WO2000061265A1 - Lit de garde pour catalyseur anti-pollution - Google Patents
Lit de garde pour catalyseur anti-pollution Download PDFInfo
- Publication number
- WO2000061265A1 WO2000061265A1 PCT/US2000/009027 US0009027W WO0061265A1 WO 2000061265 A1 WO2000061265 A1 WO 2000061265A1 US 0009027 W US0009027 W US 0009027W WO 0061265 A1 WO0061265 A1 WO 0061265A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- guard bed
- oxide
- support layer
- set forth
- phosphateable
- Prior art date
Links
- 239000003054 catalyst Substances 0.000 title description 17
- 230000003197 catalytic effect Effects 0.000 claims abstract description 37
- 239000006262 metallic foam Substances 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 14
- 239000007789 gas Substances 0.000 claims description 22
- 229910052751 metal Inorganic materials 0.000 claims description 14
- 239000002184 metal Substances 0.000 claims description 14
- 239000000758 substrate Substances 0.000 claims description 9
- PLDDOISOJJCEMH-UHFFFAOYSA-N neodymium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Nd+3].[Nd+3] PLDDOISOJJCEMH-UHFFFAOYSA-N 0.000 claims description 8
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 claims description 7
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical group O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052791 calcium Inorganic materials 0.000 claims description 5
- 239000011575 calcium Substances 0.000 claims description 5
- 238000002485 combustion reaction Methods 0.000 claims description 5
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 5
- 229910052749 magnesium Inorganic materials 0.000 claims description 5
- 239000011777 magnesium Substances 0.000 claims description 5
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 claims description 5
- 229910052684 Cerium Inorganic materials 0.000 claims description 4
- 229910052779 Neodymium Inorganic materials 0.000 claims description 4
- 229910052777 Praseodymium Inorganic materials 0.000 claims description 4
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 4
- 229910052788 barium Inorganic materials 0.000 claims description 4
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 claims description 4
- 229910000420 cerium oxide Inorganic materials 0.000 claims description 4
- 229910052746 lanthanum Inorganic materials 0.000 claims description 4
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 claims description 4
- 229910003447 praseodymium oxide Inorganic materials 0.000 claims description 4
- 229910052712 strontium Inorganic materials 0.000 claims description 4
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims description 4
- 229910052726 zirconium Inorganic materials 0.000 claims description 4
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims description 3
- MMKQUGHLEMYQSG-UHFFFAOYSA-N oxygen(2-);praseodymium(3+) Chemical compound [O-2].[O-2].[O-2].[Pr+3].[Pr+3] MMKQUGHLEMYQSG-UHFFFAOYSA-N 0.000 claims description 3
- 239000002002 slurry Substances 0.000 claims description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims 1
- 229910044991 metal oxide Inorganic materials 0.000 claims 1
- 150000004706 metal oxides Chemical class 0.000 claims 1
- 238000011144 upstream manufacturing Methods 0.000 abstract description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 6
- 239000000654 additive Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 238000005755 formation reaction Methods 0.000 description 5
- 239000002574 poison Substances 0.000 description 5
- 231100000614 poison Toxicity 0.000 description 5
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 4
- 230000002411 adverse Effects 0.000 description 4
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 231100000572 poisoning Toxicity 0.000 description 4
- 230000000607 poisoning effect Effects 0.000 description 4
- 239000010687 lubricating oil Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 239000006069 physical mixture Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 239000004071 soot Substances 0.000 description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 229910002090 carbon oxide Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000000356 contaminant Substances 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 230000001473 noxious effect Effects 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- 239000013618 particulate matter Substances 0.000 description 2
- 235000021317 phosphate Nutrition 0.000 description 2
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 229910052703 rhodium Inorganic materials 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229910000604 Ferrochrome Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- -1 Platinum Group Metals Chemical class 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000011149 active material Substances 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000006722 reduction reaction Methods 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
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- 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
- F01N3/0215—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 the filtering elements having the form of disks or plates
-
- 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
- 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
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9495—Controlling the catalytic process
-
- 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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
- F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
-
- 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
-
- 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
- F01N3/2807—Metal other than sintered metal
-
- 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
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/30—Removable or rechangeable blocks or cartridges, e.g. for filters
-
- 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
-
- 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
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/02—Lead
-
- 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
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/04—Sulfur or sulfur oxides
-
- 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
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/06—Zinc
-
- 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
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/08—Phosphorus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
- Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
Definitions
- This invention relates generally to a guard bed for protecting a catalytic converter in an emission control system, and more particularly to such a guard bed that has a porous metallic foam element disposed upstream of the catalytic converter component of the emission control system.
- Emissions control catalysts are commonly used to convert noxious emissions into less harmful products.
- noxious emissions control catalysts are widely used to control emissions from internal combustion engines, such as automobile engines.
- the acceptable emission levels from various sources have become successively lower through new regulations imposed by the Environmental Protection Agency
- Additives are needed to reduce engine wear and improve oil performance, but can have a detrimental effect on the catalyst performance due to build-up, over time, on the catalyst itself. As the acceptable emission levels decrease, catalyst poisoning becomes increasingly more significant. Limitations on additives can only go so far in reducing catalyst poisoning without reducing the effectiveness of lubricating oils to protect the engine.
- Blanchet trap includes a tubular housing with an internal peripheral wall whereby exhaust gases passing through the tubular housing are accelerated outwardly by centrifugal force and particulate matter carried in the gas is trapped in a porous lining provided in the tubular housing. Thus, particulate matter carried in the portion of the exhaust gas stream that contacts the porous lining is removed from that portion of the gas stream prior to passage through a catalytic converter.
- Another system for removing soot from diesel engine exhaust gas is described in U.S. Patent No. 5,067,319, issued November 26, 1991, to Franz Moser and titled SYSTEM FOR
- the Moser system includes an apparatus for branching the exhaust gas stream into two branch lines which are adapted to be shut off in alternation by a change-over valve.
- One of the branch lines includes a soot filter, whereas the other branch line constitutes a by-pass line.
- the change-over valve is switched to direct the exhaust gas through the soot filter.
- both of the trap systems are permanent elements of the emission control system and are not easily replaced when they become saturated or otherwise lose their effectiveness .
- the present invention is directed to overcoming the problems set forth above. It is desirable to have a guard bed for protecting a catalytic converter in an exhaust gas system that is disposed normal to the gas flow, requiring that all of the exhaust gases passing to the catalytic converter are first treated to remove compounds that would otherwise poison or adversely affect the catalytic converter. Moreover, it is desirable to have a cost-effective, replaceable, catalytically active catalyst guard bed to protect the primary catalytic converter of an emission control system from the adverse effects of poison deposition. Also, it is desirable to have such a catalyst guard bed that is not only effective at removing poisons from the exhaust gases, but also avoids creating new problems in engine and emissions system performance .
- a guard bed for protecting a catalytic converter in an emission control system is disposed at a position whereat the gases containing products of combustion discharged from internal combustion engine pass through the guard bed prior to passage through the catalytic converter.
- the guard bed includes a porous metallic foam element disposed normal to the path of the exhaust gases and provides a substrate structure on which a thermally stable phosphateable support layer is disposed.
- the thermally stable phosphateable support layer includes at least one oxide of a metal selected from the group consisting of aluminum, cerium, lanthanum, praseodymium and neodymium.
- a catalytic material comprising at least one Group VIII metal is disposed on the phosphateable support layer.
- the oxides being pre- mixed and deposited as a slurry on the substrate, and then dried and fired to form the phosphateable support layer.
- the support layer being aluminum oxide having at least one oxide selected from the group consisting of cerium oxide, lanthanum oxide, praseodymium oxide and neodymium oxide dispersed within the aluminum oxide.
- the dispersed oxides having a combined surface area from about 10m 2 /g to about 200m 2 / -
- Still other features of the catalytic converter guard bed embodying the present invention include the support layer having a phosphation promoter comprising at least one oxide of a metal selected from the group consisting of zirconium, magnesium, calcium, strontium and barium. Yet additional features include the catalytic material disposed on the phosphateable support layer comprising from about 0.02 weight percent to about 2.00 weight percent of the support layer.
- Yet another feature of the catalytic converter guard bed embodying the present invention includes the porous metallic foam element being a replaceable disposable component of the emission control system.
- FIG. 1 is a schematic diagram of an emission control system having a protective guard bed embodying the present invention incorporated therein;
- Fig. 2 is a partial cross-section of a porous metallic foam element of the guard bed embodying the present invention.
- Fig. 3 is an enlarged section of the porous metallic foam element of the guard bed embodying the present invention.
- a catalyst guard bed in the preferred embodiment of the present invention, as shown schematically in Fig. 1, a catalyst guard bed, indicated generally by the reference numeral 10, comprises a relatively thin, for example on the order of approximately one-half inch thickness, disk of a porous metallic foam 12 positioned upstream of a first catalytic converter 14 of an emission control system, indicated generally by the reference numeral 16.
- the porous metallic foam element or unit 12 is positioned immediately adjacent to the catalytic converter 14, and maintained in that position by a removable housing 18, whereby the metallic foam unit 12 can be readily removed and replaced when its performance deteriorates after a period of use.
- Porous metallic foam is cast metal with finely divided, evenly distributed gas bubbles that form a plurality of interconnecting passages throughout the body of the metal, as illustrated in Figs. 2 and 3.
- the metallic foam element 12 of the present invention is preferably formed of a FeCr alloy, a ferritic stainless alloy, Inconel, or silicon carbide, having from about five to about fifty pores per square inch of surface area, and desirably from about five to about twenty pores per square inch of surface area.
- Metallic foams formed of the above-described materials and pore densities have excellent strength properties and induce turbulent flow to exhaust gases passing through the unit. Turbulent flow improves exhaust gas interaction with the catalytic surface materials disposed on the metallic foam substrate.
- the metallic foam materials listed above have high-temperature strength characteristics whereby the integrity of the guard bed 10 is maintained under high engine exhaust gas conditions with minimal foam thickness.
- the guard bed 10 is catalyzed to maintain effective reduction of cold start emissions and also to promote the formation of phosphates on its surface.
- Platinum Group Metals (PGM) and in particular palladium, platinum and rhodium, are useful in effecting a catalytic reduction of hydrocarbons, carbon monoxide, and oxides of nitrogen.
- a second catalytic material may be used to promote formation of phosphates on the guard bed surface.
- the catalytically active materials are supported in or on a high surface area oxide support layer 20, as illustrated in Fig. 3, which is both resistant to thermal loss of surface area and easily phosphated.
- the high surface area support layer 20 comprises gamma, theta, or delta alumina, although other high surface area alumina phases may also be used.
- the support layer 20 has a surface area from about 10m 2 /g to about 200m 2 /g and preferably from about 80m 2 /g to about 160m 2 /g.
- Phosphateable materials include the aforementioned alumina and, if desired, rare earth oxides such as oxides of cerium, lanthanum, praseodymium, and neodymium oxide, or mixtures thereof. The rare earth oxides may be dispersed on the alumina support from solution using standard impregnation techniques, or added as a physical mixture.
- the rare earth oxides desirably have a surface area in the range from about 10m 2 /g to about 200m 2 /g.
- Rare earth oxide loadings are desirably from about one to about 90 weight percent of the total wash coat, and preferably in the range from about five to about 45 weight percent of the total wash coat .
- the phosphation process is also desirably promoted by the addition of catalytic additives such as Group VIII metals, in particular platinum, palladium, rhodium, and ruthenium.
- the Group VIII catalytic additives When the Group VIII catalytic additives are deposited on the support layer 20, the loadings should be from about 0.02 to about 2.00 weight percent of the support layer 20.
- the Group VIII catalytic materials also desirably affect the conversion of hydrocarbon, carbon monoxide, and oxides of nitrogen.
- the catalytic guard bed 10 desirably enhances the effectiveness of the emission control system, without significantly affecting the operation of the engine.
- the primary purpose of the catalytic guard bed 10 is to effectively remove most of the primary catalyst poisons before the exhaust gases reach the downstream catalytic converter 14.
- the porous metallic foam 12 provides a high surface- area substrate structure for the support layer 20.
- the support layer 20 disposed on the substrate structure is thermally stable and phosphateable and comprises at least one oxide of a metal selected from the group consisting of aluminum, cerium, lanthanum, praseodymium, and neodymium.
- a catalytic material comprising a Group VIII metal is disposed on or within the phosphateable support layer 20.
- the oxide of at least one metal selected from the group consisting of aluminum, cerium, lanthanum, praseodymium, and neodymium may be pre-mixed and deposited by impregnation techniques or as a physical mixture on the substrate 12 and then dried and fired to complete formation of the phosphateable support layer 20.
- the oxides dispersed in the support layer have a combined surface area of from about 10m 2 /g to about 200m 2 /g.
- the support layer 20 may desirably include a phosphation promoter comprising at least one oxide of a metal selected from a group consisted of zirconium, magnesium, calcium, strontium, and barium.
- An additional important feature of the guard bed 10 embodying the present invention includes the replaceability of the metallic foam element 12 which may be removed by opening the housing 18, removing the spent unit and replacing it with a new metallic foam element 12. This enables the guard bed 10 to remain effective, even after prolonged use under adverse conditions which would otherwise adversely affect the catalytic converter 14.
- the metallic foam element 12 should be removed and replaced with a new unit when vehicle emissions exceed acceptable limits.
- a simple replacement of the metallic foam element 12 is significantly cheaper than replacing the catalytic converter 14.
- the present invention is described in terms of a preferred exemplary embodiment, with specific illustrative phosphateable and catalytic materials, those skilled in the art will recognize that changes in those illustrative materials may be made without departing from the spirit of the invention.
- the metallic foam element 12 may have a different thickness than that stated in the illustrative embodiment and may have a shape other than that of the illustrative disk shape. Such changes are intended to fall within the scope of the following claims.
- Other aspects, features, and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims .
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Abstract
Un lit de garde catalytique (10) est placé en amont du composant convertisseur catalytique primaire (14) d'un système anti-pollution (16). Le lit de garde (10) est constitué d'une mousse métallique poreuse (12) sur laquelle une couche de support pouvant être phosphatée et stable à la chaleur, est prévue. Par ailleurs, un matériau catalytique est prévu sur la couche de support pouvant être phosphatée.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US28825899A | 1999-04-08 | 1999-04-08 | |
US09/288,258 | 1999-04-08 |
Publications (1)
Publication Number | Publication Date |
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WO2000061265A1 true WO2000061265A1 (fr) | 2000-10-19 |
Family
ID=23106396
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/009027 WO2000061265A1 (fr) | 1999-04-08 | 2000-04-05 | Lit de garde pour catalyseur anti-pollution |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2867093A1 (fr) * | 2004-03-04 | 2005-09-09 | Bosch Gmbh Robert | Dispositif pour epurer des gaz d'echappement |
WO2007078826A3 (fr) * | 2005-12-21 | 2007-08-23 | Basf Catalysts Llc | Systeme de controle du cod et des particules dans les moteurs diesels |
US7355961B2 (en) | 2000-02-22 | 2008-04-08 | Nokia Corporation | Method and arrangement for digital signal transmission using layered space-time codes |
US7785548B2 (en) * | 2004-03-15 | 2010-08-31 | Honeywell International Inc. | Apparatus and method for storing and releasing sulfur containing aromatic compounds from a fuel stream of an internal combustion engine |
WO2012000599A1 (fr) * | 2010-07-01 | 2012-01-05 | Bayerische Motoren Werke Aktiengesellschaft Patentabteilung Aj-3 | Agencement d'un catalyseur dans un système d'échappement |
US9030310B2 (en) | 2012-12-24 | 2015-05-12 | Ford Global Technologies, Llc | Capacitance-based catalytic converter protection systems and configurations |
US9145110B2 (en) | 2011-10-27 | 2015-09-29 | Ford Global Technologies, Llc | Vehicle wireless charger safety system |
US9227594B2 (en) | 2012-12-24 | 2016-01-05 | Ford Global Technologies, Llc | Resistance-based catalytic converter protection systems and configurations |
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Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7355961B2 (en) | 2000-02-22 | 2008-04-08 | Nokia Corporation | Method and arrangement for digital signal transmission using layered space-time codes |
FR2867093A1 (fr) * | 2004-03-04 | 2005-09-09 | Bosch Gmbh Robert | Dispositif pour epurer des gaz d'echappement |
US7785548B2 (en) * | 2004-03-15 | 2010-08-31 | Honeywell International Inc. | Apparatus and method for storing and releasing sulfur containing aromatic compounds from a fuel stream of an internal combustion engine |
WO2007078826A3 (fr) * | 2005-12-21 | 2007-08-23 | Basf Catalysts Llc | Systeme de controle du cod et des particules dans les moteurs diesels |
US7506504B2 (en) | 2005-12-21 | 2009-03-24 | Basf Catalysts Llc | DOC and particulate control system for diesel engines |
CN102985651A (zh) * | 2010-07-01 | 2013-03-20 | 宝马股份公司 | 排气系统中的催化器装置 |
WO2012000599A1 (fr) * | 2010-07-01 | 2012-01-05 | Bayerische Motoren Werke Aktiengesellschaft Patentabteilung Aj-3 | Agencement d'un catalyseur dans un système d'échappement |
US9145110B2 (en) | 2011-10-27 | 2015-09-29 | Ford Global Technologies, Llc | Vehicle wireless charger safety system |
US9493085B2 (en) | 2011-10-27 | 2016-11-15 | Ford Global Technologies, Llc | Vehicular charging and protection systems |
US9030310B2 (en) | 2012-12-24 | 2015-05-12 | Ford Global Technologies, Llc | Capacitance-based catalytic converter protection systems and configurations |
US9227594B2 (en) | 2012-12-24 | 2016-01-05 | Ford Global Technologies, Llc | Resistance-based catalytic converter protection systems and configurations |
US9631541B2 (en) | 2012-12-24 | 2017-04-25 | Ford Global Technologies, Llc | Capacitance-based vehicular component protection systems and configurations |
RU2630862C2 (ru) * | 2012-12-24 | 2017-09-13 | Форд Глобал Технолоджис, ЛЛК | Система защиты каталитического нейтрализатора |
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