Integrated Catalyst System for NOx Storage and Filtration
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Solution Overview
Problem
Existing Euro 6a systems with a nitrogen oxide storage catalyst/diesel particle filter combination often lack sufficient nitrogen oxide storage capacity, making them ineffective across a wide range of operating states due to limited installation space.
Innovation Solution
A catalytic converter system comprising a flow-through substrate and a wall-flow filter with specific material zones containing cerium oxide, alkaline earth and alkali compounds, platinum, and palladium, which provides a passive nitrogen oxide storage function downstream of the nitrogen oxide storage catalytic converter, optimizing the distribution and loading of noble metals to enhance NOx reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the volume of the nitrogen oxide storage catalytic converter is increased to ensure sufficient nitrogen oxide storage capacity, then the nitrogen oxide reduction effectiveness is improved, but the installation space requirement increases
Solution Approach 1:
The patent combines the nitrogen oxide storage catalytic converter and diesel particle filter into a single integrated system where the downstream portion of the particle filter provides passive nitrogen oxide storage capacity. This merging eliminates the need for a separate storage catalyst, reducing total installation space while maintaining sufficient NOx storage capacity across all operating states.
Solution Approach 2:
The diesel particle filter is designed to perform dual functions: primary soot particle filtration and passive nitrogen oxide storage. By coating the particle filter with nitrogen oxide storage catalyst material, the system achieves multi-functionality where one component handles both particle removal and NOx storage, eliminating the need for dedicated space for a separate storage catalyst.
2Reliability
If a nitrogen oxide storage catalyst and diesel particle filter are arranged separately, then each component can be optimized for its specific function, but the overall system complexity and installation space increase
Solution Approach 1:
The patent merges the nitrogen oxide storage catalyst and diesel particle filter into a single integrated component. The downstream portion of the particle filter is coated with nitrogen oxide storage catalyst material, creating a unified system that performs both soot filtration and NOx storage functions without requiring separate installations or complex multi-component arrangements.
Solution Approach 2:
The integrated particle filter-storage catalyst system performs multiple functions within a single component structure. The upstream portion handles soot particle filtration while the downstream portion provides passive nitrogen oxide storage, allowing one component to replace what would traditionally require two separate devices.
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 system achieves effective NOx conversion across a wide temperature and exhaust gas flow range, meeting Euro 6c legislation requirements without the need for increased installation space, ensuring efficient nitrogen oxide reduction in all operating states.
Implementation Method 1
The channels are alternately closed in a gas-tight manner at one of the two ends of the filter, so that first channels are formed which are open on the first side of the filter and closed on the second side of the filter, and second channels are formed on the first side of the filter closed and open on the second side of the filter. The exhaust gas flowing into the first channels, for example, can only leave the filter again via the second channels and for this purpose has to flow through the porous walls between the first and second channels. When the exhaust gas passes through the wall, the particles are retained.
Implementation Method 2
in a lean operating phase of the engine the nitrogen oxides are stored by the storage material of the storage catalytic converter mainly in the form of nitrates and these are broken down again in a subsequent rich operating phase of the engine and the nitrogen oxides released in this way with the reducing exhaust gas components on the storage catalytic converter to form nitrogen
Implementation Method 3
the nitrogen oxides released in this way with the reducing exhaust gas components on the storage catalytic converter to form nitrogen
Implementation Method 4
in a lean operating phase of the engine the nitrogen oxides are stored by the storage material of the storage catalytic converter mainly in the form of nitrates
Data Source
AI summary
The present invention relates to a catalyst comprising a support body A having a length LA designed as a flow substrate, a support body B of length LB designed as a wall-flow filter, and material zones A1, A2, B1 and B2, wherein the support body A comprises material zones A1 and A2 and the support body B comprises material zones B1 and B2, wherein material zone A1 contains a cerium oxide, an alkaline earth metal compound and/or an alkali metal compound, and also platinum and/or palladium, and material zone A2 contains cerium oxide, and also platinum and/or palladium, and is free of alkali metal and alkaline earth metal compounds, material zone B1 contains palladium supported on cerium oxide, and material zone B2 contains platinum supported on a support material.