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EP1153206A1 - Appareil de filtration/catalyse monolithique - Google Patents

Appareil de filtration/catalyse monolithique

Info

Publication number
EP1153206A1
EP1153206A1 EP00902771A EP00902771A EP1153206A1 EP 1153206 A1 EP1153206 A1 EP 1153206A1 EP 00902771 A EP00902771 A EP 00902771A EP 00902771 A EP00902771 A EP 00902771A EP 1153206 A1 EP1153206 A1 EP 1153206A1
Authority
EP
European Patent Office
Prior art keywords
cells
gaseous stream
catalyst
walls
particulate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00902771A
Other languages
German (de)
English (en)
Inventor
Hassan Windawi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson Matthey PLC
Original Assignee
Johnson Matthey PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Matthey PLC filed Critical Johnson Matthey PLC
Publication of EP1153206A1 publication Critical patent/EP1153206A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/88—Handling or mounting catalysts
    • B01D53/885—Devices in general for catalytic purification of waste gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/02—Combinations of different methods of purification filtering and catalytic conversion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction

Definitions

  • This invention relates generally to monolithic catalysts. More particularly, this invention relates to monolithic catalysts which perform both filtering and catalysis functions to treat gaseous streams containing particulate material.
  • Soot is essentially carbonaceous material and, where it is generated during combustion of diesel fuel in the cylinder of diesel engine, leaves the engine with a layer of soluble organic fraction (SOF) surrounding it. That soot, covered in the SOF is one kind of particulate material that can be problematic.
  • SOF soluble organic fraction
  • the excess particulate material can block the filter.
  • Blockage of the filter begins with an increase in pressure drop across the filter and ends with an insurmountable blockage that can damage the engine and other parts of the system.
  • An alternative method of treating an exhaust stream containing particulate material is to use only an oxidation catalyst. In such a case, relatively low conversions of SOF are achieved. Because no filter is used, however, blockage and its associated problems (as discussed above related to the use of a filter) do not normally occur.
  • An improved filter/catalyst apparatus would provide effective filtering and catalysts while preventing the harmful effects on the system associated with blockage by particulate material which may be present in the exhaust stream.
  • the present invention provides an apparatus for the control of gaseous and particulate emissions from a gaseous stream containing particulate material with carbonaceous combustible content.
  • the invention is particularly applicable to diesel exhaust streams, but applies to any stream that contains noxious or otherwise undesirable gases.
  • the invention is particularly applicable to streams containing both noxious or otherwise undesirable gases and particulate material.
  • the apparatus comprises an inlet side and an outlet side and a plurality of passageways, or cells.
  • the interior walls which separate the cells are made of a material which is permeable to the gaseous stream.
  • the cells are oriented to allow flow of the gaseous stream from the inlet to the outlet of the apparatus, and each of the cells has a first end adjacent the inlet of the apparatus and a second end adjacent the outlet of the apparatus.
  • the cell walls are coated with a catalyst.
  • a barrier is present in some, but not all, of the second ends of the cells.
  • the barrier may be comprised of a material that does not allow passage of the gaseous stream or permits passage of gases but not particulate.
  • the cells, as a group are partially blocked such that the exhaust stream can pass freely through some of the cells but not all of the cells.
  • Fig.l shows a schematic view of an apparatus according to the present invention
  • Fig.2 shows a schematic view of a cross section of an apparatus according to the present invention
  • Fig.3 is a plot showing the opacity reduction where only a monolithic catalyst is used
  • Fig.4 is a plot showing the opacity reduction where the apparatus of the present invention is used.
  • the present invention provides an apparatus for the control of gaseous and particulate emissions from a gaseous stream containing particulate material with carbonaceous combustible content.
  • the invention is particularly applicable to diesel exhaust streams.
  • the apparatus comprises an inlet side and an outlet side and a plurality of cells.
  • the cell walls are made of a material that is permeable by the gaseous stream but largely not permeable by the particulate material.
  • Fig.l shows a schematic view of an apparatus according to the present invention.
  • Cells 100 are contained in a region of the apparatus which has an inlet and an outlet, shown by arrows which indicate gas flow.
  • a typical apparatus is placed directly into the exhaust line.
  • the size of a typical apparatus might be about 15cm (6 inches) long by about 20-25cm (8 - 10 inches) in diameter, for a vehicle using a 6 liter diesel engine.
  • Fig. 2 shows a schematic view of a cross section of a portion of an apparatus according to the present invention.
  • the cells are oriented to allow flow of the gaseous stream from the inlet to the outlet of the apparatus, and each of the cells has a first end adjacent the inlet of the apparatus and a second end adjacent the outlet of the apparatus.
  • the cell walls are coated with, or otherwise contain, a catalyst.
  • a barrier is present in some, but not all, of the second ends of the cells.
  • the barrier is comprised of a material that does not allow passage of the gaseous stream.
  • the cells as a group, are partially blocked such that the exhaust stream can pass freely through some of them but not all of them.
  • the cells are alternatively blocked.
  • the cells are periodically blocked - i.e. one blocked, one open, one blocked, etc., as shown schematically in both Figs. 1 and 2.
  • the arrows indicate gaseous flow of an exhaust stream through the cells.
  • Barriers 200 and 201 are present in alternating cells. In the case illustrated, the cells are straight cells, but the cells do not have to be straight. Open cells 210, 220, and 230 allow easy passage of the gaseous stream. Closed cells 240 and 250 do not allow easy flow, as barriers 200 and 201 are present at the end of the cells.
  • Walls 260, 265, 270, 275, 280, and 285 are all permeable to the gaseous stream, but are substantially not permeable to the particulate material that is present in the stream.
  • Cells 210, 220, and 230 all allow the gaseous stream including particulate to pass freely through, as indicated by the arrows in Fig. 2.
  • Cells 240 and 250 do not allow such free flow, however, due to barriers 200 and 201.
  • gas is forced through the semi permeable walls and into cells 210, 220, and 230, as indicated by the arrows in Fig. 2.
  • the walls are considered semipermeable because they do not allow the passage of most of the particulate material (some particulate material may work its way through, but the vast majority is captured at the surface of the wall).
  • the particulate material is collected on the surface of wall 265 which is exposed to cell 240, the surface of wall 270 which is exposed to cell 240, the surface of wall 275 which is exposed to cell 250, and the surface of wall 280 which is exposed to cell 250.
  • Gas is forced through the walls from the blocked cells to the open cells because of pressure generated in the blocked cells.
  • the open cells act as eductors. The decrease in pressure at the surface of walls exposed to the open cells as gas flows through them increases the pressure drop across the wall and effectively draws the gas through the wall.
  • particulate material As particulate material accumulates on the walls, it is typically catalysed and combusted along, or on, the coated wall. Uncombusted, inorganic ash or other uncombustible material will fall free and out of the system due to forced gas flow, its own weight, and/or vibrations caused from the engine operation and other movement of the housing. Even if the particulate material does not fall free, however, blockage of the apparatus will never occur from particulate accumulation, however, because some of the cells are open to flow. Similarly, in the case of an engine malfunction such that an excess of particulate material enters the apparatus, no blockage will occur.
  • the amount of cells in a given apparatus can vary depending on the particular application. For example, for an average 6 liter diesel engine, about 15.5 cells per sq cm (100 cells per square inch) of cross section (cpsi) would probably suffice. Of course, specific operating conditions and environment would impact this design parameter. For example, differing engine designs, exhaust line designs and even fuels would require, possibly, different cell sizes. Apparati according to the present invention could have cell sizes up to about 31 cells per sq cm (200 cpsi), and even higher, depending on the necessary wall thicknesses. Other than design choice, manufacturing constraints can also create limits on cell concentration. Conveniently, half the cells are provided with the barrier.
  • the walls can be constructed from any suitable material which meets the needs described above.
  • the walls may be made of a woven or knitted wire mesh or perforated metal or a suitable ceramic material.
  • a preferred wall material is cordierite (a crystalline mineral comprising a silicate of aluminum and magnesium), but silicon carbide and stainless steel mesh may also be used.
  • the walls can be suitably designed for each engine application as the particulate emissions differ from engine to engine.
  • the catalyst coating on the walls may also be of any suitable catalyst for the desired purpose. It may, for example, be any that is effective to convert NO to NO 2 (NO 2 is an effective oxidizer, and its presence is therefore desirable for subsequent oxidation of particulate material). It may also be a high platinum loading catalyst carried on a ceramic or metal honeycomb catalyst support, separate from the wall material itself. Alternatively, the wall itself may be the support.
  • the catalyst layer may also be an alumina-based washcoat impregnated with platinum group metals (i.e. platinum, palladium, ruthenium, rhodium, osmium, iridium, etc.).
  • the catalyst may be a base metal, with or without any platinum group metal.
  • the base metal may be by itself, as in a base metal washcoat, or be present in conjunction with alumina.
  • Typical base metals include manganese, copper, iron, nickel, cobalt, and oxides of these metals.
  • rare earth eLments could comprise the base metal.
  • Such rare earth base metals would include cerium, lanthanum, praseodymium, neodymium, etc. (atomic numbers 57-71) and oxides of these elements. Of course, combinations of these metals and their oxides could also be used.
  • Many other catalyst and catalyst configurations can be employed in conjunction with the present invention and one skilled in the art can make the selection based upon each situation and the desired catalytic activity. When the catalyst is applied to the wall, care is taken not to block the pores which allow flow of the gaseous stream through the walls. Through appropriate methods of applying the catalyst, known to those skilled in the art, this blockage problem may be avoided.
  • Figs. 3 and 4 show results for opacity testing of exhaust streams from different treatment apparati.
  • Opacity is defined as the fraction of light transmitted from a source which is prevent from reaching the observer or instrument receiver, expressed in percentage. Thus, something which has opacity of 100% is completely opaque, and something with 0% opacity is completely transparent.
  • opacity measurements were taken across the exhaust stream as it traversed the test chamber. In Fig. 3, this reading was recorded as the exhaust stream exited only a monolithic catalyst chamber. In Fig. 4, the reading was recorded as the exhaust stream exited an apparatus according to the present invention.
  • Figs. 3 and 4 show the percent decrease in opacity (i.e. the percent change in percentage of light transmitted through the exhaust stream as it exited the apparatus as compared to before it entered the apparatus). Thus, a greater percent decrease in opacity translates to a greater removal of particulate material.
  • Fig. 3 shows the opacity reduction where only a monolithic catalyst is used, without the alternating blocked/unblocked cells according to the present invention. Data was generated using a 6 liter diesel engine and was collected over an approximate 5 month period. Measurements were taken four times on each day indicated and averaged. In each figure, two sets of data as shown for each measurement period.
  • Fig. 4 shows the opacity reduction where the apparatus is configured according to the present invention, that is, as shown schematically in Fig. 1.
  • opacity reduction ranges, approximately, between 30 and 50%.
  • data was collected from the use of a 6 liter diesel engine over the same approximate 5 month period. Two sets of data are shown for each measurement period. One set was taken from exhaust exiting the system while the engine was operating and was ramped from 750 to 2300 rpm in four seconds. Similarly, a second set of data was taken from exhaust exiting the system while the engine was operating and was ramped from 1500 to 2300 rpm in four seconds. Again, four data points were generated for each day under each operating condition and were then averaged to generate the point on the graph.
  • the present invention provides a system where particulate removal is enhanced and necessary catalytic activity is promoted, while simultaneously removing the possibility of the system becoming blocked (and subsequently damaged) due to excessive particulate material depositing as may arise from engine malfunction.
  • the present invention provides an advantageous system in which catalytic activity is enhanced.
  • catalytic activity is enhanced.
  • the enhanced turbulence created by wall flow eduction increases catalyst efficacy.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Environmental & Geological Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Biomedical Technology (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Filtering Materials (AREA)
  • Catalysts (AREA)

Abstract

L'invention a trait à un appareil servant à réguler les émissions particulaires et gazeuses d'un courant gazeux contenant des matières particulaires, ou d'un courant gazeux n'en contenant pas. Cet appareil comprend une entrée et une sortie, et plusieurs cellules pourvues de parois (260, 265, 270, 275, 280, 285) constituées d'un matériau perméable au courant gazeux. Lesdites cellules sont orientées afin de permettre l'écoulement (210, 220, 230, 240) du courant gazeux de l'entrée vers la sortie, et chacune des cellules a une première extrémité adjacente à l'entrée de l'appareil, et une seconde extrémité adjacente à la sortie de l'appareil. Les parois sont recouvertes d'un catalyseur. Une barrière (200, 201) est placée à certaines, mais pas à toutes, les secondes extrémités des cellules, la barrière étant constituée d'un matériau qui ne permet pas le passage du courant gazeux.
EP00902771A 1999-02-26 2000-02-11 Appareil de filtration/catalyse monolithique Withdrawn EP1153206A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US25897199A 1999-02-26 1999-02-26
US258971 1999-02-26
PCT/GB2000/000435 WO2000050745A1 (fr) 1999-02-26 2000-02-11 Appareil de filtration/catalyse monolithique

Publications (1)

Publication Number Publication Date
EP1153206A1 true EP1153206A1 (fr) 2001-11-14

Family

ID=22982931

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00902771A Withdrawn EP1153206A1 (fr) 1999-02-26 2000-02-11 Appareil de filtration/catalyse monolithique

Country Status (4)

Country Link
EP (1) EP1153206A1 (fr)
JP (1) JP2002537965A (fr)
AU (1) AU2451200A (fr)
WO (1) WO2000050745A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106268315A (zh) * 2015-05-19 2017-01-04 上海泰欣环境工程股份有限公司 Scr倾侧式颗粒催化剂模块

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3925154B2 (ja) * 2000-12-25 2007-06-06 株式会社デンソー 排ガス浄化フィルタ
JP2005519218A (ja) * 2002-03-01 2005-06-30 パー−テック リミテッド ガス流処理装置及びガス流からの汚染物質除去装置の改良品並びにその関連装置
JP4369141B2 (ja) 2003-02-18 2009-11-18 日本碍子株式会社 ハニカムフィルタ及び排ガス浄化システム
GB2457651A (en) 2008-01-23 2009-08-26 Johnson Matthey Plc Catalysed wall-flow filter

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Publication number Priority date Publication date Assignee Title
DE3205673A1 (de) * 1982-02-17 1983-09-01 Engelhard Kali-Chemie Autocat Gmbh, 3000 Hannover Vorrichtung zur reinigung der abgase von dieselmotoren, insbesondere bei kraftfahrzeugen
JPS6220613A (ja) * 1985-07-19 1987-01-29 Cataler Kogyo Kk パテイキユレ−ト除去用触媒フイルタ
US4902487A (en) 1988-05-13 1990-02-20 Johnson Matthey, Inc. Treatment of diesel exhaust gases
DE4033621C1 (en) * 1990-10-23 1992-06-25 Mercedes-Benz Aktiengesellschaft, 7000 Stuttgart, De Filter for cleansing exhaust gas, esp. from diesel engine - has filter body with longitudinal channels which are sepd. by porous sepg. walls which are not penetrated by soot particles
DE69328202T2 (de) * 1992-09-28 2000-07-20 Ford France S.A., Rueil-Malmaison Filterelement zur Steuerung der Abgasemission von Brennkraftmaschinen

Non-Patent Citations (1)

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Title
See references of WO0050745A1 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106268315A (zh) * 2015-05-19 2017-01-04 上海泰欣环境工程股份有限公司 Scr倾侧式颗粒催化剂模块
CN106268315B (zh) * 2015-05-19 2019-05-17 上海泰欣环境工程股份有限公司 Scr倾侧式颗粒催化剂模块

Also Published As

Publication number Publication date
WO2000050745A1 (fr) 2000-08-31
JP2002537965A (ja) 2002-11-12
AU2451200A (en) 2000-09-14

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