A rolling regeneration diesel particulate filter and filtering process that utilizes NO produced in the process to generate additional amounts of NO 2 than the NO 2 produced by the diesel engine. The process includes the step of flowing diesel engine combustion exhaust through a filter system incl
A rolling regeneration diesel particulate filter and filtering process that utilizes NO produced in the process to generate additional amounts of NO 2 than the NO 2 produced by the diesel engine. The process includes the step of flowing diesel engine combustion exhaust through a filter system including a first section and a second section. The first section is positioned upstream of the second section with respect to the direction of the flow of the diesel engine exhaust through the filter. The first section includes a foam constructed and arranged to trap carbon-based particulates in the exhaust. A first catalyst is carried by the foam to promote the conversion of NO in the exhaust from the diesel engine to NO 2 . The first catalyst also promotes the reaction of NO 2 with at least a portion of the carbon-based particulates trapped by the foam to form CO and NO. The first catalyst carried by the foam also promotes the oxidation of CO to CO 2 , and the oxidation of NO, generated by the reaction of NO 2 with carbon, to generate additional amounts of NO 2 . The additional amounts of NO 2 are also utilized to oxidize the carbon-based particulates. The second section of the filter system includes a wall flow monolith having a plurality of through hole cells formed therein running the longitudinal length of the monolith. The monolith is constructed and arranged to trap particulates in the exhaust and to promote the reaction of NO 2 and carbon to produce NO and CO. The ceramic foam may also be received in and surrounded by the wall flow filter.
대표청구항▼
1. A rolling regeneration diesel particulate filtering process that reuses NO produced in the process to generate additional amounts of NO 2 , comprising:flowing diesel engine combustion exhaust through a filter system comprising a first section and a second section, and wherein the first section i
1. A rolling regeneration diesel particulate filtering process that reuses NO produced in the process to generate additional amounts of NO 2 , comprising:flowing diesel engine combustion exhaust through a filter system comprising a first section and a second section, and wherein the first section is positioned upstream of the second section with respect to the flow direction of the exhaust gas, and wherein the first section includes a foam constructed and arranged to trap carbon-based particulates in the exhaust, and a first catalyst carried by the foam to promote the conversion of NO in the exhaust from the diesel engine to NO 2 , and to promote the reaction of at least a portion of the particulates trapped in the foam with NO 2 to form CO and NO, and wherein the first catalyst carried by the foam further promotes the oxidation of CO to CO 2 , and the oxidation of NO, generated by the reaction of NO 2 with carbon, to generate additional NO 2 , and wherein the second section includes a wall flow filter having at least one through hole cell formed therein running the longitudinal length of the wall flow filter, and the wall flow filter being constructed and arranged to trap particulates in the exhaust and to promote the reaction of NO 2 and C to produce NO and CO. 2. A process as set forth in claim 1 wherein the foam comprises a ceramic foam including Al 2 O 3 . 3. A process as set forth in claim 2 wherein the second section includes only a single through hole cell formed therein running the longitudinal length of the wall flow filter. 4. A process as set forth in claim 1 wherein the foam comprises a ceramic foam including ZrO 2 . 5. A process as set forth in claim 1 wherein the first catalyst comprises platinum. 6. A process as set forth in claim 1 wherein the first catalyst comprises platinum carried by the foam in a loading of at least 25 grams per cubic foot of foam. 7. A process as set forth in claim 1 wherein the foam has a porosity ranging from 80% to 90%. 8. A process as set forth in claim 1 wherein the foam includes 10 to 60 pores per inch. 9. A process as set forth in claim 1 wherein the wall flow filter includes 25 to 300 cells per square inch of cross-sectional area of the wall flow filter. 10. A process as set forth in claim 1 wherein the filter system further includes a housing, and wherein the first and second sections are carried in the housing and wherein the second section further comprises a plurality of through hole cells formed therein running the longitudinal length of the wall flow filter. 11. A rolling regeneration diesel particulate filter system comprising:a first section and a second section, and wherein the first section is positioned upstream of the second section, and wherein the first section includes a foam constructed and arranged to trap carbon-based particulates in diesel engine exhaust flowing through the filter, and a first catalyst carried by the foam to promote the conversion of NO in the diesel engine exhaust to NO 2 , and the first catalyst being designed to promote the reaction of NO 2 with at least a portion of the carbon-based particulates trapped by the foam to form CO and NO, and wherein the first catalyst carried by the foam further promotes the oxidation of CO to CO 2 , and the oxidation of NO, generated by the reaction of NO 2 with carbon, to generate additional NO 2 , and wherein the second section includes a wall flow filter having at least one through hole cell formed therein running the longitudinal length of the wall flow filter, and the wall flow filter being constructed and arranged to trap particulates in the diesel engine exhaust flowing through the wall flow filter and to promote the reaction of NO 2 and C to produce NO and CO. 12. A system as set forth in claim 11 wherein the foam comprises a ceramic foam including Al 2 O 3 . 13. A system as set forth in claim 12 wherein the second section includes only a single through hole cell formed therein runni ng the longitudinal length of the wall flow filter. 14. A system as set forth in claim 11 wherein the foam comprises a ceramic foam including ZrO 2 . 15. A system as set forth in claim 11 wherein the first catalyst comprises platinum. 16. A system as set forth in claim 11 wherein the first catalyst comprises platinum carried by the foam in a loading of at least 25 grams per cubic foot of foam. 17. A system as set forth in claim 11 wherein the foam has a porosity ranging from 80% to 90%. 18. A system as set forth in claim 11 wherein the foam includes 10 to 60 pores per inch. 19. A system as set forth in claim 11 wherein the wall flow filter includes 25 to 300 cells per square inch of cross-sectional area of the wail flow filter. 20. A system as set forth in claim 11 wherein at least a portion of the wall flow filter surrounds a portion of the foam. 21. A rolling regeneration diesel particulate filtering process that reuses NO produced in the process to generate additional amounts of NO 2 , comprising:flowing diesel engine combustion exhaust through a first section of a filter system and thereafter flowing the exhaust through a second section of the filter system, and wherein the first section includes a foam constructed and arranged to trap carbon-based particulates in the exhaust, and a first catalyst carried by the foam to promote the conversion of NO in the exhaust from the diesel engine to NO 2 , and to promote the reaction of at least a portion of the particulates trapped in the foam with NO 2 to form CO and NO, and wherein the first catalyst carried by the foam further promotes the oxidation of CO to CO 2 , and the oxidation of NO, generated by the reaction of NO 2 with carbon, to generate additional NO 2 , and wherein the second section includes a wall flow filter having at least one through hole cell formed therein running the longitudinal length of the wall flow filter, and the wall flow filter being constructed and arranged to trap particulates in the exhaust and to promote the reaction of NO 2 and C to produce NO and CO.
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이 특허에 인용된 특허 (5)
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