosure, before the NO.sub.x storage and reduction a catalyst 22a is saturated by the NO.sub.x, the air-fuel ratio of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to rich to thereby release NO.sub.x from the NO.sub.x storage and reduction catalyst 22a and to reduce or purify N.sub.2. As a result, the NO.sub.x storage amount of the NO.sub.x storage and reduction catalyst 22a is decreased and an amount of NO.sub.x which the NO.sub.x storage and reduction catalyst 22a can store is restored.
(32) That is, as shown in
(33) In this embodiment according to the present disclosure, to make the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a rich, additional fuel is injected in addition to the fuel for engine output from the fuel injector 3 to an inside of the combustion chamber 2. This additional fuel is injected at a timing where it burns, but does not contribute to engine output, that is, for example slightly before ATDC90 after compression top dead center. In another embodiment (not shown), the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is made rich, by injecting additional fuel (hydrocarbons) upstream of the NO.sub.x storage and reduction catalyst 22a inside the exhaust passage. Whatever the case, an amount of additional fuel is set so that the NO.sub.x storage amount QNOX of the NO.sub.x storage and reduction catalyst 22a becomes substantially zero.
(34) Further, in this embodiment according to the present disclosure, the NO.sub.x storage amount QNOX of the NO.sub.x storage and reduction catalyst 22a is calculated by cumulatively adding an amount qNOX of NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a per unit time when the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is lean (QNOX=QNOX+qNOX). The amount qNOX of NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a per unit time is equal to an amount of NO.sub.x which flows into the NO.sub.x storage and reduction catalyst 22a per unit time and is stored as a function of an engine operating state, for example, an amount of fuel QF for the engine output expressing the engine load and an engine speed Ne in the form of a map such as shown in
(35) A processing for reducing NO.sub.x by temporarily switching the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a in this way to the rich air-fuel ratio AFRN which is adapted for reducing the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a to N.sub.2 will below be referred to as a storage and reduction processing.
(36)
RPNOXa=(QNOXainQNOXaout)/QNOXain
(37) Referring to
(38) The NO.sub.x purification rate RPNOXa falls as the catalyst temperature TC falls from the peak temperature TCP mainly because, as the catalyst temperature TC falls from the peak temperature TCP, an NO in the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a becomes harder to oxidize to NO.sub.2 and NO.sub.x becomes harder to be absorbed at the basicity layer 57. On the other hand, the NO.sub.x purification rate RPNOXa falls as the catalyst temperature TC rises from the peak temperature TCP mainly because thermal decomposition of the nitrates in the basicity layer 57 is promoted as the catalyst temperature TC rises from the peak temperature TCP. That is, if the nitrates in the basicity layer 57 are thermally decomposed, NO.sub.x is released from the basicity layer 57 in the form of NO. At this time, the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a does not contain HC, CO, etc. much at all, so the released NO flows out from the NO.sub.x storage and reduction catalyst 22a without being reduced.
(39) Furthermore, referring to
(40) Therefore, in this embodiment according to the present disclosure, when the catalyst temperature TC is in the storage and reduction temperature range TRSR, storage and reduction processing is performed while when the catalyst temperature TC is outside the storage and reduction temperature range TRSR, the storage and reduction processing is not performed. As a result, it is possible to effectively utilize the fuel while more reliably reducing NO.sub.x. Note that the low temperature side set temperature TCSL is for example 200 C. or so. On the other hand, the high temperature side set temperature TCSH is for example 350 C. or so. In another embodiment (not shown), the high temperature side set temperature TCSH is set to a temperature higher than the above-mentioned peak temperature TCP.
(41) In this way, when the catalyst temperature TC is in the storage and reduction temperature range TRSR, storage and reduction processing is used to reduce the NO.sub.x. As opposed to this, when the catalyst temperature TC is higher than the high temperature side set temperature TCSH, in this embodiment according to the present disclosure, the NO.sub.x is reduced in the following way. That is, when the catalyst temperature TC rises beyond the high temperature side set temperature TCSH, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA which is adapted for generating ammonia from the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. As a result, the NO.sub.x storage ability of the NO.sub.x storage and reduction catalyst 22a is restored and ammonia is produced from substantially all of the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. This ammonia flows out from the NO.sub.x storage and reduction catalyst 22a, then flows into the selective reduction catalyst 22d, and then is held in the selective reduction catalyst 22d.
(42) After that, that is, when the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is returned to lean and the temperature of the NO.sub.x storage and reduction catalyst is higher than the high temperature side set temperature TCSH, the NO.sub.x which flows out from the NO.sub.x storage and reduction catalyst 22a next flows into the selective reduction catalyst 22d. In this embodiment according to the present disclosure, the air-fuel ratio of the exhaust gas which flows into the NO oxidation catalyst 22b, NO.sub.2 reduction catalyst 22c, and selective reduction catalyst 22d matches the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a. Therefore, the NO.sub.x which flows into the selective reduction catalyst 22d at this time is reduced by the ammonia which is held in the selective reduction catalyst 22d under an oxidizing atmosphere.
(43) If NO.sub.x is reduced by ammonia in the selective reduction catalyst 22d, the amount of ammonia which is held in the selective reduction catalyst 22d is gradually decreased. So long as the selective reduction catalyst 22d holds ammonia, the selective reduction catalyst 22d reduces the NO.sub.x. Note that, an amount of ammonia which is produced when the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA, that is, an initial amount of ammonia which is held in the selective reduction catalyst 22d, can fluctuate depending on the NO.sub.x storage amount of the NO.sub.x storage and reduction catalyst 22a when the air-fuel ratio of the inflowing exhaust gas AFE is switched to the rich air-fuel ratio AFRA.
(44) Furthermore, in this embodiment according to the present disclosure, even when a signal to stop engine operation is issued, that is, for example, when the ignition switch 42 is turned off, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA which is adapted for generating ammonia from the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. As a result, the NO.sub.x storage ability of the NO.sub.x storage and reduction catalyst 22a is restored and ammonia is produced from substantially all of the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. This ammonia next flows into the selective reduction catalyst 22d and is held therein. Next, the engine operation is stopped.
(45) While engine operation is stopped, the ammonia continues to be held in the selective reduction catalyst 22d. Next, when the engine operation is restarted and the catalyst temperature TC rises beyond the low temperature side set temperature TCSL, that is, when the catalyst temperature TC becomes within the storage and reduction temperature range TCSR, the above-mentioned storage and reduction processing is started whereby the NO.sub.x is reduced. On the other hand, while the catalyst temperature TC is lower than the low temperature side set temperature TCSL, storage and reduction processing is not performed. In this case, the NO.sub.x which passes through the NO.sub.x storage and reduction catalyst 22a flows into the selective reduction catalyst 22d. At this time, if the selective reduction catalyst 22d is activated, the NO.sub.x is reduced by the ammonia which is held in the selective reduction catalyst 22d.
(46) That is, in
(47) Next, as shown in
(48) Next, as shown by X4, if the catalyst temperature TC rises beyond the high temperature side set temperature TCSH, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA. As a result, the amount QNH3 of ammonia held in the selective reduction catalyst 22d is increased to an initial amount QNH3Y. So long as the catalyst temperature TC is outside of the storage and reduction temperature range TRSR, the storage and reduction processing is stopped, therefore the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is maintained lean. In this case, NO.sub.x reaches the selective reduction catalyst 22d and is reduced by the ammonia which is held in the selective reduction catalyst 22d. As a result, the amount QNH3 of ammonia held in the selective reduction catalyst 22d is gradually decreased.
(49) Next, as shown in
(50) As explained above, when the catalyst temperature TC is higher than the high temperature side set temperature TCSH, NO.sub.x is reduced by the ammonia which is held in the selective reduction catalyst 22d. In this regard, if referring to a ratio of an amount QNO of NO which is contained in the exhaust gas to a total of the amount QNO (mol) of NO and amount QNO.sub.2 (mol) of NO.sub.2 which are contained in the exhaust gas as a NO ratio (=QNO/(QNO+QNO.sub.2)), the NO.sub.x purification rate of the selective reduction catalyst 22d fluctuates in accordance with the NO ratio of the exhaust gas which flows into the selective reduction catalyst 22d. That is, as shown in
(51) In general, an exhaust gas which is discharged from the engine body 1, that is, an exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a, contains more NO than NO.sub.2. Therefore, the NO ratio RNO of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is relatively high. Further, as explained above referring to
(52) Therefore, in this embodiment according to the present disclosure, the NO oxidation catalyst 22b is arranged downstream of the NO.sub.x storage and reduction catalyst 22a to oxidize part of the NO in the exhaust gas which flows into the NO oxidation catalyst 22b to NO.sub.2, thereby the NO ratio RNO of the exhaust gas which flows out from the NO oxidation catalyst 22b is made to fall and approach the optimum ratio (0.5) of the selective reduction catalyst 22d.
(53) In this regard, in the present disclosure resulted from intensive research resulting in the following. That is, in a process of the catalyst temperature TC further rising beyond the high temperature side set temperature TCSH, if the catalyst temperature TC is relatively low or right after the catalyst temperature TC exceeds the high temperature side set temperature TCSH, the NO ratio RNO of the exhaust gas which flows out from the NO.sub.x storage and reduction catalyst 22a, that is, the NO ratio RNO of the exhaust gas which flows into the NO oxidation catalyst 22b, becomes higher as the catalyst temperature TC becomes higher, as explained above. In this regard, if the catalyst temperature TC further rises, the NO ratio RNO of the exhaust gas which flows into the NO oxidation catalyst 22b becomes lower as the catalyst temperature TC becomes higher. This is because if the catalyst temperature TC is considerably high, the NO.sub.2 in the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a becomes harder to be stored in the NO.sub.x storage and reduction catalyst 22a, therefore an amount of NO which is converted from NO.sub.2 by the NO.sub.x storage and reduction catalyst 22a becomes small. Further, in general, if the catalyst temperature TC becomes higher, the NO oxidizing ability of the NO oxidation catalyst 22b becomes higher, so if the catalyst temperature TC becomes considerably high, the amount of NO which is oxidized to NO.sub.2 in the NO oxidation catalyst 22b becomes greater. In this case, if the NO oxidation catalyst 22b causes the NO ratio RNO of the exhaust gas to fall, the NO ratio RNO of the exhaust gas which flows out from the NO oxidation catalyst 22b is liable to fall below the optimum ratio (0.5) of the selective reduction catalyst 22d and become further from the optimum ratio (0.5).
(54) Therefore, in this embodiment according to the present disclosure, the NO.sub.2 reduction catalyst 22c is arranged downstream of the NO oxidation catalyst 22b to reduce part of the NO.sub.2 in the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c to NO by the NO.sub.2 reduction catalyst 22c, thereby the NO ratio RNO of the exhaust gas which flows out from the NO.sub.2 reduction catalyst 22c, that is, the NO ratio RNO of the exhaust gas which flows into the selective reduction catalyst 22d is prevented from excessively falling and approaches the optimum ratio (0.5) of the selective reduction catalyst 22d. This will be further explained with reference to
(55)
(56) As shown in
(57) The exhaust gas which flows out from the NO.sub.x storage and reduction catalyst 22a next flows into the NO oxidation catalyst 22b. In this embodiment according to the present disclosure, as shown in
RONO=(QNObinQNObout)/QNObin
(58) As a result, as shown in
(59) The exhaust gas which flows out from the NO oxidation catalyst 22b next flows into the NO.sub.2 reduction catalyst 22c. In this embodiment according to the present disclosure, an NO.sub.2 reduction rate RRNO.sub.2, which shows the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c, as shown in
RRNO.sub.2=(QNO.sub.2cinQNO.sub.2cout)/QNO.sub.2cin
(60) As a result, as shown in
(61) Note that, in
(62) TRL which is shown in
(63)
(64) In the example which is shown in
(65) On the other hand, the NO ratio RNO when the catalyst temperature TC is within the high temperature range TRH is made to rise by the NO.sub.x storage and reduction catalyst 22a to become RNObi, is made to fall by the NO oxidation catalyst 22b to become RNOci, and is made to rise by the NO.sub.2 reduction catalyst 22c to become RNOdi. Therefore, the NO ratio difference DRNO when the catalyst temperature TC is within the high temperature range TRH is increased by the NO.sub.x storage and reduction catalyst 22a to become DRNObi, is decreased by the NO oxidation catalyst 22b to become DRNOci, and is decreased by the NO.sub.2 reduction catalyst 22c to become DRNOdi. Note that the NO ratio difference DRNO is sometimes increased or maintained by the NO oxidation catalyst 22b.
(66) In accordance with the above, when the catalyst temperature TC is both in the low temperature range TRL and in the high temperature range TRH, the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is made equal to or smaller than the NO ratio difference DRNObi of the exhaust gas which flows into the NO oxidation catalyst 22b by the NO oxidation catalyst 22b and NO.sub.2 reduction catalyst 22c. Further, when the catalyst temperature TC is both in the low temperature range TRL and in the high temperature range TRH, the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is made equal to or smaller the NO ratio difference DRNOci of the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c by the NO.sub.2 reduction catalyst 22c.
(67) Therefore, conceptually speaking, the NO oxidizing ability of the NO oxidation catalyst 22b and the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c are respectively set so that the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is equal to or smaller than the NO ratio difference DRNObi of the exhaust gas which flows into the NO oxidation catalyst 22b. Alternatively, the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c is set so that the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is equal to or smaller than the NO ratio difference DRNOci of the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c.
(68) Furthermore, when the catalyst temperature TC rises over a predetermined set temperature, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA which is adapted for generating ammonia from the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a. When the catalyst temperature TC is higher than the set temperature, the NO.sub.x in the exhaust gas which flows into the selective reduction catalyst 22d is reduced by the ammonia. Based on the above, the NO oxidizing ability of the NO oxidation catalyst 22b and the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c are respectively set so that, when the catalyst temperature TC is higher than the set temperature, the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is equal to or smaller than the NO ratio difference DRNObi of the exhaust gas which flows into the NO oxidation catalyst 22b. Alternatively, the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c is set so that, when the catalyst temperature TC is higher than the set temperature, the NO ratio difference DRNOdi of the exhaust gas which flows into the selective reduction catalyst 22d is equal to or smaller than the NO ratio difference DRNOci of the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c.
(69) Furthermore, after the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRA which is adapted for generating ammonia from the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is maintained lean until the catalyst temperature TC becomes lower than the set temperature. On the other hand, when the catalyst temperature TC is lower than the set temperature, the air-fuel ratio AFE of the exhaust gas which flows into the NO.sub.x storage and reduction catalyst 22a is temporarily switched to the rich air-fuel ratio AFRN which is adapted for reducing the NO.sub.x which is stored in the NO.sub.x storage and reduction catalyst 22a to N.sub.2.
(70) The above-mentioned set temperature is set higher than a temperature at which the NO.sub.x purification rate RPNOXa of the NO.sub.x storage and reduction catalyst 22a reaches the peak value RPNOXa, that is, the peak temperature TCP. In this already explained embodiment according to the present disclosure, the set temperature is set to the high temperature side set temperature TCSH.
(71) Furthermore, the NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c is set so that, when the catalyst temperature TC is in a temperature range lower where the NO ratio RNOci of the exhaust gas which flows into the NO.sub.2 reduction catalyst 22c is lower than a predetermined threshold NO ratio RNOTH, that is, when the catalyst temperature TC is in the high temperature range TRH, the NO.sub.2 reduction rate RRNO.sub.2 of the NO.sub.2 reduction catalyst 22c is higher than the predetermined set NO.sub.2 reduction rate RRNO.sub.2S.
(72) Note that, if setting the NO oxidizing ability of the NO oxidation catalyst 22b low, the NO ratio RNOdi of the exhaust gas which flows into the selective reduction catalyst 22d possibly can be prevented from falling below the threshold NO ratio RNOTH when the catalyst temperature TC is in the high temperature range TRH. However, if setting the NO oxidizing ability of the NO oxidation catalyst 22b low, the NO in the exhaust gas is liable to be unable to be sufficiently oxidized to NO.sub.2 when the catalyst temperature TC is in the low temperature range TRL. In this embodiment according to the present disclosure, the NO oxidizing ability of the NO oxidation catalyst 22b and NO.sub.2 reducing ability of the NO.sub.2 reduction catalyst 22c are set so that NO is reliably oxidized to NO.sub.2 in the low temperature range TRL while NO.sub.2 is reliably reduced to NO in the high temperature range TRH.
(73)
(74) Referring to
(75) Referring to
(76) Referring again to
(77) In the foregoing embodiments, the NO oxidation catalyst 22b and NO.sub.2 reduction catalyst 22c were carried on the substrates different from each other. As opposed to this, in another embodiment which is shown in
(78) While the disclosure has been described by reference to specific embodiments chosen for purposes of illustration, it should be apparent that numerous modifications could be made thereto, by those skilled in the art, without departing from the basic concept and scope of the disclosure.