Selective catalytic reduction (SCR) system for NOx storage

• US 8,813,478 B2
• Filed: 12/15/2011
• Issued: 08/26/2014
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Gonze, Eugene V., Paratore, Michael J. Jr., Kim, Chang H., Schmieg, Steven J.
• Primary Examiner(s): BOGUE, JESSE SAMUEL
• Application Number:
  US13/327,291
• Publication Number:
  US 20130152553A1
• Time in Patent Office: 985 Days
• Field of Search: 60274-324
• US Class Current: 60/286
• CPC Class Codes: F01N 11/00 Monitoring or diagnostic devices for exhaust-gas treatment apparatus , e.g. for catalytic activity safety, indicating or supervising devices for internal combustion engines F02B77/08; testing of machines G01M13/00
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 2240/16 an electric heater, i.e. a resistance heater
• CPC Class Codes: F01N 3/2013 using electric or magnetic heating means
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F01N 3/208 Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: F01N 3/2892 Exhaust flow directors or the like, e.g. upstream of catalytic device
• CPC Class Codes: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

An exhaust gas treatment system for an internal combustion engine is provided, including an exhaust gas conduit, a flow-through container of absorbent particles, an electrically heated catalyst (“EHC”) device, a selective catalytic reduction (“SCR”) device, and a control module. The exhaust gas conduit is in fluid communication with, and is configured to receive an exhaust gas from the internal combustion engine. The exhaust gas contains oxides of nitrogen (“NO_x”) and water. The flow-through container of absorbent particles is in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas. The flow-through container substantially adsorbs the water from the exhaust gas below a threshold temperature. The EHC device is in fluid communication with the exhaust gas conduit and is configured to receive the exhaust gas. The EHC device is located downstream of the flow through container, and is selectively activated to produce heat.

Claims

1. An exhaust gas treatment system for an internal combustion engine, comprising:

an exhaust gas conduit in fluid communication with, and configured to receive an exhaust gas from the internal combustion engine, the exhaust gas containing oxides of nitrogen (“

NO_x”

) and water;

an oxidation catalyst (“

OC”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the OC device treats hydrocarbon and carbon monoxide to form carbon dioxide and water;

a flow-through container of absorbent particles in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas wherein the flow-through container is located downstream of the OC device, wherein the flow-through container substantially adsorbs water from the exhaust gas below a threshold temperature;

an electrically heated catalyst (“

EHC”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the EHC device is located downstream of the OC device and the flow through container of absorbent particles, and wherein the EHC device is selectively activated to produce heat;

a selective catalytic reduction (“

SCR”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the SCR device is located downstream of the flow through container and next to the EHC device, and wherein the SCR device is selectively heated by the EHC device to a SCR light-off temperature, and wherein the overall temperature of the SCR device is represented by a SCR temperature profile; and

a control module in communication with the EHC device, comprising;

a control logic for determining the SCR temperature profile; and

a control logic for activating the EHC device if the SCR temperature profile is below the SCR light-off temperature, wherein the EHC device is selectively activated to heat the SCR device to the SCR light-off temperature before the flow-through container of absorbent particles reaches the threshold temperature.

2. The exhaust treatment system of claim 1, further comprising:

a first temperature sensor situated upstream of the SCR device; and

a second temperature sensor situated downstream of the SCR device.

3. The exhaust treatment system of claim 2, wherein the control module includes control logic for monitoring the first temperature sensor and the second temperature sensor.

4. The exhaust treatment system of claim 3, wherein the control module includes a control logic for determining an EHC temperature of the EHC device based on the first temperature sensor, and wherein the control module includes control logic for deactivating the EHC device if the EHC temperature is above an EHC light-off temperature.

5. The exhaust treatment system of claim 3, wherein the control module includes a control logic for calculating the SCR temperature profile based on signals from the first temperature sensor and the second temperature sensor, wherein the temperatures of the first temperature sensor and the second temperature sensor are averaged together to create the SCR temperature profile.

6. The exhaust treatment system of claim 5, wherein a reductant injector is in fluid communication with the exhaust gas conduit and is in signal communication with the control module, and wherein the reductant injector is configured for dosing a reductant.

7. The exhaust treatment system of claim 6, further comprising a first NO_x sensor and a second NO_x sensor that are in fluid communication with the exhaust gas conduit, the first NO_x sensor located downstream of the internal combustion engine and upstream of the SCR device and the second NO_x sensor located downstream of the SCR device, and wherein the control module includes control logic for determining an amount of NO_x in the exhaust gas reduced by the SCR device based on the first NO_x sensor, the second NO_x sensor, and the SCR temperature profile temperature.

8. The exhaust treatment system of claim 7, wherein the control module includes control logic for determining an amount of the reductant the SCR device has stored therein during a previous cold start of the internal combustion engine.

9. The exhaust treatment system of claim 8, wherein the control module includes control logic for determining an amount of the reductant that has been consumed by the SCR device to convert the amount of NO_x in the exhaust gas reduced by the SCR device.

10. The exhaust treatment system of claim 9, wherein the control module includes control logic for activating the reductant injector to replace the reductant consumed by the SCR device to the amount of the reductant the SCR device has stored therein during the previous cold start of the internal combustion engine.

11. The exhaust treatment system of claim 1, wherein the threshold temperature is about 100°

C.

12. The exhaust treatment system of claim 1, wherein the flow-through container of absorbent particles includes one of alumina particles, activated carbon particles, water absorbent zeolite materials, and water absorbent molecular sieve materials.

13. The exhaust treatment system of claim 1, wherein the flow-through container of absorbent particles includes a selective catalyst composition applied as a washcoat on surfaces of a flow-through support.

14. The exhaust treatment system of claim 1, wherein a portion of the flow-through container of absorbent particles includes a selective catalyst composition applied as a washcoat on surfaces of a flow-through support, and a remaining portion of the flow-through container of absorbent particles does not include the selective catalyst composition.

15. The exhaust treatment system of claim 1, wherein the control module includes control logic for monitoring a water holding capacity of the flow-through container of absorbent particles.

16. An exhaust gas treatment system for an internal combustion engine, comprising:

an exhaust gas conduit in fluid communication with, and configured to receive an exhaust gas from the internal combustion engine, the exhaust gas containing oxides of nitrogen (“

NO_x”

) and water;

an oxidation catalyst (“

OC”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the OC device treats hydrocarbon and carbon monoxide to form carbon dioxide and water;

a flow-through container of absorbent particles in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the flow-through container is located downstream of the OC device, wherein the flow-through container substantially adsorbs water from the exhaust gas below a threshold temperature;

an electrically heated catalyst (“

EHC”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the EHC device is located downstream of the OC device and the flow through container, and wherein the EHC device is selectively activated to produce heat;

a selective catalytic reduction (“

SCR”

) device in fluid communication with the exhaust gas conduit and configured to receive the exhaust gas, wherein the SCR device is located downstream of the flow through container and next to the EHC device, and wherein the SCR device is selectively heated by the EHC device to a SCR light-off temperature, and wherein the overall temperature of the SCR device is represented by a SCR temperature profile;

a first temperature sensor and a second temperature sensor, the first temperature sensor situated upstream of the SCR device and the second temperature sensor situated downstream of the SCR device; and

a control module in communication with the EHC device, the first temperature sensor, and the second temperature sensor, comprising;

a control logic for monitoring the first temperature sensor and the second temperature sensor;

a control logic for calculating the SCR temperature profile based on signals from the first temperature sensor and the second temperature sensor, wherein the temperatures of the first temperature sensor and the second temperature sensor are averaged together to create the SCR temperature profile; and

a control logic for activating the EHC device if the SCR temperature profile is below the SCR light-off temperature, wherein the EHC device is selectively activated to heat the SCR device to the SCR light-off temperature before the flow-through container of absorbent particles reaches the threshold temperature.

17. The exhaust treatment system of claim 16, wherein a reductant injector is in fluid communication with the exhaust gas conduit and is in signal communication with the control module, and wherein the reductant injector is configured for dosing a reductant.

18. The exhaust treatment system of claim 17, further comprising a first NO_x sensor and a second NO_x sensor that are in fluid communication with the exhaust gas conduit, the first NO_x sensor located downstream of the internal combustion engine and upstream of the SCR device and the second NO_x sensor located downstream of the SCR device, and wherein the control module includes control logic for determining an amount of NO_x in the exhaust gas reduced by the SCR device based on the first NO_x sensor, the second NO_x sensor, and the SCR temperature profile temperature.

19. The exhaust treatment system of claim 18, wherein the control module includes control logic for determining an amount of the reductant the SCR device has stored therein during a previous cold start of the internal combustion engine.

20. The exhaust treatment system of claim 19, wherein the control module includes control logic for determining an amount of the reductant that has been consumed by the SCR device to convert the amount of NO_x in the exhaust gas reduced by the SCR device, and wherein the control module includes control logic for activating the reductant injector to replace the reductant consumed by the SCR device to the amount of the reductant the SCR device has stored therein during the previous cold start of the internal combustion engine.