Diesel Exhaust Treatment Systems and Methods

• US 20140360164A1
• Filed: 06/06/2013
• Published: 12/11/2014
• Est. Priority Date: 06/06/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Sprague, Barry, Beal, Steve
• Granted Patent: US 9,771,534 B2
• Time in Patent Office: Days
• US Class Current: 60/274
• CPC Class Codes: C10L 1/106 mixtures of inorganic compounds with organic macromolecular compounds
• CPC Class Codes: C10L 1/1216 metal compounds, e.g. hydrides, carbides
• CPC Class Codes: C10L 1/1814 Chelates
• CPC Class Codes: C10L 10/00 Use of additives to fuels or fires for particular purposes additives for liquid carbonaceous fuels characterised by their chemical nature C10L1/10; using binders for briquetting solid fuels C10L5/10; using additives to improve the combustion of solid fuels C10L9/10
• CPC Class Codes: C10L 10/02 for reducing smoke development
• CPC Class Codes: C10L 10/06 for facilitating soot removal
• CPC Class Codes: C10L 2200/024 Group VIII metals: Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt
• CPC Class Codes: C10L 2200/0245 Lanthanide group metals: La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu
• CPC Class Codes: C10L 2270/026 for diesel engines, e.g. automobiles, stationary, marine
• CPC Class Codes: C10L 2300/30 Mixture of three components
• CPC Class Codes: F01N 2430/04 by adding non-fuel substances to combustion air or fuel, e.g. additives
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/20 specially adapted for catalytic conversion F01N3/22 takes precedence; Methods of operation or control of catalytic converters

Abstract

Disclosed here are systems and methods including one or more FBCs and one or more suitable aftertreatment devices, including DOCs, DPFs, and suitable combinations thereof. The systems and methods disclosed may include selecting a suitable FBC for use with a fuel with a specified sulfur content. Systems and methods disclosed here may also include using one or more ECUs to control one or more FBC dosing/metering devices to supply FBCs from one or more FBC reservoirs in the presence of a specified event.

Claims

1. A method of improving operation of a diesel engine operating with diesel fuel containing sulfur, the method comprising the steps of:

providing for adding to the diesel fuel of a fuel borne catalyst in an effective amount to lower emissions of unburned hydrocarbons and carbon monoxide upon combustion thereof, the fuel borne catalyst comprising;

a platinum group metal composition comprising at least one material selected from the group consisting of platinum, and palladium, and mixtures thereof;

at least one rare earth metal selected from the group consisting of cerium, yttrium, and mixtures thereof; and

at least one transition metal compound comprising at least one carboxylate having a general formula selected from the group consisting of M(OOCR)_n, MO_x(OOCR)_y, (MO)₂(OOCR)_y, and combinations thereof, wherein M is a transition metal, wherein R is selected from the group consisting of an alkyl, an arylallkyl, aryl, and cycloalkyl, and n, x, and y are integers.

2. The method of claim 1, wherein M is selected form the group consisting of iron, manganese, and combinations thereof.

3. The method of claim 2, wherein M comprises about 1 ppm to about 10 ppm of the diesel fuel.

4. The method of claim 1, wherein the at least one rare earth metal comprises about 1 ppm to about 10 ppm.

5. The method of claim 1, wherein the a platinum group metal comprises about 0.01 ppm to about 0.5 ppm of the diesel fuel.

6. The method of claim 1, wherein M is selected form the group consisting of chromium, gallium, colbalt, nickel, copper, niobium, molybdenum, tungsten, and combinations thereof.

7. The method of claim 6, wherein M comprises less than about 15 ppm of the diesel fuel.

8. The method of claim 1, further comprising providing for operating of the diesel engine by combusting the fuel over a sufficient period of time to produce exhaust gases and achieve a sustained reduction in the unburned hydrocarbons and carbon monoxide.

9. The method of claim 1, wherein ignition temperature of soot resuting from combustion of the diesel fuel is about 350°

C. to about 400°

C.

10. A method for improving operation of a diesel engine by lowering emissions of unburned hydrocarbons and carbon monoxide, the method comprising the steps of:

providing for a presence of a diesel fuel and combustion air;

providing a fuel borne catalyst comprising;

a platinum group metal composition comprising at least one material selected from the group consisting of platinum, and palladium, and mixtures thereof;

at least one rare earth metal selected from the group consisting of cerium, yttrium, and mixtures thereof; and

at least one transition metal compound comprising at least one carboxylate having a general formula selected from the group consisting of M(OOCR)_n, MO_x(OOCR)_y, (MO)₂(OOCR)_y, and combinations thereof, wherein M is a transition metal, wherein R is selected from the group consisting of an alkyl, an arylallkyl, aryl, and cycloalkyl, and n, x, and y are integers.

providing for combusting of the diesel fuel in the diesel engine to produce exhaust gases; and

,

providing for directing of the exhaust gases into an exhaust system;

wherein the fuel borne catalyst is introduced into the diesel fuel in amounts effective to provide the fuel borne catalyst in the exhaust system at a level of up to 10 ppm based on a volume of the diesel fuel burned to produce the exhaust gases.

11. The method of claim 10, wherein M is selected form the group consisting of iron, manganese, and combinations thereof.

12. The method of claim 11, wherein M comprises about 1 ppm to about 10 ppm of the diesel fuel.

13. The method of claim 10, wherein the at least one rare earth metal comprises about 1 ppm to about 10 ppm of the diesel fuel.

14. The method of claim 10, wherein the a platinum group metal comprises about 0.01 ppm to about 0.5 ppm of the diesel fuel.

15. The method of claim 10, wherein M is selected form the group consisting of chromium, gallium, colbalt, nickel, copper, niobium, molybdenum, tungsten, and combinations thereof.

16. The method of claim 15, wherein M comprises less than about 15 ppm of the diesel fuel.

17. The method of claim 10, further comprising providing for operating of the diesel engine by combusting the fuel over a sufficient period of time to produce the exhaust gases and achieve a sustained reduction in unburned hydrocarbons and carbon monoxide.

18. The method of claim 10, wherein ignition temperature of soot resuting from the combusting of the diesel fuel is about 350°

C. to about 400°

C.