Exhaust gas purification system for an internal combustion engine

• US 5,189,876 A
• Filed: 02/07/1991
• Issued: 03/02/1993
• Est. Priority Date: 02/09/1990
• Status: Expired due to Term

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Hirota, Shinya, Inoue, Tokuta
• Primary Examiner(s): Hart, Douglas
• Application Number:
  US07/652,193
• Time in Patent Office: 754 Days
• Field of Search: 60/274, 60/286, 60/303, 60/297
• US Class Current: 60/286
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 2240/30 a fuel reformer
• CPC Class Codes: F01N 2370/04 Zeolitic material
• CPC Class Codes: F01N 2610/03 the substance being hydrocarbons, e.g. engine fuel
• CPC Class Codes: F01N 2610/10 the substance being heated, e.g. by heating tank or supply line of the added substance
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F02B 1/04 with fuel-air mixture admission into cylinder
• CPC Class Codes: F02B 3/06 with compression ignition compression ignition engines using air or gas for blowing fuel into compressed air in cylinder F02B13/02
• CPC Class Codes: F02M 63/0225 Fuel-injection apparatus having a common rail feeding several injectors F02M63/0003 takes precedence; Means for varying pressure in common rails; Pumps feeding common rails
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust gas purification system for an internal combustion engine includes an engine 1 capable of fuel combustion at lean air-fuel ratios, a lean NOx catalyst 3 installed in an exhaust conduit 16 of the engine, an HC producing means for producing hydrocarbons of low boiling points utilizing fuel for the engine, and an HC supply means for supplying the hydrocarbons of low boiling points to the exhaust conduit upstream of the lean NOx catalyst 3. NOx reduction reaction needs hydrocarbons of low boiling points. The HC producing means produces hydrocarbons of low boiling points from diesel oil by cracking, fractional distillation, or both cracking and fractional distillation. The cracked and/or distilled fuel includes a large amount of hydrocarbons of low boiling points and increases NOx purification rate of the lean NOx catalyst when the hydrocarbons of low boiling points are introduced into the exhaust conduit by the HC supply means.

Claims

1. An exhaust gas purification system for an internal combustion engine comprising:

the internal combustion engine being capable of fuel combustion at lean air-fuel ratios, the engine having an exhaust manifold and an exhaust conduit connected to the manifold;

a catalyst installed in the exhaust conduit of the engine and constructed of zeolite carrying at least one kind of metal selected from transition metals and noble metals, said catalyst being employed to reduce nitrogen oxides included in exhaust gas from the engine under oxidizing conditions and in the presence of hydrocarbons;

an HC producing means for producing hydrocarbons of low boiling points from fuel for combustion in the engine by subjecting at least a portion of the fuel for combustion to a process selected from the group including cracking and fractional distillation; and

an HC supply means for supplying the hydrocarbons of low boiling points produced by the HC producing means to the exhaust conduit upstream of the catalyst.

2. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the HC producing means comprising means for producing hydrocarbons of low boiling points by cracking at least a portion of the fuel for the engine.

3. An exhaust gas purification system for an internal combustion engine according to claim 2, wherein the HC producing means comprises a fuel cracking chamber provided adjacent to and separated from the exhaust manifold by a heat conductive manifold wall.

4. An exhaust gas purification system for an internal combustion engine according to claim 3, wherein the HC producing means includes an injection nozzle provided at the fuel cracking- chamber for injecting fuel into the fuel cracking chamber and a branch pipe leading fuel from a fuel pump to the injection nozzle.

5. An exhaust gas purification system for an internal combustion engine according to claim 2, wherein the HC supply means includes a pipe extending from the fuel cracking chamber to the exhaust conduit upstream of the catalyst and a flow control valve installed in the pipe.

6. An exhaust gas purification system for an internal combustion engine according to claim 2, wherein the internal combustion engine comprises a diesel engine, and the fuel for combustion in the engine comprises light oil.

7. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the HC producing means includes means for producing hydrocarbons of low boiling points by fractional distillation of at least a portion of the fuel for combustion in the engine.

8. An exhaust gas purification system for an internal combustion engine according to claim 7, wherein the HC producing means comprises a fuel circulation pipe for circulating at least a portion of the fuel for combustion in the engine, a heater provided at a portion of the fuel circulation pipe so as to heat the circulated fuel to evaporate at least a portion of the circulated fuel, and a gas/liquid separator provided in the circulation pipe downstream of the heater for separating the evaporated portion from liquid components of the circulated fuel.

9. An exhaust gas purification system for an internal combustion engine according to claim 7, wherein the HC supply means comprises an HC injection nozzle for injecting the hydrocarbons of low boiling points into the exhaust conduit upstream of the catalyst, a pipe for leading the hydrocarbons of low boiling points to the HC injection nozzle, and an HC supply pump for pressurizing the hydrocarbons of low boiling points.

10. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the HC producing means includes means for producing hydrocarbons of low boiling points by both cracking and fractional distillation of at least a portion of the fuel for combustion in the engine.

11. An exhaust gas purification system for an internal combustion engine according to claim 10, wherein the HC producing means includes a fuel pump, a fuel return pipe connected to the fuel pump, a zigzag portion formed in the fuel return pipe in the vicinity of the exhaust manifold, and a gas/liquid separator located in the fuel return pipe downstream of the zigzag portion.

12. An exhaust gas purification system for an internal combustion engine according to claim 10, wherein the HC supply means includes an HC injection nozzle provided at the exhaust conduit upstream of the catalyst and an HC supply pump for pressurizing the hydrocarbons of low boiling points.