Diesel exhaust treatment systems and methods

• US 9,771,534 B2
• Filed: 06/06/2013
• Issued: 09/26/2017
• Est. Priority Date: 06/06/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Sprague, Barry, Beal, Steve
• Primary Examiner(s): Toomer, Cephia D
• Application Number:
  US13/912,023
• Publication Number:
  US 20140360164A1
• Time in Patent Office: 1,573 Days
• CPC Class Codes: C10L 1/106 mixtures of inorganic compounds with organic macromolecular compounds
• CPC Class Codes: C10L 1/1216 metal compounds, e.g. hydrides, carbides
• CPC Class Codes: C10L 1/1814 Chelates
• CPC Class Codes: C10L 10/00 Use of additives to fuels or fires for particular purposes additives for liquid carbonaceous fuels characterised by their chemical nature C10L1/10; using binders for briquetting solid fuels C10L5/10; using additives to improve the combustion of solid fuels C10L9/10
• CPC Class Codes: C10L 10/02 for reducing smoke development
• CPC Class Codes: C10L 10/06 for facilitating soot removal
• CPC Class Codes: C10L 2200/024 Group VIII metals: Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt
• CPC Class Codes: C10L 2200/0245 Lanthanide group metals: La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu
• CPC Class Codes: C10L 2270/026 for diesel engines, e.g. automobiles, stationary, marine
• CPC Class Codes: C10L 2300/30 Mixture of three components
• CPC Class Codes: F01N 2430/04 by adding non-fuel substances to combustion air or fuel, e.g. additives
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/20 specially adapted for catalytic conversion F01N3/22 takes precedence; Methods of operation or control of catalytic converters

Abstract

Disclosed here are systems and methods including one or more FBCs and one or more suitable aftertreatment devices, including DOCs, DPFs, and suitable combinations thereof. The systems and methods disclosed may include selecting a suitable FBC for use with a fuel with a specified sulfur content. Systems and methods disclosed here may also include using one or more ECUs to control one or more FBC dosing/metering devices to supply FBCs from one or more FBC reservoirs in the presence of a specified event.

Claims

1. A method for improving operation of a diesel engine by lowering emissions of unburned hydrocarbons and carbon monoxide, the method comprising the steps of:

providing for at least one fuel borne catalyst reservoir containing a fuel borne catalyst;

providing for a presence of a diesel fuel and combustion air;

providing for an engine control unit is configured to inject the fuel borne catalyst from the at least one fuel borne catalyst reservoir into the diesel fuel;

providing for combusting of the diesel fuel in the diesel engine to produce exhaust gases; and

,

providing for directing of the exhaust gases into an exhaust system;

wherein the fuel borne catalyst comprises;

a platinum group metal composition comprising at least one material selected from the group consisting of platinum, and palladium, and mixtures thereof;

at least one rare earth metal selected from the group consisting of cerium, yttrium, and mixtures thereof; and

at least one transition metal compound comprising at least one carboxylate having a general formula selected from the group consisting of M(OOCR)n, MOx(OOCR)y, (MO)2(OOCR)y, and combinations thereof, wherein M is a transition metal, wherein R is selected from the group consisting of an alkyl, an arylalkyl, aryl, and cycloalkyl, and n, x, and y are integers;

wherein the exhaust system comprises at least one of the group consisting of a diesel oxidation catalyst system and a diesel particulate filter;

wherein the engine control unit in a first state is configured to inject the fuel borne catalyst from the at least one fuel borne catalyst reservoir to the diesel fuel so that a fuel borne catalyst metal content in the diesel fuel is about 2 ppm to about 15 ppm; and

wherein the engine control unit is configured in a second state to inject an additional amount of the fuel borne catalyst from the at least one fuel borne catalyst reservoir into the diesel fuel in response to an event, wherein said event is selected from the group consisting of

an unsatisfactory back-pressure profile of one or more of the diesel oxidation catalyst system or the diesel particulate filter;

a back-pressure of the diesel oxidation catalyst system or the diesel particulate filter being above a first threshold back-pressure;

a temperature of the exhaust gases being below a threshold temperature;

a temperature of the exhaust gases being above a threshold temperature;

a back-pressure of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter is above a first threshold back-pressure;

an input value exceeds a threshold input value, wherein the input value is a back pressure of one or more of the diesel oxidation catalyst system or the diesel particulate filter, or a temperature of the exhaust gases; and

an input value is below a threshold input value, wherein the input value is a back pressure of one or more of the diesel oxidation catalyst system or the diesel particulate filter, or a temperature of the exhaust gases.

2. The method of claim 1 wherein the engine control unit is configured to return to the first state when the event ceases.

3. The method of claim 2 wherein the event is an unsatisfactory back-pressure profile of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter.

4. The method of claim 2 wherein the event is when a back-pressure of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter is above a first threshold back-pressure.

5. The method of claim 2 wherein the event is when a temperature of the exhaust gases are below a threshold temperature.

6. The method of claim 2 wherein the event is when a temperature of the exhaust gases are above a threshold temperature.

7. The method of claim 1 wherein the event is when a back-pressure of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter is above a first threshold back-pressure.

8. The method of claim 1 wherein the event is when an input value exceeds a threshold input value;

wherein the input value is at least one of a group consisting of a back-pressure and a temperature

wherein the engine control unit is configured to return to the first state when the input value falls below the threshold input value.

9. The method of claim 1 wherein the event is when an input value is below a threshold input value;

wherein the input value is at least one of a group consisting of a back-pressure and a temperature

wherein the engine control unit is configured to return to the first state when the input value exceeds the threshold input value.

10. The method of claim 8 wherein the engine control unit is configured to return to the first state when the back-pressure of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter is below the first threshold back-pressure.

11. The method of claim 8 wherein the engine control unit is configured to return to the first state when the back-pressure of the at least one of the group consisting of the diesel oxidation catalyst system and the diesel particulate filter is below a second threshold back-pressure.

12. The method of claim 1, wherein M is selected form the group consisting of iron, manganese, and combinations thereof.

13. The method of claim 1, wherein the engine control unit in the first state is configured to inject the fuel borne catalyst from the at least one fuel borne catalyst reservoir to the diesel fuel so that M comprises about 1 ppm to about 10 ppm of the diesel fuel.

14. The method of claim 1, wherein the engine control unit in the first state is configured to inject the fuel borne catalyst from the at least one fuel borne catalyst reservoir to the diesel fuel so that the at least one rare earth metal comprises about 1 ppm to about 10 ppm of the diesel fuel.

15. The method of claim 1, wherein the engine control unit in the first state is configured to inject the fuel borne catalyst from the at least one fuel borne catalyst reservoir to the diesel fuel so that a platinum group metal comprises about 0.01 ppm to about 0.5 ppm of the diesel fuel.

16. The method of claim 1, wherein M is selected form the group consisting of chromium, gallium, cobalt, nickel, copper, niobium, molybdenum, tungsten, and combinations thereof.

17. The method of claim 1, wherein ignition temperature of soot resulting from the combusting of the diesel fuel is about 350°

C. to about 400°

C.