Method and apparatus for using free radicals to reduce pollutants in the exhaust gases from the combustion of fuel

• US 6,029,442 A
• Filed: 10/07/1997
• Issued: 02/29/2000
• Est. Priority Date: 12/18/1996
• Status: Expired due to Fees

• Current Assignee: Litex Incorporated
• Original Assignee: Litex Incorporated
• Inventors: Ekchian, Leon, Ekchian, Jack A., Caren, Robert P.
• Primary Examiner(s): Look, Edward K.
• Assistant Examiner(s): TRAN, BINH Q
• Application Number:
  US08/947,287
• Time in Patent Office: 875 Days
• Field of Search: 60/274, 60/275, 60/276, 60/301, 60/303, 60/304, 60/287, 60/288, 60/308, 60/299, 123/536, 123/539, 422/168, 422/169, 422/186.04, 204/168, 204/173, 204/179
• US Class Current: 60/275
• CPC Class Codes: B01D 53/007 by irradiation
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: B01D 53/90 Injecting reactants
• CPC Class Codes: B01D 53/9445 Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
• CPC Class Codes: B01D 53/9454 characterised by a specific device
• CPC Class Codes: B01J 19/088 giving rise to electric discharges for heating purposes H05B7/00; for the production of ozone C01B13/11, H01T19/00
• CPC Class Codes: B01J 2219/0849 Corona pulse discharge
• CPC Class Codes: C10L 1/1233 oxygen containing compounds, e.g. oxides, hydroxides, acids and salts thereof
• CPC Class Codes: C10L 10/02 for reducing smoke development
• CPC Class Codes: F01N 2240/28 a plasma reactor
• CPC Class Codes: F01N 2260/022 using air
• CPC Class Codes: F01N 2610/06 the substance being in the gaseous form
• CPC Class Codes: F01N 3/0892 Electric or magnetic treatment, e.g. dissociation of noxious components electric filters F01N3/01; regeneration of exhaust filters F01N3/023; heating catalytic converters F01N3/2006
• CPC Class Codes: F01N 3/20 specially adapted for catalytic conversion F01N3/22 takes precedence; Methods of operation or control of catalytic converters
• CPC Class Codes: F01N 3/206 Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents F01N3/2066 takes precedence
• CPC Class Codes: F01N 3/2882 Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices combined with absorbents or adsorbents only F01N3/0814; combined with particulate filters F01N3/035
• CPC Class Codes: F02M 25/00 Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture adding secondary air to fuel-air mixture F02M23/00; adding exhaust gases F02M26/00; fuel-injection apparatus operating simultaneously on two or more fuels or on a liquid fuel and another liquid F02M43/00
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

The invention is directed to an apparatus and a method for the reduction of pollutants in the exhaust stream of a combustion engine. Radicals are produced using a corona discharge in the combustion gas stream of the engine, either in the precombustion gas stream or from water in the exhaust gas. When the radicals are produced from the exhaust gas stream, the radicals may be produced using a corona discharge placed directly in the exhaust stream leading to the catalytic convertor, or a portion of the exhaust stream may be diverted to a remote corona discharge radical generator. The corona discharge in the generator produces radicals in the diverted exhaust gas, and the exhaust gas containing radicals is then conveyed to the exhaust gas stream at a point upstream of the catalytic convertor.

Claims

1. An apparatus for reducing at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine, the apparatus comprising:

a catalytic convertor, having an inlet and an outlet, wherein the catalytic convertor is positioned such that at least a portion of the exhaust gas stream from the engine passes through the catalytic convertor;

a corona discharge device for producing a corona discharge in the exhaust gas, the corona discharge device comprising at least one first electrode, at least one second electrode positioned a distance from the first electrode and a dielectric material positioned between the first electrode and the second electrode; and

a high frequency power supply having an operational frequency of at least about 1,000 Hz adapted to provide electrical power to the corona discharge device,

wherein at least a portion of the exhaust gas stream is exposed to the corona discharge to produce radicals from gaseous species in the exhaust gas stream, and the radicals are introduced into the exhaust gas stream at a point upstream of or at the catalytic convertor.

2. The apparatus of claim 1, further comprising an exhaust pipe attached to the inlet of the catalytic convertor, such that at least a portion of the exhaust gas stream passes through the exhaust pipe to and through the catalytic convertor, wherein the exhaust pipe comprises a fitting for positioning the corona discharge device in the exhaust stream or a portion thereof, so that a corona discharge is produced in the exhaust stream upstream of or at the catalytic convertor.

3. The apparatus of claim 2, further comprising an oxygen sensor positioned between the corona discharge device and the inlet of the catalytic convertor.

4. The apparatus of claim 2, wherein the corona discharge device is positioned in a shunt attached to the exhaust pipe, such that at least a portion of the exhaust gas stream enters the shunt from the exhaust pipe at a first point, and re-enters the exhaust pipe at a second point upstream of or at the catalytic convertor.

5. The apparatus of claim 4, wherein the shunt comprises one or more extended surfaces for removing heat from the shunt.

6. The apparatus of claim 2, further comprising at least one flame arrester positioned to prevent flame from propagating in the exhaust pipe.

7. The apparatus of claim 6, wherein the at least one flame arrester is positioned downstream of the corona discharge device and upstream of or at the catalytic convertor.

8. The apparatus of claim 6, wherein at the least one flame arrester is positioned upstream of the corona discharge device.

9. The apparatus of claim 2, wherein the corona discharge device is positioned such that naturally occurring pressure fluctuations in the exhaust stream provide a pumping action that forces exhaust gas into the corona discharge device, and scavenges gases containing radicals produced in the corona discharge from the corona discharge device.

10. The apparatus of claim 9, further comprising a plenum positioned adjacent to the corona discharge device, such that exhaust gas pass from the exhaust pipe, through the corona discharge, into the plenum, and back into the exhaust pipe.

11. The apparatus of claim 2, wherein the exhaust pipe functions as a distant ground for the corona discharge device.

12. The apparatus according to claim 2, further comprising a device for injecting air into the exhaust stream during fuel rich cold start operating conditions, such that the corona discharge causes the combustion of residual fuel in the exhaust stream.

13. The apparatus of claim 1, wherein the corona discharge device comprises generally concentric electrodes, such that the corona discharge device forms the corona discharge in an air gap between the electrodes.

14. The apparatus of claim 13, wherein the concentric electrodes comprise an inner electrode, an outer electrode having an inner surface and an outer surface, and a dielectric material, which forms a layer on at least one of the inner electrode or the inner surface of the outer electrode.

15. The apparatus of claim 14, wherein the outer electrode comprises a wire or mesh.

16. The apparatus of claim 15, wherein the outer electrode includes a wire screen or mesh top portion, such that the air gap is totally enclosed by the electrodes and the dielectric, and the wire screen or mesh portion of the outer electrode acts as a flame arrester.

17. The apparatus of claim 14, wherein the dielectric material has a dielectric constant in the range of from about 2 to about 10.

18. The apparatus of claim 14, wherein the dielectric material comprises a layer on each of the inner electrode and the outer electrode.

19. The apparatus of claim 1, further comprising an exhaust pipe attached to the inlet of the catalytic convertor, a tailpipe attached to the outlet of the catalytic convertor, such that at least a portion of the exhaust gas stream passes from the exhaust pipe to and through the catalytic convertor and through the tailpipe,

the tailpipe having an exhaust gas takeoff for conveying a portion of the exhaust gas stream to a remote radical generator, which comprises the corona discharge device, for producing radicals in the exhaust gas in the portion of the exhaust gas stream conveyed to the remote radical generator, and

a remote radical generator output for returning the exhaust gas containing radicals from the remote radical generator to the exhaust gas stream at a point upstream of or at the catalytic convertor, where the exhaust gas containing radicals is injected into the exhaust gas stream.

20. The apparatus of claim 19, further comprising an oxygen sensor positioned between the inlet of the catalytic convertor and the point upstream of or at the catalytic convertor where the exhaust gas containing radicals is introduced into the exhaust gas stream.

21. The apparatus of claim 1, configured and adapted to expose only a portion of the exhaust gas stream to the corona discharge.

22. The apparatus of claim 1, wherein the power supply is configured and adapted to produce from about 5 to about 20 kV at a frequency of from about 1 to about 1,000 kHz.

23. The apparatus of claim 1, wherein the power supply is configured and adapted to produce from about 20 to about 50W of power during normal operations.

24. The apparatus of claim 23, wherein the power supply is configured and adapted to produce higher power for a period of up to about 100 seconds after engine startup.

25. The apparatus of claim 24, wherein the power supply is configured and adapted to produce up to about 300W for the period after startup.

26. The apparatus of claim 1, wherein the catalytic convertor comprises a three way catalyst.

27. An apparatus for reducing at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine having a combustion gas stream, which comprises a precombustion gas stream and the exhaust gas stream, the apparatus comprising:

a catalytic convertor, having an inlet and an outlet, where the catalytic convertor is positioned such that at least a portion of the exhaust gas stream from the engine passes through the catalytic convertor;

a corona discharge device for producing radicals in the combustion gas stream of the engine, the corona discharge device comprising at least one first electrode, at least one second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode; and

a high frequency power supply having an operational frequency of at least about 1,000 Hz adapted to provide electrical power to the corona discharge device, wherein

at least a portion of the combustion gas stream is exposed to the corona discharge to produce radicals from gaseous species in the combustion gas stream, wherein the radicals are introduced into the combustion gas stream upstream of or at the catalytic convertor.

28. The apparatus of claim 27, wherein the radicals are produced in the precombustion gas stream.

29. The apparatus of claim 27, wherein the radicals are injected into the precombustion gas stream.

30. The apparatus of claim 27, wherein the catalytic convertor comprises a three way catalyst.

31. An apparatus for reducing at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine, the apparatus comprising:

a catalytic convertor, having an inlet and an outlet, wherein the catalytic convertor is positioned such that at least a portion of the exhaust gas stream from the engine passes through the catalytic convertor;

a corona discharge device for producing a corona discharge in the exhaust gas stream, such that radicals are produced from gaseous species in the exhaust gas stream, and the radicals are introduced into the exhaust gas stream at a point upstream of or at the inlet of the catalytic convertor;

an exhaust pipe attached to the inlet of the catalytic convertor, such that at least a portion of the exhaust gas stream passes through the exhaust pipe to and through the catalytic convertor, the exhaust pipe comprising a fitting configured for attaching the corona discharge device to the exhaust pipe and allowing exhaust gas to enter into and exit from the corona discharge device;

wherein the corona discharge device comprises;

a first end, configured for attachment to the fitting, and to allow exhaust gas from the exhaust pipe to enter into and exit from the corona discharge device,

a second end, configured to prevent exhaust gas from leaking from the corona discharge device,

a generally cylindrical outer electrode, electrically and mechanically connected to the first end,

an inner electrode, mounted concentric with, and partially surrounded by the outer electrode, and

a dielectric, mounted concentric with, and positioned between the inner and outer electrodes, forming an air gap between the electrodes, the dielectric having a diameter that defines the corona discharge device diameter,

wherein the inner electrode has a length that is greater than that of the outer electrode to provide a corona region in the air gap near the first end and a ullage volume in the air gap near the second end.

32. The apparatus according to claim 31, wherein each dimension of the corona discharge device is minimized, such that shunt resistive and capacitive power losses of the corona discharge are substantially minimized.

33. The apparatus according to claim 32, wherein the inner electrode has a length that is at least about twice that of the outer electrode and at least about 4 times that of the diameter of the compact corona discharge device defined by the dielectric insulator, such that shunt resistive and capacitive power losses of the compact corona discharge are substantially minimized.

34. The apparatus according to claim 33, wherein the length of the inner electrode is at least about 4 time that of the outer electrode and at least about 6 time the diameter of the compact corona discharge device.

35. The apparatus according to claim 31, further comprising an extended skirt section positioned between the base and the outer electrode to provide a lower temperature environment for the compact corona discharge device.

36. The apparatus according to claim 35, wherein the extended skirt further comprises at least one extended surface to improve heat loss from the compact corona discharge device.

37. The apparatus according to claim 31, further comprising an orifice in the cap to supply a controlled air flow through the compact discharge device for cooling, wherein the base of the compact corona discharge device is attached to a Venturi section in the exhaust to provide a low pressure in the device to draw air through the orifice.

38. The apparatus according to claim 31, wherein the corona discharge device is positioned such that naturally occurring pressure fluctuations in the exhaust gas provide a pumping action that forces exhaust gas into the corona discharge device, and scavenges gases containing radicals produced in the corona discharge from the corona discharge device.

39. The apparatus of claim 31, wherein the catalytic convertor comprises a three way catalyst.

40. A method for the reduction of at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine having an exhaust pipe attached to an inlet of a catalytic convertor, the method comprising:

passing the exhaust gas stream through the exhaust pipe and the catalytic convertor;

forming radicals in at least a portion of the exhaust gas stream by generating a corona discharge therein, produced by a corona discharge device, which comprises at least one first electrode, at least one second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode,

providing electrical power to the corona discharge device with a high frequency power supply having an operational frequency of at least about 1,000 Hz; and

introducing the radicals into the exhaust gas stream upstream of or at the catalytic convertor.

41. The method according to claim 40, wherein the radicals are produced from at least one of water or residual in the exhaust gas.

42. The method according to claim 40, wherein the radicals react with gaseous species in the exhaust stream to form gaseous oxidizing species.

43. The method according to claim 42, wherein the radicals and gaseous oxidizing species comprise at least one of OH, O, H, HO₂, H₂ O₂, NO₂, or O₃.

44. The method according to claim 40, further comprising forming the radicals in the exhaust gas stream in the exhaust pipe at a point upstream of or at the catalytic convertor.

45. The method according to claim 44, wherein an oxygen sensor is positioned in the exhaust pipe between the catalytic convertor and the point upstream of or at the catalytic convertor where the radicals are formed in the exhaust gas stream in the exhaust pipe.

46. The method according to claim 40, further comprising diverting at least a portion of the exhaust gas stream, conveying the diverted exhaust gas stream to a remote radical generator, forming radicals in the diverted exhaust gas stream using a corona discharge in the radical generator, and injecting the radicals into the exhaust gas stream in the exhaust pipe at a point upstream of or at the catalytic convertor.

47. The method according to claim 46, wherein an oxygen sensor is positioned in the exhaust pipe between the catalytic convertor and the point upstream of or at the catalytic convertor where the radicals are injected into the exhaust gas stream in the exhaust pipe.

48. The method according to claim 40, further comprising removing catalytic poisons from surfaces of the catalytic convertor by the reaction of the poisons with at least one of the radicals or gaseous oxidizing species formed from the reaction of radicals and gases in the exhaust stream.

49. The method according to claim 48, wherein the catalytic poisons comprise at least one of compounds of sulfur, phosphorus, or carbon.

50. The method according to claim 40, further comprising aiding combustion of fuel or hydrocarbons in the exhaust stream with the corona discharge during cold start or misfire conditions.

51. The method according to claim 50, further comprising injecting a controlled amount of air into the exhaust gas stream during cold start conditions to provide oxygen required for the combustion.

52. The method of claim 40, further comprising forming the radicals in only a portion of the exhaust gas stream.

53. The method of claim 40, further comprising producing a corona discharge whenever the engine is operating.

54. The method of claim 40, further comprising introducing the radicals in the exhaust gas stream, and reacting the radicals with at least one pollutant in at least one of the exhaust gas stream upstream of the catalytic convertor or in the catalytic convertor.

55. The method of claim 40, further comprising reacting the radicals with the at least one pollutant within the catalytic convertor.

56. The method of claim 40, further comprising reacting the radicals with at least one pollutant in the exhaust gas stream.

57. The method of claim 40, further comprising selecting a three way catalyst as the catalytic convertor.

58. A method for the reduction of at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine having a combustion gas stream, which comprises a precombustion gas stream and an exhaust gas stream, and an exhaust pipe attached to an inlet of a catalytic convertor, the method comprising:

passing the exhaust gas stream through the exhaust pipe and the catalytic convertor;

forming radicals in at least a portion of the combustion gas stream by generating a corona discharge therein, produced by a corona discharge device, which comprises at least one first electrode, at least one second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode;

providing electrical power to the corona discharge device with a high frequency power supply having an operational frequency of at least about 1,000 Hz; and

introducing the radicals into the combustion gas stream upstream of or at the catalytic convertor.

59. The method according to claim 58, further comprising forming the radicals in the precombustion gas stream.

60. A method for improving the life and performance of an oxygen sensor of an engine having a combustion gas stream, which comprises a precombustion gas stream and an exhaust gas stream, wherein the oxygen sensor is positioned in the exhaust gas stream upstream of a catalytic convertor having an inlet and an outlet, the method comprising:

producing radicals in at least a portion of the combustion gas stream by generating a corona discharge therein, produced by a corona discharge device, which comprises at least one first electrode, at least one second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode;

providing electrical power to the corona discharge device with a high frequency power supply having an operational frequency of at least about 1,000 Hz; and

introducing the radicals into the combustion gas stream upstream of the oxygen sensor to remove or prevent the deposition of poisoning agents onto the oxygen sensor.

61. The method according to claim 60 further comprising forming the radicals in the precombustion gas stream.

62. The method according to claim 60, further comprising forming radicals from water in at least a portion of the exhaust gas from the exhaust stream.

63. The method according to claim 62, further comprising forming the radicals in the exhaust stream at a point upstream of the oxygen sensor.

64. The method according to claim 62, further comprising diverting at least a portion of the exhaust gas from the exhaust gas stream, conveying the diverted exhaust gas to a remote radical generator, forming radicals in the exhaust gas using a corona discharge in the radical generator, and injecting the radicals into the exhaust gas stream at a point upstream of or at the oxygen sensor.

65. A compact corona discharge device for forming a corona discharge in exhaust gas in an exhaust system of an internal combustion engine to reduce at least one pollutant, the compact corona discharge device comprising:

a first end, configured for attachment to a fitting in the exhaust system to allow exhaust gas from the exhaust system to enter into and exit from the corona discharge device,

a second end, configured to prevent exhaust gas from leaking from the corona discharge device,

a generally cylindrical outer electrode, electrically and mechanically connected to the first end,

an inner electrode, mounted concentric with, and partially surrounded by the outer electrode, and

a dielectric insulator, mounted concentric with, and positioned between the inner and outer electrodes, forming an air gap between the electrodes, the dielectric insulator having a diameter that defines the corona discharge device diameter,

wherein the inner electrode has a length that is greater than that of the outer electrode to provide a corona region in the air gap near the first end and a ullage volume in the air gap near the second end.

66. A method for the reduction of at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine having a combustion gas stream, which comprises a precombustion gas stream and the exhaust gas stream, and an exhaust pipe attached to an inlet of a catalytic convertor, the method comprising:

passing the exhaust gas stream through the exhaust pipe and the catalytic convertor;

forming radicals in the combustion gas stream by generating a corona discharge in at least a portion thereof;

wherein the radicals produced by the corona discharge device, which comprises at least one first electrode, at least one second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode;

providing electrical power to the corona discharge device with a high frequency power supply having an operational frequency of or at least about 1,000 Hz;

introducing the radicals into the combustion gas stream upstream of or at the catalytic convertor; and

reacting the radicals or an oxidizing species with at least one pollutant in at least one of the catalytic convertor or the exhaust gas stream upstream of the catalytic convertor, wherein the oxidizing species is produced by reaction of the radicals with gaseous species in the combustion gas stream.

67. The method of claim 66, further comprising selecting a three way catalyst as the catalytic convertor.

68. An apparatus for reducing at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine, the apparatus comprising:

a catalytic convertor, having an inlet and an outlet, wherein the catalytic convertor is positioned such that at least a portion of the exhaust gas stream from the engine passes through the catalytic convertor;

a corona discharge device for producing a corona discharge in the exhaust gas; and

a high frequency power supply having an operational frequency of at least about 1,000 Hz adapted to provide electrical power to the corona discharge device, wherein

the corona discharge device comprises;

a first, inner electrode, having a diameter of from about 0.1 to about 0.3 cm,

a second, outer electrode, having an inner diameter of about 1 to about 2 cm and a length of about 1.5 to 3 cm, positioned a distance from the first electrode, and

a dielectric material, having a thickness of from about 1 to about 3 mm positioned between the first electrode and the second electrode, and the corona discharge is positioned within at least a portion of the exhaust gas to produce radicals from gaseous species in the exhaust gas, and the radicals are introduced into the exhaust gas stream at a point upstream of or at the inlet of the catalytic convertor.

69. The method of claim 68, further comprising selecting a three way catalyst as the catalytic convertor.

70. A method for the reduction of at least one pollutant in an exhaust gas stream containing exhaust gas formed from the combustion of fuel in an engine having an exhaust pipe attached to an inlet of a catalytic convertor, the method comprising:

passing the exhaust gas stream through the exhaust pipe and the catalytic convertor;

forming radicals in at least a portion of the exhaust gas stream by generating a corona discharge therein, produced by a corona discharge device, which comprises a first electrode, a second electrode positioned a distance from the first electrode, and a dielectric material positioned between the first electrode and the second electrode;

providing electrical power to the corona discharge device with a high frequency power supply having an operational frequency of at least about 1,000 Hz;

introducing the radicals into the exhaust gas stream upstream of or at the catalytic convertor; and

removing at least a portion of at least one pollutant in the exhaust gas stream by reaction of the pollutant with the radicals in a catalytic reaction that regenerates at least a portion of the radicals.

71. The method of claim 70, wherein the radicals comprises hydroxyl radical, and the pollutant comprises at least one of a hydrocarbon or carbon monoxide.

72. The method of claim 70, further comprising further reducing the amount of the at least one pollutant by reacting at least a portion of the regenerated radicals with the at least one pollutant.

73. The method of claim 70, further comprising selecting a three way catalyst as the catalytic convertor.