Systems and methods for increasing nitrogen dioxide fraction in exhaust gas at low temperature

Patent metadata

Field	Value
Publication number	US-10022667-B2
Application number	US-201715663457-A
Country	US
Kind code	B2
Filing date	Jul 28, 2017
Priority date	Jul 29, 2016
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

An aftertreatment system includes a first oxidation catalyst, a second oxidation catalyst, and a turbocharger. The first oxidation catalyst is upstream of the turbocharger and includes a first oxidation catalyst formulation. The second oxidation catalyst is downstream of the turbocharger and includes a second oxidation catalyst formulation different than the first oxidation catalyst formulation. The second oxidation catalyst formulation is configured to promote conversion of nitric oxide (NO) to nitrogen dioxide (NO2).

First claim

What is claimed is:

1. An aftertreatment system, comprising:
a turbocharger;
a first oxidation catalyst upstream of the turbocharger, the first oxidation catalyst comprising a first oxidation catalyst formulation; and
a second oxidation catalyst downstream of the turbocharger, the second oxidation catalyst comprising a second oxidation catalyst formulation different than the first oxidation catalyst formulation, the second oxidation catalyst formulation configured to promote conversion of nitric oxide (NO) to nitrogen dioxide (NO 2 ).

2. The aftertreatment system of claim 1 , wherein, in operation, at exhaust gas temperatures of less than 200 degrees Celsius, a ratio of NO 2 to nitrogen oxide (NO x ) gases in an exhaust gas after passing through the second oxidation catalyst is in a range between about 0.4 to about 0.6, and wherein the ratio allows a selective catalytic reduction system to attain a catalytic conversion efficiency of at least 90% at an exhaust gas temperature of less than 200 degrees Celsius.

3. The aftertreatment system of claim 1 , wherein the first oxidation catalyst formulation is configured to promote oxidation of hydrocarbons included in an exhaust gas flowing through the aftertreatment system.

4. The aftertreatment system of claim 3 , wherein each of the first oxidation catalyst and the second oxidation catalyst comprises a platinum group metal, and wherein the first oxidation catalyst has a higher loading of the platinum group metal than the second oxidation catalyst.

5. The aftertreatment system of claim 4 , wherein the platinum group metal includes platinum and palladium, and wherein the first oxidation catalyst comprises a lower loading ratio of the platinum to the palladium relative to the second oxidation catalyst.

6. The aftertreatment system of claim 1 , wherein the first oxidation catalyst comprises:
a first oxidation catalyst first portion configured to promote oxidation of hydrocarbons included in the exhaust gas; and
a first oxidation catalyst second portion positioned downstream of the first oxidation catalyst first portion, the first oxidation catalyst second portion configured to promote conversion of NO included in the exhaust gas to NO 2 .

7. The aftertreatment system of claim 1 , wherein the second oxidation catalyst comprises:
a second oxidation catalyst first portion configured to promote oxidation of hydrocarbons included in the exhaust gas; and
a second oxidation catalyst second portion positioned downstream of the second oxidation catalyst first portion, the second oxidation catalyst second portion configured to promote conversion of NO included in the exhaust gas to NO 2 .

8. The aftertreatment system of claim 1 , wherein the first oxidation catalyst is positioned downstream of an exhaust gas recirculation line, the exhaust gas recirculation line positioned downstream of the engine and configured to recirculate a first portion of an exhaust gas from downstream of the engine to upstream of the engine.

9. The aftertreatment system of claim 1 , wherein the first oxidation catalyst is positioned downstream of the engine.

10. The aftertreatment system of claim 1 , wherein the second catalyst is positioned upstream of a selective catalytic reduction system.

11. An aftertreatment system, comprising:
a selective catalytic reduction system configured to decompose constituents of an exhaust gas produced by an engine;
a first oxidation catalyst upstream of a turbocharger, the first oxidation catalyst comprising a first oxidation catalyst formulation; and
a second oxidation catalyst downstream of the turbocharger and upstream of the selective catalytic reduction system, the second oxidation catalyst comprising a second oxidation catalyst formulation different than the first oxidation catalyst formulation, the second oxidation catalyst formulation configured to promote conversion of nitric oxide (NO) included in the exhaust gas to nitrogen dioxide (NO 2 ).

12. The aftertreatment system of claim 11 , wherein the first oxidation catalyst formulation is configured to promote oxidation of hydrocarbons included in the exhaust gas.

13. The aftertreatment system of claim 11 , further comprising:
an exhaust conduit communicating the exhaust gas to the turbocharger from the engine; and
a bypass line fluidly coupled to the exhaust conduit upstream of the turbocharger, the bypass line receiving at least a portion of the exhaust gas expelled by the engine and delivering at least the portion of the exhaust gas upstream of the turbocharger,
wherein the first oxidation catalyst is positioned in the bypass line.

14. The aftertreatment system of claim 13 , wherein the bypass line is selectively closed in response to an exhaust gas temperature exceeding a predetermined threshold, so as to prevent the second portion of the exhaust gas from passing through the first oxidation catalyst.

15. The aftertreatment system of claim 11 , wherein the first oxidation catalyst is positioned downstream from the engine.

16. A method, comprising:
providing an exhaust aftertreatment system, comprising:
a first oxidation catalyst positioned upstream of a turbocharger, the first oxidation catalyst comprising a first oxidation catalyst formulation; and
a second oxidation catalyst positioned downstream of the turbocharger, the second oxidation catalyst comprising a second oxidation catalyst formulation different than the first oxidation catalyst formulation, the second oxidation catalyst formulation configured to promote conversion of nitric oxide (NO) to nitrogen dioxide (NO 2 ); and

flowing exhaust gas through the first oxidation catalyst and the second oxidation catalyst.

17. The method of claim 16 , wherein the exhaust aftertreatment system further comprises:
an exhaust conduit communicating the exhaust gas to the turbocharger from an engine;
a bypass line fluidly coupled to the exhaust conduit upstream of the turbocharger, the bypass line receiving at least a portion of the exhaust gas expelled by the engine and delivering at least the portion of the exhaust gas upstream of the turbocharger, the first oxidation catalyst positioned in the bypass line; and
a first valve positioned in the exhaust conduit in parallel with the first oxidation catalyst, the first valve controllably actuatable between a closed position and an open position.

18. The method of claim 17 , further comprising controllably actuating the first valve to the closed position in response to a temperature of the exhaust gas being below a predetermined threshold so as to cause the exhaust gas to flow through the first oxidation catalyst positioned in the bypass line.

19. The method of claim 17 , wherein the exhaust aftertreatment system further comprises a second valve positioned in the bypass line upstream of the first oxidation catalyst, the second valve controllably actuatable between a closed position and an open position.

20. The method of claim 19 , further comprising controllably actuating the second valve to the closed position in response to the temperature of the exhaust gas being above the predetermined threshold so as to prevent the exhaust gas from flowing through the first oxidation catalyst positioned in the bypass line.

Assignees

• Cummins Inc

Inventors

• Zha Yuhui
• Heichelbech John K
• Cunningham Michael J

Classifications

• B01D2255/1023

  Palladium · CPC title

• B01J23/44

  Palladium · CPC title

• B01D2255/2065

  Cerium · CPC title

• B01D2258/018

  Natural gas engines · CPC title

• B01D53/565 Primary

  by treating the gases with solids · CPC title