Method of filtering particles from a flue gas, a flue gas filter means and a vehicle

• US 5,497,620 A
• Filed: 12/28/1992
• Issued: 03/12/1996
• Est. Priority Date: 04/08/1988
• Status: Expired due to Term

• Current Assignee: Chris-Invest A/S, Silentor Notox A/A
• Original Assignee: Per Stobbe
• Inventors: Stobbe, Per
• Primary Examiner(s): Lazarus, Ira S.
• Assistant Examiner(s): HEYMAN, LEONARD
• Application Number:
  US07/997,652
• Time in Patent Office: 1,170 Days
• Field of Search: 60/303, 60/311, 60/274, 60/299, 55/522, 55/523, 55/DIG. 30, 55/DIG. 5, 264/56
• US Class Current: 60/303
• CPC Class Codes: B01D 39/2034 sintered or bonded by inorganic agents
• CPC Class Codes: B01D 39/2075 sintered or bonded by inorganic agents
• CPC Class Codes: B01D 46/24494 Thermal expansion coefficient, heat capacity or thermal conductivity
• CPC Class Codes: B01D 46/58 connected in parallel
• CPC Class Codes: B01D 46/84 by heating only
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 3/1103 with particular physical characteristics
• CPC Class Codes: B22F 3/1115 comprising complex forms, e.g. honeycombs
• CPC Class Codes: B22F 3/22 for producing castings from a slip
• CPC Class Codes: B22F 3/225 by injection molding
• CPC Class Codes: C04B 38/0051 characterised by the pore size, pore shape or kind of porosity
• CPC Class Codes: F01N 2250/02 filtering and catalytic conversion
• CPC Class Codes: F01N 2330/00 Structure of catalyst support or particle filter
• CPC Class Codes: F01N 2410/04 during regeneration period, e.g. of particle filter
• CPC Class Codes: F01N 3/0215 the filtering elements having the form of disks or plates
• CPC Class Codes: F01N 3/022 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/023 using means for regenerating the filters, e.g. by burning trapped particles by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/027 using electric or magnetic heating means
• CPC Class Codes: F01N 3/032 during filter regeneration only
• CPC Class Codes: F01N 3/035 : with catalytic reactors , e.g. catalysed diesel particulate filters
• 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: Y10S 55/05 : Methods of making filter
• CPC Class Codes: Y10S 55/30 : Exhaust treatment

Abstract

In filtering particles such as soot from a flue gas a porous filter body of a particulate material bonded together in the body is employed. The material is a metal or metal-like material having a thermal conductivity in excess of 10 W/mK, and the porous filter body has a porosity of 50-90% and a maximum pore size of 10-40 um. The porous filter body also has a thermal conductivity in excess of 10 W/mK. In accordance with the method, the flue gas is conducted through the porous filter body so as to accumulate the particles in the porous filter body. The particles accumulated in the porous filter body are burned off, whereby heat is generated locally. The heat generated locally by the burning-off of the particles is conducted throughout the porous filter body so that the temperature rise generated by the burning-off heat is reduced. Consequently, the porous filter body is not exposed to fatal, thermal stresses. A particular application of the porous filter body of the flue gas filter means is in vehicles comprising combustion engines generating soot, such as in diesel engines.

Claims

1. A method for preparing a porous filter body comprising:

mixing together SiC particles having a size of 75-170 μ

m, a green or volatile binder, a plasticity or viscosity controlling a gent and a solvent to form a plastic paste;

extruding the plastic paste to form an extruded body; and

sintering the extruded body so as to bind the SiC particles together to produce a filter body having a maximum pore size of 10-100 μ

m, a thermal conductivity of at least 5 W/mK and a porosity of 30-60%.

2. The method of claim 1, wherein the thermal conductivity of the filter body is at least 10 W/mK.

3. The method of claim 1, further comprising mixing microcrystalline SiC together with the SiC particles having a size of 75-170 μ

m, the green or volatile binder, the plasticity or viscosity controlling agent and the solvent to form the plastic paste, wherein the micro crystalline SiC forms a permanent binder in the sintered body.

4. The method of claim 1, wherein the filter body is provided with a carbon oxidation catalyst constituting a coating of said filter body.

5. The method of claim 1, wherein the filter body is provided with a carbon oxidation catalyst comprising an alloy or a composition including the SiC of the filter body.

6. A means for filtering particles from a flue gas, comprising a porous filter body of particulate SiC with a particle size in the range of 75-170 μ

m bonded together in said porous filter body, said porous filter body having a porosity of 30-90%, a maximum pore size of 10-100 μ

m, and a thermal conductivity in excess of 5 W/mK.

7. A means for filtering particles from a flue gas comprising a porous filter body prepared form a particulate material having a thermal conductivity in excess of 10 W/mK and a particle size in the range of 45-170 μ

m, bonded together in said porous filter body in a sintering process, said porous filter body having a porosity of 30-90% and a maximum pore size of 10-100 μ

m, and said porous filter body having a thermal conductivity in excess of 5 W/mK.

8. The means for filtering particles from a flue gas according to claim 7, wherein the particulate material is selected from the group consisting of metal and metal-like materials.

9. The means for filtering particles from a flue gas according to claim 8, wherein the particulate material is a metal-like material.

10. The means for filtering particles from a flue gas according to claim 9, wherein the metal-like material is SiC.

11. The means for filtering particles form a flue gas according to claim 7 wherein said porous filter body has a flue gas inlet side surface and an opposite gas outlet side surface, a first plurality of blind filtration cavities extending perpendicularly into said body from said inlet side surface and a second plurality of blind filtration cavities extending perpendicularly into said body from said outlet side surface, said blind filtration cavities of said first and second pluralities being arranged spaced apart and mutually juxtaposed.

12. The means for filtering particles from a flue gas according to claim 11, wherein said porous filter body has partition walls defining a honeycomb structure.

13. The means for filtering particles from a flue gas according to claim 7, further comprising a carbon oxidation catalyst.

14. The means for filtering particles from a flue gas according to claim 13, wherein the carbon oxidation catalyst constitutes a coating of said porous filter body.

15. The means for filtering particles from a flue gas according to claim 7, wherein the porous filter body has a porosity of 40-75%.

16. The means for filtering particles from a flue gas according to claim 7, wherein the porous filter body has a maximum pore size of 25-75 μ

m.

17. The means for filtering particles from a flue gas according to claim 7, wherein the porous filter body has a thermal conductivity of 5-100 W/mK.

18. A vehicle comprising a diesel engine generating flue gas, which is exhausted from said diesel engine through a flue gas filter means comprising a porous filter body prepared from a particulate material having a thermal conductivity in excess of 10 W/mK and a particle size in the range of 45-170 μ

m, bonded together in said porous filter body in a sintering process, said porous filter body having a porosity of 30-90% and a maximum pore size of 10-100 μ

m, and said porous filter body having a thermal conductivity in excess of 5 W/mK.

19. A method for preparing a porous filter body comprising:

mixing together particles of a particulate material having a thermal conductivity in excess of 10 W/mK and having a size of 45-170 μ

m, a green or volatile binder, a plasticity or viscosity controlling agent and a solvent to form a plastic paste;

extruding the plastic paste to form an extruded body; and

sintering the extruded body so as to bind the particles together and to produce a filter body having a maximum pore size of 10-100 μ

m, a thermal conductivity of at least 5 W/mK and a porosity of 30-60%.