Dual-Fuel DOC Regeneration via Exhaust Gas Cycling

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Solution Overview

Problem

Dual-fuel engines operating on a mixture of diesel and natural gas emit higher levels of unburnt short-chain hydrocarbons, which degrade diesel oxidation catalysts (DOC) due to shifting stoichiometric ratios and higher water content in exhaust gases, leading to reduced catalytic conversion efficiency and catalyst degradation.

Innovation Solution

Regenerating the DOC by varying its temperature and alternately flowing mixed exhaust gas and diesel-only exhaust gas through the catalyst, eliminating the need for conventional hydrocarbon insertion systems and lean/rich cycles, while maintaining optimal Pd to PdO ratios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a Pd-based DOC is used to treat exhaust gas from dual-fuel engines, then catalytic conversion efficiency is improved, but the catalyst degrades due to oxidation to PdO at high temperatures and higher water content

Engineering Contradiction:
Improvecatalytic conversion efficiencyVSAvoidcatalyst stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies periodic action by cycling the DOC through alternating oxidation and reduction phases. During oxidation phases, the catalyst operates at high temperatures to convert hydrocarbons. During reduction phases, the temperature is lowered or reducing conditions are introduced to convert PdO back to Pd, preventing permanent degradation. This periodic cycling maintains catalyst effectiveness over time despite the harsh operating conditions of dual-fuel engines.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent employs parameter changes by dynamically adjusting operational parameters such as temperature, oxygen concentration, and hydrocarbon injection timing to control the oxidation state of the Pd catalyst. By changing these parameters, the system optimizes the balance between maintaining catalytic activity (requiring PdO) and preventing excessive oxidation that leads to degradation (requiring Pd), thereby resolving the contradiction between productivity and reliability.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If conventional hydrocarbon insertion systems and lean/rich cycles are used to regenerate the DOC, then catalyst performance is maintained, but system complexity and modification requirements increase

Engineering Contradiction:
Improvecatalyst performance maintenanceVSAvoidsystem modification requirements
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies self-service by utilizing the engine's own exhaust gas composition and operational cycles to regenerate the DOC, without requiring external hydrocarbon insertion systems. The natural fluctuations in exhaust gas composition during normal engine operation (including brief rich excursions) are harnessed to provide reducing conditions that convert PdO back to Pd, allowing the system to self-regenerate the catalyst using resources already present in the system.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent demonstrates universality by designing a regeneration approach that uses the existing dual-fuel engine system components for multiple purposes: the exhaust gas flow serves both as the medium to be treated and as the regenerating agent for the catalyst. The fuel injection system, already necessary for engine operation, is also utilized to provide the hydrocarbon-rich conditions needed for catalyst regeneration, eliminating the need for dedicated regeneration hardware.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 method effectively regenerates the DOC, maintaining catalytic conversion efficiency, extending catalyst lifespan, and integrating seamlessly with conventional systems without significant modifications.

Implementation Method 1

a diesel oxidation catalyst (DOC) which can include a platinum (Pt) group DOC, for example a palladium (Pd) based DOC. The Pd DOC tends to oxidize at the high temperature of the exhaust gas to convert to palladium oxide (e.g., PdO and PdO2)

Methodology Applied
Scientific EffectCatalytic oxidation: Oxidation

Implementation Method 2

providing instructions to a heater operatively coupled to the DOC to vary a temperature of the DOC

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 3

A controller is in electrical communication with the fuel insertion assembly, the temperature sensor and the heater

Methodology Applied
Scientific EffectTemperature sensing: Thermocouple

Data Source

PatentUS10145343B2Systems and methods for regeneration of a diesel oxidation catalyst in a dual-fuel engine
Publication Date: 2018.12.04 CUMMINS EMISSION SOLUTIONS INC
  • US10145343B2 patent drawing
  • US10145343B2 patent drawing
  • US10145343B2 patent drawing

AI summary

A timing-based method for regenerating a DOC included in an aftertreatment system fluidly coupled to a dual-fuel engine comprises performing at least one of the following: a temperature of the DOC is varied while flowing a mixed exhaust gas, which comprises a mixture of a diesel-only exhaust gas and a natural gas exhaust gas, generated by the dual-fuel engine through the DOC; alternately the method includes flowing (a) the mixed exhaust gas generated by the dual-fuel engine and (b) a diesel-only exhaust gas generated by the dual-fuel engine through the DOC.