Exhaust treatment system with NO2 control

• US 20090035195A1
• Filed: 07/31/2007
• Published: 02/05/2009
• Est. Priority Date: 07/31/2007
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Robel, Wade J.
• Granted Patent: US 7,799,289 B2
• Time in Patent Office: Days
• US Class Current: 422/177
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 13/011 having two or more purifying devices arranged in parallel
• CPC Class Codes: F01N 2250/02 filtering and catalytic conversion
• CPC Class Codes: F01N 2560/00 Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
• 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 3/0231 using special exhaust apparatus upstream of the filter for producing nitrogen dioxide, e.g. for continuous filter regeneration systems [CRT]
• CPC Class Codes: F01N 3/031 having means for by-passing filters, e.g. when clogged or during cold engine start
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/106 Auxiliary oxidation catalysts
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust treatment system includes a catalyzed particulate filter disposed in a first passageway and configured to receive a first portion of a flow of exhaust. The catalyzed particulate filter is at least partially coated with a catalytic material for converting NO to NO₂. The exhaust treatment system also includes a second passageway configured to direct a second portion of the flow of exhaust around the catalyzed particulate filter and a selective catalytic reduction device disposed downstream from the first passageway and the second passageway. The selective catalytic reduction device is configured to receive a combined flow of exhaust including the first and second portions of the flow of exhaust.

Claims

1. An exhaust treatment system comprising:

a catalyzed particulate filter disposed in a first passageway and configured to receive a first portion of a flow of exhaust, the catalyzed particulate filter being at least partially coated with a catalytic material for converting NO to NO₂;

a second passageway configured to direct a second portion of the flow of exhaust around the catalyzed particulate filter;

a selective catalytic reduction device disposed downstream from the first passageway and the second passageway, the selective catalytic reduction device being configured to receive a combined flow of exhaust including the first and second portions of the flow of exhaust.

2. The exhaust treatment system of claim 1, further including a particulate filter disposed in the second passageway.

3. The exhaust treatment system of claim 2, wherein at least one of the catalyzed particulate filter and the particulate filter is a flow through type filter.

4. The exhaust treatment system of claim 2, further including an oxidation device disposed upstream from the particulate filter in the second passageway, the oxidation device having a plurality of channels through which the second portion of the flow of exhaust flows, a percentage less than 100% of the channels of the oxidation device being coated with the catalytic material.

5. The exhaust treatment system of claim 1, wherein the first portion of the flow of exhaust includes approximately 50% of the combined flow of exhaust.

6. The exhaust treatment system of claim 1, further including a first valve disposed in at least one of the first passageway and the second passageway.

7. The exhaust treatment system of claim 6, wherein the first valve is configured to control an amount of flow through the valve based on a target NO:

NO₂ ratio in the combined flow of exhaust supplied to the selective catalytic reduction device.

8. The exhaust treatment system of claim 7, wherein the first valve is controlled based on a characteristic determined when operating at a predetermined operating condition when the target NO:

NO₂ ratio is achieved, the predetermined operating condition including at least one of a predetermined mass flow and a predetermined temperature.

9. The exhaust treatment system of claim 7, wherein the target NO:

NO₂ ratio in the combined flow of exhaust supplied to the selective catalytic reduction device is approximately 50;

50.

10. The exhaust treatment system of claim 6, wherein the first valve is disposed in the first passageway and a second valve is disposed in the second passageway.

11. The exhaust treatment system of claim 1, wherein the catalyzed particulate filter is substantially completely coated with the catalytic material.

12. The exhaust treatment system of claim 1, wherein the catalytic material is platinum.

13. A method for treating a flow of exhaust comprising:

generating the flow of exhaust;

passing a first portion of the flow of exhaust through a first passageway including a catalyzed particulate filter at least partially coated with a catalytic material for converting NO to NO₂;

passing a second portion of the flow of exhaust through a second passageway configured to direct the second portion of the flow of exhaust around the catalyzed particulate filter;

combining the first and second portions of the flow of exhaust downstream from the catalyzed particulate filter to form a combined flow of exhaust; and

directing the combined flow of exhaust to a selective catalytic reduction device.

14. The method of claim 13, further including adjusting an allocation of flow between the first and second portions of the flow of exhaust.

15. The method of claim 14, further including determining the allocation of flow based on a target NO:

NO₂ ratio in the flow of exhaust supplied to the selective catalytic reduction device.

16. The method of claim 14, wherein the adjusting of the allocation of flow including controlling an amount of flow through at least one of the second passageway and the first passageway.

17. The method of claim 16, wherein the controlling of the amount of flow through the at least one of the first and second passageways includes controlling a first valve disposed in the first passageway and a second valve disposed in the second passageway to restrict the flow of the first and second portions of the flow of exhaust through the respective passageways simultaneously.

18. The method of claim 13, wherein the passing of the second portion of the flow of exhaust through the second passageway includes passing the second portion of the flow of exhaust through an oxidation device and a particulate filter, the oxidation device having a plurality of channels through which the second portion of the flow of exhaust flows, a percentage less than 100% of the channels of the oxidation device being coated with the catalytic material.

19. The method of claim 13, further including injecting reductant upstream from the catalyzed particulate filter.

20. The method of claim 19, further including:

sensing a characteristic of the first portion of the catalyzed particulate filter; and

controlling the injection of reductant based on the sensed characteristic.

21. An exhaust treatment system comprising:

a catalyzed particulate filter disposed in a first passageway and configured to receive a first portion of a flow of exhaust, the catalyzed particulate filter being at least partially coated with a catalytic material for converting NO to NO₂;

an upstream injector disposed upstream from the catalyzed particulate filter, the upstream injector configured to inject reductant into the first portion of the flow of exhaust;

a second passageway configured to direct a second portion of the flow of exhaust around the catalyzed particulate filter; and

a selective catalytic reduction device disposed downstream from the catalyzed particulate filter and the second passageway, the selective catalytic reduction device being configured to receive a combined flow of exhaust including the first and second portions of the flow of exhaust.

22. The exhaust treatment system of claim 21, further including:

a sensor configured to sense a characteristic of the catalyzed particulate filter; and

a controller connected to the sensor, the controller being configured to receive a sensed characteristic and control an injection of reductant by the upstream injector based on the sensed characteristic.

23. The exhaust treatment system of claim 22, wherein the sensed characteristic is a temperature of the catalyzed particulate filter.

24. The exhaust treatment system of claim 23, wherein the injection occurs when the sensed temperature of the catalyzed particulate filter is within a predetermined range.

25. The exhaust treatment system of claim 24, wherein the predetermined range is approximately 200°

C. to 350°

C.

26. The exhaust treatment system of claim 21, wherein:

the selective catalytic reduction device is a downstream selective catalytic reduction device; and

the exhaust treatment system further includes an upstream selective catalytic reduction device disposed upstream from the catalyzed particulate filter in the first passageway and downstream from the upstream injector.

27. The exhaust treatment system of claim 26, further including:

a sensor configured to sense a characteristic of the catalyzed particulate filter; and

a controller connected to the sensor, the controller being configured to receive a sensed characteristic and control an injection of reductant by the upstream injector based on the sensed characteristic.

28. The exhaust treatment system of claim 26, further including:

an oxidation device disposed upstream from a particulate filter in the second passageway, the oxidation device having a plurality of channels through which the second portion of the flow of exhaust flows, a percentage less than 100% of the channels of the oxidation device being coated with the catalytic material;

a second selective catalytic reduction device disposed in the second passageway upstream from the particulate filter; and

a second injector disposed upstream from the second selective catalytic reduction device, the second injector configured to inject reductant into the second portion of the flow of exhaust.