Dual Catalyst Emissions Reduction via Recycle Flow
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Solution Overview
Problem
Current catalytic converters are inefficient in reducing undesirable components in internal combustion engine exhaust, such as carbon monoxide, nitrogen oxides, and volatile organic hydrocarbons, as they often require supplemental heating and urea injection, and may experience parasitic effects between catalyst materials.
Innovation Solution
The system employs a dual catalyst configuration where a first catalyst element performs oxidation or reduction reactions, and a second catalyst element, physically separated, performs a different catalytic function, with a recycle flow path diverting a portion of exhaust gases back through the first catalyst element to enhance reaction efficiency and eliminate the need for supplemental heating and urea injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single catalyst element is used in conventional catalytic converters, then the device complexity is reduced, but the emission reduction effectiveness is insufficient and requires supplemental heating and urea injection
Solution Approach 1:
The catalytic converter is divided into multiple catalyst elements (first catalyst element and second catalyst element) with distinct functions. The first catalyst element performs oxidation catalytic reactions while the second catalyst element performs reduction catalytic reactions, allowing each element to specialize in specific pollutant treatment and eliminating the need for supplemental heating and urea injection
Solution Approach 2:
The patent introduces a recycle flow path that creates a circular flow dimension, diverting a portion of exhaust gases from the outlet back to the inlet. This dimensional change in flow path allows reacted gases to mix with incoming exhaust and undergo repeated catalytic reactions, enhancing emission reduction effectiveness without additional complexity in catalyst materials
2Reliability
If multiple catalyst materials are combined in a single element, then the emission reduction coverage is improved, but parasitic effects between catalyst materials occur
Solution Approach 1:
Different catalyst materials are segmented into separate catalyst elements - the first catalyst element contains oxidation catalyst materials while the second catalyst element contains reduction catalyst materials. This physical separation eliminates parasitic effects between different catalyst materials while maintaining comprehensive emission reduction coverage through coordinated operation of both elements
Solution Approach 2:
The recycle flow path acts as an intermediary mechanism that transports reacted gases from one catalyst element back to the inlet, allowing the products of one catalytic reaction to become reactants for subsequent reactions in the other catalyst element, achieving comprehensive emission reduction without direct contact between incompatible catalyst materials
3Reliability
If supplemental heating and urea injection are added to improve catalytic reactions, then the emission reduction effectiveness is enhanced, but the device complexity and operational complexity increase
Solution Approach 1:
The dual catalyst element configuration with recycle flow path enables the system to maintain efficient catalytic reactions through self-sustaining mechanisms. The recycle of heated reacted gases provides continuous thermal energy for the reactions, and the coordinated oxidation-reduction processes naturally maintain reaction efficiency without requiring external supplemental heating or urea injection systems
4Productivity
If exhaust gases pass through the catalyst element only once, then the device simplicity is maintained, but the reaction efficiency is insufficient
Solution Approach 1:
The recycle flow path introduces a circular flow dimension that allows exhaust gases to pass through the catalyst elements multiple times. By diverting a portion of the outlet exhaust back to the inlet, the system creates repeated reaction cycles that enhance conversion efficiency without requiring significantly increased device complexity
Solution Approach 2:
The recycle flow path ensures continuous useful action by maintaining a constant circulation of exhaust gases through the catalytic elements. This continuous recycling and re-reacting process maximizes the utilization of the catalyst elements and sustains high reaction efficiency throughout operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration increases the effectiveness of emission reduction, reduces parasitic effects, and enhances the conversion of pollutants like carbon monoxide and nitrogen oxides, improving the overall efficiency of the catalytic process while potentially eliminating the need for diesel particulate filters and urea injection.
Implementation Method 1
a first catalyst element configured for oxidizing catalytic reactions
Implementation Method 2
a second catalyst element configured for reduction catalytic reactions
Data Source
AI summary
An internal combustion engine emissions reduction system in which a emissions passing through a second catalyst element having a second catalyst function are mixed with emissions passing through a first catalyst element having a first catalyst function.