Pre-catalyst Oxidizing Material Prevents Inlet Face Plugging

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Solution Overview

Problem

Inlet face plugging of diesel oxidation catalysts and diesel particulate filters in engine exhaust systems, particularly during transient or low-exhaust temperature conditions, leads to increased backpressure, reduced efficiency, and potential filter failures due to the accumulation of soot and coke deposits, which current closed-loop control strategies are ineffective in preventing or completely cleaning within a reasonable time.

Innovation Solution

A pre-catalyst device is positioned upstream of the main aftertreatment device, coated with an oxidizing material that oxidizes engine exhaust before it reaches the main device, converting NO to NO2 to enhance oxidation and prevent soot/coke deposits, and features a flow-through configuration with turbulence-inducing channels to improve flow distribution and prevent plugging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a main aftertreatment device is used to oxidize engine exhaust, then exhaust treatment effectiveness is improved, but inlet face plugging occurs due to soot and coke deposits accumulating on the inlet face

Engineering Contradiction:

Improveexhaust treatment effectivenessVSAvoidinlet face plugging

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A pre-catalyst device is positioned upstream of the main aftertreatment device to perform preliminary oxidation of engine exhaust. This pre-oxidation converts soot and coke deposits before they reach the main device, preventing inlet face plugging while maintaining effective exhaust treatment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-catalyst device acts as an intermediary component between the engine exhaust and the main aftertreatment device. It transforms the exhaust composition through preliminary oxidation, creating a cleaner stream that prevents plugging of the main device while preserving overall treatment effectiveness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If closed-loop control strategies are used to clean the aftertreatment device, then some cleaning effect is achieved, but the process takes 3 to 4 hours and may not be completely effective

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidcleaning time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The pre-catalyst device performs preliminary oxidation continuously during normal operation, preventing soot and coke accumulation before it occurs. This eliminates the need for lengthy periodic cleaning cycles, reducing cleaning time from 3-4 hours to near-zero while maintaining complete effectiveness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of periodic cleaning actions, the pre-catalyst provides continuous prevention of plugging through ongoing oxidation of exhaust materials. This continuous useful action prevents deposit accumulation rather than requiring intermittent removal, dramatically reducing time loss.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If fuel is dosed for extended amounts to attempt filter regeneration, then some regeneration effect is achieved, but fuel penalty increases with no benefit

Engineering Contradiction:

Improvefilter regenerationVSAvoidfuel consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The pre-catalyst performs preliminary oxidation that prevents soot and coke deposits from forming in the first place. This eliminates the need for fuel dosing to force regeneration, reducing fuel consumption while maintaining filter regeneration through normal oxidation processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-catalyst converts the potentially harmful exhaust materials (soot, coke, hydrocarbons) into beneficial oxidized products before they reach the main aftertreatment device. This prevents plugging and eliminates the need for fuel-intensive regeneration, turning a harmful accumulation problem into a beneficial continuous oxidation process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 pre-catalyst device effectively minimizes inlet face plugging, maintains higher regeneration temperatures, reduces fuel consumption, and enhances hydrocarbon conversion efficiency, thereby extending the life of the aftertreatment system and preventing uncontrolled thermal events.

Implementation Method 1

An oxidizing material disposed on an inlet face of the pre-catalyst device oxidizes engine exhaust before it reaches the main aftertreatment device

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

a pre-catalyst device is incorporated with an engine exhaust system. The pre-catalyst device is disposed upstream of a main aftertreatment device

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS8141351B2Pre-catalyst for preventing face-plugging on an inlet face of an aftertreatment device and method of the same

Publication Date: 2012.03.27 CUMMINS FILTRATION IP INC

AI summary

A pre-catalyst device configured to be disposed upstream of a main aftertreatment device of an engine exhaust system. An oxidizing material is disposed on an inlet face of the pre-catalyst device, where the oxidizing material is configured to oxidize engine exhaust before the engine exhaust reaches the main aftertreatment device of the engine exhaust system.