Emissions reduction system

Patent metadata

Field	Value
Publication number	US-9657626-B2
Application number	US-201514714757-A
Country	US
Kind code	B2
Filing date	May 18, 2015
Priority date	May 18, 2015
Publication date	May 23, 2017
Grant date	May 23, 2017

Abstract

An exhaust system for a diesel engine is disclosed. The exhaust system may include a diesel oxidation catalyst (DOC) configured to receive exhaust gases from the engine and oxidize hydrocarbons in the exhaust gases and a passive NOx adsorber (PNA) downstream from the DOC and configured to store NOx from the exhaust gases at temperatures up to 150° C. A selective catalytic reduction (SCR) system may be downstream from the PNA and configured to reduce NOx in the exhaust gases. The PNA may be configured to release the stored NOx at temperatures above 200° C. The DOC upstream of the PNA may reduce the amount of N 2 O that is generated by the PNA by oxidizing hydrocarbons before they reach the PNA.

First claim

What is claimed is:

1. A diesel engine exhaust system, comprising:
a diesel oxidation catalyst (DOC) brick configured to receive exhaust gases from a diesel engine and oxidize hydrocarbons therein;
a passive NOx adsorber (PNA) brick separate and downstream from the DOC brick and configured to store NOx from the exhaust gases up to 150° C.; and
a selective catalytic reduction (SCR) system downstream from the PNA brick and configured to reduce NOx in the exhaust gases;
wherein the PNA brick includes palladium and platinum and has a palladium to platinum content of at least 3:1.

2. The system of claim 1 , wherein the PNA brick is configured to store NOx from the exhaust gases at temperatures up to 180° C.

3. The system of claim 1 , wherein the PNA brick is configured to release the stored NOx at temperatures above 200° C.

4. The system of claim 1 , wherein the DOC brick includes palladium and substantially no platinum.

5. The system of claim 1 , wherein the DOC brick includes palladium and platinum and has a palladium to platinum content of at least 3:1.

6. The system of claim 1 , wherein the diesel engine exhaust system emits less than 10 ppm of N 2 O throughout a first 2,000 seconds after engine start.

7. The system of claim 1 , wherein the DOC brick is coupled to the PNA brick by an exhaust conduit.

8. The system of claim 1 , wherein the DOC brick and the PNA brick are contained in a single housing.

9. The system of claim 1 , wherein the PNA brick is configured to release substantially all stored NOx at a temperature of 350° C. or less.

10. The system of claim 1 , wherein the PNA brick contains substantially no alkali metals or alkaline-earth metals.

11. The system of claim 1 , wherein the PNA brick contains one or more rare earth elements.

12. A process, comprising:
introducing a first exhaust gas (FEG) from a diesel engine to a diesel oxidation catalyst (DOC) front-brick to generate a second exhaust gas (SEG);
introducing the SEG to a passive NOx adsorber (PNA) rear-brick downstream from the DOC front-brick to generate a third exhaust gas (TEG), the PNA rear-brick storing NOx from the SEG up to 150° C.; and
introducing the TEG to a NOx reduction system from the PNA rear-brick;
wherein throughout a first 2,000 seconds after starting the diesel engine, an output exhaust gas (OEG) from the NOx reduction system includes less than 10 ppm of N 2 O.

13. The process of claim 12 , wherein at temperatures above 200° C. the PNA rear-brick releases stored NOx into the TEG.

14. The process of claim 12 , wherein at a temperature of 400° C. or less, the PNA rear-brick releases substantially all stored NOx into the TEG.

15. The process of claim 12 , wherein the diesel engine is substantially always running with a lean air to fuel ratio.

16. An exhaust system for treating exhaust gases from a diesel engine, comprising:
a passive NOx adsorber (PNA) layer disposed on a substrate and configured to store NOx from the exhaust gases at temperatures up to 150° C.;
a diesel oxidation catalyst (DOC) layer disposed over the PNA layer and configured to contact the exhaust gases before they contact the PNA layer and to oxidize hydrocarbons in the exhaust gases; and
a selective catalytic reduction (SCR) system downstream from the PNA and DOC layers and configured to reduce NOx in the exhaust gases;
wherein the PNA layer and the DOC layer each include palladium and platinum and have a palladium to platinum content of at least 3:1.

17. The system of claim 16 , wherein the exhaust system emits less than 10 ppm of N 2 O throughout a first 2,000 seconds after engine start.

Assignees

• Ford Global Tech Llc

Inventors

• Theis Joseph Robert
• Lambert Christine Kay
• Dobson Douglas Allen

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• B01D53/9481

  Catalyst preceded by an adsorption device without catalytic function for temporary storage of contaminants, e.g. during cold start · CPC title

• F01N13/0097

  the purifying devices are arranged in a single housing · CPC title

• B01D2257/702

  Hydrocarbons · CPC title

• B01D2257/502

  Carbon monoxide · CPC title