The present invention relates to an exhaust purification system of an internal combustion engine.
Known in the art is an internal combustion engine which arranges, in an engine exhaust passage, an NOx storage catalyst which stores NOx which is contained in exhaust gas when an air-fuel ratio of inflowing exhaust gas is lean and which releases the stored NOx when the air-fuel ratio of the inflowing exhaust gas becomes rich, which arranges, in the engine exhaust passage upstream of the NOx storage catalyst, an oxidation catalyst which has an adsorption function, and which feeds hydrocarbons into the engine exhaust passage upstream of the oxidation catalyst to make the air-fuel ratio of the exhaust gas flowing into the NOx storage catalyst rich when releasing NOx from the NOx storage catalyst (for example, see Patent Literature 1).
In this internal combustion engine, the hydrocarbons which are fed when releasing NOx from the NOx storage catalyst are made gaseous hydrocarbons at the oxidation catalyst, and the gaseous hydrocarbons are fed to the NOx storage catalyst. As a result, the NOx which is released from the NOx storage catalyst is reduced well.
However, there is the problem that when the NOx storage catalyst becomes a high temperature, the NOx purification rate falls.
An object of the present invention is to provide an exhaust purification system of an internal combustion engine which can obtain a high NOx purification rate even if the temperature of the exhaust purification catalyst becomes a high temperature.
According to the present invention, there is provided an exhaust purification system of an internal combustion engine wherein a hydrocarbon feed valve for feeding hydrocarbons is arranged inside of an engine exhaust passage, an exhaust purification catalyst for reacting NOx contained in exhaust gas and reformed hydrocarbons is arranged inside of the engine exhaust passage downstream of the hydrocarbon feed valve, a precious metal catalyst is carried on an exhaust gas flow surface of the exhaust purification catalyst and a basic exhaust gas flow surface part is formed around the precious metal catalyst, the exhaust purification catalyst has a property of reducing the NOx which is contained in exhaust gas if a predetermined amount of hydrocarbons is injected by a predetermined feed period from the hydrocarbon feed valve and has a property of being increased in storage amount of NOx which is contained in exhaust gas if lengthening the feed period of the hydrocarbons from the predetermined feed period, at the time of engine operation, the predetermined amount of hydrocarbons is injected from the hydrocarbon feed valve by the predetermined feed period, and, at this time, an feed pressure of the hydrocarbons from the hydrocarbon feed valve is increased in accordance with an increase in an oxidizing strength of the exhaust purification catalyst.
Even if the temperature of the exhaust purification catalyst becomes a high temperature, a high NOx purification rate can be obtained.
Referring to
On the other hand, the exhaust manifold 5 is connected to an inlet of an exhaust turbine 7b of the exhaust turbocharger 7. The outlet of the exhaust turbine 7b is connected through an exhaust pipe 12 to an inlet of the exhaust purification catalyst 13, while the outlet of the exhaust purification catalyst 13 is connected to a particulate filter 14 for trapping particulate which is contained in the exhaust gas. Inside the exhaust pipe 12 upstream of the exhaust purification catalyst 13, a hydrocarbon feed valve 15 is arranged for feeding hydrocarbons comprised of diesel oil or other fuel used as fuel for a compression ignition type internal combustion engine. This hydrocarbon feed valve 15 is fed with hydrocarbons which are stored at a hydrocarbon storer 16. The hydrocarbon storer 16 is fed with fuel in the fuel tank 17, that is, hydrocarbons, through a feed pump 18. The hydrocarbon storer 16 is provided with a pressure sensor 19 for detecting the pressure of the hydrocarbons in the hydrocarbon storer 16, that is, the injection pressure of the hydrocarbons from the hydrocarbon feed valve 15. The injection pressure of the hydrocarbons is made to become a target pressure by control of the feed pump 18 based on the output signal of the pressure sensor 19.
In the embodiment shown in
On the other hand, the exhaust manifold 5 and the intake manifold 4 are connected with each other through an exhaust gas recirculation (hereinafter referred to as an “EGR”) passage 20. Inside the EGR passage 20, an electronically controlled EGR control valve 21 is arranged. Further, around the EGR passage 20, a cooling device 22 is arranged for cooling EGR gas flowing through the inside of the EGR passage 20. In the embodiment shown in
An electronic control unit 30 is comprised of a digital computer provided with a ROM (read only memory) 32, a RAM (random access memory) 33, a CPU (microprocessor) 34, an input port 35, and an output port 36, which are connected with each other by a bidirectional bus 31. Downstream of the exhaust purification catalyst 13, a temperature sensor 26 is attached for detecting the exhaust gas temperature. At the particulate filter 14, a differential pressure sensor 27 is attached for detecting a differential pressure before and after the particulate filter 14. Output signals of this temperature sensor 26, differential pressure sensor 27, pressure sensor 19, and intake air amount detector 8 are input through respectively corresponding AD converters 37 to the input port 35. Further, the accelerator pedal 40 has a load sensor 41 connected to it which generates an output voltage proportional to the amount of depression L of the accelerator pedal 40. The output voltage of the load sensor 41 is input through a corresponding AD converter 37 to the input port 35. Furthermore, at the input port 35, a crank angle sensor 42 is connected which generates an output pulse every time a crankshaft rotates by, for example, 15°. On the other hand, the output port 36 is connected through corresponding drive circuits 38 to each fuel injector 3, a step motor for driving the throttle valve 10, hydrocarbon feed valve 15, feed pump 18, EGR control valve 21, and fuel pump 25.
On the other hand, in
If hydrocarbons are injected from the hydrocarbon feed valve 15 into the exhaust gas, the hydrocarbons are reformed by the exhaust purification catalyst 13. In the present invention, at this time, the reformed hydrocarbons are used to remove the NOx at the exhaust purification catalyst 13.
Furthermore, at this time, a large amount of reducing intermediate containing nitrogen and hydrocarbons continues to be held or adsorbed on the surface of the basic layer 53, that is, on the basic exhaust gas flow surface part 54 of the exhaust purification catalyst 13. It is learned that this reducing intermediate plays a central role in obtaining a high NOx purification rate. Next, this will be explained with reference to
Now, as will be understood from
On the other hand, if hydrocarbons are fed from the hydrocarbon feed valve 15, as shown in
Note that, at this time, the first produced reducing intermediate is considered to be a nitro compound R—NO2. If this nitro compound R—NO2 is produced, the result becomes a nitrile compound R—CN, but this nitrile compound R—CN can only survive for an instant in this state, so immediately becomes an isocyanate compound R—NCO. This isocyanate compound R—NCO, when hydrolyzed, becomes an amine compound R—NH2. However, in this case, what is hydrolyzed is considered to be part of the isocyanate compound R—NCO. Therefore, as shown in
On the other hand, as shown in
In this way, in the exhaust purification catalyst 13, by making the concentration of hydrocarbons flowing into the exhaust purification catalyst 13 higher, a reducing intermediate is produced. By making the concentration of hydrocarbons flowing into the exhaust purification catalyst 13 lower and raising the oxygen concentration, the active NO2* reacts with the reducing intermediate and the NOx is removed. That is, in order for the exhaust purification catalyst 13 to remove the NOx, the concentration of hydrocarbons flowing into the exhaust purification catalyst 13 has to be periodically changed.
Of course, in this case, it is necessary to raise the concentration of hydrocarbons to a concentration sufficiently high for producing the reducing intermediate and it is necessary to lower the concentration of hydrocarbons to a concentration sufficiently low for making the produced reducing intermediate react with the active NO2*. That is, the concentration of hydrocarbons flowing into the exhaust purification catalyst 13 has to be made to vibrate within a predetermined range of amplitude. Note that, in this case, a sufficient amount of reducing intermediate R—NCO or R—NH2 has to be held on the basic layer 53, that is, on the basic exhaust gas flow surface part 24, until the produced reducing intermediate reacts with the active NO2*. For this reason, the basic exhaust gas flow surface part 24 is provided.
On the other hand, if lengthening the feed period of the hydrocarbons, the time in which the oxygen concentration becomes higher becomes longer in the period after the hydrocarbons are fed until the hydrocarbons are next fed. Therefore, the active NO2* is absorbed in the basic layer 53 in the form of nitrates without producing a reducing intermediate. To avoid this, it is necessary to make the concentration of hydrocarbons flowing into the exhaust purification catalyst 13 vibrate by within a predetermined range of period.
Therefore, in an embodiment of the present invention, to make the NOx contained in the exhaust gas and the reformed hydrocarbons react and produce the reducing intermediate R—NCO or R—NH2 containing nitrogen and hydrocarbons, precious metal catalysts 51 and 52 are carried on the exhaust gas flow surface of the exhaust purification catalyst 13. To hold the produced reducing intermediate R—NCO or R—NH2 inside the exhaust purification catalyst 13, a basic exhaust gas flow surface part 54 is formed around the precious metal catalysts 51 and 52. Due to the reducing action of the reducing intermediate R—NCO or R—NH2 which is held on the basic exhaust gas flow surface part 54, the NOx is reduced. The vibration period of the hydrocarbon concentration is made the vibration period required for continuation of the production of the reducing intermediate R—NCO or R—NH2. Incidentally, in the example shown in
If the vibration period of the hydrocarbon concentration, that is, the feed period of the hydrocarbons HC, is made longer than the above predetermined range of period, the reducing intermediate R—NCO or R—NH2 disappears from the surface of the basic layer 53. At this time, the active NO2* which is produced on the platinum Pt 53, as shown in
On the other hand,
Note that, at this time, sometimes the basic layer 53 temporarily adsorbs the NOx. Therefore, if using the term of storage as a term including both absorption and adsorption, at this time, the basic layer 53 performs the role of an NOx storage agent for temporarily storing the NOx. That is, in this case, if the ratio of the air and fuel (hydrocarbons) which are fed into the engine intake passage, combustion chambers 2, and exhaust passage upstream of the exhaust purification catalyst 13 is called the air-fuel ratio of the exhaust gas, the exhaust purification catalyst 13 functions as an NOx storage catalyst which stores the NOx when the air-fuel ratio of the exhaust gas is lean and releases the stored NOx when the oxygen concentration in the exhaust gas falls.
In this way, when the catalyst temperature TC becomes 400° C. or more, the NOx purification rate falls because if the catalyst temperature TC becomes 400° C. or more, the nitrates break down by heat and are released in the form of NO2 from the exhaust purification catalyst 13. That is, so long as storing NOx in the form of nitrates, when the catalyst temperature TC is high, it is difficult to obtain a high NOx purification rate. However, in the new NOx purification method shown from
Therefore, in the present invention, a hydrocarbon feed valve 15 for feeding hydrocarbons is arranged inside of an engine exhaust passage, an exhaust purification catalyst 13 for reacting NOx contained in exhaust gas and reformed hydrocarbons is arranged inside of an engine exhaust passage downstream of the hydrocarbon feed valve 15, and precious metal catalysts 51 and 52 are carried on the exhaust gas flow surface of the exhaust purification catalyst 13. Around the precious metal catalysts 51 and 52, a basic exhaust gas flow surface part 54 is formed. The exhaust purification catalyst 13 has the property of reducing the NOx which is contained in exhaust gas if the hydrocarbon feed valve 15 injects a predetermined amount of hydrocarbons in a predetermined feed period and has the property of being increased in the storage amount of NOx which is contained in exhaust gas if the feed period of the hydrocarbons is made longer than the predetermined feed period. At the time of engine operation, the hydrocarbon feed valve 15 injects the predetermined amount of hydrocarbons by the predetermined feed period. Due to this, the NOx which is contained in the exhaust gas is reduced in the exhaust purification catalyst 13.
That is, the NOx purification method which is shown from
Next, referring to
Furthermore, in
In other words, in
In the example shown in
In this case, whether the demanded minimum air-fuel ratio X becomes rich or becomes lean depends on the oxidizing strength of the exhaust purification catalyst 13. In this case, the exhaust purification catalyst 13, for example, becomes stronger in oxidizing strength if increasing the carried amount of the precious metal 51 and becomes stronger in oxidizing strength if strengthening the acidity. Therefore, the oxidizing strength of the exhaust purification catalyst 13 changes due to the carried amount of the precious metal 51 or the strength of the acidity.
Now, if using an exhaust purification catalyst 13 with a strong oxidizing strength, as shown in
On the other hand, when using an exhaust purification catalyst 13 with a weak oxidizing strength, as shown in
That is, it is learned that the demanded minimum air-fuel ratio X, as shown in
Now, if the base air-fuel ratio (A/F)b becomes larger, that is, if the oxygen concentration in the exhaust gas before the hydrocarbons are fed becomes higher, the feed amount of hydrocarbons required for making the air-fuel ratio (A/F) in the demanded minimum air-fuel ratio X or less increases and along with this the excess amount of hydrocarbons which does not contribute the production of the reducing intermediate also increases. In this case, to remove the NOx well, as explained above, it is necessary to make the excess hydrocarbons oxidize. Therefore, to remove the NOx well, the larger the amount of excess hydrocarbons, the larger the amount of oxygen which is required.
In this case, if raising the oxygen concentration in the exhaust gas, the amount of oxygen can be increased. Therefore, to remove the NOx well, when the oxygen concentration in the exhaust gas before the hydrocarbons are fed is high, it is necessary to raise the oxygen concentration in the exhaust gas after feeding the hydrocarbons. That is, the higher the oxygen concentration in the exhaust gas before the hydrocarbons are fed, the larger the amplitude of the hydrocarbon concentration that has to be made.
In this regard, the base air-fuel ratio (A/F)b becomes the lowest at the time of an acceleration operation. At this time, if the amplitude ΔH of the hydrocarbon concentration is about 200 ppm, it is possible to remove the NOx well. The base air-fuel ratio (A/F)b is normally larger than the time of acceleration operation. Therefore, as shown in
On the other hand, it is learned that when the base air-fuel ratio (A/F)b is the highest, if making the amplitude ΔH of the hydrocarbon concentration 10000 ppm or so, an excellent NOx purification rate is obtained. Further, if the amplitude ΔH of the hydrocarbon concentration is over 10000 ppm, there is the danger that the air-fuel ratio (A/F) in will become rich. Therefore, there is the danger that the new NOx purification method which is shown from
Further, if the vibration period ΔT of the hydrocarbon concentration becomes longer, the oxygen concentration around the active NO2* becomes higher in the time after the hydrocarbons are fed to when the hydrocarbons are next fed. In this case, if the vibration period ΔT of the hydrocarbon concentration becomes longer than about 5 seconds, the active NO2* starts to be absorbed in the form of nitrates inside the basic layer 53. Therefore, as shown in
On the other hand, if the vibration period ΔT of the hydrocarbon concentration becomes about 0.3 second or less, the fed hydrocarbons start to build up on the exhaust gas flow surface of the exhaust purification catalyst 13, therefore, as shown in
Now, in the present invention, by changing the injection amount and injection timing of hydrocarbons from the hydrocarbon feed valve 15, the amplitude ΔH and the vibration period ΔT of the hydrocarbon concentration are controlled to the optimum values in accordance with the operating state of the engine, that is, so that a good NOx purification action is performed by the new NOx purification method. In this case, in this embodiment of the present invention, the injection amount of hydrocarbons is determined by controlling the injection pressure and injection time of the hydrocarbons of the hydrocarbon feed valve 15.
Now, when the oxidizing strength of the exhaust purification catalyst 13 is strong, if forming atomized fuel Fa with a low hydrocarbon concentration such as shown in
On the other hand, when the oxidizing strength of the exhaust purification catalyst 13 is weak, if forming atomized fuel Fa with a low hydrocarbon concentration such as shown in
Therefore, in the present invention, when the new NOx purification method is being worked, that is, when, at the time of engine operation, the predetermined amount of hydrocarbons is injected from the hydrocarbon feed valve 15 by the predetermined feed period, the injection pressure WP of hydrocarbons from the hydrocarbon feed valve 15 is increased in accordance with the increase in the oxidizing strength of the exhaust purification catalyst 13.
In this regard, in this case, the oxidizing strength of the exhaust purification catalyst 13 increases the higher the temperature of the exhaust purification catalyst 13. Therefore, in this embodiment according to the present invention, the injection pressure of the hydrocarbons is increased in accordance with an increase in the temperature of the exhaust purification catalyst 13. Specifically speaking, in this embodiment according to the present invention, the relationship between the correction coefficient KP1 for the reference injection pressure WP0 of hydrocarbons and the catalyst temperature TC of the exhaust purification catalyst 13 shown in
That is, in this embodiment according to the present invention, from
Further, the oxidizing strength of the exhaust purification catalyst 13 becomes stronger if the sulfur poisoning of the exhaust purification catalyst 13 increases. That is, exhaust gas includes SOx. If this SOx flows into the exhaust purification catalyst 13, sometimes it will be stored in the basic layer 53 in the form of sulfates. This storage action of SOx first occurs at the upstream side end of the exhaust purification catalyst 13, therefore, along with the elapse of time, the amount of sulfates which are stored in the basic layer 53 gradually increases at the upstream side end of the exhaust purification catalyst 13.
If the stored amount of sulfates increases, the basicity of the basic layer 53 will weaken and, as a result, the oxidizing ability of the precious metal 51 at the upstream side end of the exhaust purification catalyst 13 will increase. When the oxidizing ability of the precious metal 51 at the upstream side end of the exhaust purification catalyst 13 increases in this way, to cause the production of the reducing intermediate, it is preferable to form atomized fuel Fb with a high hydrocarbon concentration such as shown in
Therefore, in this embodiment according to the present invention, the injection pressure WP of hydrocarbons is increased in accordance with an increase in sulfur poisoning at the upstream side end of the exhaust purification catalyst 13. Specifically speaking, in this embodiment according to the present invention, the relationship between the correction coefficient KP2 for the reference injection pressure WPO of hydrocarbons and the sulfur poisoning ΣS of the exhaust purification catalyst 13 such as shown in
That is, in this embodiment, from
On the other hand, if the flow rate of the exhaust gas becomes faster, that is, if the intake air amount increases, the concentration of hydrocarbons in the atomized fuel of the hydrocarbons will become thinner. At this time, it is preferable to increase the concentration of hydrocarbons in the atomized fuel of the hydrocarbons so as to produce the reducing intermediate well, that is, to raise the injection pressure WP. Therefore, in this embodiment according to the present invention, the injection pressure WP of hydrocarbons is increased in accordance with an increase in the intake air amount, that is, in accordance with an increase in the flow rate of the exhaust gas which flows through the inside of the engine exhaust passage.
Specifically speaking, in this embodiment according to the present invention, the relationship between the correction coefficient KP3 for the reference injection pressure WP0 of the hydrocarbons and the intake air amount GA such as shown in
Note that, the reference injection time WT0 shown in
Further, for example, at the time of regeneration of the particulate filter 14, the particulate filter 14 has to be raised in temperature. At this time, the injection amount of hydrocarbons from the hydrocarbon feed valve 15 is increased. In this regard, when the injection amount of hydrocarbons is increased in this way, if maintaining the injection pressure WP of hydrocarbons at the reference injection pressure WP0, the hydrogen concentration in the atomized fuel of hydrocarbons becomes extremely high. As a result, it becomes difficult to cause all of the hydrocarbons which are injected to be partially oxidized. Therefore, the situation is caused where part of the hydrocarbons pass straight through the exhaust purification catalyst 13.
Therefore, in this embodiment according to the present invention, the injection pressure WP of hydrocarbons is increased in accordance with an increase in the injection amount of hydrocarbons from the hydrocarbon feed valve 15. Specifically speaking, in this embodiment according to the present invention, the relationship between the correction coefficient KP4 for the reference injection pressure WP0 of the hydrocarbons and the injection amount of hydrocarbons W such as shown in
That is, in this embodiment according to the present invention, from
Referring to
That is, the amount of the SOx which is contained in the exhaust gas is determined accordingly when the operating state of the engine is determined. The SOx amount SOXA which is exhausted from the engine per unit time is stored as a function of the engine operating state in advance in the ROM 32. The SOx amount which is stored in the exhaust purification catalyst 13 is considered to be proportional to the SOx amount SOXA which is exhausted from the engine. Therefore, at step 63, ΣS is added to the product of the SOx amount SOXA and a proportional constant C so as to calculate the sulfur poisoning ΣS. At step 64, this calculated sulfur poisoning ΣS is used to calculate the values of the correction coefficients KP2 and KT2 from the relationship shown in
Next, at step 65, the intake air amount GA which is detected by the intake air amount detector 8 is used to calculate the values of the correction coefficients KP3 and KT3 from the relationship shown in
Note that, as another embodiment, in the engine exhaust passage upstream of the exhaust purification catalyst 13, an oxidation catalyst for modifying the hydrocarbons can be arranged.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2010/056345 | 4/1/2010 | WO | 00 | 10/12/2011 |
Publishing Document | Publishing Date | Country | Kind |
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WO2011/125198 | 10/13/2011 | WO | A |
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WO 2011114499 | Sep 2011 | WO |
WO 2011114501 | Sep 2011 | WO |
WO 2011118044 | Sep 2011 | WO |
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Number | Date | Country | |
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20130011302 A1 | Jan 2013 | US |