Filter system for the removal of hydrocarbon deposits from a cooled exhaust gas recirculating engine

A for reducing hydrocarbon deposits in an exhaust, gas recirculation cooler in an internal combustion engine, comprising:

• an air intake;
• an internal combustion engine connected in fluidic communication with the air intake;
• an exhaust manifold connected in fluidic communication with the internal combustion engine;
• a hydrocarbon filter connected in fluidic communication with the exhaust manifold further comprising:
• a microwave-absorbent refractory ceramic material adapted to allow fluid flow therethrough;
• a microwave source;
• a waveguide positioned to receive microwaves from the microwave source and direct them to the microwave-absorbent refractory ceramic material;
• an exhaust gas recirculation cooler connected in fluidic communication with the hydrocarbon filter and connected in fluidic communication to the air intake;
• and
• a valve operationally connected in fluidic communication with the hydrocarbon filter and the exhaust gas recirculation cooler;
• wherein the at least some of the hydrocarbons from the exhaust gasses deposit on the microwave-absorbent refractory ceramic material;
• wherein the exhaust manifold is adapted to emit exhaust gasses containing hydrocarbons when the engine is actuated;
• wherein the valve is adapted to control the fluid flow between the hydrocarbon filter and the exhaust gas recirculation cooler;
• wherein hydrocarbon-containing exhaust gasses exiting the exhaust manifold are routed through the hydrocarbon filter;
• wherein at least some of the hydrocarbons passing through the hydrocarbon filter are removed from the exhaust gas;
• wherein the filtered exhaust gasses exiting the hydrocarbon filter are circulated through the exhaust gas recirculation cooler and into the air intake for recirculation through the engine;
• wherein removing the at least some of the hydrocarbons from the exhaust gasses retards buildup of hydrocarbon residue in the exhaust gas recirculation cooler;
• wherein removal of the at least some of the hydrocarbons from the exhaust gasses reduces hydrocarbon emissions from the engine;
• wherein the microwave source may be selectively actuated to heat the microwave-absorbent refractory ceramic material past a predetermined temperature threshold;
• and
• wherein heating the microwave-absorbent refractory ceramic material past a predetermined temperature threshold actuates the oxidation of the hydrocarbons deposited in the hydrocarbon filter.

A diesel fuel exhaust system comprising:

• an exhaust gas recirculation filter assembly positioned to receive exhaust gasses from a diesel engine exhaust manifold;
• and
• an exhaust gas recirculation cooler fluidically coupled to the exhaust gas recirculation filter and adapted to receive filtered exhaust gasses therefrom and recirculate cooled filtered exhaust gasses back into the engine;
• wherein the exhaust gas recirculation filter assembly includes:
• a porous refractory substrate adapted to allow fluidic communication therethrough;
• and
• a catalytic metal coating at least some of the pores;
• wherein hydrocarbons flowing through the coated pores are catalytically oxidized.

A diesel fuel exhaust system comprising:

• an exhaust gas recirculation filter assembly positioned to receive exhaust gasses from a diesel engine exhaust manifold;
• and
• an exhaust gas recirculation cooler fluidically coupled to the exhaust gas recirculation filter and adapted to receive filtered exhaust gasses therefrom and recirculate cooled filtered exhaust gasses back into the engine;
• wherein the exhaust gas recirculation filter assembly includes:
• a microwave-absorbent refractory ceramic material adapted to allow fluid flow therethrough;
• a microwave source;
• and
• a waveguide positioned to receive microwaves from the microwave source and direct them to the microwave-absorbent refractory ceramic material;
• wherein the at least some of the hydrocarbons from the exhaust gasses deposit on the microwave-absorbent refractory ceramic material;
• wherein the microwave source may be selectively actuated to heat the microwave-absorbent refractory ceramic material past a predetermined temperature threshold;
• and
• wherein heating the microwave-absorbent refractory ceramic material past a predetermined temperature threshold actuates the oxidation of the hydrocarbons deposited in the hydrocarbon filter.

A method of removing hydrocarbons from internal combustion engine exhaust gasses, comprising the steps of:

• a) providing an internal combustion engine having an air intake and an exhaust manifold, wherein the exhaust manifold emits exhaust gasses containing hydrocarbons when the engine is running;
• b) providing a filter adapted to receive exhaust gasses from the exhaust manifold;
• c) circulating exhaust gasses from the exhaust manifold into the filter;
• d) removing at least some of the hydrocarbons from the exhaust gasses;
• e) cooling filtered exhaust gasses;
• and
• f) recirculating filtered and cooled exhaust gasses into the air intake;
• wherein the filter includes:
• a microwave-absorbent refractory ceramic material adapted to allow fluid flow therethrough;
• a microwave source;
• a waveguide positioned to receive microwaves from the microwave source and direct them to the microwave-absorbent refractory ceramic material;
• wherein the at least some of the hydrocarbons from the exhaust gasses deposit on the microwave-absorbent refractory ceramic material;
• wherein the microwave source may be selectively actuated to heat the microwave-absorbent refractory ceramic material past a predetermined temperature threshold;
• and
• wherein heating the microwave-absorbent refractory ceramic material past a predetermined temperature threshold actuates the. oxidation of the hydrocarbons deposited in the filter.

A method of removing hydrocarbons from internal combustion engine exhaust gasses, comprising the steps of:

• a) providing an internal combustion engine having an air intake and an exhaust manifold, wherein the exhaust manifold emits exhaust gasses containing hydrocarbons when the engine is running;
• b) providing a filter adapted to receive exhaust gasses from the exhaust manifold;
• c) circulating exhaust gasses from the exhaust manifold into the filter;
• d) removing at least some of the hydrocarbons from the exhaust gasses;
• e) cooling filtered exhaust gasses;
• and
• f) recirculating filtered and cooled exhaust gasses into the air intake;
• wherein the filter includes:
• a porous refractory substrate adapted to allow fluidic communication therethrough;
• and
• a catalytic metal including cerium and at least one element from column VIIIA and rows 5 and 6 of the periodic table coating at least some of the pores;
• wherein hydrocarbons flowing through the coated pores are catalytically oxidized.

A method of removing engine exhaust by-products from internal combustion engine exhaust gasses, comprising the steps of:

• a) providing an internal combustion engine having an air intake and an exhaust manifold, wherein the exhaust manifold emits exhaust gasses containing volatile combustion by products when the engine is running;
• b) providing a filter adapted to receive exhaust gasses from the exhaust manifold;
• c) circulating exhaust gasses from the exhaust manifold into the filter;
• d) removing at least some of the volatile combustion by products from the exhaust gasses;
• e) cooling filtered exhaust gasses;
• and
• f) recirculating filtered and cooled exhaust gasses into the air intake;
• wherein the filter includes:
• a porous refractory substrate adapted to allow fluidic communication therethrough;
• and
• a catalytic metal including cerium and at least one element from column VIIIA and rows 5 and 6 of the periodic table coating at least some of the pores;
• wherein at least some of the volatile combustion by-products flowing through the coated pores are catalytically oxidized.

A method of removing engine exhaust by-products from internal combustion engine exhaust gasses, comprising the steps of:

• a) providing an internal combustion engine having an air intake and an exhaust manifold, wherein the exhaust manifold emits exhaust gasses containing volatile combustion by products when the engine is running;
• b) providing a filter adapted to receive exhaust gasses from the exhaust manifold;
• c) circulating exhaust gasses from the exhaust manifold into the filter;
• d) removing at least some of the volatile combustion by-products from the exhaust gasses;
• e) cooling filtered exhaust gasses;
• and recirculating filtered and cooled exhaust gasses into the air intake;
• wherein the filter includes:
• a microwave-absorbent refractory ceramic material adapted to allow fluid flow therethrough;
• a microwave source;
• a waveguide positioned to receive microwaves from the microwave source and direct them to the microwave-absorbent refractory ceramic material;
• wherein the at least some of the volatile combustion by-products from the exhaust gasses deposit on the microwave-absorbent refractory ceramic material;
• wherein the microwave source may be selectively actuated to heat the microwave-absorbent refractory ceramic material past a predetermined temperature threshold;
• and
• wherein heating the microwave-absorbent refractory ceramic material past a predetermined temperature threshold actuates the oxidation of a predetermined amount of the volatile combustion by-products deposited in the filter.