Exhaust gas treatment systems utilizing a single electrically heated catalyst

• US 10,641,147 B2
• Filed: 07/26/2017
• Issued: 05/05/2020
• Est. Priority Date: 07/26/2017
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Solbrig, Charles, Miao, Yong
• Primary Examiner(s): Maines, Patrick D
• Assistant Examiner(s): Singh, Dapinder
• Application Number:
  US15/660,233
• Publication Number:
  US 20190032533A1
• Time in Patent Office: Days
• Field of Search: 60274, 60286, 60295, 60299-301
• CPC Class Codes: B01D 2251/206 Ammonium compounds
• CPC Class Codes: B01D 2255/102 Platinum group metals
• CPC Class Codes: B01D 2255/904 Multiple catalysts
• CPC Class Codes: B01D 2255/91 NOx-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2255/912 HC-storage component incorporated in the catalyst
• 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 53/944 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: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/06 of zinc, cadmium or mercury
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 23/44 Palladium
• CPC Class Codes: B01J 23/462 Ruthenium
• CPC Class Codes: B01J 23/464 Rhodium
• CPC Class Codes: B01J 23/466 Osmium
• CPC Class Codes: B01J 23/468 Iridium
• CPC Class Codes: B01J 23/58 with alkali- or alkaline earth metals
• CPC Class Codes: B01J 23/60 with zinc, cadmium or mercury
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 23/745 : Iron
• CPC Class Codes: B01J 23/894 : with rare earths or actinides
• CPC Class Codes: B01J 23/8946 : with alkali or alkaline earth metals
• CPC Class Codes: B01J 35/19 : Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/56 : Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0215 : Coating
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: F01N 13/009 : having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2240/16 : an electric heater, i.e. a resistance heater
• CPC Class Codes: F01N 2370/02 : used in catalytic reactors
• CPC Class Codes: F01N 2510/02 : for thermal insulation
• CPC Class Codes: F01N 2510/06 : for exhaust purification, e.g. catalytic reaction
• CPC Class Codes: F01N 2610/00 : Adding substances to exhaust gases
• CPC Class Codes: F01N 2610/1453 : Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
• CPC Class Codes: F01N 3/0814 : combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/0835 : Hydrocarbons
• CPC Class Codes: F01N 3/0842 : Nitrogen oxides
• CPC Class Codes: F01N 3/103 : Oxidation catalysts for HC and CO only
• CPC Class Codes: F01N 3/106 : Auxiliary oxidation catalysts
• CPC Class Codes: F01N 3/2013 : using electric or magnetic heating means
• CPC Class Codes: F01N 3/2026 : directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
• 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: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Exhaust gas systems include an oxidation catalyst (OC) capable of receiving exhaust gas and oxidizing one or more of combustible hydrocarbons (HC) and one or more nitrogen oxide (NOx) species, a selective catalytic reduction device (SCR) disposed downstream from and in fluid communication with the OC via a conduit, and an electrically heated catalyst (EHC) disposed at least partially within the conduit downstream from the OC and upstream from the SCR. The EHC comprises a heating element having an outer surface including one or more second oxidation catalyst materials capable of oxidizing CO, HC, and one or more NOx species. The OC includes one or more storage materials individually or collectively capable of storing NOx and/or HC species. Exhaust gas can be supplied by an internal combustion engine which can optionally power a vehicle.

Claims

1. An exhaust gas treatment system, the system comprising:

an oxidation catalytic device (OC) configured to receive exhaust gas at an upstream side and release exhaust gas at a downstream side, and comprising a catalytic composition including;

one or more first oxidation catalyst materials capable of oxidizing carbon monoxide (CO), hydrocarbons (HC), and one or more nitrogen oxide (NOx) species, and

one or more storage materials individually or collectively capable of storing NOx and HC species;

a selective catalytic reduction device (SCR) disposed downstream from the OC and in fluid communication therewith via a conduit, and configured to store NOx species and/or reduce NOx species in the presence of a reductant;

a reductant injector configured to deliver the reductant into the conduit at a reductant injection position between the OC and the SCR; and

an electrically heated catalyst (EHC) disposed at least partially within the conduit downstream from all catalytic composition of the OC and upstream from the reductant injection position, wherein the EHC comprises a heating element having an outer surface including one or more second oxidation catalyst materials capable of oxidizing CO, HC, and one or more NOx species and is configured to directly heat the SCR.

2. The exhaust gas treatment system of claim 1, wherein the one or more first oxidation catalyst materials and/or the second oxidation catalyst materials comprise one or more platinum group metal catalysts and/or one or more metal oxide catalysts.

3. The exhaust gas treatment system of claim 2, wherein one or more of the first oxidation catalyst materials and/or the second oxidation catalyst materials include the platinum group metal catalysts, and the one or more platinum group metal catalysts comprise platinum, palladium, rhodium, ruthenium, osmium, and/or iridium.

4. The exhaust gas treatment system of claim 2, wherein one or more of the first oxidation catalyst materials and/or the second oxidation catalyst materials include the metal oxide catalysts, and the one or more metal oxide catalysts comprise iron oxides, zinc oxides, aluminum oxides, and/or perovskites.

5. The exhaust gas treatment system of claim 1, wherein the one or more storage material comprises a NOx storage material and includes one or more of an alkali metal, alkaline earth metal, and/or a rare earth metal, including respective oxides, carbonates, and hydroxides thereof.

6. The exhaust gas treatment system of claim 1, wherein the one or more storage material comprises a HC storage material and includes one or more of alumina, silica, zeolite, zirconia, titania, and lanthana.

7. The exhaust gas treatment system of claim 1, wherein the one or more storage material comprises a cold storage material capable of storing NOx species and/or HC species at or below a threshold temperature and releasing stored NOx species and/or HC species at a temperature above the threshold temperature.

8. The exhaust gas treatment system of claim 1, wherein the reductant comprises one or more of urea and/or decomposition products thereof, ammonia, and compounds capable of decomposing or otherwise reacting in the presence of exhaust gas and/or heat to form ammonia.

9. The exhaust gas treatment system of claim 1, wherein the heating element is disposed in a coiled configuration.

10. The exhaust gas treatment system of claim 1, wherein at least a portion of the conduit between the OC and the SCR is insulated.

11. An internal combustion engine (ICE) exhaust gas treatment system, the system comprising:

an ICE configured to emit exhaust gas to a conduit;

an oxidation catalytic device (OC) configured to receive exhaust gas from the ICE via the conduit at an upstream side and release exhaust gas into the conduit at a downstream side, and comprising a catalytic composition including;

one or more first oxidation catalyst materials capable of oxidizing carbon monoxide (CO), hydrocarbons (HC), and one or more nitrogen oxide (NOx) species, and

at least one storage material capable of storing NOx and/or HC species;

a selective catalytic reduction device (SCR) disposed downstream from the OC and in fluid communication therewith via the conduit, and configured to store NOx species and/or reduce NOx species in the presence of a reductant; and

an electrically heated catalyst (EHC) disposed at least partially within the conduit downstream from all catalytic composition of the OC and upstream from the SCR, wherein the EHC comprises a heating element having an outer surface including one or more second oxidation catalyst materials capable of oxidizing CO, HC, and one or more NOx species, and is configured to directly heat the SCR.

12. The ICE exhaust gas treatment system of claim 11, wherein the one or more first oxidation catalyst materials and/or the second oxidation catalyst materials comprise one or more platinum group metal catalysts.

13. The ICE exhaust gas treatment system of claim 12, wherein the one or more platinum group metal catalysts comprise platinum, palladium, rhodium, ruthenium, osmium, and/or iridium.

14. The ICE exhaust gas treatment system of claim 11, wherein the one or more first oxidation catalyst materials and/or the second oxidation catalyst materials comprise one or more metal oxide catalysts.

15. The ICE exhaust gas treatment system of claim 14, wherein the one or more metal oxide catalysts comprise iron oxides, zinc oxides, aluminum oxides, and/or perovskites.

16. The ICE exhaust gas treatment system of claim 11, wherein the at least one storage material comprises a NOx storage material and includes one or more of an alkali metal, alkaline earth metal, and/or a rare earth metal, including respective oxides, carbonates, and hydroxides thereof.

17. The ICE exhaust gas treatment system of claim 11, wherein the at least one storage material comprises a HC storage material and includes one or more of a porous ceramic matrix or a molecular sieve.

18. The ICE exhaust gas treatment system of claim 11, wherein the at least one storage material comprises a cold storage material.

19. The ICE exhaust gas treatment system of claim 11, wherein the EHC is contiguous with a downstream side of the OC catalytic composition.

20. The ICE exhaust gas treatment system of claim 11, wherein the one or more NOx species and/or HC species which pass through the OC unoxidized are oxidized by the one or more second oxidation catalyst materials.