Improved emission control apparatus

Abstract: Emission control apparatus for use with an internal combustion engine having a housing (1) with an inlet (9) connected to the exhaust of the engine and an outlet (11) connected to a discharge pipe. Mounted in the housing (1) at spaced locations are a first catalytic cell (20) and a second catalytic cell (30) through which the engine exhaust gases pass for conversion to less noxious compounds. Surrounding each catalytic cell (20, 30) is an annular wall (23, 33), which devide the housing (1) into three chambers: an inlet chamber (40), an intermediate chamber (50) and an outlet chamber (60). The gases entering the inlet chamber (40) by a silencer diffuser tube (45) are passing through first catalytic cell (20) into the intermediate chamber (50). Some of the gases return from the intermediate chamber (50) through ports (24) and silencing tubes (41) into the inlet chamber (40) for recirculation through the first catalytic cell (20). All of the gases pass from the intermediate chamber (50) through the second catalytic cell (30) into the outlet chamber (60).

Description: Background of the Invention 1. Field of the Invention The present invention pertains to apparatus for use with internal combustion engines to reduce noxious gases emitted therefrom. In particular, the present invention pertains to apparatus particularly suitable for use with natural gas fueled engines and for converting nitrogen oxides, carbon monoxides and unburned hydrocarbons from the exhaust of such engines to less noxious compounds and for reducing the noise emitted therefrom. 2. Brief Description of the Prior Art Silencers or mufflers for internal combustion engines have existed for many years. Most industrial silencers utilize some type of housing in which is mounted various types of baffles or other silencing components for reducing the noise produced at the exhaust of an internal combustion engine. In addition to noise reduction, a great deal of attention has also been directed, in recent years, to reducing the noxious gases emitted from the exhaust of an internal combustion engine, e.g. nitrogen oxide, carbon monoxide and other unburned hydrocarbons. As interest and concern about pollution of the atmosphere increases, the search continues for effective means for reducing these noxious emissions. Increased regulation by state and federal authorities mandates that more effective means be found. The most effective means of reducing noxious emissions at this time appears to be those methods which utilize some type of catalyst which converts the noxious gases to water, nitrogen, carbon dioxide and other harmless emissions. Most exhaust emission control apparatus of the prior art utilizes separate devices for noise reduction and noxious gas reduction. This is probably due to the fact that silencers or mufflers are commonly made by one manufacturer and catalytic converters by another. Since these devices are made separately but must be connected in series to an engine exhaust, the pressure drop therethrough is relatively great, resulting in decreased fuel efficiency. In addition to increased operating expense, two separate units usually result in greater installation and maintenance costs. In recent years, some emission control apparatus have been manufactured which combine the functions of noise reduction and noxious gas reduction in a single device or apparatus. Examples may be seen in U. S. Patent Nos. 4,209,493 and 4,601,168. While these devices are substantially more efficient and cost effective than those of the prior art, continued concern over noise and air pollution dictates even more efficient and effective apparatus. US-3180712-A and GB-A-1519343 disclose a two-stage converter with two catalytic beds, with all of the exhaust gas passing through the first bed and with all of the partially converted gas then being passed to, and through, the second bed. GB-A-1519343 additionally discloses a similar converter but in which part of the exhaust gases by-passes the first bed. According to one aspect of the present invention, there is provided an emission control apparatus intended for use with an internal combustion engine, the apparatus having a cylindrical housing 1 with an inlet 9 at one end thereof intended for connection to the exhaust of such an engine and an outlet 11 at the opposite end thereof; converter means 20, 30 being mounted in the housing 1 for reducing noxious gases emitted from the engine by converting nitrogen oxides, carbon monoxide and unburned hydrocarbons to less noxious compounds for discharge through the outlet, wherein the converter means comprises: a first catalytic cell 20 transversely disposed in the cylindrical housing 1 at a fixed distance from the housing inlet 9 and a second catalytic cell 30 transversely disposed in the cylindrical housing 1 at a fixed distance from the first catalytic cell 20, such that in use at least part of the engine exhaust passes through the first catalytic cell 20 prior to passage through the second catalytic cell 30 and all of said engine exhaust passes through the second catalytic cell 30 prior to being discharged through the housing outlet 11: characterised in that the cross-sectional area of the first catalytic cell 20 is less than the cross-sectional area of the cylindrical housing 1 leaving one or more return areas 24 which allow at least some of the engine exhaust passing in use through the first catalytic cell 20 to return through the return areas 24 for recirculation through the first catalytic cell 20 before passing to the second catalytic cell 30. The reference numerals in the immediately preceding paragraph identify the corresponding components in Figure 1 of the accompanying drawings but are not intended to have any limiting effect. Conveniently the first catalytic cell is circular in cross-section and is coaxially mounted on the axis of the cylindrical housing, the return areas being provided by a plurality of ports radially disposed around the axis between the outside diameter of the first catalytic cell and the inside diameter of the cylindrical housing. Such apparatus may include a plurality of tubular members, one for each of the ports, extending from the ports toward the inlet and through which in use some of the engine exhaust which has passed through the first catalytic cell may return for recirculation through the first catalytic cell. Preferably the walls of the tubular members are perforated by a plurality of holes allowing some of the engine exhaust to enter or exit the tubular members therethrough. Conveniently the plurality of tubular members have their axes parallel to a central axis of the housing. The apparatus may also include noise reduction means mounted in the housing for reducing the noise emitted from the engine, the noise reduction means including at least one tubular member in fluid communication with the housing inlet and opening toward the first catalytic cell. The noise reduction means may also comprise a second tubular member one end of which is positioned to receive the converted exhaust gases leaving the second catalytic cell and the opposite end of which is attached to the housing outlet so that the converted exhaust gases may be discharged therethrough. Preferably the walls of at least one of the noise reduction tubular members is perforated to allow passage of exhaust gases therethrough. Preferably the housing is divided into three chambers, namely: an inlet chamber between the one end of the housing and the first catalytic cell; an intermediate chamber between the first and second catalytic cells; and an outlet chamber between the second catalytic cell and the opposite end of the housing, the arrangement being such that in use engine exhaust passes through the inlet chamber, the first catalytic cell, the intermediate chamber, the second catalytic cell and the outlet chamber prior to discharge through said outlet, but with some of the exhaust gases which has passed through the first catalytic cell into the intermediate chamber returning through the return areas to the inlet chamber for recirculation through the first catalytic cell. Preferably the first and second catalytic cells are of substantially the same cross-sectional flow area, and the area between the outside perimeter of the second catalytic cell and the inside diameter of the housing is closed so that in use all of the engine exhaust is directed through the second catalytic cell for passage through the outlet chamber and exit through the housing outlet. The apparatus may also include an inlet tube directed at one end towards the housing inlet and the opposite end of which opens toward the first catalytic cell. Preferably the inlet tube is frustoconical, the diameter thereof increasing from the inlet end toward the first catalytic cell. The apparatus may also include noise reduction means mounted in the housing for reducing noise emitted from the engine, the noise reduction means including a plurality of perforated tubular members upstream of the first catalytic cell and a plurality of perforated tubular members downstream of the second catalytic cell and through which the exhaust gases may pass. According to another aspect of the present invention, there is provided an emission control apparatus intended for use with an internal combustion engine, the apparatus having an enclosed housing at one end of which is an inlet intended for connection with the exhaust of the engine and at the opposite end of which is an outlet, converter means being mounted in the housing for reducing noxious gases emitted from the engine by converting nitrogen oxides, carbon monoxide and unburned hydrocarbons to less noxious compounds for discharge through the outlet, wherein the converter means comprises: a first catalytic cell transversely disposed in the housing and separating an inlet chamber thereof from a downstream intermediate chamber and through which in use at least some of said engine exhaust gases pass; and a second catalytic cell transversely disposed in the housing separating the intermediate chamber from another chamber downstream thereof and through which in use all of the engine exhaust gases pass prior to discharge through the said outlet; characterised in that there are provided return means providing fluid communication between the intermediate chamber and the inlet chamber to allow at least a portion of the exhaust gases which have passed though the first catalytic cell to return from the intermediate chamber to the inlet chamber for recirculation though the first catalytic cell. Preferably a transverse wall surrounds the first catalytic cell providing a dividing wall between the inlet chamber and the first-mentioned intermediate chamber, the return means comprising one or more ports through the dividing wall. Preferably the return means are associated with one or more silencing tubes, one end of which is connected to one of the ports and the opposite end of which opens into the inlet chamber. The housing may include an outlet chamber downstream of said another chamber and separated therefrom by a dividing wall, said another chamber and the outlet chamber being in fluid communication through one or more baffle tubes projecting through the dividing wall. The walls of the silencing tubes and the walls of the baffle tubes are preferably perforated by a plurality of holes to reduce noise emitted from the engine. The apparatus may include an inlet tube connected to the housing inlet and projecting therefrom into the inlet chamber and through which all of the exhaust gases enter the housing, the walls of the inlet tube being perforated by a plurality of holes to further reduce noise emitted from the engine. Preferably the cross-sectional flow area of the second catalytic cell is not substantially greater than the cross-sectional flow area of the first catalytic cell. Preferably the cross-sectional flow area of the return means is less than the cross-sectional flow area of the first catalytic cell. Preferably the housing is cylindrical and each of the catalytic cells is circular in cross-section, each of the catalytic cells being surrounded by an annular wall defining opposite ends of the intermediate chamber, the wall surrounding the first catalytic cell having ports therethrough providing the return means. Where, as preferred, the noise reduction components and emission control components are provided in a single housing there can be some considerable economy as some of the parts which are normally duplicated in systems utilizing separate noise and gas emission control devices are combined for common usage. This results in reduced installation and maintenance costs. Furthermore, pressure drop through the emission control of the present apparatus is much less than those which utilize separate noise and gas emission control apparatus. This results in substantial fuel savings. Most importantly, noise abatement and noxious gas emission reduction is enhanced and made more effective with the apparatus of the present invention. Many other objects and advantages of the invention will be apparent from reading the description which follows in conjunction with the accompanying drawings. Brief Description of the Drawings Fig. 1 is a longitudinal view, in section, of combination noise and emission control apparatus according to a preferred embodiment of the invention; Fig. 2 is a cross-sectional view of the combination noise and emission control apparatus of Fig. 1, taken along lines II-II thereof; and Fig. 3 is a longitudinal view, in section, of combination noise and emission control apparatus according to another preferred embodiment of the invention. Description of Preferred Embodiments Referring first to Figs. 1 and 2, there is shown combination noise and emission control apparatus which includes a cylindrical housing 1 which may actually be made of three cylindrical sections 2, 3, 4 joined at support rings 5 and 6 by bolting, welding or any other suitable method and closed at opposite ends by heads 7 and 8. The head 7 is provided with an inlet 9 surrounding which is a flange 10 by which the apparatus may be connected to the exhaust (not shown) of an internal combustion engine (not shown). The opposite head 8 is provided with an outlet 11 surrounding which is a flange 12. The flange 12 may be connected to a discharge pipe (not shown) for discharge into the atmosphere or for additional handling. Sample ports such as 13, 14 and 15 may be provided for sensing temperature, pressure, gas analysis, etc. Transversely disposed in the housing 1 at fixed distances from the housing inlet 9 is a first catalytic cell 20 and, downstream thereof, a second catalytic cell 30. These catalytic cells 20, 30 are normally made of metallic substances and compounds which are effective in converting nitrogen oxide, carbon monoxide and other unburned hydrocarbons to nitrogen, carbon dioxide, water and other harmless products. The cells 20, 30 illustrated in Figs 1 and 2 are cylindrical cells coaxially aligned with the longitudinal axis of the cylindrical housing 1. Each catalytic cell 20, 30 may be surrounded and held in place by a cylindrical containment chamber 21, 31. Each of these chambers 21, 31 may be centrally supported in the housing 1 by a plurality of radial support members 22, 32 which are welded or bolted to the inside walls of the housing 1. These containment chambers 21, 31 also support the cells 20, 30 against stress and pressure from backfire explosions and other occurences. It should be noted that surrounding each catalytic cell 20, 30 is an annular wall or partition 23, 33. Thus it can be said that the housing 1 is divided into three chambers: an inlet chamber 40, an intermediate chamber 50 and outlet chamber 60. As will be noted from the drawings, the annular wall 23 surrounding the first catalytic cell 20 is provided with a plurality of ports or passageways 24. Connected to each of these ports 24 and extending toward the inlet end of the housing 1 is a plurality of tubular members 41, one for each port 24. These tubular members 41 terminate at some distance from the inlet head 7 and open into the inlet chamber 40. In addition, the walls of each of the tubular members 41 are perforated by holes 42 which allow exhaust gases to freely enter and exit the tubular members 41 therethrough. Structural support members 43 may aid in supporting the open or free ends of the tubular members 41. These tubular members 41 are sometimes referred to as internal connector silencing tubes and serve functions for both noise reduction and noxious gas conversion that wall be more fully understood hereafter. Centrally supported in the inlet chamber 40 is an inlet silencer/diffuser tube 45 one end of which is connected to the inlet 9 and the opposite end of which terminates somewhere near the midsection of the inlet chamber 40. The walls of the silencer/diffuser tube 45 maybe perforated with a plurality of holes 46 and may be flared outwardly from the inlet 9 toward the first catalytic cell 20. A conical diffuser 47 may be centrally disposed within the throat of the silencer/diffuser tube. The diffuser 47 and the flared shape of the silencer/diffuser tube 45 aids in diffusing and distributing exhaust gases across the catalytic cell 20. Attached to the outlet 11 and extending in a direction toward the second catalytic cell 30 is an outlet tube 61. The walls of the outlet tube 61 are perforated by a plurality of holes 62 allowing gases to enter and exit said tube therethrough. In operation, exhaust gases from an internal combustion engine with which the apparatus of the present invention is used, first flow through the inlet 9 and silencer/diffuser tube 45 for relatively even distribution into the inlet chamber 20. From the inlet chamber 20, at least a portion of these exhaust gases pass through the catalytic cell 20 for conversion into less noxious gases. Some of the gases entering the intermediate chamber 50 return through the ports 24 and the silencing tubes 41 for reentry into the inlet chamber 40. They are then recirculated through the first catalytic cell 20. All of the gases eventually exit from the intermediate chamber 50 through the second catalytic cell 30 into the outlet chamber 60. Further conversion of the noxious gases occur through the catalytic cell 30 and the less noxious gases and compounds eventually exit the apparatus through the outlet tube 61 and outlet 11. It will be noted that there are no ports or return passages surrounding the second catalytic cell 30 so that all of the gases entering the outlet chamber 60 must exit through the outlet 11. The operational theory of providing dual catalyst cells is that dual catalyst cells provide more exposure surface for gas flow. In addition, the return ports provided through the wall 23 surrounding the first catalytic cell 20 permits recirculation of some of the exhaust gases through the first catalytic cell. In addition, the inlet chamber 40, intermediate chamber 50 and the silencer/diffusor tubes 41 act in combination to suppress and reduce surges through the apparatus resulting in the exhaust gases being in residence longer over a greater catalyst surface. These features, along with the concomitant reduction of gas velocity, provide a greater time of residence for the gases. This results in substantially greater efficency and performance with as much as seventy percent (70%) greater emissions reduction than other designs. Furthermore, the components of the apparatus, particularly the diffuser 47, inlet silencer/diffuser tube 45, silencing tubes 41 and outlet tube 61 result in substantial noise reduction making the apparatus especially acceptable for industrial noise silencing and/or abatement. Referring now to Fig. 3, an alternate embodiment of the invention will be described which provides even greater noise reduction than the embodiment of Figs. 1 and 2. Many of the components of the embodiment of Fig. 3 are similar or identical to the embodiment of Figs. 1 and 2. These components will be designated by the same reference numerals and many of them will not be redescribed. In fact, the embodiment of Figs. 1 and 2 may be easily modified to provide the embodiment of Fig. 3. As shown, all of the components of the apparatus of Fig. 3 from the inlet flange 10 to the cylindrical housing section 4 may be identical to the embodiment of Figs. 1 and 2. At this point, an additional cylindrical section 71 may be added and provided with a head 72, outlet 73 and surrounding flange 74. An outlet tube 75, similar to the outlet tube 61 of Fig 1 except that it is perhaps longer, is also provided with perforated holes 76. Additional bracing 77 may be required. A dividing wall 78, much like the head 8 of the apparatus of Fig. 1, is provided to separate what was the outlet chamber 60 (now another intermediate chamber) from a new outlet chamber 70. The chamber 60 and the outlet chamber 70 are in fluid communication with each other through a plurality (four in the exemplary embodiment) of baffle tubes 80. The baffle tubes 80 are open at both ends and extend to somewhat a midpoint of chambers 60 and 70, respectively. Support braces 81 may be provided to maintain the parallel disposition of the baffle tubes 80. The walls of the baffle tubes 80 may be perforated by a plurality of holes 82. The perforated baffle tubes 80 and the lengthened outlet tube 75 serve to further reduce noise emitted from the engine to which the apparatus is attached. Operation of the apparatus of Fig. 3 is essentially the same as the apparatus of Figs. 1 and 2, the noxious gases passing through the dual catalyst cells 20, 30 eventually into the chamber 60. From the chamber 60, the less noxious gases and compounds which are converted by the catalytic cells 20, 30 pass through the baffle tubes 80 into the outlet chamber 70 and eventually exit the apparatus through the outlet tube 75. While the conversion of noxious gases is substantially the same in the embodiment of Fig. 3 as in the embodiment of Figs. 1 and 2, the noise reduction characteristics thereof are substantially better. In fact, tests have indicated that this embodiment meets noise abatement requirements in many residential environments. Thus, the combination noise and emission control apparatus of the present invention provides apparatus of greater efficiency and effectiveness than apparatus of the prior art. Its design results in highly competitive manufacturing and maintenance costs and more importantly results in cost savings in fuel consumption due to less pressure drop than designs of the prior art. Most importantly, the apparatus of the present invention results in much improved, efficient reduction of air and noise pollution.

Claims: An emission control apparatus intended for use with an internal combustion engine, the apparatus having a cylindrical housing with an inlet at one end thereof intended for connection to the exhaust of such an engine and an outlet at the opposite end thereof; converter means being mounted in the housing for reducing noxious gases emitted from the engine by converting nitrogen oxides, carbon monoxide and unburned hydrocarbons to less noxious compounds for discharge through the outlet, wherein the converter means comprises: a first catalytic cell transversely disposed in the cylindrical housing at a fixed distance from the housing inlet and a second catalytic cell transversely disposed in the cylindrical housing at a fixed distance from the first catalytic cell, such that in use at least part of the engine exhaust passes through the first catalytic cell prior to passage through the second catalytic cell and all of said engine exhaust passes through the second catalytic cell prior to being discharged through the housing outlet: characterised in that the cross-sectional area of the first catalytic cell is less than the cross-sectional area of the cylindrical housing leaving one or more return areas which allow at least some of the engine exhaust passing in use through the first catalytic cell to return through the return areas for recirculation through the first catalytic cell before passing to the second catalytic cell. An apparatus as claimed in claim 1, in which the first catalytic cell is circular in cross-section and is coaxially mounted on the axis of the cylindrical housing, the return areas being provided by a plurality of ports radially disposed around the axis between the outside diameter of the first catalytic cell and the inside diameter of the cylindrical housing. An apparatus as claimed in claim 2, including a plurality of tubular members, one for each of the ports, extending from the ports toward the inlet and through which in use some of the engine exhaust which has passed through the first catalytic cell may return for recirculation through the first catalytic cell. An apparatus as claimed in claim 3, in which the walls of the tubular members are perforated by a plurality of holes allowing some of the engine exhaust to enter or exit the tubular members therethrough. An apparatus as claimed in claim 3 or 4, in which the plurality of tubular members have their axes parallel to a central axis of the housing. An apparatus as claimed in any preceding claim, also including noise reduction means mounted in the housing for reducing the noise emitted from the engine, the noise reduction means including at least one tubular member in fluid communication with the housing inlet and opening toward the first catalytic cell. An apparatus as claimed in claim 6, in which the noise reduction means comprises a second tubular member one end of which is positioned to receive the converted exhaust gases leaving the second catalytic cell and the opposite end of which is attached to the housing outlet so that the converted exhaust gases may be discharged therethrough. an apparatus as claimed in claim 7, in which the walls of at least one of the noise reduction tubular members is perforated to allow passage of exhaust gases therethrough. An apparatus as claimed in any preceding claim, in which the housing is divided into three chambers, namely: an inlet chamber between the one end of the housing and the first catalytic cell; an intermediate chamber between the first and second catalytic cells; and an outlet chamber between the second catalytic cell and the opposite end of the housing, the arrangement being such that in use engine exhaust passes through the inlet chamber, the first catalytic cell, the intermediate chamber, the second catalytic cell and the outlet chamber prior to discharge through said outlet, but with some of the exhaust gases which has passed through the first catalytic cell into the intermediate chamber returning through the return areas to the inlet chamber for recirculation through the first catalytic cell. An apparatus as claimed in claim 9, in which the first and second catalytic cells are of substantially the same cross-sectional flow area, and the area between the outside perimeter of the second catalytic cell and the inside diameter of the housing is closed so that in use all of the engine exhaust is directed through the second catalytic cell for passage through the outlet chamber and exit through the housing outlet. An apparatus as claimed in any preceding claim, including an inlet tube directed at one end towards the housing inlet and the opposite end of which opens toward the first catalytic cell. An apparatus as claimed in claim 11, in which the inlet tube is frustoconical, the diameter thereof increasing from the inlet end toward the first catalytic cell. An apparatus as claimed in any preceding claim, including noise reduction means mounted in the housing for reducing noise emitted from the engine, the noise reduction means including a plurality of perforated tubular members upstream of the first catalytic cell and a plurality of perforated tubular members downstream of the second catalytic cell and through which the exhaust gases may pass. An emission control apparatus intended for use with an internal combustion engine, the apparatus having an enclosed housing at one end of which is an inlet intended for connection with the exhaust of the engine and at the opposite end of which is an outlet, converter means being mounted in the housing for reducing noxious gases emitted from the engine by converting nitrogen oxides, carbon monoxide and unburned hydrocarbons to less noxious compounds for discharge through the outlet, wherein the converter means comprises: a first catalytic cell transversely disposed in the housing and separating an inlet chamber thereof from a downstream intermediate chamber and through which in use at least some of said engine exhaust gases pass; and a second catalytic cell transversely disposed in the housing separating the intermediate chamber from another chamber downstream thereof and through which in use all of the engine exhaust gases pass prior to discharge through the said outlet; characterised in that there are provided return means providing fluid communication between the intermediate chamber and the inlet chamber to allow at least a portion of the exhaust gases which have passed through the first catalytic cell to return from the intermediate chamber to the inlet chamber for recirculation through the first catalytic cell. An apparatus as claimed in claim 14, in which a transverse wall surrounds the first catalytic cell providing a dividing wall between the inlet chamber and the first-mentioned intermediate chamber, the return means comprising one or more ports through the dividing wall. An apparatus as claimed in claim 14 or 15, in which the return means are associated with one or more silencing tubes, one end of which is connected to one of the ports and the opposite end of which opens into the inlet chamber. An apparatus as claimed in claim 16, in which the housing includes an outlet chamber downstream of said another chamber and separated therefrom by a dividing wall, said another chamber and the outlet chamber being in fluid communication through one or more baffle tubes projecting through the dividing wall. An apparatus as claimed in claim 17, in which the walls of the silencing tubes and the walls of the baffle tubes are perforated by a plurality of holes to reduce noise emitted from the engine. An apparatus as claimed in any one of claims 14 to 18, including an inlet tube connected to the housing inlet and projecting therefrom into the inlet chamber and through which all of the exhaust gases enter the housing, the walls of the inlet tube being perforated by a plurality of holes to further reduce noise emitted from the engine. An apparatus as claimed in any one of claims 14 to 19, in which the cross-sectional flow area of the second catalytic cell is not substantially greater than the cross-sectional flow area of the first catalytic cell. An apparatus as claimed in any one of claims 14 to 20, in which the cross-sectional flow area of the return means is less than the cross-sectional flow area of the first catalytic cell. An apparatus as claimed in any one of claims 14 to 21, in which the housing is cylindrical and each of the catalytic cells is circular in cross-section, each of the catalytic cells being surrounded by an annular wall defining opposite ends of the intermediate chamber, the wall surrounding the first catalytic cell having ports therethrough providing the return means.

Inventors: HARRIS HAROLD L, HARRIS, HAROLD L.
Applicants: HARRIS INT SALES, HARRIS INTERNATIONAL SALES CORPORATION
Application year: 1990
Main classification: F01N3
IPC codes: F01N3