Exhaust aftertreatment system

• US 10,526,947 B2
• Filed: 04/12/2018
• Issued: 01/07/2020
• Est. Priority Date: 04/12/2018
• Status: Active Grant

• Current Assignee: Ai Alpine Us Bidco LLC
• Original Assignee: Ai Alpine Us Bidco LLC
• Inventors: Devarakonda, Maruthi Narasinga Rao, Kandasamy, Srinivas, Url, Michael, Kopecek, Herbert
• Primary Examiner(s): Vanoy, Timothy C
• Application Number:
  US15/951,272
• Publication Number:
  US 20190316506A1
• Time in Patent Office: 635 Days
• CPC Class Codes: B01D 2251/2062 Ammonia
• CPC Class Codes: B01D 2251/2067 Urea
• CPC Class Codes: B01D 53/9418 for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
• CPC Class Codes: B01D 53/9431 Processes characterised by a specific device
• CPC Class Codes: B01D 53/9436 Ammonia
• CPC Class Codes: B01D 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 11/007 the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2560/00 Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2610/00 Adding substances to exhaust gases
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 2610/146 Control thereof, e.g. control of injectors or injection valves
• CPC Class Codes: F01N 2610/148 Arrangement of sensors
• CPC Class Codes: F01N 2900/0408 using a feed-back loop
• CPC Class Codes: F01N 2900/0416 using the state of a sensor, e.g. of an exhaust gas sensor
• CPC Class Codes: F01N 2900/1812 Flow rate
• CPC Class Codes: F01N 3/106 Auxiliary oxidation catalysts
• CPC Class Codes: F01N 3/2066 : Selective catalytic reduction [SCR]
• CPC Class Codes: F01N 3/208 : Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 : Engine management systems

Abstract

The present application provides an aftertreatment system for treating an exhaust stream of an engine. The aftertreatment system may include a selective catalyst reduction system positioned downstream of the engine, a secondary catalyst positioned downstream of the selective catalyst reduction system, a first gas sensor positioned between the engine and the selective catalyst reduction system, a second gas sensor positioned between the selective catalyst reduction system and the secondary catalyst, and a third gas sensor positioned downstream of the secondary catalyst.

Claims

1. An aftertreatment system for treating an exhaust stream of an engine, comprising:

a selective catalyst reduction system positioned downstream of the engine;

a secondary catalyst positioned downstream of the selective catalyst reduction system;

a first gas sensor positioned between the engine and the selective catalyst reduction system;

a second gas sensor positioned between the selective catalyst reduction system and the secondary catalyst; and

a third gas sensor positioned downstream of the secondary catalyst, wherein at least the second gas sensor and the third gas sensor obtain sensor input to determine concentrations of ammonia (NH₃) in the exhaust stream.

2. The aftertreatment system of claim 1, wherein the first gas sensor, the second gas sensor, and the third gas sensor comprise nitrogen oxide sensors.

3. The aftertreatment system of claim 1, wherein the first gas sensor, the second gas sensor, and the third gas sensor determine concentrations of nitric oxide (NO), nitrogen dioxide (NO₂), and ammonia (NH₃) in the exhaust stream.

4. The aftertreatment system of claim 1, wherein the first, second, and third gas sensors obtain sensor input to determine concentrations of ammonia (NH₃) in the exhaust stream.

5. The aftertreatment system of claim 1, wherein the selective catalyst reduction system comprises an injector for a stream of a reductant, and the reductant comprises urea or ammonia.

6. The aftertreatment system of claim 1, wherein the selective catalyst reduction system comprises an injector for a stream of a reductant, further comprising a controller and wherein the controller is in communication with the first gas sensor, the second gas sensor, the third gas sensor, and the injector.

7. The aftertreatment system of claim 6, wherein the controller varies a flow rate of the stream of the reductant based upon inputs from the first gas sensor, the second gas sensor, and the third gas sensor.

8. The aftertreatment system of claim 6, further comprising a selective catalyst reduction estimator in communication with the controller, the first gas sensor, and the second gas sensor so as to determine changes in the exhaust stream over the selective catalyst reduction system.

9. The aftertreatment system of claim 8, wherein the selective catalyst reduction estimator determines changes in the concentrations of nitric oxide (NO), nitrogen dioxide (NO₂), and ammonia (NH₃) in the exhaust stream and surface coverage of ammonia (theta).

10. The aftertreatment system of claim 8, further comprising a secondary catalyst estimator in communication with the controller, the second gas sensor, and the third gas sensor so as to determine changes in the exhaust stream over the secondary catalyst.

11. The aftertreatment system of claim 10, wherein the secondary catalyst estimator determines changes in the concentrations of nitric oxide (NO), nitrogen dioxide (NO₂), and ammonia (NH₃) in the exhaust stream and surface coverage of ammonia (theta).

12. The aftertreatment system of claim 6, further comprising a control algorithm in communication with the controller, the selective catalyst reduction estimator, and the secondary catalyst estimator to determine a flow rate for the stream of the reductant.

14. The aftertreatment system of claim 1, wherein the secondary catalyst comprises an oxidation catalyst or an ammonia slip catalyst.

15. The system of claim 1, wherein the first gas sensor comprises a first NOx sensor and a first ammonia (NH₃) sensor, the second gas sensor comprises a second NOx sensor and a second ammonia (NH₃) sensor, and the third gas sensor comprises a third NOx sensor and a third ammonia (NH₃) sensor.

13. The aftertreatment system of 12, wherein the controller sends a reductant command signal to the injector with the flow rate for the stream of the reductant.

16. A method determining a flow rate of a reductant in an aftertreatment system for an exhaust stream of an engine, comprising:

receiving a first input from one or more first gas sensors positioned between the engine and a selective catalyst reduction system to determine a first concentration of ammonia (NH₃) and a first concentration of NOx in the exhaust stream;

receiving a second input from one or more second gas sensors positioned between the selective catalyst reduction system and a secondary catalyst to determine a second concentration of ammonia (NH₃) and a second concentration of NOx in the exhaust stream;

receiving a third input from one or more third gas sensors positioned downstream of the secondary catalyst to determine a third concentration of ammonia (NH₃) and a third concentration of NOx in the exhaust stream;

estimating a first change in the exhaust steam between the first gas sensor and the second gas sensor;

estimating a second change in the exhaust stream between the second gas sensor and the third gas sensor; and

varying a flow rate of a reductant to the selective catalyst reduction system based upon the first change and the second change.

17. An aftertreatment system for treating an exhaust stream of a lean burn engine, comprising:

a selective catalyst reduction system positioned downstream of the lean burn engine;

the selective catalyst reduction system comprising an injector for a stream of a reductant;

a secondary catalyst positioned downstream of the selective catalyst reduction system;

a first gas sensor positioned between the engine and the selective catalyst reduction system;

a second gas sensor positioned between the selective catalyst reduction system and the secondary catalyst;

a third gas sensor positioned downstream of the secondary catalyst; and

a controller in communication with the first gas sensor, the second gas sensor, the third gas sensor, and the injector, wherein the controller receives sensor input from at least the second gas sensor and the third gas sensor to determine concentrations of ammonia (NH₃) in the exhaust stream.

18. The aftertreatment system of claim 17, wherein the controller varies a flow rate of the stream of the reductant based upon inputs from the first gas sensor, the second gas sensor, and the third gas sensor.

19. The aftertreatment system of claim 17, further comprising a selective catalyst reduction estimator in communication with the controller, the first gas sensor, and the second gas sensor so as to determine changes in the exhaust stream over the selective catalyst reduction system.

20. The aftertreatment system of claim 19, further comprising a selective catalyst estimator in communication with the controller, the second gas sensor, and the third gas sensor so as to determine changes in the exhaust stream over the secondary catalyst.

21. The aftertreatment system of claim 20, further comprising a control algorithm in communication with the controller, the selective catalyst reduction estimator, and the secondary catalyst estimator to determine a flow rate for the stream of the reductant.

22. The system of claim 17, wherein the controller receives sensor input from the first, second, and third gas sensors to determine concentrations of ammonia (NH₃) in the exhaust stream.

23. The system of claim 17, wherein the first gas sensor comprises a first NOx sensor and a first ammonia (NH₃) sensor, the second gas sensor comprises a second NOx sensor and a second ammonia (NH₃) sensor, and the third gas sensor comprises a third NOx sensor and a third ammonia (NH₃) sensor.