Segmented Particle Separator for Exhaust Gas
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Solution Overview
Problem
Existing particle separators for internal combustion engines face challenges such as high exhaust gas counter pressure, frequent filter replacement, and insufficient oxidation of particles due to intermittent NO2 availability and limited particle storage capacity, leading to increased fuel consumption and potential engine damage.
Innovation Solution
A particle separator with flow cells that deflect and split the exhaust gas stream, creating flow dead zones and turbulence for effective particle removal, and utilizing a bypass for NO2 supply to enhance oxidation, with a catalytically active surface for improved particle adhesion and oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a particle filter is used to separate carbon particles from exhaust gas, then particle removal is achieved, but exhaust gas counter pressure increases significantly
Solution Approach 1:
The particle separator is divided into multiple flow cells (2-10 cells) arranged in series, with each cell containing a structural surface for particle separation. This segmentation allows the exhaust gas to flow through multiple stages of particle removal, reducing the counter pressure compared to a single large filter while maintaining effective particle separation capability.
2Reliability
If a particle filter is used to remove particles, then particle separation is achieved, but the filter requires frequent replacement due to deposition of non-combustible constituents
Solution Approach 1:
A bypass channel is introduced as an intermediary element that allows a portion of the exhaust gas containing NO2 to flow directly to a oxidation zone downstream of the flow cells. This bypass enables in-situ oxidation of deposited particles on the structural surfaces, converting them to gas phase and preventing the accumulation of non-combustible constituents that would otherwise clog the filter.
3Quantity of substance
If particles are stored in a fleece or fiber layer for later oxidation, then particle storage is achieved, but the storage capacity is limited and manufacturing cost is high
Solution Approach 1:
The system uses the exhaust gas itself as the oxidation agent by bypassing a portion of it directly to the oxidation zone. The NO2 present in the exhaust gas oxidizes the stored particles on the structural surfaces, eliminating the need for external oxidation systems or expensive specialized storage materials like fleece or fiber layers.
4Reliability
If the exhaust gas stream is constantly deflected along a structural surface, then particle removal by diffusion is achieved, but insufficient NO2 is available for oxidizing removed soot under intermittent operation
Solution Approach 1:
The bypass channel is designed to continuously transport NO2-containing exhaust gas to the oxidation zone in advance, ensuring that sufficient oxidizing agent is available when particles are stored on the structural surfaces. This preliminary action of delivering NO2 beforehand enables effective oxidation even during intermittent engine operation when NO2 availability would otherwise be insufficient.
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 solution enables reliable and efficient particle removal with reduced fuel consumption and extended filter life by effectively collecting and oxidizing particles, even under varying engine conditions.
Implementation Method 1
the exhaust gas stream is guided along a structural surface and is constantly deflected, in order to be able to remove or separate very fine particles out of the exhaust gas stream, in particular by diffusion
Implementation Method 2
the NO contained in the exhaust gas stream of the internal combustion engine can be oxidized on a platinum-containing catalyst to form NO2
Implementation Method 3
a catalytically active surface for improved particle adhesion and oxidation
Data Source
AI summary
A particle separator and method for removing particles from an exhaust gas stream of an internal combustion engine. A prescribed number of flow cells are formed in the particle separator. The exhaust gas stream flows into and/or out of the flow cells via, as viewed in a main direction of flow of the exhaust gas stream, side wall regions of the flow cells. At least one storage space is formed in the flow cells for storing particles removed from the exhaust gas stream, which flows through at least portions of the particle separator.