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CN1429130A - 从废气中去除炭黑颗粒的方法和对应的捕集元件 - Google Patents

从废气中去除炭黑颗粒的方法和对应的捕集元件 Download PDF

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CN1429130A
CN1429130A CN01809527A CN01809527A CN1429130A CN 1429130 A CN1429130 A CN 1429130A CN 01809527 A CN01809527 A CN 01809527A CN 01809527 A CN01809527 A CN 01809527A CN 1429130 A CN1429130 A CN 1429130A
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J·霍格森
R·布吕克
M·赖齐格
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Abstract

本发明涉及一种从内燃机(1)特别是柴油机的废气中排除炭黑颗粒的方法。根据所述方法，废气被引导经过一捕集元件(5)，废气可自由流过捕集元件，但是它设有许多转向部位和/或涡流和平稳区。至少一部分颗粒停留或环绕涡流在所述捕集元件内，直至那里具有足够大的概率，以使它和亚硝气体发生反应，直至绝大部分被捕获的颗粒被排除为止。这种类型的捕集元件具有这样的流通路径(13；23)，废气可以自由地流过这个路径，但是这种流通路径(13；23)具有转向部位(15，16；25，26)或涡流区和平稳区。

Description

从废气中去除炭黑颗粒的方法 和对应的捕集元件
本发明涉及一种从特别是内燃机的废气中去除炭黑颗粒的方法，和一种适合于它的捕集元件，特别是它是可以再生的，并且可以装入一管子例如汽车的排气管内。
内燃机的废气除气态的组成部分外还包含颗粒。它们和废气一起直接进入周围环境—这是不希望的，或常常堆积在排气系统的某个部位，使得例如在载荷变化时以颗粒云的形式喷出来。
通常采用捕集颗粒的过滤器。但是封闭的过滤系统带来两个明显的缺点，一方面这些过滤器可能堵塞，另一方面它造成不希望的压降，如果不使用过滤器，那么没有直接进入周围大气的颗粒有可能积聚在用来净化其它有害物质成分的内置催化器的涂层上，并在那里导致毒化或至少减小有效的催化表面。在环境保护法规越来越严的情况下需要进一步降低有害物质和颗粒的排放。在废气净化方面除了排除颗粒以外减少氮氧化物也起重要作用。对此由DE 4203807已知一种装置，其中喷出一种氧化剂并与废气混合。
本发明的目的是，提供一种从废气中去除炭黑颗粒的方法以及制造一种用于废气流中的颗粒的捕集元件。
这个目的用具有权利要求1特征的方法和按权利要求5特征的捕集元件来实现。其它优良的结构在各从属权利要求中说明。此外还提供捕集元件优选的应用场合。
在用混合元件做试验时，如例如在WO 91/01807或WO 91/01178中所述，和为了使喷入排气系统的添加剂更好地分布所进行的试验时，令人惊讶地表明，这种元件也可以促使炭黑颗粒的减少。估计颗粒通过在气流转向部位形成的在混合元件内部的涡旋被留住或几乎是喷射在混合元件的内壁上-类似于重力分选，然后牢固地附着在上面。在颗粒附着时金属-炭黑可能的相互作用和/或废气/通道壁温度梯度也有影响。也可以观察到颗粒强烈的附聚作用，特别是在未涂覆的和金属的壁时。这种认识对于本发明是有用的，其中捕集元件这样设计，使炭黑颗粒在那里停留这么久，使得存在足够大的概率，使颗粒和存在于废气中的氮氧化物起反应。
也就是说不走常用的途径，即使炭黑颗粒通过多孔壁等等所谓强制式地100％完全滤出，而是简单地通过延长炭黑颗粒在捕集元件内的逗留时间，提高炭黑颗粒与氮氧化物反应的概率。这在畅通的流通路径中通过足够数量的旋涡区和平稳区(Beruhigungszonen)和/或通过转向进行，它们有利于颗粒沉积在壁上。与废气一起流动的颗粒只有很少的机会与其它废气成分发生反应，而如果颗粒保留在一个旋涡区或沉积在壁上，则这种机会大大提高。这样所有从旁边经过的氮氧化物都可能进行反应，使炭黑颗粒迅速减少。因此捕集元件不可能堵塞，而是不断地再生。
在通道内具有小的流动速度的区域称为平稳区，没有流体运动的区域称为死区。
因此与封闭的系统相反捕集元件称作自由流通的，因为不存在流通死胡同。因此捕集元件不会象有可能会被填充(堵)的孔的普通过滤系统那样堵塞，因为事先气流将颗粒带出。这里转向部位设计成这样，使得每处约有还包含在废气中的颗粒的2％至15％甩到捕集元件50的壁11，12，21，22上，其中优先的范围在4％到8％之间，这样做特别有利。“还包含在废气中的颗粒”的表达方法是考虑到，在废气流径常转向的情况下沿流动方向颗粒数量越来越少。特别是为此转向部位的数量这样来选择，使得至少就统计方面而言，整个废气流朝捕集元件的壁导向，碰撞的颗粒或者使转向的废气流在数量方面的限制有这样的好处，即在捕集元件上只出现很小的压降。
为了覆盖汽车驱动系统各种不同的(动态)载荷状况，优选一种圆锥形系统。如例如在WO93/20339中所述的这种系统具有扩展的通道，使得在通道的任意一个部位在任一种质量流量时必然形成对于捕集颗粒特别有利的情况—如果它配备相应的转向或旋涡结构的话。
捕集元件的材料最好是金属，但是也可以是塑料、无机(陶瓷、纤维材料)、有机或金属有机的天然物质和/或烧结材料。其中捕集元件的壁可以涂有或不涂有Washcoat和/或催化活性材料。
壁厚优先在0.02至0.11mm范围内，特别优先在0.04至0.08mm之间。
捕集元件的单格密度(单位横截面上的通道数)优先在每平方英寸25至1000个通道(cpsi)范围内，最好在200到400cpsi之间。
典型的捕集元件具有例如200cpsi，对于柴油机而言，体积为约每100kw 0.5至0.8立升，或者几何表面面积为每100kw 1至2m2，其在流动路径内最好存在间距为3至20mm的转向或旋涡结构。
捕集元件可以连续或周期地再生，其中在柴油机排气管内既可以通过在250℃以上的温度下通过氮氧化物(NO2)，也可以在温度为500℃以上时用空气或氧气(O2)和/或通过喷入添加剂(例如铈Cer)通过炭黑的氧化进行再生。
借助于NO2，例如通过按
的连续再生捕集器(CRT)的机理的炭黑氧化反应要求，在排气管内的捕集元件的前面安装一氧化催化器，它使NO足够数量地氧化成NO2。试验表明，作为化学计算的要求应该在捕集元件内输入两倍，尤其是1.2倍(相当于约2.4Mol)的NO2，以使炭黑完全氧化。但是反应物的数量比还主要与流体的混合有关，因此根据捕集元件结构的不同也应该采用不同的数量比。
在不同的实施形式时捕集元件在装入例如汽车排气管时还可以有许多希望的辅助效应：
按照一种实施形式捕集元件除分离颗粒外还有使废气和其它流体混和的任务，例如柴油机废气与氨气或尿素溶液混合，以例如在应用SCR(可选择的催化还原)方法时产生还原反应。为此捕集元件与至少一种添加剂输入装置结合使用。
通过捕集元件优良的结构设计还优化了流过的流体的流动分布，例如用于随后输入还原催化器。按照一种实施形式采用与一连接在前面的添加剂输入装置组合的捕集元件。
按照一种实施形式采用与至少一个催化器组合的捕集元件。氧化催化器、带有前置或后置加热盘的加热催化器、水解催化器和/或还原催化器特别适合于作为这种催化器和/或前置催化器。作为氧化催化器也采用那种将NOx(亚硝气体)氧化成二氧化氮(NO2)，还有将碳氢化合物和一氧化碳氧化成二氧化碳的氧化催化器，催化器是管状或圆锥状的。
捕集元件与至少一个催化器和一个涡流增压器(Turbolader)的组合或捕集元件与一个涡流增压器的组合是有利的。其中连接在涡流增压器后面的捕集元件可以安装在发动机附近或底盘位置上。
也采用捕集器与前置或后置炭黑过滤器的组合，其中后置炭黑过滤器可以比普通炭黑过滤器小得多，因为它只应该提供附加的防护以消除颗粒的排放。例如100kw的柴油机0.5至1m2大小的过滤器就足够了，相反不用捕集元件的话每100kw需要约4m2大小的过滤器。
下面这些例子表示，捕集元件与催化元件、涡流增压器、炭黑过滤器和添加剂输入装置沿汽车排气管铺设的许多可能的组合的布局。
A)氧化催化器—涡流增压器—捕集元件，其中捕集元件可以安装在发动机附近或底盘位置上；
B)前置催化器—捕集元件—涡流增压器；
C)氧化催化器—涡流增压器—氧化催化器—捕集元件；
D)加热催化器—捕集元件1—捕集元件2(其中捕集元件1和2可以是相同的或不同的)；
E)捕集元件1—排气管的锥形开口—捕集元件2；
F)添加剂输入装置—捕集元件—水解催化器—还原催化器；
G)前置催化器—氧化催化器—添加剂输入装置—(可能的炭黑过滤器)—捕集元件例如圆锥形的，在某些情况下带有水解涂层—(可能的炭黑过滤器)—(可能是圆锥形以提高管子横截面的)还原催化器。
根据实施形式的不同捕集元件可以具有不同的涂层，它们分别具有确定的功能。例如捕集元件除存储、混合、流动分布功能外还可以具有作为水解催化器的功能。
下面借助于优选的结构方案对本发明作较详细的说明。
图1示意表示一内燃机的排气装置。
图2表示一按本发明的捕集元件的实施形式的一小部分。
图3表示一按本发明的捕集元件的另一种实施形式的一小部分。
图1中表示一台内燃机1，特别是柴油机，其废气引入一排气管2内。排气管具有至少一个氧化催化器3，它前面还可以连接一个未画出的设置在非常靠近出口处的前置催化器。此外在这个区域内还可以存在一个同样未画出的涡流增压器。在排气管内后面接着有一个用于添加剂。特别是尿素的输入装置4。在这个输入装置的下游设有一个按本发明的捕集元件，它后面又连接一个SCR-催化器。
图2表示按本发明的捕集元件的一个实施例的一小部分。它由形成波纹结构(strukturiert)的板层11和光滑的板层12构成，其中产生可畅通无阻的流通路径13，但是它们通过形成波纹结构的板层11的特殊结构具有转向部位15、16。这些转向部位使废气产生涡流，使颗粒在捕集元件内停留较长时间，并可以与废气的其它成分容易发生反应。根据转向部位15、16确切的结构的不同废气还有颗粒甩向通过板层11、12构成的流通路径13的壁，颗粒便附着在那里。转向部位15、16具有例如20°至90°的张开角或偏(入射)角。相对于流动方向的偏角越大，所达到的转向和涡流便越大，但是造成按指数增加的压力损失。角度的最佳值在40°至50°之间，在这种角度时在压力损失可以承受的情况下产生很好的涡流。转向部位15、16最好与形成波纹结构的板层11上的开口17相组合，由此形成强烈的旋涡，并达到在相邻流通路径13内的气流的完全混合。
图3中表示另一个实施例，同样仅仅作为一捕集元件的一小部分。捕集元件由一形成波纹结构的板层21和一带缺口28的光滑板层22构成，并形成可自由流通的流通路径23。叶片状的转向部位25、26连同曲线形的开口27造成和上面所述的相同的效果。光滑板层22上的缺口28有利于涡流的形成，和在捕集元件内废气的完全混合。
已经确定，颗粒的沉积特别是发生在捕集元件的入口和出口表面区域内。因此按照一种实施形式采用作为盘状元件的顺序连接的窄的蜂窝体形式的捕集元件。这里在每个盘的入口和出口区分别形成转向和/或涡流部位。其中优先采用最多10个盘的捕集元件。
本发明推荐一种用于炭黑颗粒的捕集系统，它可以代替普通的过滤系统，并相对于这种系统带来突出的优点：
一方面它不会堵塞，并且由于这种系统产生的压降不象在过滤系统时那样随着运行时间的加长而迅速增大，因为颗粒附着在气流之外，另一方面相对而言它造成较小的压力损失，因为它是一个开式的系统。
                        附图标记表
   1   内燃机                 2   排气管
   3   氧化催化器             4   添加剂输入装置
   5   捕集元件               6   SCR-催化器
   11  形成波纹结构的板层     12  光滑板层
   13  流通路径               15  转向部位
   16  转向部位               17  开口
   21  形成波纹结构的板层     22  光滑板层
   23  流通路径               25  转向部位
   26  转向部位               27  开口
   28  缺口

Claims (15)

1.从内燃机(1)特别是柴油机的废气中排除炭黑颗粒的方法，其中废气被引导通过一对于废气可自由流通的，但设有许多转向部位(15，16；25，26)和/或涡流和平稳区的捕集元件(5)，在捕集元件内至少一部分颗粒停留或环绕涡流这样长的时间，使得存在足够大的概率，使颗粒与废气中存在的氮氧化物发生反应，直至完全排除捕获的颗粒。
2.按权利要求1所述的方法，其中捕集元件(5)同时是一个用来使还原剂，特别是尿素均匀分布的混合元件，并在捕集元件之前输入还原剂(4)。
3.按权利要求1或2所述的方法，其中颗粒通过废气的转向部位(15，16；25，26)甩向捕集元件(5)的壁(11，12，21，22)，使颗粒附着在那里和/或可以与其它颗粒附聚。
4.按权利要求3所述的方法，其中用一个转向部位(15，16；25，26)每次使还包含在废气中的颗粒的2％至15％甩向捕集元件(5)的壁(11，12，21，22)，其中最好准备这么多转向部位(15，16；25，26)，使得全数颗粒甩向壁(11，12，21，22)。
5.用来捕集流过捕集元件(5)的废气中的炭黑颗粒的捕集元件(5)，其中捕集元件具有对于废气可自由流通的流通路径(13；23)，但是流通路径(13，23)设计成这样，使得产生转向部位(15，16；25，26)或涡流区和平稳区。
6.按权利要求5所述的捕集元件，其中捕集元件(5)包括至少一个由板层(11，12；21，22)组成的金属蜂窝体，其中板层(11，12；21，22)以公知的方法至少局部形成这样的结构构造，使得产生对于废气可自由流通的、具有障碍或转向部位(15，16；25，26)的流通路径。
7.按权利要求6所述的捕集元件，其中障碍或转向部位(15，16；25，26)设计成这样，使得每次还包含在废气中的颗粒的2％至15％甩向捕集元件(5)的壁(11，12，21，22)。
8.按权利要求5至7之任一项所述的捕集元件，其中捕集元件(5)的流通路径(13；23)的壁(11，12；21，22)的至少一部分是涂覆的，特别是用由氧化铝组成的Washcoat涂覆。
9.按权利要求5至8之任一项所述的捕集元件，其中捕集元件(5)是锥形的。
10.至少一个按权利要求5至9之任一项所述的捕集元件(5)在内燃机(1)特别是柴油机的排气管(2)中的应用。
11.按权利要求5至9之任一项所述的捕集元件(5)与至少一个前置或后置添加剂输入装置(4)组合应用。
12.按权利要求5至9之任一项所述的捕集元件(5)与至少一个催化器(3，6)组合应用。
13.按权利要求5至9之任一项所述的捕集元件(5)与至少一个前置或后置的氧化催化器(3)组合应用，其中至少一种亚硝气体(NOx)氧化成二氧化氮(NO2)。
14.按权利要求5至9之任一项所述的捕集元件(5)与至少一个前置或后置的涡流增压器组合应用，其中捕集元件安装在发动机附近和/或底盘位置上。
15.按权利要求5至9之任一项所述的捕集元件(5)与一前置的，前面又连接一氧化催化器的涡流增压器组合应用在柴油机排气管内。
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