Method and apparatus for reducing nitrogen oxides from internal combustion engine

• US 5,272,871 A
• Filed: 05/22/1992
• Issued: 12/28/1993
• Est. Priority Date: 05/24/1991
• Status: Expired due to Fees

• Current Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho (Toyota Motor Corporation)
• Original Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho (Toyota Motor Corporation)
• Inventors: Oshima, Yujiro, Yokota, Koji, Fukui, Masayuki, Kawahara, Kazuo, Muraki, Hideaki, Abe, Katsushi
• Primary Examiner(s): Hart, Douglas
• Application Number:
  US07/887,133
• Time in Patent Office: 585 Days
• Field of Search: 60/274, 60/301, 60/286, 60/303, 60/309, 60/275, 60/299, 60/297
• US Class Current: 60/274
• CPC Class Codes: B01D 2251/102 Oxygen
• CPC Class Codes: B01D 2251/202 Hydrogen
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/9431 Processes characterised by a specific device
• CPC Class Codes: B01F 25/3131 with additional mixing means other than injector mixers, e.g. screens, baffles or rotating elements
• CPC Class Codes: B01F 25/31331 Perforated, multi-opening, with a plurality of holes
• CPC Class Codes: B01F 25/433 Mixing tubes wherein the shape of the tube influences the mixing, e.g. mixing tubes with varying cross-section or provided with inwardly extending profiles
• CPC Class Codes: B01F 25/4337 Mixers with a diverging-converging cross-section
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2330/08 Granular material
• CPC Class Codes: F01N 2470/02 Tubes being perforated
• CPC Class Codes: F01N 2470/24 Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled
• CPC Class Codes: F01N 2610/04 the substance being hydrogen
• 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 3/2066 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: Y02T 10/12 Improving ICE efficiencies

Abstract

Hydrogen gas from a hydrogen generator which creates hydrogen gas by the electrolysis of water or water vapor is supplied at the entrance to a catalyzer provided in an exhaust line. The catalyzer performs a catalytic reaction between hydrogen gas and nitrogen oxides to achieve decomposition into nitrogen gas and water vapor in the exhaust from an internal combustion engine. The nitrogen oxides are directly reduced with said hydrogen gas in a low temperature atmosphere not higher than 350° C. to achieve efficient reduction in the nitrogen oxides. The improved method and apparatus provide a catalytic system with which the nitrogen oxides in the exhaust from a lean burnt engine or a diesel engine can be effectively reduced irrespective of the concentration of oxygen gas in the exhaust without impairing the good fuel economy of those engines.

Claims

1. A method for reducing nitrogen oxides in exhaust gases from an internal combustion engine, comprising the steps of:

supplying a hydrogen gas from a hydrogen generator for mixing into exhaust gases including nitrogen oxides and oxygen gas at an upstream position of the catalyzer and in a muffler or a downstream position of said muffler, said muffler being positioned close to said catalyzer, said catalyzer and muffler being provided in an exhaust line, said hydrogen generator producing said hydrogen gas by electrolysis of water or water vapor and said catalyzer causing a catalytic reaction between the hydrogen gas and nitrogen oxides to decompose into nitrogen gas and water vapor; and

directly reducing said nitrogen oxides in said exhaust gases with said hydrogen gas under a low temperature atmosphere of not higher than 350°

.

2. An apparatus for reducing nitrogen oxides from exhaust gases including nitrogen oxides and an oxygen gas from an internal combustion engine, said apparatus comprising:

a catalyzer for reducing said nitrogen oxides into a nitrogen gas and water vapor by a catalytic reaction between a hydrogen gas and nitrogen oxides, said catalyzer being provided in an exhaust line;

a muffler located upstream and close to said catalyzer, said muffler being provided in said exhaust line; and

a hydrogen generator for producing the hydrogen gas by the electrolysis of water or water vapor, thereby supplying said hydrogen gas into said exhaust gases at an upstream position of said catalyzer and in said muffler or a downstream position of said muffler;

whereby said nitrogen oxides are directly reduced with said hydrogen gas from said hydrogen generator under a low temperature atmosphere of not higher than 350°

C.

3. An apparatus for reducing nitrogen oxides according to claim 2, further comprising oxidizing means for oxidizing HC, CO and other products of incomplete combustion, said oxidizing means being provided upstream of said catalyzer.

4. An apparatus for reducing nitrogen oxides according to claim 3, wherein oxygen gas emitted from said hydrogen generator is transferred into at least one of the atmosphere, an intake-manifold of said engine and said oxidizing means.

5. An apparatus for reducing nitrogen oxides according to claim 3, further comprising a soot trap upstream of said oxidizing means for removing diesel particulate.

6. An apparatus for reducing nitrogen oxides according to claim 3, wherein said oxidizing means is at least one of an oxidation catalyst, a three-way catalyst and an exhaust reactor.

7. An apparatus for reducing nitrogen oxides according to claim 2, wherein said hydrogen generator is applied to said water or water vapor by means of a water tank.

8. An apparatus for reducing nitrogen oxides according to claim 2, wherein said hydrogen generator is applied to said water or water vapor from at least one of ventilation gas from a crankcase of said engine and a part of said exhaust gas.

9. An apparatus for reducing nitrogen oxides according to claim 2, wherein said hydrogen generator uses a solid electrolyte having a proton or hydroxyl ion conducting capability for supplying said water or water vapor.

10. An apparatus for reducing nitrogen oxides according to claim 2, wherein said hydrogen generator uses an aqueous solution of one of alkali hydroxide and sulfuric acid and an ion conductive membrane for supplying said water or water vapor.

11. An apparatus for reducing nitrogen oxides according to claim 2, wherein oxygen gas emitted from said hydrogen generator is transferred in the atmosphere or an intake-manifold of said engine.

12. An apparatus for reducing nitrogen oxides according to claim 2, wherein an appropriate hydrogen level emitted from said hydrogen generator is controlled by a rate of NOx which is computed from outputs of a NOx sensor and an air intake sensor on said exhaust pipe.

13. An apparatus for reducing nitrogen oxides according to claim 2, wherein an appropriate hydrogen level emitted from said hydrogen generator is controlled by a predictive rate of NOx which is computed from outputs of sensors to be capable of detecting various conditions of operation in said internal combustion engine such as rotational speed, a negative pressure on said intake pipe, an opening of an intake control valve and an amount of a fuel injection as a fuel feeder.

14. An apparatus for reducing nitrogen oxides according to claim 2, wherein said hydrogen generator is provided with a mixer for mixing uniformly said hydrogen gas into said exhaust gas, in which said mixer consists of a flared diameter portion of said exhaust pipe and an injecting nozzle having a few orifices.

15. An apparatus for reducing nitrogen oxides according to claim 14, wherein said injecting nozzle consists of a small-diameter injecting nozzle and a large-diameter tube with a bottom having a plurality of injecting orifices in the side wall to be disposed downstream of said small-diameter injecting nozzle.

16. An apparatus for reducing nitrogen oxides according to claim 2, wherein said catalyzer uses either Pt/zeolite or Pt/alumina or Pt/silica catalyst.

17. An apparatus for reducing nitrogen oxides according to claim 2, further comprising a muffler for reducing noise of said combustion from said engine positioned near by an outlet for exhaust gas, wherein said exhaust muffler is unified with said catalyzer.

18. An apparatus for reducing nitrogen oxides from exhaust gases including nitrogen oxides and an oxygen gas from an internal combustion engine, said apparatus comprising:

a catalyzer for reducing said nitrogen oxides into a nitrogen gas and water vapor by a catalytic reaction between a hydrogen gas and nitrogen oxides, said catalyzer being provided in an exhaust line; and

a hydrogen generator for producing the hydrogen gas by the electrolysis of water or water vapor, thereby supplying said hydrogen gas into said exhaust gases at an upstream position of said catalyzer;

wherein;

said nitrogen oxides are directly reduced with said hydrogen gas from said hydrogen generator under a low temperature atmosphere of not higher than 350°

C.; and

said hydrogen generator is provided with a mixer for mixing uniformly said hydrogen gas into said exhaust gas, in which said mixer consists of a flared diameter portion of said exhaust pipe and an injecting nozzle having a few orifices.

19. An apparatus for reducing nitrogen oxides according to claim 18, wherein said injecting nozzle consists of a small-diameter injecting nozzle and a large-diameter tube with a bottom having a plurality of injecting orifices in the side wall to be disposed downstream of said small-diameter injecting nozzle.

20. An apparatus for reducing nitrogen oxides from exhaust gases including nitrogen oxides and an oxygen gas from an internal combustion engine, said apparatus comprising:

a catalyzer for reducing said nitrogen oxides into a nitrogen gas and water vapor by a catalytic reaction between a hydrogen gas and nitrogen oxides, said catalyzer and being provided in an exhaust line;

a muffler located upstream and close to said catalyzer, said muffler being provided in said exhaust line; and

a hydrogen generator for producing the hydrogen gas by the electrolysis of an aqueous methanol or a vapor of a mixture of methanol and water, thereby supplying said hydrogen gas into said exhaust gases at an upstream position of said catalyzer and in said muffler or a downstream position of said muffler; and

whereby said nitrogen oxides are directly reduced with said hydrogen gas from said hydrogen generator under a low temperature atmosphere of not higher than 350°

C.