SCR catalyst ammonia surface coverage estimation and control

• US 8,733,083 B2
• Filed: 04/26/2010
• Issued: 05/27/2014
• Est. Priority Date: 04/26/2010
• Status: Active Grant

• Current Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Original Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Inventors: Ofoli, Abdul R., Mohammed, Hasan
• Primary Examiner(s): Bomberg, Kenneth
• Assistant Examiner(s): AYALA DELGADO, ANTHONY
• Application Number:
  US12/767,664
• Publication Number:
  US 20110262329A1
• Time in Patent Office: 1,492 Days
• Field of Search: 60272-324, 423/213.2, 422/177, 422/110
• US Class Current: 60/286
• CPC Class Codes: B01D 2251/2062 Ammonia
• CPC Class Codes: B01D 2251/2067 Urea
• CPC Class Codes: B01D 2251/208 Hydrocarbons
• CPC Class Codes: B01D 2255/20723 Vanadium
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/911 NH3-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/90 Injecting reactants
• CPC Class Codes: B01D 53/9431 Processes characterised by a specific device
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2570/18 Ammonia
• CPC Class Codes: F01N 2900/0411 using a feed-forward control
• CPC Class Codes: F01N 2900/0412 using pre-calibrated maps, tables or charts
• CPC Class Codes: F01N 2900/0418 using integration or an accumulated value within an elapsed period
• CPC Class Codes: F01N 2900/1402 Exhaust gas composition
• CPC Class Codes: F01N 2900/1411 Exhaust gas flow rate, e.g. mass flow rate or volumetric flow rate
• CPC Class Codes: F01N 2900/1602 : Temperature of exhaust gas apparatus
• CPC Class Codes: F01N 2900/1616 : NH3-slip from catalyst
• CPC Class Codes: F01N 2900/1622 : Catalyst reducing agent absorption capacity or consumption amount
• CPC Class Codes: F01N 3/035 : with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/208 : Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Described herein are various embodiments of an apparatus, a system, and a methods for reducing NO_x emissions using ammonia storage on an SCR catalyst. For example, according to one embodiment, an apparatus for controlling an SCR system of an internal combustion engine system includes an ammonia storage module and a reductant dosing module. The ammonia storage module determines an ammonia storage surface coverage on an SCR catalyst of the SCR system and an ammonia compensation value based on one of an excess ammonia flow rate entering the SCR catalyst and an excess NO_x flow rate entering the SCR catalyst. The reductant dosing module that generates a reductant dosing command based on the ammonia compensation value.

Claims

1. An apparatus for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

an ammonia storage module that determines an actual ammonia storage surface coverage on an SCR catalyst of the SCR system based on one of an excess ammonia flow rate entering an SCR catalyst and an excess NO_x flow rate entering the SCR catalyst, wherein the excess ammonia flow rate, excess NO_x flow rate, and actual ammonia storage surface coverage is determined without input from a NO_x concentration sensor downstream of the SCR system, the ammonia storage module being further configured to determine an ammonia compensation value based on the actual ammonia storage surface coverage, the ammonia storage module comprising;

a mode determination module that determines the operating mode of the SCR system based on a pre-calibrated zero ammonia slip threshold as one of;

an ammonia adsorption mode when an ammonia/NOx ratio of exhaust gas entering the SCR catalyst is greater than the pre-calibrated zero ammonia slip threshold,

an ammonia desorption mode when the ammonia/NOx ratio is less than the pre-calibrated zero ammonia slip threshold, and

a neutral mode when the ammonia/NOx ratio is equal to the pre-calibrated zero ammonia slip threshold; and

a reductant dosing module that generates a reductant dosing command based on the ammonia compensation value;

wherein the ammonia storage module, reductant dosing module, and mode determination module each comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

12. The apparatus of claim 1, wherein the ammonia compensation value comprises an ammonia compensation flow rate, the ammonia compensation flow rate being based on a difference between the determined actual ammonia storage surface coverage and a predetermined ammonia storage surface coverage threshold.

2. An apparatus for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

an ammonia storage module that determines an actual ammonia storage surface coverage on an SCR catalyst of the SCR system based on one of an excess ammonia flow rate entering an SCR catalyst and an excess NOx flow rate entering the SCR catalyst, wherein the excess ammonia flow rate, excess NOx flow rate, and actual ammonia storage surface coverage is determined without input from a NOx concentration sensor downstream of the SCR system, the ammonia storage module being further configured to determine an ammonia compensation value based on the actual ammonia storage surface coverage, the ammonia storage module comprising;

a mode determination module that determines the operating mode of the SCR system as one of an ammonia absorption mode, an ammonia desorption mode, and a neutral mode based on a pre-calibrated zero ammonia slip threshold, and

an excess ammonia flow rate module that determines the excess ammonia flow rate when the mode determination module determines the SCR system is operating in the adsorption mode;

wherein, when the mode determination module determines the SCR system is operating in the adsorption mode, the ammonia compensation value is at least partially based on the excess ammonia flow rate; and

a reductant dosing module that generates a reductant dosing command based on the ammonia compensation value;

wherein the ammonia storage module, reductant dosing module, mode determination module, and excess flow rate module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

3. The apparatus of claim 2, wherein the ammonia storage module further comprises an ammonia adsorption mode module that estimates an actual ammonia storage surface coverage of the SCR catalyst based on the excess ammonia flow rate and a current temperature of the SCR catalyst, and wherein the ammonia adsorption mode module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

4. The apparatus of claim 3, wherein the ammonia adsorption mode module comprises stored system dynamic adsorption time constant values relative to excess ammonia flow rates and SCR catalyst temperatures, the ammonia adsorption mode module estimating a rate of change of the actual ammonia storage surface coverage by comparing the excess ammonia flow rate and a current temperature of the SCR catalyst to the stored system dynamic time constant values, wherein the actual ammonia storage surface coverage is based on a mathematical integration of the estimated rate of change of the actual ammonia storage surface coverage.

5. The apparatus of claim 3, wherein the stored actual ammonia storage surface coverage values for SCR catalyst temperatures above high temperature threshold are approximately zero percent such that the estimated actual ammonia storage surface coverage is automatically reset following high exhaust temperature events.

6. The apparatus of claim 3, wherein:

the ammonia storage module further comprises an ammonia storage control module that determines the ammonia compensation value based on the estimated actual ammonia storage surface coverage and a predetermined ammonia storage surface coverage threshold;

the ammonia compensation value is negative if the estimated actual ammonia storage surface coverage is greater than the predetermined ammonia storage surface coverage threshold;

the ammonia compensation value is positive if the estimated actual ammonia storage surface coverage is less than the predetermined ammonia storage surface coverage threshold; and

wherein the ammonia storage control module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

7. An apparatus for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

an ammonia storage module that determines an actual ammonia storage surface coverage on an SCR catalyst of the SCR system based on one of an excess ammonia flow rate entering an SCR catalyst and an excess NOx flow rate entering the SCR catalyst, wherein the excess ammonia flow rate, excess NOx flow rate, and actual ammonia storage surface coverage is determined without input from a NOx concentration sensor downstream of the SCR system, the ammonia storage module being further configured to determine an ammonia compensation value based on the actual ammonia storage surface coverage, the ammonia storage module comprising;

an excess NOx flow rate module that determines the excess NOx flow rate when the mode determination module determines the SCR system is operating in the desorption mode;

wherein, when the mode determination module determines the SCR system is operating in the desorption mode, the ammonia compensation value being at least partially based on the excess NOx flow rate; and

a reductant dosing module that generates a reductant dosing command based on the ammonia compensation value;

wherein the ammonia storage module, reductant dosing module, mode determination module, and excess NOx flow rate module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

8. The apparatus of claim 7, wherein the ammonia storage module further comprises an ammonia desorption mode module that estimates an actual ammonia storage surface coverage of the SCR catalyst based on the excess NO_x flow rate and a current temperature of the SCR catalyst, wherein the ammonia desorption module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

9. The apparatus of claim 8, wherein the ammonia desorption mode module comprises stored system dynamic desorption time constant values relative to excess NO_x flow rates and SCR catalyst temperatures, the ammonia desorption mode module estimating a rate of change of the actual ammonia storage surface coverage by comparing the excess NO_x flow rate and a current temperature of the SCR catalyst to the stored system dynamic time constant values, wherein the actual ammonia storage surface coverage is based on a mathematical integration of the estimated rate of change of the actual ammonia storage surface coverage.

10. The apparatus of claim 8, wherein:

the ammonia storage module further comprises an ammonia storage control module that determines the ammonia compensation value based on the estimated actual ammonia storage surface coverage and a predetermined ammonia storage surface coverage threshold;

the ammonia compensation value is negative if the estimated actual ammonia storage surface coverage is greater than the predetermined ammonia storage surface coverage threshold;

the ammonia compensation value is positive if the estimated actual ammonia storage surface coverage is less than the predetermined ammonia storage surface coverage threshold;

wherein the ammonia storage control module comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

11. An apparatus for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

an ammonia storage module that determines an actual ammonia storage surface coverage on an SCR catalyst of the SCR system based on one of an excess ammonia flow rate entering an SCR catalyst and an excess NOx flow rate entering the SCR catalyst, wherein the excess ammonia flow rate, excess NOx flow rate, and actual ammonia storage surface coverage is determined without input from a NOx concentration sensor downstream of the SCR system, the ammonia storage module being further configured to determine an ammonia compensation value based on the actual ammonia storage surface coverage; and

a reductant dosing module that generates a reductant dosing command based on the ammonia compensation value;

wherein the ammonia storage module utilizes a feedforward model exclusively for determining the ammonia surface coverage and the ammonia compensation value;

wherein the ammonia storage module and reductant dosing module each comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

13. A selective catalytic reduction (SCR) system, comprising:

a reductant dosing system that doses reductant into an exhaust gas stream via a reductant doser;

an SCR catalyst that receives the exhaust gas stream and is positioned downstream of the reductant dosing system, wherein the SCR catalyst stores thereon ammonia present in the exhaust gas stream; and

a controller that controls a dosing rate of reductant dosed into the exhaust gas stream by the reductant dosing system based on an excess ammonia flow rate in the exhaust gas stream in an ammonia storage adsorption mode and an excess NOx flow rate in the exhaust gas stream in an ammonia storage desorption mode, wherein the controller determines an actual ammonia storage surface of the SCR catalyst based on one of the excess ammonia and excess NOx flow rates without input from a NOx sensor downstream from the SCR catalyst;

wherein the excess ammonia flow rate is based on the difference between an ammonia flow rate in the exhaust gas stream and the product of a NOx flow rate in the exhaust gas stream and a zero slip ammonia/NOx ratio;

wherein the excess NOx flow rate is based on the difference between a NOx flow rate in the exhaust gas stream and the product of an ammonia flow rate in the exhaust gas stream and the zero slip ammonia/NOx ratio;

wherein the controller comprises one or more of logic hardware and executable code, the executable code stored on one or more non-transitory machine-readable storage media.

14. The SCR system of claim 13, wherein:

the controller estimates all the actual ammonia storage surface coverage of the SCR catalyst based on the excess ammonia flow rate in the ammonia storage adsorption mode and the excess NOx flow rate in the ammonia storage desorption mode; and

the controller increases the dosing rate if the estimated actual ammonia storage surface coverage is less than a predetermined desired ammonia storage surface coverage threshold and decreases the dosing rate if the estimated actual ammonia storage surface coverage is more than the predetermined desired ammonia storage surface coverage threshold.

15. The SCR system of claim 14, wherein the desired ammonia storage surface coverage threshold is dependent on an age of the SCR catalyst.

16. A method for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

determining a nominal reductant dosing rate for the SCR system;

determining an operating mode of the SCR system as one of;

an adsorption mode if an ammonia/NOx ratio in the exhaust gas stream is greater than a pre-calibrated zero slip ammonia/NOx ratio for a given SCR catalyst temperature, and

a desorption mode if the ammonia/NOx ratio in the exhaust gas stream is less than the pre-calibrated zero slip ammonia/NOx ratio for the given SCR catalyst temperature;

if the determined operating mode of the SCR system is the adsorption mode, estimating an actual ammonia storage surface coverage of the SCR system based on an excess ammonia flow rate in an exhaust gas stream flowing through the SCR system without input from a NOx sensor downstream from the SCR system;

if the determined operating mode of the SCR system is the desorption mode, estimating the actual ammonia storage surface coverage of the SCR system based on an excess NOx flow rate in the exhaust gas stream independently of the concentration of NOx in the exhaust gas stream downstream from the SCR system;

if the estimated actual ammonia storage surface coverage is greater than a desired ammonia storage surface coverage threshold, reducing the determined nominal reductant dosing rate;

if the estimated actual ammonia storage surface coverage is less than a desired ammonia storage surface coverage threshold, increasing the determined nominal reductant dosing rate; and

dosing reductant into the exhaust gas stream according to one of the reduced or increased nominal reductant dosing rates.

17. A method for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system, comprising:

determining a nominal reductant dosing rate for the SCR system;

determining an operating mode of the SCR system as one of an adsorption and desorption mode;

if the determined operating mode of the SCR system is the adsorption mode, estimating an actual ammonia storage surface coverage of the SCR system based on an excess ammonia flow rate in an exhaust gas stream flowing through the SCR system without input from a NOx sensor downstream from the SCR system;

if the determined operating mode of the SCR system is the desorption mode, estimating the actual ammonia storage surface coverage of the SCR system based on an excess NOx flow rate in the exhaust gas stream independently of the concentration of NOx in the exhaust gas stream downstream from the SCR system;

if the estimated actual ammonia storage surface coverage is greater than a desired ammonia storage surface coverage threshold, reducing the determined nominal reductant dosing rate;

if the estimated actual ammonia storage surface coverage is less than a desired ammonia storage surface coverage threshold, increasing the determined nominal reductant dosing rate;

dosing reductant into the exhaust gas stream according to one of the reduced or increased nominal reductant dosing rates; and

automatically resetting the estimated ammonia storage surface area to zero to account for high exhaust temperature events by estimating the actual ammonia storage surface coverage of the SCR system.