Method and apparatus for controlling a gas-emitting process and related devices

• US 7,231,290 B2
• Filed: 10/14/2003
• Issued: 06/12/2007
• Est. Priority Date: 04/05/2002
• Status: Expired due to Fees

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Morris, Patricia A., Barnes, John James, Steichen, John Carl
• Primary Examiner(s): Wolfe, Jr.; Willis R.
• Assistant Examiner(s): Hoang; Johnny H.
• Application Number:
  US10/406,970
• Publication Number:
  US 20040039514A1
• Time in Patent Office: 1,337 Days
• Field of Search: 701/103, 701/109, 701/106, 701/108, 701/114, 123/703, 123/674, 123/704, 602/76, 602/78, 602/85, 700/32
• US Class Current: 701/109
• CPC Class Codes: F01N 11/002 the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus
• CPC Class Codes: F01N 11/007 the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus
• CPC Class Codes: F01N 2430/06 by varying fuel-air ratio, e.g. by enriching fuel-air mixture
• CPC Class Codes: F01N 2560/022 for measuring or detecting CO or CO2
• CPC Class Codes: F01N 2560/023 for measuring or detecting HC
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2560/027 for measuring or detecting SOx
• CPC Class Codes: F01N 2560/028 for measuring or detecting humidity or water
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F02D 2041/1468 the characteristics being an ammonia content or concentration of the exhaust gases
• CPC Class Codes: F02D 2041/147 the characteristics being a hydrogen content or concentration of the exhaust gases
• CPC Class Codes: F02D 41/1441 Plural sensors
• CPC Class Codes: F02D 41/1444 characterised by the characteristics of the combustion gases
• CPC Class Codes: F02D 41/1459 the characteristics being a hydrocarbon content or concentration
• CPC Class Codes: F02D 41/146 the characteristics being an NOx content or concentration
• CPC Class Codes: G01N 33/0031 comprising two or more sensors, e.g. a sensor array electrochemical electrode arrays G01N27/27
• 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: Y02T 10/40 Engine management systems

Abstract

Disclosed herein is a method and apparatus for controlling a process, such as a chemical reaction, that emits a multi-component mixture of gases; and for controlling a device to which is transmitted a product of a chemical reaction that emits a multi-component mixture of gases.

Claims

1. A method for controlling a process that emits a multi-component mixture of gases, wherein the mixture is comprised of various individual component gases each of which has an individual concentration within the mixture;

wherein a subgroup of the mixture is comprised of at least two but less than all of the component gases of the mixture;

wherein the members of a subgroup of gases together have a collective concentration within the mixture; and

wherein the method comprises

(a) providing at least first and second signals, the first signal being related to the individual concentration within the unseparated components of the emitted gas mixture of an individual component gas therein, and the second signal being related to the collective concentration within the unseparated components of the emitted gas mixture of a subgroup of the component gases therein;

(b) inputting the signal(s) to a decision-making routine for controlling the process; and

(c) outputting a signal from the decision-making routine for adjusting an operating characteristic of the process.

2. A method according to claim 1 comprising providing a third signal that is related to the individual concentration within the emitted gas mixture of a second individual component gas therein.

3. A method according to claim 1 comprising providing a third signal that is related to the collective concentration within the emitted gas mixture of a second subgroup of component gases therein.

4. A method according to claim 1 wherein at least one signal is the concentration within the emitted gas mixture of an individual component gas or a subgroup of component gases.

5. A method according to claim 1 wherein at least one signal is related to voltage, current, resistance, impedance, or capacitance.

6. A method according to claim 1 wherein the individual component gas within the gas mixture is selected from the group consisting of oxygen, carbon monoxide, hydrogen, sulfur dioxide, ammonia, CO₂, H₂S, methanol, and water.

7. A method according to claim 1 wherein the individual component gas within the gas mixture is not oxygen.

8. A method according to claim 1 wherein the components of a subgroup comprise hydrocarbons or nitrogen oxides.

9. A method according to claim 1 wherein the process is a chemical reaction in which reactants are reacted, and the adjusted operating characteristic is the relative amount of the reactants in the reaction.

10. A method according to claim 1 wherein the process is combustion in an internal combustion engine.

11. A method according to claim 10 wherein the signal is provided from an array of chemo/electro-attive materials, and the array is located upstream or downstream from a catalytic converter or a device for the storage or abatement of NO_x.

12. A method according to claim 1 wherein the process is a biochemical reaction.

13. A method according to claim 1 wherein (a) the process is a chemical reaction (b) a product of the chemical reaction is transmitted to a device, and (c) the method further comprises situating an operating characteristic of the device.

14. A method according to claim 1 or 13 wherein at least one signal is provided by exposing an array of chemo/electro-active materials to the gas mixture.

15. A method according to claim 14 wherein at least one signal is proportional to the electrical resistance of a chemo/electro-active material when exposed to the gas mixture.

16. A method according to claims 1 or 15 wherein the first and second signals are determined on the occasion of being provided for input into the decision-making routine.

17. A method according to claims 1 or 15 wherein the first and second signals are inputted to a map.

18. A method according to claim 17 wherein the map relates information about the composition of the emitted gas mixture to information about an operating characteristic of the process.

19. A method according to claim 1 or 15 wherein an individual component gas within the gas mixtute is oxygen, and the components of a subgroup comprise hydrocarbons.

20. A method according to claim 1 or 13 wherein an individual component gas within the gas mixture is a reducing agent, and the components of a subgroup comprise nitrogen oxides.

21. A method according to claim 13 wherein the device is an internal combustion engine or a pollution abatement device.

22. A method according to claim 21 wherein the first and second signals are provided from an array of at least four chemo/electro-active materials, and the array is located upstream or downstream from a catalytic converter or a device for the storage or abatement of NO_x.

23. A method according to claim 10 or 21 wherein the decision-making routine controls the ratio of air to fuel supplied to the engine, controls an exhaust gas recycle valve for the engine, controls engine speed, or controls a pollution abatement device.

24. A method according to claim 12 wherein the biochemical reaction comprises fermentation.

25. A method according to claim 14 or 22 wherein the array of chemo/electro-active materials comprises at least four chemo/electro-active materials.

26. A method according to claim 14 or 22 wherein the chemo/electro-active materials comprise

(a) one or more members of the group consisting of M¹O_x, M¹_aM²_bO_x and M¹_aM²_bM³_cO_x wherein M¹, M², M³, a, b, c and x are as set forth below:

M¹ is selected from the group consisting of Al, Ce, Cr, Cu, Fe, Ga, Mn, Nb, Ni, Pr, Sb, Sn, Ta, Ti, W and Zn;

M² and M³ are each independently selected from the group consisting of Ga, La, Mn, Ni, Sn, Sr, Ti, W, Y, Zn;

M¹ and M² ave each different in M¹_aM²_bO_x, and M¹, M² and M³ are each different in M¹_aM²_bM³_cO_x;

a, b and c are each independently about 0.0005 to about 1; and

x is a number sufficient so tat the oxygen present balances the charges of the other elements in the chemo/electro-active material;

or

(b) one or more members of the group consisting of Al_aNi_bO_x, CeO₂, Cr_aMn_bO_x, Cr_aTi_bO_x, Cr_aY_bO_x, Cu_aGa_bO_x, Cu_aLa_bO_x, CuO, Fe_aLa_bO_x, Fe_aNi_bO_x, Fe_aTi_bO_x, Ga_aTi_bZn_cO_x, Mn_aTi_bO_x, Nb_aSr_bO_x, Nb_aTi_bO_x, Nb_aTi_bZn_cO_x, Nb_aW_bO_x, NiO, Ni_aZn_bO_x, Pr₆O₁₁, Sb_aSn_bO_x, SnO₂, Ta_aTi_bO_x, Ti_aZn_bO_x, WO₃ and ZnO;

wherein a, b, and c are each independently about 0.0005 to about 1; and

wherein x is a number sufficient so that the oxygen present balances the charges of the other elements in the chemo/electro-active material.

27. An apparatus for controlling a process that emits a multi-component mixture of gases, wherein the mixture is comprised of various individual component gases each of which has an individual concentration within the mixture;

wherein a subgroup of the mixture is comprised of at least two but less than all of the component gases of the mixture;

wherein the members of a subgroup of gases together have a collective concentration within the mixture; and

wherein the apparatus comprises

(a) an array of chemo/electro-active materials;

(b) means for determining the electrical response of each chemo/electro-active material upon exposure of the array to the unseparated components of the emitted gas mixture;

(c) means for determining (i) information related to the individual concentration within the emitted gas mixture of an individual component gas therein, and (ii) information related to the collective concentration within the emitted gas mixture of a subgroup of the component gases therein; and

(d) a decision-making routine for controlling the process in view of the information determined about the composition of the emitted gas mixture.

28. An apparatus according to claim 27 wherein (a) the process is a chemical reaction (b) a product of the chemical reaction is transmitted to a device, and (c) the decision-making routine controls the operation of the device.

29. An apparatus according to claim 27 wherein (a) the process is a chemical reaction (b) a product of the chemical reaction is transmitted to a device, and (c) the apparatus further comprises a decision-making routine for controlling the operation of the device in view of the information determined about the composition of the emitted gas mixture.

30. An apparatus according to claim 27, 28 or 29 which comprises means to determine the information about the composition of the emitted gas mixture, to be provided to the decision making routine, on the occasion of providing the information to the decision-making routine.

31. An apparatus according to claim 27, 28 or 29 further comprising a map to which the information about the composition of the emitted gas mixture is inputted.

32. An apparatus according to claim 31 wherein the map relates information about the composition of the emitted gas mutture to information about an operating characteristic of the process.

33. An apparatus according to claim 27 wherein the information about the composition of the gas mixture comprises the individual concentration therein of an individual component gas of the mixture.

34. An apparatus according to claim 27 wherein the information about the composition of the gas mixture comprises the collective concentration within the emitted gas mixture of a subgroup of the component gases therein.

35. An apparatus according to claim 27 wherein an individual component gas within the gas mixture is selected from the group consisting of oxygen, carbon monoxide, hydrogen, sulfur dioxide, ammonia, CO₂, H₂S, methanol and water.

36. An apparatus according to claim 27 wherein the conponents of a subgroup comprise hydrocarbons or nitrogen oxides.

37. An apparatus according to claim 27, 28 or 29 wherein an individual component gas within the gas mixture is oxygen, and the components of a subgroup comprise hydrocarbons.

38. An apparatus according to claim 27, 28 or 29 wherein an individual component gas within the gas mixture is a reducing agent and the components of a subgroup comprise nitrogen oxides.

39. An apparatus according to claim 27 wherein the process is a chemical reaction in which reactants are reacted, and the decision-making routine adjusts the relative amount of reactants in the reaction.

40. An apparatus according to claim 27 wherein the controlled process is combustion in an internal combustion engine.

41. An apparatus according to claim 28 or 29 wherein the device is an internal combustion engine or a pollution abatement device.

42. An apparatus according to claim 40 wherein the array of chemo/electro-active materials is located upstream or downstream from a catalytic converter or a device for the storage or abatement of NO_x.

43. An apparatus according to claim 41 wherein the array of chemo/electro-active materials is located upstream or downstream from a catalytic converter or a device for the storage or abatement of NO_x.

44. An apparatus according to claim 40 wherein the decision-making routine controls the ratio of air to fuel supplied to the engine, or controls an exhaust gas recycle valve for the engine, controls engine speed, or controls a pollution abatement device.

45. An apparatus according to claim 27 wherein the process or reaction is a biochemical reaction.

46. An apparatus according to claim 45 wherein the biochemical reaction is fermentation.

47. An apparatus according to claim 27, 28 or 29 wherein the array of chemo/electro-active materials comprises at least four chemo/electro-active materials.

48. A method according to claim 27, 28 or 29 wherein the chemo/electro-active materials comprise

(a) one or more members of the group consisting of M¹O_x, M¹_aM²_bO_x and M¹_aM²_bM³_cO_x wherein M¹, M², M³, a, b, c and x are as set forth below:

M¹ is selected from the group consisting of Al, Ce, Cr, Cu, Fe, Ga, Mn, Nb, Ni, Pr, Sb, Sn, Ta, Ti, W and Zn;

M² and M³ are each independently selected from the group consisting of Ga, La, Mn, Ni, Sn, Sr, Ti, W, Y, Zn;

M¹ and M² are each different in M¹_aM²_bO_x, and M¹, M² and M³ are each different in M¹_aM²_bM³_cO_x;

a, b and c are each independently about 0.0005 to about 1; and

x is a number sufficient so that the oxygen present balances the charges of the other elements in the chemo/electro-active material;

or

(b) one or more members of the group consisting of Al_aNi_bO_x, CeO₂, Cr_aMn_bO_x, Cr_aTi_bO_x, Cr_aY_bO_x, Cu_aGa_bO_x, Cu_aLa_bO_x, CuO, Fe_aLa_bO_x, Fe_aNi_bO_x, Fe_aTi_bO_x, Ga_aTi_bZn_cO_x, Mn_aTi_bO_x, Nb_aSr_bO_x, Nb_aTi_bO_x, Nb_aTi_bZn_cO_x, Nb_aW_bO_x, NiO, Ni_aZn_bO_x, Pr₆O₁₁, Sb_aSn_bO_x, SnO₂, Ta_aTi_bO_x, Ti_aZn_bO_x, WO₃ and ZnO;

wherein a, b, and c are each independently about 0.0005 to about 1; and

wherein x is a number sufficient so that the oxygen present balances the charges of the other elements in the chemo/electro-active material.

49. An apparatus according to claim 27, 28 or 29 which is a component part of a vehicle for transportation or a piece of equipment for construction, maintenance or industrial operations.