Exhaust aftertreatment system for an internal combustion engine and method for operating same

• US 9,243,537 B1
• Filed: 09/17/2014
• Issued: 01/26/2016
• Est. Priority Date: 09/17/2014
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Ge, Xinyu
• Primary Examiner(s): Tran, Binh Q
• Application Number:
  US14/488,830
• Time in Patent Office: 496 Days
• Field of Search: 602/74, 602/86, 602/87, 602/88, 602/89, 602/92, 602/95, 602/97, 603/03, 603/24
• US Class Current: 1/1
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 2260/06 for improving exhaust evacuation or circulation, or reducing back-pressure
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F01N 3/103 Oxidation catalysts for HC and CO only
• CPC Class Codes: F01N 3/2053 By-passing catalytic reactors, e.g. to prevent overheating
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust aftertreatment system for an engine includes an exhaust valve assembly having a first port, a second port, and a third port, the exhaust valve assembly being configured to effect selective fluid communication between the first port, the second port, and the third port; an exhaust conduit fluidly coupled to an exhaust port of the engine and fluidly coupled to the first port of the exhaust valve assembly; an exhaust aftertreatment device fluidly coupled to the second port of the exhaust valve assembly; a bypass conduit fluidly coupled to the third port of the exhaust valve assembly, the bypass conduit configured to bypass a flow of exhaust around the exhaust aftertreatment device; a reductant supply in selective fluid communication with the exhaust conduit; and a controller operatively coupled to the exhaust valve assembly and the reductant supply.

Claims

1. An exhaust aftertreatment system for an engine, comprising:

an exhaust valve assembly having a first port, a second port, and a third port, the exhaust valve assembly being configured to effect selective fluid communication between the first port, the second port, and the third port;

an exhaust conduit fluidly coupled to an exhaust port of the engine and fluidly coupled to the first port of the exhaust valve assembly;

an exhaust aftertreatment device fluidly coupled to the second port of the exhaust valve assembly;

a bypass conduit fluidly coupled to the third port of the exhaust valve assembly, the bypass conduit configured to bypass a flow of exhaust around the exhaust aftertreatment device;

a reductant supply in selective fluid communication with the exhaust conduit; and

a controller operatively coupled to the exhaust valve assembly, the reductant supply, and the engine, the controller being configured to regenerate the exhaust aftertreatment device according to a first regeneration procedure when the engine operates in a substantially non-premixed mode, the first regeneration procedure including

delivering a first flow of reductant from the reductant supply to the exhaust aftertreatment device,

effecting fluid communication between the first port and the second port, and

blocking fluid communication between the first port and the third port.

2. The exhaust aftertreatment system of claim 1, wherein the substantially non-premixed mode is a conventional direct-injection compression ignition mode.

3. The exhaust aftertreatment system of claim 1, wherein the controller is further configured to block fluid communication between the first port and the second port, and effect fluid communication between the first port and the third port when the engine operates in a substantially premixed mode and the exhaust aftertreatment device is not being regenerated.

4. The exhaust aftertreatment system of claim 3, wherein the substantially premixed mode is one of a homogeneous charge compression ignition (HCCI) mode and a piloted-HCCI mode.

5. The exhaust aftertreatment system of claim 3, wherein the exhaust conduit includes an oxidation catalyst, the exhaust port of the engine being in fluid communication with the first port of the exhaust valve assembly via the oxidation catalyst.

6. The exhaust aftertreatment system of claim 5, wherein the controller is further configured to regenerate the exhaust aftertreatment device according to a second regeneration procedure when the engine operates in the substantially premixed mode, the second regeneration procedure including

delivering a second flow of reductant from the reductant supply to the exhaust aftertreatment device,

effecting fluid communication between the first port and the third port, and

effecting fluid communication between the first port and the second port, such that at least a portion of exhaust flow from the engine flows through the exhaust aftertreatment device.

7. The exhaust aftertreatment system of claim 5, wherein the controller is further configured to regenerate the exhaust aftertreatment device according to a second regeneration procedure when the engine operates in the substantially premixed mode, the second regeneration procedure including

delivering a second flow of reductant from the reductant supply to the exhaust aftertreatment device,

effecting fluid communication between the first port and the third port, and

blocking fluid communication between the first port and the second port.

8. The exhaust aftertreatment system of claim 5, wherein the controller is further configured to regenerate the exhaust aftertreatment device according to the first regeneration procedure when the engine operates in the substantially premixed mode.

9. The exhaust aftertreatment system of claim 3, wherein the substantially premixed mode is mainly fueled by a gaseous fuel, and the substantially non-premixed mode is mainly fueled by a liquid fuel.

10. The exhaust aftertreatment system of claim 3, wherein the substantially premixed mode and the substantially non-premixed mode are both mainly fueled by a liquid fuel.

11. The exhaust aftertreatment system of claim 1, wherein the controller is further configured to effect fluid communication between the first port and the second port, and block fluid communication between the first port and the third port when the engine operates in the substantially non-premixed mode and the exhaust aftertreatment device is not being regenerated.

12. The exhaust aftertreatment system of claim 1, wherein the exhaust aftertreatment system does not include a particulate filter.

13. The exhaust aftertreatment system of claim 1, wherein the exhaust aftertreatment device includes a selective catalytic reduction catalyst configured to reduce NOx into nitrogen.

14. The exhaust aftertreatment system of claim 1, wherein the exhaust aftertreatment device is a NOx adsorber.

15. The exhaust aftertreatment system of claim 14, wherein the reductant supply is in further fluid communication with a source of gaseous fuel, and the reductant supply is configured to convert at least a portion of gaseous fuel from the source of gaseous fuel into hydrogen for reducing NOx stored in the NOx adsorber.

16. A method for operating an exhaust gas aftertreatment system for an engine, the exhaust gas aftertreatment system including:

an exhaust valve assembly having a first port, a second port, and a third port, the exhaust valve assembly being configured to effect selective fluid communication between the first port, the second port, and the third port,

an exhaust conduit fluidly coupled to an exhaust port of the engine and fluidly coupled to the first port of the exhaust valve assembly,

an exhaust aftertreatment device fluidly coupled to the second port of the exhaust valve assembly,

a bypass conduit fluidly coupled to the third port of the exhaust valve assembly, the bypass conduit configured to bypass a flow of exhaust around the exhaust aftertreatment device; and

a reductant supply in selective fluid communication with the exhaust conduit,

the method comprising;

receiving a flow of exhaust gas at the first port of an exhaust valve assembly;

operating the engine in a substantially non-premixed mode; and

regenerating the exhaust aftertreatment device while the engine operates in the substantially non-premixed mode according to a first regeneration procedure, including

delivering a flow of reductant from the reductant supply to the exhaust aftertreatment device,

effecting fluid communication between the first port and the second port, and

blocking fluid communication between the first port and the third port.

17. An exhaust aftertreatment system, comprising:

a first housing;

a second housing in fluid communication with the first housing via a crossover duct;

an upstream aftertreatment device disposed in the first housing;

an exhaust valve assembly disposed downstream of the upstream aftertreatment device and upstream of the crossover duct in a direction of exhaust flow through the exhaust aftertreatment system;

a downstream aftertreatment device disposed in the second housing; and

a bypass duct in fluid communication with the exhaust valve assembly and an outlet of the second housing, wherein;

the exhaust valve assembly includes a first port, a second port, and a third port,

the first port is fluidly coupled with an outlet of the upstream aftertreatment device,

the second port is fluidly coupled with the second housing via the crossover duct,

a first configuration of the exhaust valve assembly effects fluid communication between the first port and the second port, and blocks fluid communication between the first port and the third port, and

a second configuration of the exhaust valve assembly blocks fluid communication between the first port and the second port, and effects fluid communication between the first port and the third port.

18. The exhaust aftertreatment system of claim 17, wherein the upstream aftertreatment device includes an oxidation catalyst.

19. The exhaust aftertreatment system of claim 18, wherein the downstream aftertreatment device includes a NOx adsorber.

20. The exhaust aftertreatment system of claim 17, wherein the upstream aftertreatment device consists of an oxidation catalyst and the downstream aftertreatment device consists of a NOx adsorber.