Reduced-emissions combustion utilizing multiple-component metallic combustion catalyst and lightly catalyzed diesel particulate filter

a technology of metallic combustion catalyst and diesel particulate filter, which is applied in the direction of combustion using catalytic materials, combustion types, separation processes, etc., can solve the problems of large quantities of excess no/sub>2 /sub>escaping the system, spark-ignition counterparts, and present problems more severe, so as to reduce system costs and reduce the requirement for platinum catalyst.

Inactive Publication Date: 2005-07-28
CLEAN DIESEL TECHNOLOGIES
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0011] It is another object of the invention to provide a system that can reduce system costs by lowering the r...

Problems solved by technology

From the standpoint of emissions, however, they present problems more severe than their spark-ignition counterparts.
In all cases, they are expensive due in significant part to the cost of precious metals used required to be effective.
A result of this approach is large quantities of excess NO2 escaping the system.
How...

Method used

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Examples

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embodiment

Preferred Embodiment

[0032] The preferred CWMF is a stainless steel wire mesh filter with an alumina wash coat that is catalyzed with a light coating of precious metal. In the subject invention this catalytic loading is under 15 gr / cu ft and typically 7-14 gr / cu ft which has the advantages of reduced cost, lower conversion of sulfur to sulfate and reduced NO2 emissions. Used with an FBC the CWMF exhibits good PM reductions of 45-75% as well as low temperature soot oxidation without the need for upstream NO2 generation.

[0033] A typical CWMF filtration unit employs multiple rings of wire mesh formed from a mat of wire mesh as described in EP Application EP1 350 933 A1. That EP Application describes the use of a catalyzed wire mesh filter in conjunction with an upstream oxidation catalyst to generate NO2. It also teaches the use of wire diameter, the formation of the mat, compression density and other features to adjust filter performance.

[0034] In the current invention, a wire diamet...

example 1

[0040] Testing was conducted on a 1990 DTA-466 International 7.6 liter engine over three twenty minute hot transient test cycles. Average emissions for NOx, NO and NO2 and particulates were measured in grams / hp-hr are presented in the table below.

[0041] Baseline emissions on commercial No. 2D (>300 ppm Sulfur) and ULSD (2 emissions as a percentage of total NOx species at 17 and 18% of total nitrogen species. Particulates were slightly lower for the ULSD at 0.244 gram / hp-hr.

[0042] Installation in the exhaust of a heavily catalyzed diesel oxidation catalyst (HCDOC) with 75 g / cu ft loading of PGM and a lightly catalyzed wire mesh filter (LCWMF) with 14 g / cu ft loading of platinum group metal (PGM) used with a bimetallic platinum / cerium FBC at 0.5 / 7.5 ppm in ULSD fuel produced reduction in particulates of 59%, but increased NO2 emissions to 58% of total nitrogen oxide species. The cerium additive was cerium hydroxy oleate and the platinum additive was platinum COD.

[0043] When the DOC...

example 2

[0045] A preferred system will contain a wire mesh DPF of the type of EP 1350933, having a loading of 14 gm / ft3 of platinum metal. This device with its construction and loading is of a type not heretofore known. Data from a 1990 (Certified 1991 Emissions) Cummins 8.3 liter engine were generated over replicate hot start test cycles on an engine dymamometer. Baseline particulate emissions for No. 2D and ULSD were similar at 0.202 gr / hp-hr and 0.201 gr / hp-hr. Overall NO2 emissions as a percentage of total nitrogen oxides were also similar for the baseline fuels at 15% and 14%.

[0046] Use of FBC treated No. 2D fuel at 0.15 / 7.5 with a six section wire mesh filter catalyzed with 14 gr / cu ft precious metal reduced PM by 71% to 0.059 gr / hp-hr with NO2 emissions at 20%.

[0047] Testing of the same CWMF with FBC treated ULSD using 0.5 Pt / 7.5 Ce increased PM reduction to 77% with NO2 at 33% of total NOx emissions. Thus high PM reductions were achieved without extensive emissions of NO2 as typic...

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Abstract

An improved, robust diesel emission control system employs a lightly diesel particulate filter (DPF), preferably with a platinum containing fuel borne catalyst (FBC) in the fuel. The DPF is preferably of wire mesh construction and at least partially lightly catalyzed with precious metal catalyst, e.g., platinum group metal, having a metal loading of from about 3 to 15 grams per cubic foot to minimize formation of NO2 in the exhaust gas. Preferred fuel borne catalyst levels will be low, e.g., from 0.05 to 0.5 ppm for platinum and 3 to 8 ppm for cerium and/or iron, thereby providing effective engine out emissions reductions without discharging excessive amounts of NO2 to the atmosphere.

Description

RELATED APPLICATIONS AND PRIORITY [0001] This is a continuation in part of and claims priority to pending U.S. patent application Ser. No. 10 / 306,954 filed 29 Nov. 2002, which claims priority to U.S. Provisional Patent Application No. 60 / 354,435 filed 04 Feb. 2002 (hereinafter, both referred to as priority applications).BACKGROUND OF THE INVENTION [0002] The invention concerns a new process for to reduce emission of pollutants of the type generated by incomplete combustion, e.g., particulates, unburned hydrocarbons and carbon monoxide, while avoiding increasing the production of NO2. [0003] Diesel engines have a number of important advantages over engines of the Otto type. Among them are fuel economy, ease of repair and long life. From the standpoint of emissions, however, they present problems more severe than their spark-ignition counterparts. Emission problems relate to particulate matter (PM), nitrogen oxides (NOx), unburned hydrocarbons (HC) and carbon monoxide (CO). NOx is a t...

Claims

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Application Information

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IPC IPC(8): F02M27/02C10L1/30C10L10/14F23C6/04F23C13/00F23J7/00F23K5/08
CPCB01D53/90F23K2900/05081B01D2255/1021B01D2255/206B01D2255/20738C10L1/10C10L1/1208C10L1/1814C10L1/1881C10L1/305C10L10/02C10L10/06F01N3/022F01N3/0231F01N3/035F01N2330/12F01N2370/02F01N2430/04F01N2510/065F23J7/00F23K5/08F23K2301/103B01D53/944C10L10/14F23K2300/103F01N3/00F23J1/00
Inventor VALENTINE, JAMES M.SPRAGUE, BARRY N.
Owner CLEAN DIESEL TECHNOLOGIES
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