Exhaust purification system of internal combustion engine

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 NO x storage catalyst which stores NO x which is contained in exhaust gas when the air-fuel ratio of the inflowing exhaust gas is lean and which releases the stored NO x when the air-fuel ratio of the inflowing exhaust gas becomes rich, which arranges, in the engine exhaust passage upstream of the NO x 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 NO x storage catalyst rich when releasing NO x from the NO x storage catalyst (for example, see Patent Literature 1).

In this internal combustion engine, the hydrocarbons which are fed when releasing NO x from the NO x storage catalyst are made gaseous hydrocarbons at the oxidation catalyst, and the gaseous hydrocarbons are fed to the NO x storage catalyst. As a result, the NO x which is released from the NO x storage catalyst is reduced well.

Patent Literature

Patent Literature 1: Japanese Patent No. 3969450

Technical Problem

However, there is the problem that when the NO x storage catalyst becomes a high temperature, the NO x 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 NO x purification rate even if the temperature of the exhaust purification catalyst becomes a high temperature.

Solution to Problem

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 an engine exhaust passage, an exhaust purification catalyst for reacting NO x contained in exhaust gas and hydrocarbons which are injected from the hydrocarbon feed valve and are partially oxidized is arranged in the engine exhaust passage downstream of the hydrocarbon feed valve, a precious metal catalyst is carried on the exhaust purification catalyst and a basic layer is formed on the exhaust purification catalyst, the exhaust purification catalyst has a property of reducing the NO x which is contained in the exhaust gas when hydrocarbons are injected from the hydrocarbon feed valve at predetermined feed intervals while maintaining an air-fuel ratio of an exhaust gas flowing into the exhaust purification catalyst lean and has a property of being increased in storage amount of NO x which is contained in the exhaust gas when the feed intervals of the hydrocarbons are longer than the predetermined feed intervals, and, at the time of engine operation, a first NO x purification method which injects hydrocarbons from the hydrocarbon feed valve at the predetermined feed intervals while maintaining the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst lean so as to remove the NO x contained in the exhaust gas and a second NO x purification method which switches the air-fuel ratio of the exhaust gas which flows to the exhaust purification catalyst from lean to rich by intervals longer than the predetermined feed intervals so as to remove the NO x are selectively used in accordance with an operating state of an engine.

Advantageous Effects of Invention

By selectively using the first NO x purification method and the second NO x purification method, it is possible to obtain a high NO x purification rate regardless of the operating state of the engine.

FIG. 1 is an overall view of a compression ignition type internal combustion engine.

FIG. 2 is a view schematically showing a surface part of a catalyst carrier.

FIG. 3 is a view for explaining an oxidation reaction in an oxidation catalyst.

FIG. 4 is a view showing a change of an air-fuel ratio of exhaust gas flowing into an exhaust purification catalyst.

FIG. 5 is a view showing an NO x purification rate.

FIG. 6 is view for explaining an oxidation reduction reaction in an exhaust purification catalyst.

FIG. 7 is a view for explaining an oxidation reduction reaction in an exhaust purification catalyst.

FIG. 8 is a view showing a change of an air-fuel ratio of exhaust gas flowing into an exhaust purification catalyst etc.

FIG. 9 is a view showing a map of an exhausted NO x amount NOXA.

FIG. 10 is a view showing a fuel injection timing.

FIG. 11 is a view showing an NO x purification rate.

FIG. 12 is a view showing a map of a hydrocarbon injection amount.

FIG. 13 is a view showing an NO x discharge rate etc.

FIG. 14 is a view showing a change in an air-fuel ratio of exhaust gas (A/F) in etc. when switching from a second NO x purification method to a first NO x purification method.

FIG. 15 is a flow chart for NO x purification control.

FIG. 16 is a view showing a flow chart etc. showing another embodiment of an NO x purification method determining part A shown in FIG. 15 .

FIG. 17 is a view showing a flow chart etc. showing still another embodiment of an NO x purification method determining part A shown in FIG. 15 .

FIG. 18 is a view showing a flow chart etc. showing another embodiment of an NO x purification method determining part A shown in FIG. 15 .

FIG. 19 is a timing chart showing a change in an air-fuel ratio of exhaust gas (A/F) in etc. when switching from a second NO x purification method to a first NO x purification method.

FIG. 20 is a timing chart showing a change in an air-fuel ratio of exhaust gas (A/F) in etc. when switching from a second NO x purification method to a first NO purification method.

FIG. 21 is a view showing an increase coefficient.

FIG. 22 is a partial enlarged cross-sectional view of another catalyst for removing NO x .

FIG. 1 is an overall view of a compression ignition type internal combustion engine.

Referring to FIG. 1 , 1 indicates an engine body, 2 a combustion chamber of each cylinder, 3 an electronically controlled fuel injector for injecting fuel into each combustion chamber 2 , 4 an intake manifold, and 5 an exhaust manifold. The intake manifold 4 is connected through an intake duct 6 to an outlet of a compressor 7 a of an exhaust turbocharger 7 , while an inlet of the compressor 7 a is connected through an intake air amount detector 8 to an air cleaner 9 . Inside the intake duct 6 , a throttle valve 10 driven by a step motor is arranged. Furthermore, around the intake duct 6 , a cooling device 11 is arranged for cooling the intake air which flows through the inside of the intake duct 6 . In the embodiment shown in FIG. 1 , the engine cooling water is guided to the inside of the cooling device 11 where the engine cooling water is used to cool the intake air.

On the other hand, the exhaust manifold 5 is connected to an inlet of the exhaust turbine 7 b of the exhaust turbocharger 7 , while the outlet of the exhaust turbine 7 b is connected through an exhaust pipe 12 to an inlet of a hydrocarbon partial oxidation catalyst 13 able to partially oxidize the hydrocarbons HC. In the embodiment shown in FIG. 1 , this hydrocarbon partial oxidation catalyst 13 is comprised of an oxidation catalyst. An outlet of the hydrocarbon partial oxidation catalyst, that is, the oxidation catalyst 13 , is connected to an inlet of an exhaust purification catalyst 14 , while an outlet of the exhaust purification catalyst 14 is connected to a particulate filter 15 for trapping particulate which is contained in the exhaust gas. Inside of the exhaust pipe 12 upstream of the oxidation catalyst 13 , a hydrocarbon feed valve 16 is arranged for feeding hydrocarbons comprised of diesel oil or other fuel used as fuel of a compression ignition type internal combustion engine. In the embodiment shown in FIG. 1 , diesel oil is used as the hydrocarbons which are fed from the hydrocarbon feed valve 16 . Note that, the present invention can also be applied to a spark ignition type internal combustion engine which burns fuel under a lean air-fuel ratio. In this case, hydrocarbons comprised of gasoline or other fuel which is used as fuel of a spark ignition type internal combustion engine are fed from the hydrocarbon feed valve 16 .

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 17 . Inside the EGR passage 17 , a electronically controlled EGR control valve 18 is arranged. Further, around the EGR passage 17 , a cooling device 19 is arranged for cooling EGR gas flowing through the inside of the EGR passage 17 . In the embodiment shown in FIG. 1 , the engine cooling water is guided to the inside of the cooling device 19 where the engine cooling water is used to cool the EGR gas. On the other hand, each fuel injector 3 is connected through a fuel feed tube 20 to a common rail 21 . This common rail 21 is connected through an electronically controlled variable discharge fuel pump 22 to a fuel tank 23 . The fuel which is stored inside of the fuel tank 23 is fed by the fuel pump 22 to the inside of the common rail 21 . The fuel which is fed to the inside of the common rail 21 is fed through each fuel feed tube 20 to the fuel injector 3 .

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 . At the oxidation catalyst 13 , a temperature sensor 24 is attached for detecting the temperature of the oxidation catalyst 13 . At the exhaust purification catalyst 14 , a temperature sensor 25 is attached for detecting the temperature of the exhaust purification catalyst 14 . The output signals of these temperature sensors 24 and 25 and intake air amount detector 8 are input through 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 , the hydrocarbon feed valve 16 , the FGR control valve 18 , and the fuel pump 22 .

FIG. 2(A) schematically shows a surface part of a catalyst carrier carried on a substrate of an oxidation catalyst 13 . As shown in FIG. 2(A) , for example, a catalyst 51 comprised of platinum Pt or another such precious metal or silver Ag or copper Cu or other such transition metal is carried on a catalyst carrier 50 comprised of alumina.

On the other hand, FIG. 2(B) schematically shows a surface part of a catalyst carrier which is carried on a substrate of the exhaust purification catalyst 14 . At this exhaust purification catalyst 14 , as shown in FIG. 2(B) , for example, there is provided a catalyst carrier 52 made of alumina on which precious metal catalysts 53 and 54 are carried. Furthermore, on this catalyst carrier 52 , a basic layer 55 is formed which includes at least one element selected from potassium K, sodium Na, cesium Cs, or another such alkali metal, barium Ba, calcium Ca, or another such alkali earth metal, a lanthanoid or another such rare earth and silver Ag, copper Cu, iron Fe, iridium Ir, or another metal able to donate electrons to NO x . The exhaust gas flows along the top of the catalyst carrier 53 , so the precious metal catalysts 53 and 54 can be said to be carried on the exhaust gas flow surface of the exhaust purification catalyst 14 . Further, the surface of the basic layer 55 exhibits basicity, so the surface of the basic layer 55 is called the basic exhaust gas flow surface part 56 .

In FIG. 2(B) , the precious metal catalyst 53 is comprised of platinum Pt, while the precious metal catalyst 54 is comprised of rhodium Rh. That is, the precious metal catalysts 53 and 54 which are carried on the catalyst carrier 52 are comprised of platinum Pt and rhodium Rh. Note that, on the catalyst carrier 52 of the exhaust purification catalyst 14 , in addition to platinum Pt and rhodium Rh, palladium Pd may be further carried or, instead of rhodium Rh, palladium Pd may be carried. That is, the precious metal catalysts 53 and 54 which are carried on the catalyst carrier 52 are comprised of platinum Pt and at least one of rhodium Rh and palladium Pd.

When hydrocarbons are injected from the hydrocarbon feed valve 16 into the exhaust gas, the hydrocarbons are oxidized on the oxidation catalyst 13 . In the present invention, at this time, the hydrocarbons are partially oxidized at the oxidation catalyst 13 and the partially oxidized hydrocarbons are used to remove the NO x at the exhaust purification catalyst 14 . In this case, if making the oxidizing strength of the oxidation catalyst 13 too strong, the hydrocarbons end up being oxidized without being partially oxidized at the oxidation catalyst 13 . To make the hydrocarbons partially oxidize, it is necessary to weaken the oxidizing strength of the oxidation catalyst 13 . Therefore, in an embodiment of the present invention, as an oxidation catalyst 13 , a catalyst with a little carried amount of the precious metal catalyst, a catalyst carrying a base metal, or a catalyst with a small volume is used.

FIG. 3 schematically shows an oxidation reaction which is performed in the oxidation catalyst 13 . As shown in FIG. 3 , the hydrocarbons HC which are injected from the hydrocarbon feed valve 16 become radical hydrocarbons HC with a small carbon number due to the catalyst 51 . Note that, at this time, part of the hydrocarbons HC bond with the NO to become nitroso compounds such as shown in FIG. 3 , while part of the hydrocarbons HC bond with NO 2 to form nitro compounds. These radical hydrocarbons etc. produced at the oxidation catalyst 13 are sent to the exhaust purification catalyst 14 .

Next, referring to FIG. 4 to FIG. 6 , a first NO x purification method discovered by the inventors will be explained.

Note that, FIG. 4 shows the change in the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 , while FIG. 5 shows the NO x purification rate by the exhaust purification catalyst 14 with respect to the catalyst temperatures TC of the exhaust purification catalyst 14 when changing the air-fuel ratio (A/F) in of the exhaust gas flowing to the exhaust purification catalyst 14 as shown in FIG. 4 .

Now, the inventors engaged in repeated research on NO x purification over a long period of time and, in the process of research, learned that, as shown in FIG. 4 , if intermittently lowering the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 by later explained certain time intervals within a range of a lean air-fuel ratio, an extremely high NO x purification rate is obtained even in a 400° C. or more high temperature region as shown in FIG. 5 . Furthermore, it was learned that, at this time, a large amount of a reducing intermediate containing nitrogen and hydrocarbons continues to be held or adsorbed on the surface of the basic layer 55 , that is, on the basic exhaust gas flow surface part 56 of the exhaust purification catalyst 14 , and this reducing intermediate plays a central role in obtaining a high NO x purification rate.

Next, this will be explained with reference to FIGS. 6(A) and 6(B) . Note that, these FIGS. 6(A) and 6(B) schematically show the surface part of the catalyst carrier 52 of the exhaust purification catalyst 14 . These FIGS. 6(A) and 6(B) show the reaction which is presumed to occur when the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 is intermittently reduced within the range of a lean air-fuel ratio as shown in FIG. 4 .

That is, as will be understood from FIG. 4 , the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst 14 is maintained lean, so the exhaust gas which flows into the exhaust purification catalyst 14 becomes a state of oxygen excess. Therefore, the NO which is contained in the exhaust gas, as shown in FIG. 6(A) , is oxidized on the platinum 53 and becomes NO 2 . Next, this NO 2 is further oxidized and becomes stable nitrate ions NO 3 − .

On the other hand, when nitrates NO 3 − are produced, the nitrates NO 3 − are pulled back in a direction of reduction by the hydrocarbons HC which are sent on to the surface of the basic layer 55 , have the oxygen disassociated, and becomes unstable NO 2 *. This unstable NO 2 * is strong in activity. Below, this unstable NO 2 − is called the active NO 2 *. This active NO 2 *, as shown in FIG. 6(A) , reacts with the mainly radical hydrocarbons HC which are adhered on the surface of the basic layer 55 or on the rhodium Rh 54 or with the mainly radical hydrocarbons HC contained in the exhaust gas on the rhodium Rh 54 , whereby a reducing intermediate is produced. This reducing intermediate is adhered or adsorbed on the surface of the basic layer 55 .

Note that, at this time, the first produced reducing intermediate is believed to be a nitro compound R—NO 2 . If this nitro compound R—NO 2 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—NH 2 . However, in this case, what is hydrolyzed is considered to be part of the isocyanate compound R—NCO. Therefore, as shown in FIG. 6(A) , the majority of the reducing intermediate which is held or adsorbed on the surface of the basic layer 55 is believed to be the isocyanate compound R—NCO and amine compound R—NH 2 .

On the other hand, as shown in FIG. 6(B) , the active NO 2 * reacts with the reducing intermediate R—NCO or R—NH 2 on the rhodium Rh 54 to form N 2 , CO 2 , and H 2 O and consequently the NO x is removed. That is, if no reducing intermediate R—NCO or R—NH 2 is held or adsorbed on the basic layer 55 , the NO x is not removed. Therefore, to obtain a high NO x purification rate, it is necessary to ensure the continuous presence of a sufficient amount of the reducing intermediate R—NCO or R—NH 2 for making the active NO 2 * N 2 , CO 2 , and H 2 O on the basic layer 55 , that is, the basic exhaust gas flow surface part 26 , at all times.

That is, as shown in FIGS. 6(A) and 6(B) , to oxidize the NO on the platinum Pt 53 , the air-fuel ratio (A/F) in of the exhaust gas must be lean. It is necessary to hold a sufficient amount of the reducing intermediate R—NCO or R—NH 2 for making the produced active NO 2 * N 2 , CO 2 , and H 2 O on the surface of the basic layer 55 , that is, it is necessary to provide the basic exhaust gas flow surface part 26 for holding the reducing intermediate R—NCO or R—NH 2 .

Therefore, as shown in FIGS. 6(A) and 6(B) , to react the NO x contained in the exhaust gas and the partially oxidized hydrocarbons and produce a reducing intermediate R—NCO or R—NH 2 containing nitrogen and hydrocarbon, precious metal catalysts 53 and 54 are carried on the exhaust gas flow surface of the exhaust purification catalyst 14 , a basic exhaust gas flow surface part 26 is formed around the precious metal catalysts 53 and 54 to hold the produced reducing intermediate R—NCO or R—NH 2 in the exhaust purification catalyst 14 , and the NO x is reduced by the reducing action of the reducing intermediate R—NCO or R—NH 2 held on the basic exhaust gas flow surface part 26 . Therefore, in this first NO x purification method, hydrocarbons HC are intermittently fed from the hydrocarbon feed valve 16 by predetermined feed intervals while maintaining the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst 14 lean. The predetermined feed intervals of the hydrocarbons HC are made the feed interval required for continuing to ensure the presence of the reducing intermediate R—NCO or R—NH 2 on the basic exhaust gas flow surface part 56 .

In this case, if the injection amount becomes too large or the injection interval becomes too short, the amount of hydrocarbons becomes excessive and a large amount of hydrocarbons HC is exhausted from the exhaust purification catalyst 14 , while if the injection amount becomes too small or the injection interval becomes too long, the reducing intermediate R—NCO or R—NH 2 can no longer remain on the basic exhaust gas flow surface part 56 . Therefore, in this case, what is important is setting the injection amount and injection interval of hydrocarbons so that so that no excess hydrocarbons HC are exhausted from the exhaust purification catalyst 14 and so that the reducing intermediate R—NCO or the R—NH 2 continues on the basic exhaust gas flow surface part 26 . Incidentally, in the example shown in FIG. 4 , the injection interval is made 3 seconds.

Next, while referring to FIG. 7 to FIG. 11 , the second NO x purification method will be explained. In the case shown in FIG. 4 , if making the feed intervals of the hydrocarbons HC longer than the above-mentioned predetermined feed intervals, the hydrocarbons HC and the reducing intermediate R—NCO or R—NH 2 disappear from the surface of the basic layer 55 . At this time, no pullback force in a direction, which reduces nitrate ions NO 3 − , acts on the nitrate ions NO 3 − produced on the platinum Pt 53 . Therefore, at this time, the nitrate ions NO 3 − diffuse in the basic layer 55 and becomes nitrates as shown in FIG. 7(A) . That is, at this time, the NO x in the exhaust gas is absorbed in the form of nitrates inside the basic layer 55 .

On the other hand, FIG. 7(B) shows the case where the air-fuel ratio of the exhaust gas which flows into the exhaust purification catalyst 14 is made the stoichiometric air-fuel ratio or rich when the NO x is absorbed in the form of nitrates inside of the basic layer 55 . In this case, the oxygen concentration in the exhaust gas falls, so the reaction proceeds in the opposite direction (NO 3 − →NO 2 ) and consequently the nitrates absorbed in the basic layer 55 become nitrate ions NO 3 − one by one and, as shown in FIG. 7(B) , are released from the basic layer 55 in the form of NO 2 . Next, the released NO 2 is reduced by the hydrocarbons HC and CO contained in the exhaust gas.

FIG. 8 shows a second NO x purification method utilizing the adsorption and release action of NO x . That is, in this second NO x purification method, as shown in FIG. 8 , when the stored NO x amount ΣNOX which is stored in the basic layer 55 exceeds a predetermined allowable amount MAX, the air-fuel ratio (A/F) in of the exhaust gas which flows into the exhaust purification catalyst 14 is temporarily made rich. If the air-fuel ratio (A/F) in of the exhaust gas is made rich, the NO x which was absorbed at the basic layer 55 when the air-fuel ratio (A/F) in of the exhaust gas was lean, is released all at once from the basic layer 55 and reduced. Due to this, the NO x is removed.

The stored NO x amount ΣNOX is, for example, calculated from the NO x amount which is exhausted from the engine. In an embodiment of the present invention, the exhausted NO x amount NOXA which is exhausted from the engine per unit time is stored as a function of the engine load L and engine speed N in the form of a map such as shown in FIG. 9 in advance in the ROM 32 . The stored NO x amount ΣNOX is calculated from this exhausted NO x amount NOXA. The period by which the air-fuel ratio (A/F) in of the exhaust gas is made rich is far longer than the period by which the air-fuel ratio (A/F) in of the exhaust gas is lowered, as shown in FIG. 4 , and the period by which the air-fuel ratio (A/F) in of the exhaust gas is made rich is usually 1 minute or more.

In the second NO x purification method, when the air-fuel ratio (A/F) in of the exhaust gas is lean, the NO x which is contained in the exhaust gas is absorbed in the basic layer 55 . Therefore, the basic layer 55 performs the role of an absorbent for temporarily absorbing NO x . Note that, at this time, sometimes the basic layer 55 temporarily adsorbs the NO x . Therefore, if using term of storage as a term including both absorption and adsorption, at this time, the basic layer 55 performs the role of an NO x storage agent for temporarily storing the NO x . That is, 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 14 is called the air-fuel ratio of the exhaust gas, in this second NO x purification method, the exhaust purification catalyst 14 functions as an NO x storage catalyst which stores the NO x when the air-fuel ratio of the exhaust gas is lean and releases the stored NO x when the oxygen concentration in the exhaust gas falls.

Further, in this second NO x purification method, as shown in FIG. 10 , in addition to the combustion use fuel M from the fuel injector 3 , additional fuel W is injected into the combustion chamber 2 whereby the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 is made rich. Note that, the abscissa of FIG. 10 shows the crank angle. This additional fuel W is injected at a timing where it is burned, but does not appear as engine output, that is, slightly before ATDC90° after compression top dead center. Of course, in this case, it is also possible to make the feed amount of hydrocarbons from the hydrocarbon feed valve 16 increase so as to make the air-fuel ratio (A/F) in of the exhaust gas rich.

FIG. 11 shows the NO x purification rate when making the exhaust purification catalyst 14 function as an NO x storage catalyst. Note that, the abscissa of the FIG. 11 shows the catalyst temperature TC of the exhaust purification catalyst 14 . When making the exhaust purification catalyst 14 function as an NO x storage catalyst, as shown in FIG. 11 , when the catalyst temperature TC is 300° C. to 400° C., an extremely high NO x purification rate is obtained, but when the catalyst temperature TC becomes a 400° C. or higher high temperature, the NO x purification rate falls.

In this way, when the catalyst temperature TC becomes 400° C. or more, the NO x 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 NO 2 from the exhaust purification catalyst 14 . That is, so long as storing NO x in the form of nitrates, when the catalyst temperature TC is high, it is difficult to obtain a high NO x purification rate. However, in the first NO x purification method shown from FIG. 4 to FIGS. 6(A) and 6(B) , as will be understood from FIGS. 6(A) and 6(B) , nitrates are not formed or even if formed are extremely fine in amount, consequently, as shown in FIG. 5 , even when the catalyst temperature TC is high, a high NO x purification rate is obtained.

That is, the first NO x purification method shown from FIG. 4 to FIGS. 6(A) and 6(B) can be said to be a new NO x purification method which removes NO x without formation of almost any nitrates when using an exhaust purification catalyst which carries a precious metal catalyst and forms a basic layer which can absorb NO x . In actuality, when using this first NO x purification method, the nitrates which are detected from the basic layer 53 become much smaller in amount compared with the case of using the second NO x purification method.

On the other hand, to use the first NO x purification method to remove NO x , it is necessary to feed a certain amount or more of hydrocarbons by a short period even when the NO x concentration in the exhaust gas is low. Therefore, when the NO x concentration of the exhaust gas is low, the NO x purification efficiency deteriorates. As opposed to this, in the second NO x purification method, when the NO x concentration in the exhaust gas is low, the time until the stored NO x amount ΣNOX reaches the allowable value MAX becomes longer, and thus the period for making the air-fuel ratio (A/F) in of the exhaust gas rich become longer. Accordingly, the NO x purification efficiency does not become poor. Therefore, when the NO x concentration in the exhaust gas is low, it can be said to be preferable to use the second NO x purification method rather than the first NO x purification method.

That is, which of the first NO x purification method and the second NO x purification method should be used changes in the operating state of the engine. Therefore, in the present invention, on the exhaust purification catalyst 14 , precious metal catalysts 53 and 54 are carried and a basic layer 55 is formed, and the exhaust purification catalyst 14 has the property of reducing the NO x which is contained in the exhaust gas when hydrocarbons are injected from the hydrocarbon feed valve 16 at predetermined feed intervals while maintaining the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst 14 is maintained lean and has the property of being increased in the storage amount of NO x which is contained in exhaust gas when the feed intervals of the hydrocarbons are made longer than the predetermined feed intervals. At the time of engine operation, a first NO x purification method which injects hydrocarbons from the hydrocarbon feed valve 16 at the predetermined feed intervals while maintaining the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst 14 lean so as to remove the NO x contained in the exhaust gas and a second NO x purification method which switches the air-fuel ratio of the exhaust gas which flows to the exhaust purification catalyst 14 from lean to rich by intervals longer than the predetermined feed intervals so as to remove the NO x are selectively used in accordance with the operating state of the engine.

Next, referring to FIG. 12 to FIG. 15 , a representative embodiment according to the present invention will be explained.

FIG. 12(A) shows the hydrocarbon feed amount QE from the hydrocarbon feed valve 16 , while FIG. 12(B) shows the additional fuel amount W which is fed into a combustion chamber 2 . The hydrocarbon feed amount QE is stored as a function of the engine load QE and engine speed N in the form of a map such as shown in FIG. 12(A) in advance in the ROM 32 . The additional fuel amount W is also stored as a function of the engine load QE and engine speed N in the form of a map such as shown in FIG. 12(B) in advance in the ROM 32 .

FIG. 13(A) shows a discharge rate NOXD of stored NO x which is discharged from the exhaust purification catalyst 14 when the air-fuel ratio (A/F) in of the exhaust gas is lean. As explained above, the NO x which is stored in the form of nitrates is broken down by heat and discharged if the temperature TC of the exhaust purification catalyst 14 rises. At this time, the NO x discharge rate NOXD, that is, the NO x amount NOXD which is discharged per unit time, rapidly rises when the temperature TC of the exhaust purification catalyst 14 exceeds the heat breakdown start temperature of about 450° C.

On the other hand, FIG. 13(B) shows the storage rate SX of the NO x which is stored in the exhaust purification catalyst 14 when the first NO x purification method is used to perform the purification action of NO x . When the first NO x purification method is used to perform the purification action of NO x , normally NO x is not stored in the exhaust purification catalyst 14 . However, if the flow rate of the exhaust gas becomes faster, that is, if the intake air amount GA increases, the reaction time becomes shorter and the reaction can no longer be sufficiently performed, so active NO 2 * is not formed and the NO x which is absorbed at the basic layer 55 increases. Therefore, as shown in FIG. 13(B) , when the intake air amount GA becomes larger than a certain value, the NO x storage rate SX starts to increase.

In this way, even when the first NO x purification method is used to perform an NO x purification action, sometimes NO x is stored in the exhaust purification catalyst 14 . At this time, the amount of NO x stored per unit time becomes the value SX·NOXA of the NO x storage rate SX multiplied with the NO x amount NOXA exhausted per unit time. In an embodiment of the present invention, SX·NOXA is cumulatively added to calculate the stored NO x amount which is stored when the first NO x purification method is used to perform the NO x purification action. When switched from the first NO x purification method to the second NO x purification method, the stored NO x amount which is calculated at the time of the first NO purification method is used as the basis to start to calculate the stored NO x amount.

That is, in a representative example according to the present invention, when switched from the first NO x purification method to the second NO x purification method, the NO x storage amount which was calculated when the first NO x purification method is used and the NO x storage amount which was calculated after switching to the second NO x purification method are totaled up. When this total value ΣNOX exceeds a predetermined allowable value MAX, the air-fuel ratio of the exhaust gas flowing into the exhaust purification catalyst 14 is made temporarily rich. In this case, if ignoring the stored NO x amount of the time when using the first NO x purification method, the timing at which the air-fuel ratio (A/F) in of the exhaust gas is made rich when switched to the second NO x purification method becomes slower and consequently part of the NO x is exhausted into the atmosphere without being stored. However in an embodiment of the present invention, the NO x storage amount of the time when the first NO x purification method is used is taken into consideration. Therefore, the above such problem does not arise.

On the other hand, when switched from the second NO x purification method to the first NO x purification method, if stored NO x remains in the exhaust purification catalyst 14 , the stored NO x is discharged from the NO x purification catalyst 14 when the temperature TC of the exhaust purification catalyst 14 is caused to rise due to the feed of hydrocarbons. When an NO x purification action is performed by the first NO x purification method, no reducing action is performed on the thus discharged NO x , consequently the NO x is exhausted into the atmosphere.

However, if making the air-fuel ratio (A/F) in of the exhaust gas rich, it is possible to reduce the stored NO x which remained in the exhaust purification catalyst 14 and consequently possible to block the NO x from being exhausted into the atmosphere. Therefore, in an embodiment of the present invention, as shown in FIG. 14 , when switched from the second NO x purification method to the first NO x purification method, the air-fuel ratio of the exhaust gas which flows into the exhaust purification catalyst 14 is temporarily made rich to release and reduce the NO x which was stored in the exhaust purification catalyst 14 .

In this case, in the embodiment shown in FIG. 14 , right before being switched from the second NO x purification method to the first NO x purification method, additional fuel W is fed into the combustion chamber 2 whereby the air-fuel ratio of the exhaust gas which flows into the exhaust purification catalyst 14 is made rich. Note that, FIG. 14 shows the change of the air-fuel ratio (A/F) in of the exhaust gas which flows into the exhaust purification catalyst 14 and the stored NO x amount ΣNOX which is stored in the exhaust purification catalyst 14 . As will be understood from FIG. 14 , when the first NO x purification method is started, the stored NO x amount ΣNOX becomes zero and consequently NO x is kept from being exhausted into the atmosphere.

On the other hand, the NO x purification action by the first NO x purification method is not performed so long as the oxidation catalyst 13 is not activated. Therefore, in an embodiment of the present invention, the first NO x purification method is used only when the temperature TB of the oxidation catalyst 13 becomes the activation temperature TB 0 or more. When the temperature TB of the oxidation catalyst 13 is lower than the activation temperature TB 0 , use of the first NO x purification method is prohibited. At this time, that is, when the temperature TB of the oxidation catalyst 13 is lower than the activation temperature TB 0 , the second NO x purification method is used.

Note that, in a representative embodiment of the present invention, when the temperature TB of the oxidation catalyst 13 is the activation temperature TB 0 or more, either of the first NO x purification method or the second NO x purification method is used. In this case, when using the first NO x purification method would result in a higher NO x purification efficiency compared with using the second NO x purification method, the first NO x purification method is used, while when using the second NO x purification method would result in a higher NO x purification efficiency compared with using the first NO x purification method, the second NO x purification method is used.

FIG. 15 shows the NO x purification control routine for executing the representative embodiment of the present invention. This routine is executed by interruption every predetermined time interval.

Referring to FIG. 15 , first, at step 60 , the NO x amount NOXA exhaust per unit time is calculated from the map shown in FIG. 9 . Next, the routine proceeds to an NO x purification method determining part A for determining whether to use the first NO x purification method or use the second NO x purification method. With this NO x purification method determination part A, first, at step 61 , it is judged if the temperature TB of the oxidation catalyst 13 is the activation temperature TB 0 or more. When TB<TB 0 , it is judged that the second NO x purification method should be used. At this time, the routine proceeds to step 64 .

As opposed to this, when TB≧TB 0 , the routine proceeds to step 62 where the NO x purification efficiency F 1 when using the first NO x purification method and the NO x purification efficiency F 2 when using the second NO x purification method are calculated. The NO x purification efficiencies F 1 and F 2 express the amounts of consumption of fuel or hydrocarbons per unit time required for obtaining a unit NO x purification rate. In this case, the NO x purification efficiency F 1 is calculated from the hydrocarbon feed amount QE and hydrocarbon injection interval shown in FIG. 12A and the NO x purification rate shown in FIG. 5 , while the NO x purification efficiency F 2 is calculated from the additional fuel amount W shown in FIG. 12B , the interval between timings where the rich air-fuel ratio is set in FIG. 8 , and the NO x purification rate shown in FIG. 11 .

Next, at step 63 , it is judged if the NO x purification efficiency F 1 is higher than the NO x purification efficiency F 2 . When F 1 ≧F 2 , it is judged that the first NO x purification method should be used. At this time, the routine proceeds to step 68 . As opposed to this, when F 1 <F 2 , it is judged that the second NO x purification method should be used, and the routine proceeds to step 64 .

Next, the second NO x purification method which is performed from step 64 to step 67 will be explained. First, at step 64 , the exhausted NO x amount NOXA shown in FIG. 9 is added to ΣNOX to calculate the stored NO x amount ΣNOX. Next, at step 65 , it is judged if the stored NO x amount ΣNOX exceeds the allowable value MAX. When ΣNOX>MAX, the routine proceeds to step 66 where the additional fuel amount W is calculated from the map shown in FIG. 12B , then the additional fuel injection action is performed. Next, at step 67 , ΣNOX is cleared.

Next, the first NO x purification method which is performed from step 68 to step 74 will be explained. First, at step 68 , it is judged if stored NO x processing is being performed for processing the stored NO x remaining inside the exhaust purification catalyst 14 . When stored NO x processing is not being performed, the routine proceeds to step 69 where it is judged if a decision to switch from the second NO x purification method to the first NO x purification method has now been made. If a decision to switch from the second NO x purification method to the first NO x purification method has now been made, the routine proceeds to step 70 where it is judged if the stored NO x amount ΣNOX is smaller than a predetermined small value MIN.

When ΣNOX>MIN, the routine proceeds to step 71 where stored NO x processing is performed. In this embodiment, as shown in FIG. 14 , right before being switched from the second NO x purification method to the first NO x purification method, the air-fuel ratio (A/F) in of the exhaust gas is temporarily made rich. Next, at step 72 , ΣNOX is cleared. Note that, when the stored NO x processing has started, the routine jumps from step 68 to step 71 until the stored NO x processing is completed.

On the other hand, when it is judged at step 69 that a decision to switch from the second NO x purification method to the first NO x purification method has not now been made, the routine proceeds to step 73 . Further, when it is judged at step 70 that ΣNOX<MIN, that is, even when it is judged that almost no NO x is stored, the routine proceeds to step 73 . At step 73 , the hydrocarbon feed amount QE is calculated from the map such as shown in FIG. 12(A) , so hydrocarbon injection processing is performed. Next, at step 74 , the following formula is used as the basis to calculate the NO x amount ΣNOX which is stored in the exhaust purification catalyst 14 during an NO x purification action by the first NO x purification method.

where, SX·NOXA, as explained above, is the NO x amount which is stored per unit time and NOXD is the discharge rate shown in FIG. 13A . When switched from the first NO x purification method to the second NO x purification method, at step 64 , NOXA is added to the ΣNOX calculated at step 74 .

FIG. 16 shows another embodiment. In this embodiment, the engine operating region where the NO x purification efficiency F 2 becomes higher than the NO x purification efficiency F 1 is set in advance as shown by the hatching in FIG. 16(A) , for example, as a function of the engine load L and engine speed N. When the oxidation catalyst 13 is activated, the NO x purification method is determined in accordance with FIG. 16(A) .

FIG. 16(B) shows another embodiment of the NO x purification method determining part A of FIG. 15 . Referring to FIG. 16(B) , at step 61 , when the temperature TB of the oxidation catalyst 13 is lower than the activation temperature TB 0 , it is judged that the second NO x purification method should be used, then the routine proceeds to step 64 of FIG. 15 . As opposed to this, when it is judged at step 61 that TB≧TB 0 , the routine proceeds to step 61 a where it is judged if the operating state of the engine is a region shown by the hatching in FIG. 16 (A) where the second NO x purification method should be used. When the operating state of the engine is a region where the second NO x purification method should be used, the routine proceeds to step 64 of FIG. 15 . As opposed to this, when it is judged that the operating state of the engine is not a region where the second NO x purification method should be used, the routine proceeds to step 68 of FIG. 15 .

FIG. 17 shows still another embodiment of the NO x purification method determining part A of FIG. 15 . That is, the NO x purification rate when using the first NO x purification method, as shown in FIG. 5 , is rapidly lowered when the temperature TC of the exhaust purification catalyst 14 becomes the limit temperature TC 0 or less. As opposed to this, as shown in FIG. 11 , the NO x purification rate when using the second NO x purification method falls relatively slowly when the temperature TC of the exhaust purification catalyst 14 falls. Therefore, in this embodiment, when the temperature TC of the exhaust purification catalyst 14 is higher than the limit temperature TC 0 the first NO x purification method is used, while when the temperature TC of the exhaust purification catalyst 14 is lower than the limit temperature TC 0 the second NO x purification method is used.

That is, referring to FIG. 17 , at step 61 , when the temperature TB of the oxidation catalyst 13 is lower than the activation temperature TB 0 , it is judged that the second NO x purification method should be used then the routine proceeds to step 64 of FIG. 15 . As opposed to this, when it is judged at step 61 that TB≧TB 0 , the routine proceeds to step 61 a where it is judged if the temperature TC of the exhaust purification catalyst 14 is higher than the limit temperature TC 0 . When TC<T 0 , the routine proceeds to step 64 of FIG. 15 . As opposed to this, when TC≧T 0 , it is judged that the first NO x purification method should be used then the routine proceeds to step 68 of FIG. 15 .

FIG. 18 shows still another embodiment of the NO x purification method determining part A of FIG. 15 . That is, the first NO x purification method can give a high NO x purification rate as compared with the second NO x purification method when the NO x amount to be reduced is large, that is, when the NO x concentration in the exhaust gas is high. Therefore, in this embodiment, it is judged whether to use the first NO x purification method or to use the second NO x purification method by whether the NO x concentration D in the exhaust gas exceeds a set value D 0 .

That is, referring to FIG. 18 , at step 61 , when the temperature TB of the oxidation catalyst 13 is lower than the activation temperature TB 0 , it is judged that the second NO x purification method should be used, then the routine proceeds to step 64 of FIG. 15 . As opposed to this, when it is judged at step 61 that TB≧TB 0 , the routine proceeds to step 61 a where it is judged if the temperature TC of the exhaust purification catalyst 14 is higher than the limit temperature TC 0 . When TC<T 0 , the routine proceeds to step 64 of FIG. 15 . As opposed to this, when TC≧T 0 , the routine proceeds to step 61 b where it is judged if the NO x concentration D in the exhaust gas which is detected by for example, the NO x concentration sensor is higher than the set value D 0 . When D<D 0 , the routine proceeds to step 64 of FIG. 15 . As opposed to this, when D≧D 0 , it is judged that the first NO x purification method should be used, then the routine proceeds to step 68 of FIG. 15 .

FIG. 19 shows another embodiment of the stored NO x processing which is performed at step 71 of FIG. 15 . In this embodiment, right after being switched from the second NO x purification method to the first NO x purification method as well, the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 is made rich. At this time, the amount of hydrocarbons which is fed from the hydrocarbon feed valve 16 is increased so that the air-fuel ratio (A/F) in of the exhaust gas is made rich.

That is, when a decision has been made to switch from the second NO x purification method to the first NO x purification method, if the stored NO x amount ΣNOX is large, if just injecting additional fuel to the inside of the combustion chamber 2 so as to make air-fuel ratio (A/F) in of the exhaust gas rich just once, sometimes it is not possible to release the total stored NO x for reduction. In such a case, as shown in FIG. 19 , when the NO x purification action by the first NO x purification method is started, by increasing the feed amount of hydrocarbons, the air-fuel ratio (A/F) in of the exhaust gas is made rich whereby the total stored NO x is released and reduced.

On the other hand, if injecting additional fuel into the combustion chamber 2 , the temperature inside the combustion chamber 2 rises. Therefore, at the time of a high load operation where the combustion temperature becomes higher, sometimes the air-fuel ratio (A/F) in of the exhaust gas cannot be made rich by injecting the additional fuel into the combustion chamber 2 . In such a case, the air-fuel ratio (A/F) in of the exhaust gas is made rich by stopping the injection of the additional fuel and increasing the feed amount of hydrocarbons.

FIG. 20 shows still another embodiment of the stored NO x processing which is performed at step 71 of FIG. 15 . In this embodiment, after being switched from the second NO x purification method to the first NO x purification method, the NO x purification action is started by the first NO x purification method, then the air-fuel ratio (A/F) in of the exhaust gas flowing into the exhaust purification catalyst 14 is made rich. In this embodiment, when the stored NO x is discharged from the exhaust purification catalyst 14 , this discharged NO x is reduced by feeding additional fuel to the combustion chamber 2 or increasing the feed amount of hydrocarbons to make the air-fuel ratio (A/F) in of the exhaust gas rich.

On the other hand, if the sulfur which is contained in the exhaust gas sticks to the surface of the precious metal, that is, if the precious metal is poisoned by sulfur, active NO 2 * becomes harder to produce. Therefore, it is preferable to increase the feed amount of hydrocarbons QE as the sulfur poisoning amount of the precious metal is increased so that the amount of production of active NO 2 * does not fall even if the precious metal is poisoned by sulfur. In the embodiment shown in FIG. 21 , the increase coefficient for the hydrocarbon feed amount QE is increased along with the increase in the sulfur poisoning amount so that the amount of production of active NO 2 * does not fall even if the sulfur poisoning amount is increased.

FIG. 22 shows the case of forming the hydrocarbon partial oxidation catalyst 13 and the exhaust purification catalyst 14 shown in FIG. 1 by a single catalyst. This catalyst is for example provided with a large number of exhaust gas channels extending in the direction of flow of the exhaust gas. FIG. 22 shows an enlarged cross-sectional view of the surface part of the inner circumferential wall 80 of an exhaust gas channel of the catalyst. As shown in FIG. 22 , on the surface of the inner circumferential wall 80 of the exhaust gas channel, a bottom coat layer 81 is formed. On this bottom coat layer 81 , a top coat layer 82 is formed. In the example shown in FIG. 22 , both the coat layers 81 and 82 are comprised of powder aggregates. FIG. 22 shows enlarged views of the powder forming the coat layers 81 and 82 . From the enlarged views of the powder, it is learned that the top coat layer 82 is comprised of the hydrocarbon partial oxidation catalyst shown in FIG. 2(A) , for example, an oxidation catalyst, while the bottom coat layer 81 is comprised of the exhaust purification catalyst shown in FIG. 2(B) .

When the catalyst shown in FIG. 22 is used, as shown in FIG. 22 , the hydrocarbons HC which are contained in the exhaust gas diffuse inside the top coat layer 82 and are partially oxidized. The partially oxidized hydrocarbons diffuse inside the bottom coat layer 81 . That is, in the example shown in FIG. 22 as well, in the same way as the example shown in FIG. 1 , the hydrocarbon partial oxidation catalyst and the exhaust purification catalyst are arranged so that the hydrocarbons which were partially oxidized at the hydrocarbon partial oxidation catalyst flow to the exhaust purification catalyst. On the other hand, in the catalyst shown in FIG. 22 , when the first NO x purification method is used, the NO x which is contained in the exhaust gas diffuses to the inside of the bottom coat layer 81 and becomes active NO 2 *. At this time, at the bottom coat layer 81 , the reducing intermediate R—NCO or R—NH 2 is produced from the active NO 2 * and the partially oxidized hydrocarbons. Furthermore, the active NO 2 * reacts with the reducing intermediate R—HCO or R—NH 2 to become N 2 , CO 2 , and H 2 O.

On the other hand, as shown in FIG. 2(B) , on the catalyst carrier 52 of the exhaust purification catalyst 14 , precious metals 53 and 54 are carried. Therefore, inside of the exhaust purification catalyst 14 as well, it is possible to reform the hydrocarbons to radical hydrocarbons HC with a small carbon number. In this case, if the hydrocarbons can be sufficiently reformed inside the exhaust purification catalyst 14 , that is, if the hydrocarbons can be sufficiently partially oxidized inside of the exhaust purification catalyst 14 , it is not necessary to arrange the oxidation catalyst 13 as shown in FIG. 1 upstream of the exhaust purification catalyst 14 . Therefore, in an embodiment according to the present invention, no oxidation catalyst 13 is attached inside of the engine exhaust passage. Therefore, in this embodiment, the hydrocarbons which are injected from the hydrocarbon feed valve 16 are directly fed to the exhaust purification catalyst 14 .

In this embodiment, the hydrocarbons which are injected from the hydrocarbon feed valve 16 are partially oxidized inside of the exhaust purification catalyst 14 . Furthermore, inside of the exhaust purification catalyst 14 , active NO 2 * is produced from the NO x which is contained in the exhaust gas. Inside of the exhaust purification catalyst 14 , the reducing intermediate R—NCO and R—NH 2 is produced from these active NO 2 * and partially oxidized hydrocarbons. Furthermore, the active NO 2 * reacts with the reducing intermediate R—NCO or R—NH 2 to become N 2 , CO 2 , and H 2 O. That is, in this embodiment, the exhaust purification catalyst 14 for reacting the hydrocarbons injected from the hydrocarbon feed valve 16 and partially oxidized and the NO x contained in the exhaust gas is arranged inside of the engine exhaust passage downstream of the hydrocarbon feed valve 16 .

4 . . . intake manifold

5 . . . exhaust manifold

7 . . . exhaust turbocharger

12 . . . exhaust pipe

13 . . . oxidation catalyst

14 . . . exhaust purification catalyst

16 . . . hydrocarbon feed valve