Doc and dpf reactor and diesel engine exhaust treatment system

Abstract

The application provides a DOC and DPF reactor and a diesel engine exhaust treatment system, the DOC and DPF reactor comprising: an air inlet section having an air inlet; a catalyst section connected with the air inlet section, at least two surfaces of the catalyst section being provided with a plurality of catalyst integrated modules in a single layer; a collection section connected with the catalyst section; an air outlet connected with the collection section; flue gas being input from the air inlet, after catalytic reaction with the catalyst integrated modules in the catalyst section, entering the collection section and being output from the air outlet. The catalyst section is composed of a plurality of catalyst integrated modules in a single layer with multiple surfaces, so that the land occupation of the reactor can be saved and the cost can be reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of diesel engine exhaust treatment, in particular to a DOC and DPF reactor and a diesel engine exhaust treatment system. Background Art

[0002] Diesel engine exhaust contains large amounts of particulate matter (PM) and nitrogen oxides (NOx), which are major sources of atmospheric pollution. Currently, the primary method for reducing NOx and PM emissions from marine diesel engines is to install a Selective Catalytic Reduction (SCR) system and an exhaust gas scrubber system, respectively, after the engine's exhaust pipe. The SCR system injects a urea solution into the exhaust pipe. Under the action of a catalyst, NOx in the exhaust reacts with NH3 generated by the thermal decomposition and hydrolysis of urea to produce N2 and H2O.

[0003] Traditional diesel engine exhaust treatment systems primarily consist of a DOC ceramic filter element (catalytic honeycomb ceramic carrier) and a DPF ceramic filter element (catalytic particulate filter) coated with precious metals and a unique molecular sieve adsorbent. The DOC catalytic carrier element primarily converts carbon monoxide, hydrocarbons, and NO in exhaust gas into CO2, H2O, and NO2 through a catalytic oxidation reaction. The DPF removes particulate matter from the flue gas, achieving a soot capture efficiency exceeding 90%. Black smoke containing carbon particles enters the DFP through a dedicated pipeline, where it passes through an internal filter and is adsorbed by the soot particles. When a certain amount of particulate matter accumulates on the filter, a burner automatically ignites, converting it into CO2 and expelling it.

[0004] At present, DOC and DPF reactors are generally divided into the following types according to their integration form:

[0005] (1) DOC and DPF are treated separately, that is, the gas first passes through the DOC reactor and then enters the DPF reactor.

[0006] (2) DOC and DPF integration: This involves integrating the DOC and DPF into the same reactor, but with the DOC and DPF modules packaged separately. Since DOC and DPF reactors typically use a single-layer, one-sided catalyst, if the flue gas volume is large, the catalyst cross-section will be large. Using a single-layer, one-sided catalyst layout will result in an excessively large reactor cross-section, increasing the footprint. Increasing the number of catalyst layers will increase the pressure drop of the equipment after the flue gas flows through the multiple layers of catalyst. Summary of the Invention

[0007] The present invention provides a DOC and DPF reactor and a diesel engine exhaust treatment system, which are used to solve the problems of large volume and large pressure drop of the DOC and DPF reactors in the prior art.

[0008] In a first aspect, the present invention provides a DOC and DPF reactor, wherein the DOC and DPF reactor comprises:

[0009] an air intake section having an air intake port;

[0010] A catalyst section connected to the air inlet section, wherein at least two surfaces of the catalyst section are provided with a single layer of multiple catalyst integrated modules;

[0011] a collecting section connected to the catalyst section;

[0012] an air outlet connected to the collecting section;

[0013] The flue gas is input from the air inlet, enters the collecting section after a catalytic reaction occurs between the catalyst section and the catalyst integrated module, and is output from the air outlet.

[0014] In one embodiment of the present invention, the catalyst section is located in the upper half of the DOC and DPF reactor, the side surfaces of the DOC and DPF reactor have a first surface, a second surface, a third surface and a fourth surface, the catalyst integrated module is arranged on at least two surfaces of the first surface, the second surface and the third surface, the inner side of the catalyst integrated module on at least two surfaces of the first surface, the second surface and the third surface is provided with a pressure plate and the outer side is provided with a baffle, the fourth surface is provided with an inspection panel, and the bottom of the catalyst section is provided with a blind plate.

[0015] In one embodiment of the present invention, the catalyst section includes a diffusion area and a reaction area, the diffusion area is a spatial area surrounded by the pressure plate, the inspection panel and the blind plate, and the reaction area is the area where the catalyst integrated module is located on at least two of the first surface, the second surface and the third surface.

[0016] In one embodiment of the present invention, the DOC and DPF reactors are further provided with multiple layers of grids between the top and the bottom, with each layer of grids spaced a preset distance apart and parallel to the blind plate.

[0017] In one embodiment of the present invention, the converging section includes an outer area of ​​the catalyst section and a lower area of ​​the DOC and DPF reactor, the outer area refers to the space area between the baffles of the first surface, the second surface and the third surface and the inner walls of the DOC and DPF reactor respectively, the lower area is the area below the blind plate, and the outer area is connected to the lower area.

[0018] In one embodiment of the present invention, the DOC and DPF reactor further includes a bypass section, which is used to connect the diffusion area and the collection section. The bypass section includes a bypass line and a regulating valve. The inlet of the bypass line is located on the inspection panel and above the blind plate. The outlet of the bypass line is connected to the gas outlet. The regulating valve is arranged on the bypass line to allow the gas in the diffusion area to directly enter through the inlet of the bypass line and be output from the gas outlet.

[0019] In one embodiment of the present invention, the catalyst integrated module is a packaged module integrating a DPF catalyst and a DOC catalyst, and each catalyst integrated module is provided with a sealing strip at a gap between the pressure plate and the baffle.

[0020] In one embodiment of the present invention, the air inlet and the air outlet of the air inlet section are both provided with interfaces for a temperature sensor and a pressure difference sensor, and the inspection panel is provided with at least one inspection port.

[0021] In one embodiment of the present invention, each of the first surface, the second surface, and the third surface includes a plurality of small areas, and each small area is used to install one of the catalyst integrated modules.

[0022] In a second aspect, the present invention further provides a diesel engine exhaust treatment system, the device comprising the DOC and DPF reactor as described in any one of the first aspects.

[0023] The DOC and DPF reactors and diesel exhaust treatment systems provided by the present invention utilize catalyst segments comprised of multiple, multi-faceted, single-layer integrated catalyst modules, saving reactor space and reducing costs. Furthermore, the use of multiple integrated catalyst modules allows for the placement of more catalysts within a limited cross-section, resulting in simplified block division, ease of installation, and structural stress resistance, making the system suitable for a variety of spatial configurations and improving capture and conversion efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the present invention or the prior art, a brief introduction is given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0025] Figure 1 1 is a front view of a DOC and DPF reactor provided by an embodiment of the present invention;

[0026] Figure 2is a side view of a DOC and DPF reactor provided by an embodiment of the present invention;

[0027] Figure 3 yes Figure 1 A top view of the AA section of the DOC and DPF reactor;

[0028] Figure 4 Schematic diagram of the structure of the catalyst integrated module provided by an embodiment of the present invention;

[0029] Figure 5 It is a schematic structural diagram of the catalyst section provided in an embodiment of the present invention.

[0030] Reference numerals:

[0031] 10: DOC and DPF reaction 11: intake section; 12: catalyst section;

[0032] response device;

[0033] 13: Collection section; 14: Air outlet; 15: Bypass section;

[0034] 101: first side; 102: second side; 103: third side;

[0035] 104: fourth side; 111: air inlet; 121: catalyst integrated module;

[0036] 122: diffusion area; 123: reaction area; 124: pressure plate;

[0037] 125: baffle; 126: blind plate; 127: access panel;

[0038] 128: Inspection port; 129: Grille; 130: Sealing strip;

[0039] 131: Outer area; 132: Lower area; 133: Excretion outlet;

[0040] 134: Support leg; 151: Bypass line; 152: Control valve. DETAILED DESCRIPTION

[0041] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0042] The terms "first," "second," and the like in the description and claims of the present invention and the accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a particular order or precedence. It should be understood that the terms used in this manner are interchangeable where appropriate, such that the embodiments described herein can be practiced in an order other than that shown or described herein.

[0043] Currently, DOC and DPF reactors typically use a single-layer, one-sided catalyst. If the flue gas volume is high, the catalyst cross-section will be large. Using a single-layer, one-sided catalyst layout will result in a larger reactor cross-section and increased floor space. Increasing the number of catalyst layers will increase the pressure drop of the equipment after the flue gas flows through multiple layers of catalyst.

[0044] Therefore, to address the above-mentioned issues, the present invention provides a DOC and DPF reactor and diesel exhaust treatment system. The catalyst segment, comprised of multiple, multi-faceted, single-layer integrated catalyst modules, reduces reactor space and costs. Furthermore, the use of multiple integrated catalyst modules allows for the layout of more catalysts within a limited cross-section, resulting in simplified block division, ease of installation, and structural stress-bearing, making the system suitable for a variety of spatial configurations and improving capture and conversion efficiency.

[0045] The following combination Figure 1-Figure 4 Describe the DOC and DPF reactor and diesel exhaust treatment system of the present invention. Please refer to Figure 1 、 Figure 2 as well as Figure 3 , Figure 1 1 is a front view of a DOC and DPF reactor provided by an embodiment of the present invention, Figure 2 : is a side view of a DOC and DPF reactor provided by an embodiment of the present invention, Figure 3 yes Figure 1 The DOC and DPF reactor 10 of the present invention comprises an air inlet section 11, a catalyst section 12, a collecting section 13 and an air outlet 14 connected in sequence.

[0046] Exemplarily, the main part of the DOC and DPF reactor 10 is a rectangular parallelepiped, the air intake section 11 is connected to the exhaust port of the diesel engine through a pipeline, the flue gas is input from the air intake 111, and after the catalytic reaction between the catalyst section 12 and the catalyst integrated module 121 occurs, it enters the collecting section 13 and is output from the air outlet 14 to the SCR reactor.

[0047] Exemplarily, the air inlet section 11 is in the form of a square connected to a circle, which can diffuse the smoke to a larger cross-section in advance, and is provided with a temperature sensor and a pressure difference sensor interface at the air inlet 111 to monitor the temperature and pressure drop of the smoke.

[0048] Exemplarily, the catalyst section 12 is connected to the air inlet section 11 , and at least two surfaces of the catalyst section 12 are provided with a single layer of multiple catalyst integrated modules 121 .

[0049] Specifically, the catalyst section 12 is located in the upper half of the DOC and DPF reactor 10, as shown in FIG. Figure 3 As shown, the side surface of the DOC and DPF reactor 10 includes a first surface 101, a second surface 102, a third surface 103 and a fourth surface 104. The catalyst integrated module 121 can be arranged on at least two surfaces of the first surface 101, the second surface 102 and the third surface 103. The structure of the catalyst integrated module 121 is as follows: Figure 4 The catalyst integrated module 121 on at least two of the first surface 101 , the second surface 102 and the third surface 103 is provided with a pressure plate 124 on its inner side and a baffle 125 on its outer side.

[0050] It should be noted that Figure 3 It is shown that the catalyst integrated module 121 is arranged on the first surface 101, the second surface 102 and the third surface 103, that is, the catalyst integrated module 121 can be arranged on three surfaces, and each of the first surface 101, the second surface 102 and the third surface 103 is provided with a pressure plate 124 on the inner side and a baffle 125 on the outer side.

[0051] For example, the pressure plate 124 and the baffle 125 can be made of unequal-sided steel. In order to reduce the obstruction of the catalyst integrated module 121, the narrow side can be pressed against the flanges of the two rows of catalyst integrated modules 121, and a sealing strip 130 (such as Figure 4 The sealing strip is made of glass fiber and has a temperature resistance of 500°C or higher. The width of the sealing strip 130 can range from 50mm to 70mm. The sealing strip 130 must be firmly fixed to the adhesive surface. The function of the sealing strip 130 is to eliminate the gap between the catalyst integrated module 121 and the pressure plate 124 and baffle 125.

[0052] Therefore, the pressure plate 124 and baffle 125 arranged on the inner and outer sides of the catalyst integrated module 121 ensure the stability of the catalyst during operation. The pressure plate 124 and the baffle 125 are both pasted with glass fiber cotton, which can reduce the effect of flue gas short-circuiting caused by the gap between each catalyst integrated module 121 and also ensure the stability of the catalyst.

[0053] It should be noted that a catalyst integrated module 121 can be a packaged module that integrates a DPF catalyst and a DOC catalyst, but the catalyst used in the DOC and DPF reactors of the present invention is not limited to DPF catalysts and DOC catalysts, and can also be an SCR catalyst. Each of the first surface 101, the second surface 102, and the third surface 103 of the side of the DOC and DPF reactor 10 of the present invention can be subdivided into several small areas, and each small area can be installed with a catalyst integrated module 121. Therefore, the DOC and DPF reactors of the present invention use a single-layer three-sided form to install the catalyst integrated module 121, which can facilitate the installation, maintenance and structural stress of the catalyst.

[0054] For example, the specifications of a catalyst integrated module are 315mm*315mm*500mm. Figure 5 As shown, each of the first, second and third surfaces is divided into three sections (i.e., section one, section two, and section three), and each section can be set to 2 areas, i.e., each surface can be set to 6 areas, and a total of 18 areas can be set on the three surfaces, and each area can be installed with 4*5=20 catalyst integrated modules 121 ( Figure 4 One of the areas is shown), a total of 18*20=360 catalyst integrated modules 121 can be installed.

[0055] For example, Figure 1 As shown, the fourth side 104 is provided with an access panel 127, and the access panel 127 is provided with at least one access opening 128. Figure 1 Two access ports 128 are shown, and a grille 129 may be provided on the access panel 127 to facilitate routine maintenance of the catalyst.

[0056] For example, Figure 5 As shown, multiple layers of grilles 129 are provided between the top and bottom of the DOC and DPF reactors 10. Each layer of grilles 129 is spaced apart by a predetermined distance and is parallel to the blind plate 126. For example, a layer of grilles 129 is provided between each catalyst partition. This does not affect the flow of flue gas in the diffusion area 122, and can also serve as a support platform for catalyst maintenance.

[0057] Illustratively, a blind plate 126 is provided at the bottom of the catalyst section 12 , and the blind plate 126 may be in the form of a grid 129 plus a panel.

[0058] For example, Figure 3As shown, the catalyst section 12 includes a diffusion region 122 and a reaction region 123. The diffusion region 122 is the spatial area enclosed by a pressure plate 124, an access panel 127, and a blind plate 126. The reaction region 123 is the area on the first, second, and third surfaces 101, 102, and 103 where the catalyst integrated module 121 is located. The blind plate 126 serves to isolate the diffusion region 21, directing the flue gas flow toward the catalyst integrated module 121.

[0059] The flue gas enters the diffusion area 122 from the air inlet 111 of the air inlet section 11, and after further diffusion and uniform flow, reaches the catalyst integrated module 121 on three sides of the single layer. After fully contacting and reacting with the catalyst in the reaction area 123, the gas flows into the collection section 13.

[0060] Figure 2 The catalyst section 12 is shown as being divided into three sections, but the present invention is not limited to three sections and can be configured to any desired number. A grille 129 is provided at the partition between each catalyst section 12, and an access port 128 is provided on the access panel 127. This arrangement ensures flue gas flow within the diffusion area 122 and facilitates catalyst maintenance. The grille structure is also lightweight, effectively reducing the weight of the equipment.

[0061] For example, Figure 1 As shown, the converging section 13 includes an outer region 131 of the catalyst section 12 and a lower region 132 of the DOC and DPF reactor 10. The outer region 131 is the space between the baffles 125 on the first side 101, the second side 102, and the third side 103 and the inner walls of the DOC and DPF reactor 10, respectively. The lower region 132 is the area below the blind plate 126. The outer region 131 and the lower region 132 are connected. After passing through the catalyst on the first side 101, the second side 102, and the third side 103 of the catalyst section 12, the flue gas converges in the converging section 13 and is discharged through the outlet 14.

[0062] For example, the bottom of the DOC and DPF reactor 10 of the present invention is further provided with a drain port 133 for discharging condensate from the equipment.

[0063] From the above Figures 1 to 4 It can be seen that the working principle of the DOC and DPF reactors of the present invention is:

[0064] The flue gas enters from the air inlet of the air inlet section 11, and after further diffusion and uniform flow in the diffusion area of ​​the catalyst section 12, reaches the reaction area 123 on three sides of the catalyst section 12. After the flue gas undergoes catalytic reaction with the catalyst integrated module 121 in the reaction area 123 on each side, it converges from the outer area and the lower area of ​​the converging section 13 and is discharged from the outlet 14.

[0065] For example, to meet emission requirements in different operating areas, the DOC and DPF reactor 10 of the present invention further includes a bypass section 15 , which is a curved pipe structure and can be supported by supporting legs 134 . The bypass section 15 is used to connect the diffusion region 122 and the converging section 13 .

[0066] Specifically, bypass section 15 includes a bypass line 151 and a regulating valve 152. The inlet of bypass line 151 is located on access panel 127 and above blind plate 126. The outlet of bypass line 151 is connected to gas outlet 14. Regulating valve 152 is provided on bypass line 151 to allow gas from diffusion region 122 to enter directly through the inlet of bypass line 151 and exit through gas outlet 14. If the flue gas does not need to flow through catalyst section 12, regulating valve 152 is opened, and the flue gas flows directly from bypass line 151 to gas outlet 14.

[0067] Therefore, the provision of the bypass section 15 solves the problem that the DOC and DPC reactors in the prior art have no bypass pipeline, resulting in a single working mode and being unable to meet the emission requirements of different regions.

[0068] Exemplarily, the gas outlet 14 is further provided with a temperature sensor and a pressure difference sensor interface for monitoring the temperature and pressure drop of the flue gas.

[0069] In summary, the present invention integrates the DPF catalyst and the DOC catalyst into a single catalyst integrated module, which can save space for the catalyst segment and reduce fixtures, thereby reducing costs. Furthermore, the catalyst segment of the present invention adopts a single-layer three-sided catalyst format, which can also accommodate more catalysts within a limited cross-section. The simple block structure facilitates installation, maintenance, and structural stress, making it suitable for a variety of spatial structures and improving capture and conversion efficiency.

[0070] In addition, the present invention also provides a diesel engine exhaust treatment system, which includes the DOC and DPF reactors as described above.

[0071] In some embodiments of the present invention, the diesel engine exhaust treatment system further includes an exhaust port of the diesel engine, which is connected to the air inlet of the DOC and DPF reactor to purify the gas exhausted by the diesel engine.

[0072] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A DOC and DPF reactor, characterized in that, The DOC and DPF reactors include: an air intake section having an air intake port; A catalyst section connected to the air intake section, wherein at least two surfaces of the catalyst section are provided with a single-layer plurality of catalyst integrated modules; the catalyst section is located in the upper half of the DOC and DPF reactor, and the side surfaces of the DOC and DPF reactor have a first surface, a second surface, a third surface, and a fourth surface; the catalyst integrated modules are arranged on at least two of the first surface, the second surface, and the third surface; the inner sides of the catalyst integrated modules on at least two of the first surface, the second surface, and the third surface are provided with pressure plates and the outer sides are provided with baffles; the fourth surface is provided with an inspection panel, and the bottom of the catalyst section is provided with a blind plate; a collecting section connected to the catalyst section; an air outlet connected to the collecting section; The flue gas is input from the air inlet, enters the collecting section after a catalytic reaction occurs between the catalyst section and the catalyst integrated module, and is output from the air outlet.

2. The DOC and DPF reactor according to claim 1, characterized in that The catalyst section includes a diffusion area and a reaction area. The diffusion area is a spatial area surrounded by the pressure plate, the inspection panel and the blind plate. The reaction area is the area where the catalyst integrated module is located on at least two of the first surface, the second surface and the third surface.

3. The DOC and DPF reactor according to claim 1, characterized in that The DOC and DPF reactors are further provided with multiple layers of grids between the top and bottom thereof, with each layer of grids spaced a preset distance apart and parallel to the blind plate.

4. The DOC and DPF reactor according to claim 3, characterized in that: The converging section includes the outer area of ​​the catalyst section and the lower area of ​​the DOC and DPF reactor. The outer area refers to the space area between the baffles of the first surface, the second surface and the third surface and the inner walls of the DOC and DPF reactor respectively. The lower area is the area below the blind plate, and the outer area is connected to the lower area.

5. The DOC and DPF reactor according to claim 2, characterized in that: The DOC and DPF reactor also includes a bypass section, which is used to connect the diffusion area and the collection section. The bypass section includes a bypass pipeline and a regulating valve. The inlet of the bypass pipeline is located on the inspection panel and above the blind plate. The outlet of the bypass pipeline is connected to the gas outlet. The regulating valve is arranged on the bypass pipeline to allow the gas in the diffusion area to directly enter through the inlet of the bypass pipeline and be output from the gas outlet.

6. The DOC and DPF reactor according to claim 1, characterized in that The catalyst integrated module is a packaged module integrating a DPF catalyst and a DOC catalyst. A sealing strip is provided at the gap between each catalyst integrated module and the pressure plate and the baffle.

7. The DOC and DPF reactor according to claim 1, characterized in that The air inlet and the air outlet of the air inlet section are both provided with interfaces for a temperature sensor and a pressure difference sensor, and the inspection panel is provided with at least one inspection port.

8. The DOC and DPF reactor according to claim 4, characterized in that Each of the first surface, the second surface and the third surface includes a plurality of small areas, and each small area is used to install one of the catalyst integrated modules.

9. A diesel engine exhaust treatment system, characterized in that: The system comprises the DOC and DPF reactor according to any one of claims 1 to 8.

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