Exhaust catalyst system

• US 7,743,606 B2
• Filed: 11/18/2004
• Issued: 06/29/2010
• Est. Priority Date: 11/18/2004
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Shahed, Syed M., Samad, Tariq, Rhodes, Michael L., Lu, Joseph Z., Havlena, Vladimir
• Primary Examiner(s): Tran; Binh Q
• Application Number:
  US10/992,254
• Publication Number:
  US 20060101812A1
• Time in Patent Office: 2,049 Days
• Field of Search: 602/74, 602/86, 602/87, 602/88, 602/91, 602/92, 602/95, 602/96, 602/97, 602/98, 603/11, 603/24
• US Class Current: 60/295
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/0093 the purifying devices are of the same type
• CPC Class Codes: F01N 13/011 having two or more purifying devices arranged in parallel
• CPC Class Codes: F01N 2410/04 during regeneration period, e.g. of particle filter
• CPC Class Codes: F01N 2410/12 in case of absorption, adsorption or desorption of exhaust gas constituents
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/0807 by using absorbents or adsorbents
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F01N 3/085 Sulfur or sulfur oxides
• CPC Class Codes: F01N 3/0878 Bypassing absorbents or adsorbents
• CPC Class Codes: F01N 3/2053 By-passing catalytic reactors, e.g. to prevent overheating
• 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 3/2093 Periodically blowing a gas through the converter, e.g. in a direction opposite to exhaust gas flow or by reversing exhaust gas flow direction
• CPC Class Codes: F01N 9/005 using models instead of sensors to determine operating characteristics of exhaust systems, e.g. calculating catalyst temperature instead of measuring it directly

Abstract

A catalyst system that may regenerate while removing pollutants from an exhaust gas of an engine. The system may have a converter with multiple segments of chambers. At least one of the chambers may be regenerated while the remaining chambers are removing pollutants from the exhaust. The chambers may be rotated in turn for one-at-a-time regeneration. More than one chamber may be regenerated at a time to remove collected pollutants. The system may have plumbing and valves, and possibly mechanical movement of the chambers, within the system to effect the changing of a chamber for regeneration. The chambers connected to the exhaust may be in series or parallel. A particulate matter filter may be connected to the system, and it also may be regenerated to remove collected matter.

Claims

1. A catalyst device comprising:

a plurality of sections having a material for adsorbing and catalyst for appropriate chemical treatment of NOx, the plurality of sections for connection to an exhaust of an engine;

a source of regeneration fluid; and

a plurality of valves positioned between the sections, the valves regulating flow of exhaust through the sections and regulating flow of regeneration fluid through the sections, wherein the valves are configured to allow flow in only one direction through each section;

wherein each section, one at a time, is in a regeneration stage to reduce adsorbed NOx.

2. The device of claim 1, wherein the sections of the plurality of sections, except the section in the regeneration stage, are connected in series.

3. The device of claim 1, wherein the plurality of sections, except the section in the regeneration stage, is interconnected in parallel.

4. The device of claim 1, wherein the section in the regeneration stage is connected to a flow which heats up the section sufficiently to reduce adsorbed NOx.

5. The device of claim 4, wherein:

each section of the plurality of sections is disconnected from the exhaust and connected to the flow which heats up the section; and

the section in the regeneration stage is reconnected to the exhaust.

6. The device of claim 3, wherein the section in the regeneration stage is connected to a flow which heats up the section sufficiently to reduce accumulated SOx in the section.

7. The device of claim 6, further comprising a filter.

8. The device of claim 7, wherein the filter is connected to at least one of the plurality sections.

9. The device of claim 8, wherein the filter, at certain times, is connected to a flow that is sufficient to regenerate the filter.

10. The device of claim 9, wherein to regenerate the filter is to oxidize particulate matter in the filter.

11. A catalyst system comprising:

at least two chambers having a catalyst material, the chambers connected to an exhaust of an engine; and

wherein the at least two chambers are separately connectable one at a time to a regenerating fluid, wherein regeneration flow through the chambers is independent of exhaust flow through the chambers, wherein regeneration fluid flows through the chambers in the same direction as exhaust flow.

12. The system of claim 11, wherein the regenerating fluid is for reducing the amount of adsorbed NOx in a chamber.

13. The system of claim 11, wherein the regenerating fluid is for reducing an amount of adsorbed SOx in a chamber.

14. The system of claim 11, further comprising a filter connected to at least one chamber of the at least two chambers.

15. The system of claim 14, wherein the regenerating fluid is for reducing an amount of particulate matter in the filter.

16. The system of claim 12, wherein the at least two chambers minus one are connected to an exhaust of an engine.

17. A catalytic converter comprising:

a housing having a plurality of chambers; and

wherein;

at least two chambers of the plurality of chambers are for processing an engine exhaust fluid;

at least one chamber of the plurality of chambers is temporarily for being regenerated; and

a plurality of valves positioned between the chambers, the valves configured to divert fluid flow from the chamber being regenerated such that it bypasses the chambers for processing exhaust fluid, wherein the valves are configured to direct a regeneration fluid through the chamber being regenerated in the same direction as the exhaust fluid flows through the chambers processing the exhaust fluid.

18. The converter of claim 17, wherein the at least one chamber temporarily for being regenerated is subject to being occasionally replaced by another at least one chamber temporarily for being regenerated.

19. The converter of claim 17, wherein:

the processing is removing at least some of the NOx and/or SOx from the exhaust gas; and

the being regenerated is an elimination of at least some of the NOx and/or SOx in the at least one chamber.

20. The converter of claim 19, wherein the at least two chambers are connected in series.

21. The converter of claim 19, further comprising a particulate matter filter connected to the at least one chamber for processing the fluid.

22. The converter of claim 21, wherein the filter is occasionally regenerated to reduce an amount of particulate matter in the filter.

23. The converter of claim 22, wherein the at least two chambers are connected in parallel.

24. A method for attaining a regenerative catalyst system, comprising:

providing a multi-unit catalyst system;

connecting the system to an exhaust system so that at least one unit is not connected to the exhaust system;

connecting the at least one unit to a source of gas to regenerate the at least one unit without reversing flow direction; and

upon a partial or more regeneration of the at least one unit, exchanging the at least one unit with another at least one unit of the multi-unit catalyst system, for a partial or more regeneration of the another at least one unit.

25. The method of claim 24, further comprising:

a plurality of valves situated between the units; and

operating the valves to exchange the at least one unit with another unit of the multi-unit system for a partial or more regeneration of the another at least one unit.

26. The method of claim 25, further comprising:

attaching actuators to the valves;

connecting the actuators to a processor; and

programming the processor to operate the valves to achieve the method of the preceding claims.

27. The method of claim 26, further comprising:

connecting a filter to the multi-unit catalyst system; and

regenerating the filter as needed.

28. Means for regenerating a catalyst, comprising:

means for removing pollutants from an exhaust of an engine; and

means for regenerating; and

wherein;

the means for removing pollutants is partitioned into a plurality of segments;

at least one segment of the plurality of segments is connected to the means for regenerating; and

the at least one segment is exchanged occasionally with another at least one segment from the plurality of segments;

wherein flow through the regenerating segment is independent of and in the same direction as flow through remaining segments.

29. The means of claim 28, wherein the at least one segment is replaced with another at least one segment from the plurality of segments when the at least one segment is at least partially regenerated.

30. The means of claim 29, further comprising a means for filtering particulate matter from the exhaust of an engine.

31. The means of claim 29, further comprising:

means for exchanging segments;

sensors situated in the plurality of segments; and

a processor connected to the sensors and the means for exchanging segments.

32. A regeneration system comprising:

a unit having at least two catalyst segments;

a mechanism for selecting out a segment from the unit for regeneration;

sensors in the segments;

a plurality of valves situated between the segments, the valves configured to divert flow for regeneration without reversing flow direction; and

a controller connected to the sensors and to the mechanism for selecting out a segment.

33. The system of claim 32, further comprising a filter connected to the unit having at least two catalyst segments.