Catalyst subassembly, device comprising same for purifying exhaust gases from an internal combustion engine, modular system for the subassembly, and method for manufacturing the subassembly

• US 10,107,162 B2
• Filed: 10/20/2016
• Issued: 10/23/2018
• Est. Priority Date: 04/22/2014
• Status: Active Grant

• Current Assignee: Bayerische Motoren Werke AG
• Original Assignee: Bayerische Motoren Werke AG
• Inventors: Bruene, Hans-Juergen
• Primary Examiner(s): MATTHIAS, JONATHAN R
• Application Number:
  US15/298,309
• Publication Number:
  US 20170037755A1
• Time in Patent Office: 733 Days
• 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 2250/02 filtering and catalytic conversion
• CPC Class Codes: F01N 2330/00 Structure of catalyst support or particle filter
• CPC Class Codes: F01N 2340/00 Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses
• CPC Class Codes: F01N 2450/00 Methods or apparatus for fitting, inserting or repairing different elements
• CPC Class Codes: F01N 2450/02 Fitting monolithic blocks into the housing
• CPC Class Codes: F01N 2610/00 Adding substances to exhaust gases
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 3/0211 Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/023 using means for regenerating the filters, e.g. by burning trapped particles by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F01N 3/28 Construction of catalytic reactors
• CPC Class Codes: F01N 3/2807 Metal other than sintered metal F01N3/2832 and F01N3/2835 take precedence
• CPC Class Codes: F01N 3/2825 Ceramics F01N3/2832, F01N3/2835 take precedence
• CPC Class Codes: F01N 3/2842 specially adapted for monolithic supports, e.g. of honeycomb type F01N3/2853 - F01N3/2871 take precedence
• CPC Class Codes: F01N 3/2882 Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices combined with absorbents or adsorbents only F01N3/0814; combined with particulate filters F01N3/035
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A catalyst subassembly for a device for purifying exhaust gases from an internal combustion engine, in particular a diesel engine, includes an SCRF catalyst and an SCR catalyst upstream of the SCRF catalyst. The two catalysts are arranged in a common catalyst housing. The catalyst housing, the SCRF catalyst and the SCR catalyst can be selected from a modular system for different variants of the internal combustion engine.

Claims

1. A catalyst subassembly for a device for purifying exhaust gases from an internal combustion engine, the catalyst subassembly comprising:

a common catalyst housing;

a regeneratable particulate filter and an integral SCRF catalyst on the particulate filter for selective reduction of nitrogen oxides, where the common catalyst housing and the SCRF catalyst are usable for a plurality of variants of an internal combustion engine; and

an SCR catalyst for selective reduction of nitrogen oxides, wherein

the SCR catalyst is arranged upstream of the SCRF catalyst,

the SCRF catalyst and the SCR catalyst are arranged in the common catalyst housing, and

the SCR catalyst is variably dimensioned depending on a selected engine variant among the plurality of variants of the internal combustion engine, while the common catalyst housing and the SCRF catalyst each are identically dimensioned independently of the selected engine variant.

2. The catalyst subassembly according to claim 1, wherein the SCR catalyst comprises a metallic or ceramic through-flow substrate.

3. The catalyst subassembly according to claim 2, wherein the ceramic through-flow substrate is a disc-shaped honeycomb monolith.

4. The catalyst subassembly according to claim 1, further comprising at least one spacer element arranged between the SCR catalyst and either the SCRF catalyst or an axial wall surface of the common catalyst housing, such that a different axial extent of the SCR catalyst depending on the selected engine variant is compensated in the common catalyst housing.

5. The catalyst subassembly according to claim 1, wherein the catalyst subassembly is for a device for purifying exhaust gases from a diesel engine.

6. A modular system for a catalyst subassembly for a device for purifying exhaust gases from an internal combustion engine, the catalyst subassembly comprising a common catalyst housing;

a regeneratable particulate filter and an integral SCRF catalyst on the particulate filter for selective reduction of nitrogen oxides, where the common catalyst housing and the SCRF catalyst are usable for a plurality of variants of an internal combustion engine; and

an SCR catalyst for selective reduction of nitrogen oxides, wherein the SCR catalyst is arranged upstream of the SCRF catalyst, and the SCRF catalyst and the SCR catalyst are arranged in the common catalyst housing,

wherein the modular system comprises;

a plurality of the common catalyst housings and a plurality of the SCRF catalysts, where each common catalyst housing and each SCRF catalyst are dimensioned independently of a selected engine variant among the plurality of variants of the internal combustion engine; and

a set of different SCR catalysts, where each SCR catalyst is differently dimensioned depending on the selected engine variant.

7. The modular system according to claim 6, wherein the SCRF catalysts of the modular system have an identical ratio of length to cross-section.

8. The modular system according to claim 7, wherein the SCRF catalysts of the modular system have identical external dimensions.

9. The modular system according to claim 8, wherein the differently dimensioned SCR catalysts have a different axial extent matched to a respective engine variant.

10. The modular system according to claim 6, wherein the SCRF catalysts of the modular system have identical external dimensions.

11. The modular system according to claim 6, wherein the differently dimensioned SCR catalysts have a different axial extent matched to a respective engine variant.

12. The modular system according to claim 6, further comprising a set of different spacer elements, the different spacer elements each being matched to dimensions of the plurality of SCR catalysts.

13. A device for purifying exhaust gases from an internal combustion engine, the device comprising:

a catalyst subassembly, the catalyst subassembly comprising;

a common catalyst housing;

a regeneratable particulate filter and an integral SCRF catalyst on the particulate filter for selective reduction of nitrogen oxides, where the common catalyst housing and the SCRF catalyst are usable for a plurality of variants of an internal combustion engine; and

an SCR catalyst for selective reduction of nitrogen oxides, wherein

the SCR catalyst is arranged upstream of the SCRF catalyst,

the SCRF catalyst and the SCR catalyst are arranged in the common catalyst housing, and

the SCR catalyst is variably dimensioned depending on a selected engine variant among the plurality of variants of the internal combustion engine, while the common catalyst housing and the SCRF catalyst each are identically dimensioned independently of the selected engine variant.

14. The device according to claim 13, further comprising:

a reducing agent supply unit arranged upstream of the catalyst subassembly.

15. The device according to claim 14, further comprising:

an oxidation catalyst and/or an NOx storage catalyst arranged upstream of the catalyst subassembly and upstream of the reducing agent supply unit.

16. The device according to claim 15, further comprising an ammonia barrier catalyst arranged downstream of the catalyst subassembly.

17. The device according to claim 13, wherein the device is for a diesel engine.

18. A method for producing a catalyst subassembly from a modular system for use with a plurality of engine variants of an internal combustion engine, the method comprising the acts of:

providing a plurality of catalyst housings and a plurality of SCRF catalysts, each catalyst housing and each SCRF catalyst being identically dimensioned independently of a selected engine variant among the plurality of variants of the internal combustion engine;

selecting an SCR catalyst from a set of different SCR catalysts, the selected SCR catalyst being variably dimensioned depending on the selected engine variant; and

assembling the selected SCR catalyst with the SCRF catalyst in a common catalyst housing to form the catalyst subassembly.

19. The method according to claim 18, further comprising the acts of:

selecting a spacer element from a set of the different spacer elements in accordance with dimensions of the SCR catalyst; and

installing the selected spacer element in the catalyst housing.