Particulate Filter Regeneration with Hydrocarbon Preheat

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Solution Overview

Problem

Existing exhaust after-treatment systems face challenges in stabilizing regeneration processes due to accumulation of hydrocarbons, which can lead to uncontrolled exothermic reactions and damage to particulate filters during regeneration.

Innovation Solution

A system and method that includes a controller to monitor and select a regeneration profile, incorporating a preheat step to evaporate accumulated hydrocarbons before soot oxidation, thereby preventing uncontrolled reactions and optimizing regeneration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If regeneration is performed to remove accumulated particulate matter, then filter performance is restored, but uncontrolled exothermic reactions may occur due to hydrocarbon accumulation causing damage to the filter

Engineering Contradiction:

Improvefilter integrityVSAvoiduncontrolled exothermic reactions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system performs a preheat step before the main regeneration oxidation phase. During this preliminary action, the filter is heated to a temperature sufficient to evaporate accumulated hydrocarbons but below the ignition point. This preliminary evaporation removes the harmful hydrocarbons that would otherwise cause uncontrolled exothermic reactions during subsequent oxidation, thereby protecting filter integrity while maintaining regeneration effectiveness

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The regeneration process is divided into distinct segments: a preheat segment for hydrocarbon evaporation and a main oxidation segment for particulate matter removal. By segmenting the regeneration process, the system can control the temperature profile to first evaporate hydrocarbons safely, then proceed with oxidation, preventing harmful uncontrolled reactions while achieving filter restoration

Inventive Principle:

Principle #1Segmentation

2Reliability

If hydrocarbons are evaporated through preheating, then uncontrolled reactions are prevented, but additional time and energy are required for the regeneration process

Engineering Contradiction:

Improveregeneration stabilityVSAvoidregeneration duration

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system dynamically adjusts temperature parameters during the preheat phase based on detected hydrocarbon accumulation levels. By optimizing the preheat temperature and duration parameters, the system achieves sufficient hydrocarbon evaporation to prevent uncontrolled reactions while minimizing the time and energy required. The controller monitors conditions and terminates the preheat step once hydrocarbon removal is adequate, avoiding unnecessary time extension

Inventive Principle:

Principle #35Parameter changes

3Productivity

If a single high-temperature oxidation step is used for regeneration, then particulate matter is removed efficiently, but accumulated hydrocarbons cause uncontrolled exothermic reactions

Engineering Contradiction:

Improveparticulate matter removal efficiencyVSAvoidexothermic reactions

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Before applying high-temperature oxidation to efficiently remove particulate matter, the system performs a preliminary low-temperature evaporation step. This preliminary action removes accumulated hydrocarbons that would otherwise react uncontrollably during the high-temperature oxidation phase. The sequence ensures both efficient particulate removal and prevention of harmful exothermic reactions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system maintains continuous temperature application throughout the regeneration process, transitioning smoothly from the evaporation phase to the oxidation phase without interruption. This continuous heating ensures that hydrocarbons are progressively removed and particulate matter oxidation proceeds efficiently, maintaining productivity while preventing harmful reactions through controlled temperature management

Inventive Principle:

Principle #20Continuity of useful action

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

The approach effectively reduces the likelihood of uncontrolled exothermic reactions during regeneration, maintaining filter integrity and optimizing the regeneration process by addressing hydrocarbon accumulation.

Implementation Method 1

incorporating a preheat step to evaporate accumulated hydrocarbons before soot oxidation

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

oxidation of particulate matter at a second temperature higher than the first temperature

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS8407989B2Regeneration strategy for engine exhaust

Publication Date: 2013.04.02 CATERPILLAR INC

AI summary

A method of regenerating a particulate filter of an exhaust system of an engine system is disclosed. The method may include determining a condition indicative of an accumulation of hydrocarbons in the particulate filter, and monitoring the particulate filter to determine when to initiate regeneration of the particulate filter. The method may also include selecting a regeneration profile for regeneration of the particulate filter based on the determined condition, and regenerating the particulate filter in accordance with the regeneration profile.