EVAPORATIVE FUEL VAPOR EMISSION CONTROL SYSTEMS

• US 20180030871A1
• Filed: 08/14/2017
• Published: 02/01/2018
• Est. Priority Date: 10/10/2012
• Status: Active Grant

• Current Assignee: Ingevity South Carolina, LLC (Ingevity Corp.)
• Original Assignee: Ingevity South Carolina, LLC (Ingevity Corp.)
• Inventors: Hiltzik, Laurence H., McCrae, Peter D., Miller, James R., Williams, Roger S.
• Granted Patent: US 10,323,553 B2
• Time in Patent Office: Days
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/3425 Honeycomb shape
• CPC Class Codes: B01D 2257/70 Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
• CPC Class Codes: B01D 2257/7022 Aliphatic hydrocarbons
• CPC Class Codes: B01D 2258/02 Other waste gases
• CPC Class Codes: B01D 2259/401 using a single bed
• CPC Class Codes: B01D 2259/402 using two beds
• CPC Class Codes: B01D 2259/404 using four beds
• CPC Class Codes: B01D 2259/406 using more than four beds
• CPC Class Codes: B01D 2259/41 using plural beds of the same adsorbent in series
• CPC Class Codes: B01D 2259/4145 arranged in series
• CPC Class Codes: B01D 2259/4516 for fuel vapour recovery systems
• CPC Class Codes: B01D 2259/4566 for use in transportation means
• CPC Class Codes: B01D 53/0407 Constructional details of adsorbing systems
• CPC Class Codes: B01D 53/0415 Beds in cartridges
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28045 Honeycomb or cellular structures; Solid foams or sponges
• CPC Class Codes: F01N 3/0807 by using absorbents or adsorbents
• CPC Class Codes: F01N 3/0835 Hydrocarbons
• CPC Class Codes: F02M 2025/0881 with means to heat or cool the canister
• CPC Class Codes: F02M 25/0854 : Details of the absorption canister
• CPC Class Codes: F02M 25/0872 : Details of the fuel vapour pipes or conduits
• CPC Class Codes: F02M 25/089 : Layout of the fuel vapour installation
• CPC Class Codes: F02M 35/10222 : Exhaust gas recirculation [EGR]; Positive crankcase ventilation [PCV]; Additional air admission, lubricant or fuel vapour admission
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

An evaporative emission control canister system comprises an initial adsorbent volume having an effective incremental adsorption capacity at 25° C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25° C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, an effective butane working capacity (BWC) of less than 3 g/dL, and a g-total BWC of between 2 grams and 6 grams. The evaporative emission control canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg at no more than 210 liters of purge applied after the 40 g/hr butane loading step.

Claims

1. An evaporative emission control canister system for a hybrid vehicle, including one or more canisters and comprising:

a fuel-side adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane; and

at least one vent-side subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, a butane working capacity (BWC) of less than 3 g/dL, and a g-total BWC of ≦

6 grams,

wherein the fuel-side adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and the at least one subsequent adsorbent volume are located within a single canister, or in separate canisters that are connected to permit sequential contact by fuel vapor.

2. The canister system of claim 1, wherein the canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg as determined by the 2012 California Bleed Emissions Test Procedure (BETP).

3. The canister system of claim 2, wherein the two-day DBL is no more than 20 mg at no more than 210 liters of purge applied after a 40 g/hr butane loading step.

4. The canister system of claim 1 wherein the at least one subsequent adsorbent volume has a g-total BWC of between 2 g and 6 g.

5. The canister system of claim 1, wherein the at least one subsequent adsorbent volume has an effective incremental adsorption capacity at 25°

C. of 24 or less grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

6. The canister system of claim 1, wherein the at least one subsequent adsorbent volume has an effective incremental adsorption capacity at 25°

C. of 16 or less grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

7. The canister system of claim 1, further comprising at least one additional subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

8. The canister system of claim 7, wherein the at least one additional subsequent adsorbent volume has a lower effective incremental adsorption capacity relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

9. The canister system of claim 7, wherein each additional subsequent adsorbent volume has a lower effective incremental adsorption capacity than any preceding subsequent adsorbent volume.

10. The canister system of claim 7, wherein each additional subsequent adsorbent volume has a gram-total BWC of less than 6 g.

11. The canister system of claim 10, wherein each additional subsequent adsorbent volume has a lower gram-total BWC relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

12. The canister system of claim 1, wherein the system further includes at least one heat input unit for heating one or more adsorbent volumes.

13. The canister system of claim 12, wherein the heat input unit include at least one of an internal resistive element, external resistive element, or heat input unit associated with the adsorbent.

14. The canister system of claim 12, wherein the heat input unit includes at least one of a heat transfer fluid, a heat exchanger, a heat conductive element, or a positive temperature coefficient material.

15. The canister system of claim 1, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, zeolites, clays, porous polymers, porous alumina, porous silica, molecular sieves, kaolin, titania, ceria, and combinations thereof.

16. The canister system of claim 15, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, and combinations thereof.

17. The canister system of claim 16 wherein the activated carbon is derived from a material including a member selected from the group consisting of wood, wood dust, wood flour, cotton linters, peat, coal, coconut, lignite, carbohydrates, petroleum pitch, petroleum coke, coal tar pitch, fruit pits, fruit stones, nut shells, nut pits, sawdust, palm, vegetables, synthetic polymer, natural polymer, lignocellulosic material, and combinations thereof.

18. The canister system of claim 17 wherein a form of adsorbent in the initial adsorbent volume, the at least one subsequent adsorbent volume, or both includes a member selected from the group consisting of granular, pellet, spherical, honeycomb, monolith, pelletized cylindrical, particulate media of uniform shape, particulate media of non-uniform shape, structured media of extruded form, structured media of wound form, structured media of folded form, structured media of pleated form, structured media of corrugated form, structured media of poured form, structured media of bonded form, non-wovens, wovens, sheet, paper, foam, hollow-cylinder, star, twisted spiral, asterisk, configured ribbons, and combinations thereof.

19. The canister system of any of claim 1, wherein the at least one subsequent adsorbent volume includes a volumetric diluent.

20. The canister system of claim 19, wherein the volumetric diluent includes a member selected from the group consisting of inert spacer particles, trapped air spaces, foams, fibers, screens, and combinations thereof.

21. The canister system of claim 19, wherein the volumetric diluent includes an adsorbent material formed into a high voidage shape selected from the group consisting of stars, hollow tubes, asterisks, spirals, cylinders, configured ribbons, honeycombs, monoliths, and combinations thereof.

22. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane; and

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and a g-total BWC of less than 6 grams,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor, and

wherein the canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg at no more than about 210 liters of purge applied after the 40 g/hr butane loading step.

23. The canister system of claim 22, wherein the at least one subsequent adsorbent volume has an effective incremental adsorption capacity at 25°

C. of 24 or less grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

24. The canister system of claim 22, wherein the at least one subsequent adsorbent volume has an effective incremental adsorption capacity at 25°

C. of 16 or less grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

25. The canister system of claim 22, further comprising at least one additional subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

26. The canister system of claim 25, wherein the at least one additional subsequent adsorbent volume has a lower effective incremental adsorption capacity relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

27. The canister system of claim 25, wherein each additional subsequent adsorbent volume has a lower effective incremental adsorption capacity than any preceding subsequent adsorbent volume.

28. The canister system of claim 25, wherein each additional subsequent adsorbent volume has a gram-total BWC of from 2 g to 6 g.

29. The canister system of claim 25, wherein each additional subsequent adsorbent volume has a lower gram-total BWC relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

30. The canister system of claim 22, wherein the system further includes at least one heat input unit for heating one or more adsorbent volumes.

31. The canister system of claim 30, wherein the heat input unit include at least one of an internal resistive element, external resistive element, or heat input unit associated with the adsorbent.

32. The canister system of claim 30, wherein the heat input unit includes at least one of a heat transfer fluid, a heat exchanger, a heat conductive element, or a positive temperature coefficient material.

33. The canister system of claim 22, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, zeolites, clays, porous polymers, porous alumina, porous silica, molecular sieves, kaolin, titania, ceria, and combinations thereof.

34. The canister system of claim 33, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, and combinations thereof.

35. The canister system of claim 34, wherein the activated carbon is derived from a material including a member selected from the group consisting of wood, wood dust, wood flour, cotton linters, peat, coal, coconut, lignite, carbohydrates, petroleum pitch, petroleum coke, coal tar pitch, fruit pits, fruit stones, nut shells, nut pits, sawdust, palm, vegetables, synthetic polymer, natural polymer, lignocellulosic material, and combinations thereof.

36. The canister system of claim 22, wherein a form of adsorbent in the initial adsorbent volume, the at least one subsequent adsorbent volume, or both includes a member selected from the group consisting of granular, pellet, spherical, honeycomb, monolith, pelletized cylindrical, particulate media of uniform shape, particulate media of non-uniform shape, structured media of extruded form, structured media of wound form, structured media of folded form, structured media of pleated form, structured media of corrugated form, structured media of poured form, structured media of bonded form, non-wovens, wovens, sheet, paper, foam, hollow-cylinder, star, twisted spiral, asterisk, configured ribbons, and combinations thereof.

37. The canister system of claim 22, wherein the at least one subsequent adsorbent volume includes a volumetric diluent.

38. The canister system of claim 37, wherein the volumetric diluent includes a member selected from the group consisting of inert spacer particles, trapped air spaces, foams, fibers, screens, and combinations thereof.

39. The canister system of claim 37, wherein the volumetric diluent includes an adsorbent material formed into a high voidage shape selected from the group consisting of stars, hollow tubes, asterisks, spirals, cylinders, configured ribbons, honeycombs, monoliths, and combinations thereof.

40. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane;

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and a g-total BWC of 2-6 grams; and

a heat input unit for heating one or more adsorbent volumes,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor,

wherein the canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg at no more than about 210 liters of purge applied after the 40 g/hr butane loading step.

41. The canister system of claim 40, further comprising at least one additional subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane.

42. The canister system of claim 41, wherein the at least one additional subsequent adsorbent volume has a lower effective incremental adsorption capacity relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

43. The canister system of claim 41, wherein each additional subsequent adsorbent volume has a lower effective incremental adsorption capacity than any preceding subsequent adsorbent volume.

44. The canister system of claim 41, wherein each additional subsequent adsorbent volume has a gram-total BWC of between 2 grams and 6 grams.

45. The canister system of claim 41, wherein each additional subsequent adsorbent volume has a lower gram-total BWC relative to the subsequent adsorbent volume that precedes it in the flow path from fuel side to vent side.

46. The canister system of claim 40, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, zeolites, clays, porous polymers, porous alumina, porous silica, molecular sieves, kaolin, titania, ceria, and combinations thereof.

47. The canister system of claim 46, wherein the initial adsorbent volume, subsequent volume or both includes an adsorbent selected from the group consisting of activated carbon, carbon charcoal, and combinations thereof.

48. The canister system of claim 47, wherein the activated carbon is derived from a material including a member selected from the group consisting of wood, wood dust, wood flour, cotton linters, peat, coal, coconut, lignite, carbohydrates, petroleum pitch, petroleum coke, coal tar pitch, fruit pits, fruit stones, nut shells, nut pits, sawdust, palm, vegetables, synthetic polymer, natural polymer, lignocellulosic material, and combinations thereof.

49. The canister system of claim 40, wherein a form of adsorbent in the initial adsorbent volume, the at least one subsequent adsorbent volume, or both includes a member selected from the group consisting of granular, pellet, spherical, honeycomb, monolith, pelletized cylindrical, particulate media of uniform shape, particulate media of non-uniform shape, structured media of extruded form, structured media of wound form, structured media of folded form, structured media of pleated form, structured media of corrugated form, structured media of poured form, structured media of bonded form, non-wovens, wovens, sheet, paper, foam, hollow-cylinder, star, twisted spiral, asterisk, configured ribbons, and combinations thereof.

50. The canister system of claim 40, wherein the at least one subsequent adsorbent volume includes a volumetric diluent.

51. The canister system of claim 50, wherein the volumetric diluent includes an adsorbent material formed into a high voidage shape selected from the group consisting of stars, hollow tubes, asterisks, spirals, cylinders, configured ribbons, honeycombs, monoliths, and combinations thereof.

52. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane; and

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and an effective butane working capacity (BWC) of less than 3 g/dL,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor,

wherein the canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg as determined by the 2012 California Bleed Emissions Test Procedure (BETP).

53. The canister system of claim 52, wherein the two-day DBL is no more than 20 mg at no more than 210 liters of purge applied after a 40 g/hr butane loading step.

54. The canister system of claim 52 wherein the at least one subsequent adsorbent volume has a g-total BWC of between 2 g and 6 g.

55. The canister system of claim 52, wherein the two-day DBL is no more than 20 mg at no more than 100 bed volumes (BV) of purge applied after a 40 g/hr butane loading step.

56. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane;

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and an effective butane working capacity (BWC) of less than 3 g/dL; and

a heat input unit for heating one or more adsorbent volumes,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor,

wherein the canister system has a two-day diurnal breathing loss (DBL) emissions of no more than 20 mg as determined by the 2012 California Bleed Emissions Test Procedure (BETP).

57. The canister system of claim 56, wherein the two-day DBL is no more than 20 mg at no more than 210 liters of purge applied after a 40 g/hr butane loading step.

58. The canister system of claim 57 wherein the at least one subsequent adsorbent volume has a g-total BWC of between 2 g and 6 g.

59. The canister system of claim 56, wherein the two-day DBL is no more than 20 mg at no more than 100 bed volumes (BV) of purge applied after a 40 g/hr butane loading step.

60. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane; and

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and a g-total BWC of ≦

6 grams,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor,

wherein the two-day DBL is no more than 20 mg at no more than 100 bed volumes (BV) of purge applied after a 40 g/hr butane loading step.

61. The canister system of claim 60 wherein the at least one subsequent adsorbent volume has a g-total BWC of between 2 g and 6 g.

62. The canister system of claim 60 wherein the at least one subsequent adsorbent volume has a an effective butane working capacity (BWC) of less than 3 g/dL.

64. The canister system of claim 60 wherein the at least one subsequent adsorbent volume has a g-total BWC of between 2 g and 6 g.

65. The canister system of claim 60 wherein the at least one subsequent adsorbent volume has a an effective butane working capacity (BWC) of less than 3 g/dL.

63. An evaporative emission control canister system, including one or more canisters and comprising:

an initial adsorbent volume having an effective incremental adsorption capacity at 25°

C. of greater than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane; and

at least one subsequent adsorbent volume having an effective incremental adsorption capacity at 25°

C. of less than 35 grams n-butane/L between vapor concentration of 5 vol % and 50 vol % n-butane, and a g-total BWC of ≦

6 grams; and

a heat input unit for heating one or more adsorbent volumes,

wherein the initial adsorbent volume and the at least one subsequent adsorbent volume are located within a single canister, or the initial adsorbent volume and the at least one subsequent adsorbent volume are located in separate canisters that are connected to permit sequential contact by fuel vapor,

wherein the two-day DBL is no more than 20 mg at no more than 100 bed volumes (BV) of purge applied after a 40 g/hr butane loading step.