Partial Flow Heated Catalyst for Exhaust Back-Pressure Reduction
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Solution Overview
Problem
Existing exhaust emission control systems face challenges in operating efficiently at low exhaust gas temperatures, particularly during cold starts and part-load operations, leading to increased fuel consumption and reduced engine power due to the need for high electric heating power and increased back-pressure.
Innovation Solution
The implementation of a heated catalyst assembly within the exhaust gas line, which reacts fuel with exhaust gases to generate heat, allowing for partial flow heating of the exhaust gas treatment system, reducing back-pressure and optimizing fuel consumption without compromising engine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an electric resistance heater is arranged in the full flow of the exhaust gas line to heat the exhaust gas catalytic converter, then the catalytic converter reaches operating temperature more quickly, but the exhaust gas back-pressure increases significantly
Solution Approach 1:
The exhaust gas flow is segmented into a main flow and a partial flow. The heated catalyst assembly is positioned to heat only the partial flow, which then mixes with the main flow downstream. This segmentation allows heating function to be separated from the full flow path, reducing back-pressure while maintaining heating effectiveness.
Solution Approach 2:
The heated catalyst assembly is designed to process only a partial flow of exhaust gas rather than the full flow. By applying heating locally to a portion of the exhaust stream, the system achieves temperature increase without creating significant back-pressure across the entire exhaust system.
2Temperature
If high electric heating power is used to heat the exhaust gas treatment system after cold start, then the system reaches operating temperature quickly, but fuel consumption increases
Solution Approach 1:
The system uses the exhaust gas itself as the heating medium. By directing a partial flow of exhaust gas through the heated catalyst assembly, the system leverages the existing hot exhaust to heat the treatment system, eliminating the need for separate electric heating elements and reducing overall energy consumption.
Solution Approach 2:
The system changes the heating approach from external electric heating to internal exhaust gas utilization. By modifying the flow parameters and using the exhaust stream itself for heating, the system reduces energy input requirements while maintaining effective heating of the treatment system.
3Use of energy by moving object
If a heated catalyst assembly is arranged in the partial flow of the exhaust gas set, then fuel consumption is reduced and back-pressure is minimized, but the heating efficiency may be compromised
Solution Approach 1:
The system dynamically adjusts the partial flow rate through the heated catalyst assembly based on operating conditions. By making the flow rate variable rather than fixed, the system optimizes the balance between heating efficiency and fuel consumption, adapting to different engine loads and temperature requirements.
Solution Approach 2:
The control unit monitors temperature and flow conditions to regulate the partial flow rate through the heated catalyst assembly. This feedback mechanism ensures that heating efficiency is maintained while minimizing fuel consumption, adjusting the system parameters in real-time based on actual operating conditions.
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 solution enables rapid heating of exhaust gas treatment systems at low temperatures, reducing fuel consumption and maintaining engine power while minimizing back-pressure, even at full load conditions, thus improving overall efficiency and emissions control.
Implementation Method 1
a heated catalyst assembly (2) which is designed to react supplied fuel with exhaust gas
Implementation Method 2
heated catalyst assembly (2) which is designed to react supplied fuel with exhaust gas
Data Source
AI summary
An exhaust emission control device has at least one exhaust gas line, at least one particulate filter and/or at least one exhaust gas catalytic converter connected to the exhaust gas line, and a heated catalyst assembly arranged upstream of the particulate filter and/or the exhaust gas catalytic converter. The heated catalyst assembly is designed to react fuel with exhaust gas, and has a housing provided with an inlet and an outlet connected to the exhaust gas line such that a partial flow of the exhaust gas flowing in the exhaust gas line can be fed through the inlet into the housing and can be discharged from the housing through the outlet back into the exhaust gas line downstream of the inlet. An exhaust emission control device of this type may be used in conjunction with an internal combustion engine, and may be used for emission control of exhaust gas.