The present invention relates to microwave processing of exhaust gases.
The invention is particularly, although not exclusively, applicable to processing of exhaust gases from internal combustion engines. In many countries regulations now govern the emission of environmentally undesirable gases including CO, NOx and VOC, as well as particulate combustion products, by motor vehicle exhausts. At present new motor vehicles are typically fitted with three-way catalytic converters utilizing the precious metals platinum, rhodium and palladium to catalyse reactions in which undesirable exhaust gases are converted to less damaging compounds. Problems for the industry include (1) the expense and uncertain supply of the required precious metals; (2) the serious reduction in fuel economy (as much as 10%) caused by use of the catalytic converter; (3) its limited lifetime and susceptibility to poisoning and other deleterious effects in operation; and (4) the need to attain a working temperature in the region of 300° C before the catalyst becomes effective, as a result of which the catalyst typically does not function well on short journeys with a cold engine.
It has previously been proposed to utilise microwave energy in exhaust gas processing.
U.S. Pat. No. 4,934,141 (Ollivon et al) discloses a device for “microwave elimination of carbon particles” in exhaust gas wherein the gas is passed through a filter which is arranged in a microwave cavity, the stated purpose of the microwave power being only to clean the filter. There is no suggestion that microwaves should be used to create a plasma in the exhaust gas.
U.S. Pat. No. 5,782,085 (Steinwandel et al) proposes removal of nitrous oxides from oxygen rich exhaust gas by feeding into the gas a “reactive nitrogen-containing plasma jet”. A nitrogen gas source separate from the exhaust itself is seemingly required, the plasma jet being formed by microwave action on this gas which is subsequently ejected through a nozzle into the exhaust gas stream. It is believed that installation of such a system in a motor vehicle would be problematic. A somewhat similar proposal, utilising a microwave plasma jet for exhaust gas processing, has been made by Al-Shamma'a, Wylie, Lucas and Pau in a paper in the Journal of Physics (J. Phys. D: Appl. Phys. 34 (2001) 2734-2741).
U.S. Pat. No. 6,422,002 (Whealton et al) discloses application of pulsed microwave fields directly to a catalyst material for exhaust gas treatment. The proposed apparatus has a microwave waveguide intersecting a quartz tube carrying the gases under treatment (quartz seemingly being chosen for its properties with respect to the microwave fields). Frequencies of 100 MHz and higher are used. Adapting the device to mass production and installation in a motor vehicle appears problematic. Whealton is considered by the inventors to exemplify the approach which researchers have typically taken in this field, which is to provide a passage or chamber for the exhaust gas, this passage being formed of dielectric material. So far as the inventors are aware this approach has not led to production of a practical device.
Patent Office searches have also made the applicants aware of published international patent application PCT/AU/00325 (publication number WO 00/62904) which teaches passing effluent gases through a “treatment zone” and directing microwave energy to the zone to establish a plasma in it, in which effluent gases are ionised, permitting their recombination.
The provision of a practical exhaust gas reactor using microwave energy is an object of the present invention.
In accordance with a first aspect of the present invention there is an exhaust gas reactor comprising a microwave source, a microwave-resonant reactor chamber having an electrically conductive boundary, and means for coupling microwaves from the source into the reactor chamber, wherein the reactor chamber is formed as or communicates with a combustion chamber, the reactor chamber receiving in either case exhaust gases released by combustion in the combustion chamber and communicating with an outlet through which the exhaust gases pass to reach the atmosphere, the exhaust gases being consequently subject to microwave energy and being thereby converted, in an interaction zone of the processor, into a plasma whereby chemical reactions in the exhaust gas are promoted.
In accordance with a second aspect of the present invention there is a method of processing exhaust gases comprising receiving the exhaust gases in a microwave-resonant reactor cavity, out of which the exhaust gases subsequently pass to reach the atmosphere, and coupling microwaves into the cavity thereby to convert the exhaust gases, in an interaction zone, into a plasma and so to promote chemical reactions in the exhaust gas.
The present invention is found to be remarkably effective in generating plasma and so promoting the necessary reactions in the exhaust gases, yet provides a potentially very simple, robust and highly economical construction.
Specific embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
The reactor illustrated in the drawings is a working test apparatus and has been used in experimental trials for processing of exhaust gases from the internal combustion engine of a motor car. However it is anticipated that in the process of developing a production version of the processor various aspects of its construction will be modified.
The reactor uses a microwave plasma, created by use of microwave energy within a chamber which acts as a microwave resonator, to reduce the levels of polluting gases emitted in the exhaust from a combustion chamber (or typically the several combustion chambers formed by the cylinders of an internal combustion engine). It is found that, in an “interaction zone” within the reactor, the effect is to generate plasma and to promote reactions by which environmentally undesirable combustion products are converted into less damaging compounds. Examples of such reactions are:
2 NO→N2+O2
2CO+O2→2CO2
C7H16+11O2→7CO2+8H2O
Looking at
Microwaves generated by the magnetron 2 must be coupled into the reactor chamber 6. While the magnetron could be connected via electrical cabling to an antenna in the reactor chamber 6, the approach adopted in the illustrated embodiment is to couple the magnetron's output into the reactor chamber 6 through a waveguide 7. The waveguide in this embodiment takes the form of a hollow, conductive enclosure having the same depth and width as the reactor chamber 6 itself. For ease of installation in a motor vehicle, the illustrated waveguide is flexible by virtue of a concertina-type formation of its walls. That is, the walls of the waveguide 7 are folded back and forth, changes in the angles of the folds allowing the waveguide as a whole to flex.
Provision of the waveguide, between the magnetron 2 and the reactor chamber 6, allows these two parts to be remote from one another, which is considered potentially advantageous in automotive applications. The magnetron could for example be mounted in a car boot, the waveguide leading downward to the reactor chamber 6, which could be mounted on the car underside to form part of the exhaust manifold.
Earlier prototypes of the reactor have used a “matched load” coupled to the reactor chamber or waveguide and performing an impedance matching function, maximising microwave power to the reactor chamber. Optimised design of the waveguide and chamber are considered to make this unnecessary, however, and the illustrated embodiment does not incorporate this feature.
Similarly, earlier embodiments have used movable metal stubs (not illustrated) which project an adjustable distance into the chamber 6. Adjustment of these stubs allowed fine tuning of the performance of the processor, their effect being to alter the wave pattern within the cavity 6. A production system may use such features to adjust performance, but it is preferred to rely instead on optimised design of the cavity to provide a suitable wave pattern. Modes of microwave propagation are schematically indicated by arrows 8,10 in
Throughput of exhaust gases is provided for by means of an input port 18 and an outlet tube 20 both communicating with the chamber 6. In
The principles of plasma generation will be familiar to the skilled person. Microwaves cause oscillation of electrons in the exhaust gas and given sufficient electron energy (of the order of 20 eV) electrons are capable upon collision of ionising gas modules. The free electrons thereby created increase the likelihood of ion-producing collisions and so promote plasma generation. The process is self reinforcing and consequently easier to maintain than it is to initiate or “strike”. In the illustrated reactor the high electrical field strength in the vicinity of the spike 22 creates the conditions required for striking the plasma discharge in that region. The plasma is then found to spread more widely within the chamber 6. A field of approximately 30 kilovolts per centimetre is considered suitable to achieve striking, although this is dependent on various operating parameters.
In
In
It should be understood that different means could be used to promote striking, e.g. appropriate formation of the chamber wall, to locally intensify the electrical field, or design of the reactor chamber to provide a sufficiently high Q factor to achieve striking. It may be that, given suitable chamber design and input power, it is not necessary to locally intensify field strength in order to achieve striking of the plasma.
The microwave power input to the chamber 6 is modulated (or more specifically, in the illustrated reactor, pulsed). By modulating input power, an increased instantaneous power level can be provided for a given average power level. It is found that, for a given average input power, the size of the plasma discharge and of the interaction zone, in which the desirable chemical reactions take place, is increased by the power modulation.
It is believed that power modulation is also beneficial in avoiding problems due to “quenching” of the plasma discharge. The continuous throughput of exhaust material, and particularly the presence of water molecules in the exhaust gases, has been observed in previous experimental studies to tend to quench—ie halt—the plasma discharge. The illustrated reactor has been found to be less susceptible to this problem and to produce reliable plasma discharge in trials on motor vehicle exhaust gases. The inventors have conjectured that the high instantaneous microwave power provided by the reactors embodying their invention may break down water molecules into hydrogen and oxygen, whose presence assists in sustaining the plasma. Hence the presence of water, problematic in other systems, may actually be beneficial in the illustrated reactor. Striking of plasma discharge is also promoted by the high instantaneous power provided by virtue of the power modulation.
Excessively high average input powers and correspondingly high effective temperatures in the exhaust gases would potentially favour undesirable reactions in the exhaust gases. By modulating input power the high instantaneous power required to achieve and sustain plasma discharge is provided without excessive average power. The frequency of power modulation is sufficiently high to ensure plasma is continuously present throughout the modulation cycle. Frequencies in the region of 10-100 kHz are considered suitable.
Modulation of microwave power also provides a convenient means of controlling power input. The illustrated processor provides for control of power input to the reactor in dependence upon demand. The demand may be determined in a variety of ways. The illustrated reactor senses the pollutant concentration in its output through NO and/or CO sensors housed in a branch 26 of the outlet tube 20. In fact two further sensors are incorporated in the illustrated arrangement at 39 and 41, making it possible to monitor exhaust gas properties upstream, downstream and within the reactor. This is useful for research purposes in the prototype system although a more simple arrangement may well be used in a production version. The sensors′outputs are led to control electronics which set the input microwave power, which is thus adjusted as necessary e.g. to achieve a target pollutant level in the output gases. An alternative, or complementary, control mode would be to control microwave power in dependence on engine operating parameters such as throttle position, temperature etc. which influence the nature and composition of the exhausted material. This control could be implemented by the engine controller.
A temperature sensor may also be provided to protect the device from overheating and to influence the power control.
In the illustrated reactor, power control is achieved by adjustment of the power modulation and more specifically by variation of the mark-space ratio of the (pulsed) power input to the magnetron.
A circuit 500 for switching the power input to the magnetron, to provide pulsing of the microwave signal, is illustrated in
Circuitry used to provide the high voltage required to drive the magnetron is illustrated in
Subsequently the transformer secondary (output) voltage swings into the negative half-cycle and increases in a negative direction to the negative peak of the supply voltage (2800 volts). The transformer secondary and the charged capacitor are now essentially two EMFs in series. The 2800 volts across the transformer winding adds to the 2800 volts stored in the capacitor and the sum voltage of 5600 volts is applied to the magnetron cathode 610 to drive the magnetron 609.
There are two fundamental characteristics of this high voltage output that should be noted. First, because a voltage doubler is also a rectifier, the output is a DC voltage. Second, the resulting output voltage that is applied to the magnetron tube is actually a pulsed DC voltage. This is because the doubler generates an output only during the negative half-cycle of the transformer's output (secondary) voltage. Hence, the magnetron tube is, in fact, pulsed on and off at the supply frequency (e.g. 50 Hz, in the case of a domestic UK mains supply.
To remove the supply frequency pulsing of the high voltage, a three phase supply can be used with the circuit 700 illustrated in
A substantially constant DC high voltage output is provided by the doubler circuit 700.
The entire magnetron drive circuit 800 is schematically indicated in
The illustrated circuits have been used for testing purposes with mains electrical supplies. It will be apparent that some adaptation will be required for motor vehicle applications.
In tests the above described reactor has proven highly effective. The reactor has been used with a 1.8 litre petrol engine of a Mitsubishi Gallant (Registered trade mark) motor car and also with diesel and LPG engines, none of them using a conventional catalytic converter. It is found that the resultant emissions readily satisfy not only current European Emissions standards but also the stricter standards expected to be introduced in the European Community in 2006, the engines being operated on the appropriate test cycle for engine speed and load. Performance was particularly good with the diesel engine. As well as gaseous emission, regulations govern emission of particulate material. The forthcoming European standard for particulate emission is 2 gm/mile for a diesel engine; an output of only 1 gm of particulates per mile was found in tests on the present reactor. The dramatic effect of the reactor on gaseous emissions can be recognised in
Compared with a conventional catalytic converter, the illustrated reactor has several important benefits.
Gas flow from the exhaust is not obstructed. Such obstructions directly relate to the efficiency losses associated with the catalytic converter. In this respect the illustrated reactor offers a fuel saving of the order of 10%. The microwave power required by the illustrated reactor amounts to roughly 2% of the engine power, in the test arrangements, so that overall an 8% fuel saving is achieved.
The reactor is expected to be cheaper to manufacture than the conventional catalytic converter and does not require expensive rare earth materials-platinum, rhodium, palladium.
Tests show that the reactor works almost immediately following engine start-up, without need of a warm up period (an important consideration for numerous short journeys in which the catalytic converter may not reach its operating temperature).
The reactor is able to efficiently oxidise HC and carbon particles including the micro-particles which are a major health concern.
The inventors consider that combustion of unburnt fuel in the exhaust manifold, promoted by the reactor, contributes significantly to its efficiency. It is conjectured that perhaps two thirds of the required energy is provided in this way, reducing the energy input required of the microwave source.
The arrangement illustrated in
Arranged across the mouth of the exhaust passage can be seen a filter structure 1017 which is illustrated in more detail in
The filter element 1018 is mounted in a circular opening of a filter plate 1020 which is bolted to the upper face of the cavity plate 1010, being sandwiched between plate 1010 and the flange 1015 of the exhaust passage.
The present embodiment comprises a second filter 1022 within the exhaust muffler 1016 and formed as a porous ceramic filter for capturing particles including those of less than 10 micrometres size. The microwave output 1006 to the muffler 1016 serves to cause dielectric heating in the ceramic, thereby destroying the smaller particulate material. In this embodiment provision is made to switch microwave power between the two cables 1004, 1006 as required to perform the dual cleaning action. Alternatively provision may be made to vary the relative power levels through the two cables.
If it becomes necessary in future to remove even ultra fine carbon particles, small enough to pass through the two filters of the illustrated embodiment, then the exhaust gases could be passed through a microwave plasma which has a sufficient transit time for removal of these ultra fine particles.
In current prototypes a proportional integral controller (PIC) has been used to control microwave power, based upon feedback relating to composition of the exhausted material and/or upon temperature. Hence power can be optimised for reduction of both gases and particulates. Networked microcontroller software, written in Delphi (registered trade mark), has been designed and implemented with the capability of monitoring and logging the exhaust gases, particulates and emissions from the reactor system. This package has the ability to be incorporated into a vehicle's networked management system. It provides the facility to display data concerning exhaust emissions. Such information can be provided to the driver, e.g. through a dashboard display. For example the driver may be provided with information relating to emission of any of CO, NO, O2, HC and particulate material. This information could be in the form of a digital readout, perhaps with averaging, or of a graph.
It will be appreciated that the above described embodiments serve merely as examples of ways the present invention can be implemented. Production systems are expected to differ in various respects due for example to packaging and mounting requirements in motor vehicles. The magnetron used as a microwave source in the embodiments is considered highly suitable for the purpose but progress in this field—for example, the anticipated development of solid state microwave generators—may mean that other types of source will be used for the reactor. The actual form of the microwave chamber maybe varied without departing from the scope of the invention. While applications of the invention to internal combustion engines are considered highly important, the inventors consider the invention to be potentially applicable to jet engines and other devices in which combustion produces exhaust gases. The reactor chamber may, with suitable selection of microwave frequency to achieve resonance, be formed not in the exhaust gas manifold but in the combustion chambers (cylinders) themselves.
Number | Date | Country | Kind |
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0302905.5 | Feb 2003 | GB | national |
Number | Date | Country | |
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Parent | PCT/GB04/00504 | Feb 2004 | US |
Child | 11233853 | Sep 2005 | US |