SCR Catalyst Sulfur Regeneration via NO Increase and Lower Temperature
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Solution Overview
Problem
Current sulfur removal processes for aftertreatment components in internal combustion engine systems require high temperatures, leading to catalyst deactivation, increased component aging, and operational inefficiencies, which are costly and inconvenient.
Innovation Solution
A method and system that increase the NO amount incident to the SCR catalyst by adjusting engine operations, such as exhaust gas temperature, EGR flow, and oxidation catalyst bypass, to regenerate the catalyst below typical high-temperature sulfur removal ranges, thereby reducing component aging and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature sulfur removal processes are used, then sulfur is effectively removed from the SCR component, but catalyst deactivation and component aging occur
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperatures (>650°C) to a lower temperature range (350-550°C), and simultaneously changes the chemical composition parameter by introducing specific organic compounds (alcohols, esters, or ketones) to enable effective sulfur removal at these lower temperatures without causing catalyst deactivation
Solution Approach 2:
The patent introduces an intermediary substance (organic compound such as alcohol, ester, or ketone) that mediates between the sulfur-contaminated catalyst and the desired clean state, enabling sulfur removal through chemical reaction at lower temperatures that do not damage the catalyst structure
2Reliability
If high temperature sulfur removal processes are used, then sulfur is removed from the SCR component, but component aging is accelerated
Solution Approach 1:
The patent fundamentally changes the temperature parameter from >650°C to 350-550°C, and introduces chemical composition parameters (specific organic compounds) to achieve sulfur removal at these gentler conditions, thereby extending component service life while maintaining effectiveness
3Reliability
If high temperature sulfur removal is performed during operation, then sulfur is removed from the SCR component, but fuel economy deteriorates
Solution Approach 1:
The patent changes the temperature parameter to a lower range (350-550°C) that requires less energy input, and introduces chemical compounds that facilitate sulfur removal through more energy-efficient chemical reactions, thereby improving fuel economy during regeneration operations
4Reliability
If sulfur removal is performed as a service event, then the SCR component can be regenerated, but system downtime increases
Solution Approach 1:
The patent enables the aftertreatment system to perform its own sulfur removal operation while remaining in service, using the engine's own exhaust heat and chemical compounds introduced into the exhaust stream, eliminating the need to take the vehicle offline for regeneration
5Reliability
If the entire aftertreatment system is heated for sulfur removal, then the SCR component can be regenerated, but upstream components experience excessive heating
Solution Approach 1:
The patent applies local quality by concentrating the sulfur removal action specifically at the SCR component location through targeted introduction of organic compounds downstream of the oxidation catalyst, allowing localized chemical reactions that remove sulfur without requiring uniform high-temperature heating of the entire aftertreatment system
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 approach allows for effective sulfur regeneration at lower temperatures, extending catalyst life, improving fuel economy, and reducing downtime, while minimizing the aging of aftertreatment system components.
Implementation Method 1
an oxidation catalyst operationally coupled to the exhaust aftertreatment system at a position upstream of the SCR component
Implementation Method 2
a selective catalytic reduction (SCR) component disposed in the exhaust gas flow
Data Source
AI summary
Systems, methods, and apparatuses are provided for determining an SCR component sulfur value, determining whether the SCR component sulfur value exceeds a sulfur regeneration threshold and increasing an engine NO amount incident to an SCR catalyst in response to the SCR component sulfur value exceeding the sulfur regeneration threshold.