Upstream SO3 Trap for Diesel Exhaust Sulfur Management
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Solution Overview
Problem
Sulfur in diesel fuel adsorbs onto aftertreatment system components, reducing their performance and requiring frequent replacement of sulfur traps, especially in systems without active regeneration or with inefficient thermal particulate filter regeneration, leading to decreased efficiency and fuel economy.
Innovation Solution
A system and method for selectively trapping sulfur trioxide (SO3) from the exhaust gas effluent of an internal combustion engine using a trap with basic sulfur-trapping materials, such as metal oxides or salts, that preferentially adsorbs SO3, allowing less acidic sulfur constituents to pass through, eliminating the need for upstream oxidation catalysts and reducing the need for trap replacement or regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfur traps are used to remove sulfur from exhaust gas, then sulfur adsorption performance is improved, but the trap requires frequent replacement due to high sulfur accumulation
Solution Approach 1:
The invention segments the sulfur removal function by placing the sulfur trap upstream of the oxidation catalyst, separating the SO3 trapping function from the oxidation function. This segmentation allows the trap to handle only SO3 rather than all sulfur compounds, reducing overall sulfur accumulation and extending service life while maintaining adsorption performance for the most harmful component.
Solution Approach 2:
The sulfur trap performs preliminary action by removing SO3 from the exhaust gas before it reaches the oxidation catalyst and other downstream components. This preliminary removal prevents sulfur accumulation on downstream components, extending their service life and maintaining system performance without requiring frequent trap replacement.
2Reliability
If thermal particulate filter regeneration is used to remove adsorbed sulfur, then component performance is restored, but efficiency and fuel economy decrease
Solution Approach 1:
The invention extracts the most harmful sulfur component (SO3) from the exhaust stream using the upstream trap, removing it before it can adsorb onto downstream components. This extraction approach prevents sulfur accumulation that would otherwise require energy-intensive thermal regeneration, thereby maintaining component performance without the fuel economy penalty of frequent regeneration cycles.
3Reliability
If oxidation catalysts are placed upstream to convert sulfur, then sulfur conversion is improved, but system complexity and cost increase
Solution Approach 1:
Instead of placing the oxidation catalyst upstream to convert sulfur compounds to SO3 for subsequent trapping (the conventional approach), the invention inverts the sequence by placing the sulfur trap upstream of the oxidation catalyst. This inversion allows the trap to directly adsorb SO3 formed during combustion without requiring upstream oxidation, simplifying the system by eliminating the need for upstream oxidation catalysts while maintaining sulfur removal effectiveness.
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 effectively extends the operating life of the sulfur trap and aftertreatment components by minimizing sulfur loading, allowing for longer service intervals and reducing maintenance needs, while maintaining system performance without the need for regeneration or oxidation components.
Implementation Method 1
A system and method for selectively trapping sulfur trioxide (SO3) from the exhaust gas effluent of an internal combustion engine using a trap with basic sulfur-trapping materials, such as metal oxides or salts, that preferentially adsorbs SO3
Data Source
AI summary
Systems, apparatus, and methods for selectively, preferentially, and/or actively removing or trapping SO3 from un-oxidized sulfur constituents in an exhaust gas effluent produced by an internal combustion engine are disclosed. Also disclosed are embodiments for regenerating an SO3 trap.