Exhaust gas cleaning apparatus and method for internal combustion engine

• US 6,272,848 B1
• Filed: 07/17/1998
• Issued: 08/14/2001
• Est. Priority Date: 07/17/1997
• Status: Expired due to Fees

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Kuroda, Osamu, Ogawa, Toshio, Shinotsuka, Norihiro, Iizuka, Hidehiro, Yamashita, Hisao, Kitahara, Yuichi, Hiratsuka, Toshifumi, Okude, Kojiro, Doi, Ryouta, Azuhata, Shigeru
• Primary Examiner(s): Chapman, Jeanette
• Assistant Examiner(s): VARMA, SNEH K
• Application Number:
  US09/116,708
• Time in Patent Office: 1,124 Days
• Field of Search: 602/74, 602/85, 602/86, 602/95, 603/01, 603/11, 606/45, 422/177, 502/328, 502/313, 502/314, 502/247
• US Class Current: 60/274
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 2570/04 Sulfur or sulfur oxides
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F01N 3/085 Sulfur or sulfur oxides
• CPC Class Codes: F02D 2041/288 for performing a transformation into the frequency domain, e.g. Fourier transformation
• CPC Class Codes: F02D 41/0285 the exhaust gas treating apparatus being a SOx trap or adsorbent

Abstract

An apparatus and method of highly efficiently purifying nitrogen oxides are provided. An NOx chemisorption reduction catalyst chemically absorbs NOx under a condition that an exhaust gas of an internal combustion engine is an oxidizing atmosphere and deoxidizes adsorbed NOx under a reducing atmosphere. An SOx absorbent absorbs SOx contained in the exhaust gas of the oxidizing atmosphere, and deoxidizes and release SOx absorbed in the reducing atmospheric exhaust gas. The catalyst and absorbent are arranged in the exhaust path to purify the exhaust gas while preventing or suppressing SOx-poisoning of the NOx chemisorption reduction catalyst.

Claims

1. An exhaust gas purifying apparatus for an internal combustion engine, having a SOx absorbent and a NOx purifying catalyst each arranged in an exhaust path of the internal combustion engine in which lean burn is effected, said SOx absorbent absorbing SOx in an inflow exhaust gas under an oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, and releasing the absorbed SOx under a reducing atmosphere in which the O_s concentration of an exhaust gas is lower than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, said NOx purifying catalyst capturing NOx in said exhaust gas under the oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a purifying component contained in said exhaust gas,

wherein as said NOx purifying catalyst, there is provided a NOx chemisorption reduction catalyst chemically capturing NOx as NO₂ on a surface of said NOx purifying catalyst under said oxidizing atmosphere and reducing the chemically captured NO₂ with said reductive component to N₂ to release the N₂ from the surface of said NOx purifying catalyst under said reducing atmosphere.

2. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein as said SOx absorbent, there is provided a SOx absorbent reducing the SOx absorbed under said oxidizing atmosphere to SO₂ to release it under said reducing atmosphere.

3. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said SOx absorbent is arranged in said exhaust path at an upstream side of said NOx chemisorption reduction catalyst.

4. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein a component forming said SOx absorbent and a component forming said NOx chemisorption reduction catalyst are supported on a common support.

5. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein a coating layer of said SOx absorbent is provided on an upper layer of said NOx chemisorption reduction catalyst.

6. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said SOx absorbent comprises at least one kind of element selected from a group consisting of platinum, rhodium and palladium, and an oxide of at least one kind of element selected from a group consisting of oxides of aluminum, cobalt and zinc.

7. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said NOx chemisorption reduction catalyst includes a porous support of inorganic oxide, an oxide of a NOx chemisorption component, an oxide of a rare-earth metal and a noble metal, and said NOx chemisorption component comprises at least one kind of element selected from a group consisting of lithium, sodium, kalium, strontium, magnesium and calcium, and titanium.

8. An exhaust gas purifying apparatus for an internal combustion engine according to claim 7, wherein said NOx chemisorption component comprises a complex oxide of at least one kind of element selected from a group consisting of lithium, sodium, kalium, strontium, magnesium and calcium, and titanium.

9. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said SOx absorbent comprises a porous support of alumina, and at least one noble metal selected from a group consisting of platinum, palladium and rhodium, and a zinc oxide, supported on said porous support of alumina.

10. An exhaust gas purifying apparatus for an internal combustion engine according to claim 9, wherein said zinc is contained by 7-40 wt % on the metal basis per 100 wt % of said alumina.

11. An exhaust gas purifying apparatus for an internal combustion engine according to claim 9, wherein said noble metal is contained by 0.5-3 wt % per 100 wt % of said alumina.

12. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said SOx absorbent comprises a porous support of alumina, and at least one noble metal selected from a group consisting of platinum, palladium and rhodium, supported on said porous support of alumina.

13. An exhaust gas purifying apparatus for an internal combustion engine according to claim 12, wherein said noble metal is contained by 0.5-3 wt % per 100 wt % of said alumina.

14. An exhaust gas purifying apparatus for an internal combustion engine according to claim 1, wherein said SOx absorbent comprises a porous support of alumina, and at least one noble metal selected from a group consisting of platinum, palladium and rhodium, and a cobalt oxide, supported on said porous support of alumina.

15. An exhaust gas purifying apparatus for an internal combustion engine according to claim 4, wherein said common support is alumina, and components composing said NOx chemisorption reduction catalyst and zinc are supported on porous supports of said alumina.

16. An exhaust gas purifying apparatus for an internal combustion engine according to claim 5, wherein a coating layer made of SOx absorbent powders composed of zinc and platinum supported on porous supports of alumina is provided on an upper layer of said NOx chemisorption reduction catalyst.

17. An exhaust gas purifying apparatus for an internal combustion engine, having a SOx absorbent and a NOx reduction catalyst each arranged in an exhaust path of the internal combustion engine in which lean burn is effected, said SOx absorbent absorbing SOx in an inflow exhaust gas under an oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, and releasing the absorbed SOx under a reducing atmosphere in which the O₂ concentration of an exhaust gas is lower than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, said NOx purification catalyst capturing NOx in said exhaust gas under the oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas,

wherein as said NOx purifying catalyst, there is provided a NOx chemisorption reduction catalyst chemically capturing NOx as NO₂ on a surface of said NOx purifying catalyst under said oxidizing atmosphere and reducing the chemically captured NO₂ with said reductive component to N₂ to release the N₂ from the surface of said NOx purifying catalyst under said reducing atmosphere, an operational condition determining means for determining an operational condition of said internal combustion engine, and an air fuel ratio controlling means, and

wherein said NOx chemisorption reduction catalyst includes a porous support of inorganic oxide, an oxide of a NOx chemisorption component, an oxide of a rare-earth metal and a noble metal, and said NOx chemisorption component comprises at least one kind of element selected from a group consisting of lithium, sodium, potassium, strontium, magnesium and calcium, and titanium.

18. An exhaust gas purifying method of purifying NOx contained in an exhaust gas, by arranging, in an exhaust path of an internal combustion engine, in which lean burn is effected, a SOx absorbent absorbing SOx in an inflow exhaust gas under an oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, and releasing the absorbed SOx under a reducing atmosphere in which the O₂ concentration of an exhaust gas is lower than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas, and a NOx purification catalyst capturing NOx in said exhaust gas under the oxidizing atmosphere in which the O₂ concentration of said exhaust gas is higher than a stoichiometric ratio required for completely burning a reductive component contained in said exhaust gas,

wherein said NOx purification catalyst, is formed of a NOx chemisorption reduction catalyst chemically capturing NOx as NO₂ on a surface of said NOx purifying catalyst under said oxidizing atmosphere and reducing the chemically captured NO₂ with said reductive component to the N₂ from the surface of said NOx purifying catalyst under said reducing atmosphere, and the NOx chemically captured on a surface of said NOx chemisorption reduction catalyst when an exhaust gas flowed in said NOx chemisorption reduction catalyst is under said oxidizing atmosphere, is reduced and released as N₂ by controlling an air fuel ratio so that the exhaust gas flowed in said NOx chemisorption reduction catalyst becomes a reducing atmosphere, and

wherein said NOx chemisorption reduction catalyst includes a porous suppport of inorganic oxide, an oxide of a NOx chemisorption component, an oxide of a rare-earth metal and a noble metal, and said NOx chemisorption component comprises at last one kind of element selected from a group consisting of lithium, sodium, potassium, strontium and calcium, and titanium.

19. An exhaust gas purifying method according to claim 18,

wherein an operating condition determining means for determining an operating condition of said internal combustion engine and an air fuel ratio control means are provided, said operating condition determining means having an SOx absorbed amount estimating means and a SOx released amount estimating means;

an amount of SOx absorbed by the SOx absorbent under said oxidizing atmosphere is estimated by said SOx absorbed amount estimating means, an operating condition of an combustion chamber is switched so as to produce a reducing atmospheric exhaust gas by said air fuel ratio control means if said SOx absorbed amount estimating means judges that a cumulative value of said amount of absorbed SOx reaches a predetermined value;

an amount of SOx released from the SOx absorbent under said reducing atmosphere is estimated by said SOx released amount estimating means, an operating condition of the combustion chamber is switched so as to produce an oxidizing atmospheric exhaust gas by said air fuel ratio control means if said SOx released amount estimating means judges that a cumulative value of said amount of released SOx reaches a predetermined value.

20. An exhaust gas purifying method according to claim 18,

wherein the NOx in the exhaust gas is cleaned while the NOx purifying catalyst is being prevented or suppressed to absorb SOx by providing an exhaust gas temperature measuring means for measuring an exhaust gas temperature flowing to said SOx absorbing material, a time measuring means for respectively measuring a time period in which the exhaust gas is an oxidizing atmosphere and a time period in which the exhaust gas is a reductive atmosphere, an exhaust gas velocity estimating means for estimating a velocity of the exhaust gas discharged from a combustion chamber, an operating condition determining means including an SOx absorbed amount estimating means and an SOx discharged amount estimating means, and an air-to-fuel ratio control means;

and said method

estimating an SOx absorbed amount under said oxidizing atmosphere by said SOx absorbed amount estimating means using a fuel injection rate obtained from said air-to-fuel ratio control means, an exhaust gas flow rate obtained from said exhaust gas amount determining means, an exhaust gas temperature obtained from said exhaust gas temperature measuring means and an operating time obtained from said time measuring means;

switching an operating condition of an combustion chamber so as to produce a reductive atmosphere exhaust gas by said air-to-fuel ratio control means if said SOx absorbed amount estimating means judges that a cumulative value of said amount of absorbed SOx reaches a predetermined value;

estimating a time period required for discharging SOx under said reductive atmosphere by said SOx discharged amount estimating means using an exhaust gas temperature and an exhaust gas flow rate and a predetermined SOx discharged amount from the SOx absorbing material;

measuring a time period in which the exhaust gas is a reductive atmosphere by said time measuring means; and

switching an operating condition of the combustion chamber so as to produce an oxidizing atmosphere exhaust gas by said air-to-fuel ratio control means if said SOx discharged amount estimating means judges that said time period in which the exhaust gas is the reductive atmosphere exceeds said estimated time period.

21. A method of recovering a NOx chemisorption reduction catalyst, arranged in an exhaust path of an internal combustion engine and detracted from the NOx purifying ability by adsorption or absorption of SOx in an exhaust gas, wherein when a running distance or time reaches a predetermined condition, an operation is switched to a fuel rich combustion operation or stoichiometric combustion operation to release SOx from said NOx chemisorption reduction catalyst even if the operation is in a fuel lean combustion operation.

22. A method of recovering a NOx chemisorption reduction catalyst, arranged in an exhaust path of an internal combustion engine and detracted from the NOx purifying ability by adsorption or absorption of SOx in an exhaust gas, wherein

said method comprises the steps of

estimating an amount of sulfur oxides discharged to the exhaust gas from a sulfur concentration contained in a fuel and a consumed amount of the fuel;

estimating an amount of said sulfur oxides absorbed into said catalyst, a produced amount of sulfurous salts and a converted amount from the sulfurous salts to sulfuric salts from an exhaust gas temperature and/or a catalyst temperature; and

allowing a rich gas or a stoichiometric gas to flow through said passage to reduce and decompose the sulfurous salts by forming a reductive atmosphere when an amount of the sulfurous salts or the sulfuric salts existing in the catalyst estimated from the cumulative values reaches a predetermined value.

23. A method of recovering a NOx chemisorption reduction catalyst, arranged in an exhaust path of an internal combustion engine and detracted from the NOx purifying ability by adsorption or absorption of SOx in an exhaust gas, wherein

said method comprises the steps of

estimating an amount of sulfur oxides discharged to the exhaust gas from a sulfur concentration contained in a fuel and a consumed amount of the fuel;

estimating an amount of said sulfur oxides absorbed into said catalyst, a produced amount of sulfurous salts and a converted amount from the sulfurous salts to sulfuric salts from an exhaust gas temperature and/or a catalyst temperature; and

allowing a rich gas or a stoichiometric gas to flow through said passage to reduce and decompose the sulfurous salts by forming a reductive atmosphere when an amount of the sulfurous salts or the sulfuric salts existing in the catalyst estimated from the accumulated amounts under an oxygen rich atmosphere reaches a predetermined value.

24. A method of recovering a NOx chemisorption reduction catalyst, arranged in an exhaust path of an internal combustion engine and detracted from the NOx purifying ability by adsorption or absorption of SOx in an exhaust gas, wherein

said method comprises the steps of

detecting a concentration of nitrogen oxides in the exhaust gas at the timing when a predetermined time elapses after switching from operating under a reductive atmosphere condition to operation under an oxygen rich condition using a signal from a nitrogen oxide sensor arranged downstream of the exhaust gas purifying catalyst of the exhaust gas passage;

estimating a decreasing ratio of nitrogen oxide purifying rate from said concentration of nitrogen oxides by calculation; and

allowing a rich gas or a stoichiometric gas to flow through said passage to reduce and decompose the sulfurous salts by forming a reductive atmosphere when an amount of the sulfurous salts and an amount of the sulfuric salts existing in the catalyst estimated from the decreasing ratio of nitrogen oxide purifying rate reaches a predetermined value.