CN109630248A - 柴油机排放流体的混合 - Google Patents

柴油机排放流体的混合 Download PDF

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CN109630248A
CN109630248A CN201811107934.XA CN201811107934A CN109630248A CN 109630248 A CN109630248 A CN 109630248A CN 201811107934 A CN201811107934 A CN 201811107934A CN 109630248 A CN109630248 A CN 109630248A
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cylindrical housings
cylindrical
mixing bowl
bottom end
canister assembly
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CN109630248B (zh
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S·D·布林克迈尔
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Caterpillar Inc
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
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    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2892—Exhaust flow directors or the like, e.g. upstream of catalytic device
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
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    • B01F23/213—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids
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    • B01F23/213—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids
    • B01F23/2132—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids using nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01F2025/91—Direction of flow or arrangement of feed and discharge openings
    • B01F2025/916—Turbulent flow, i.e. every point of the flow moves in a random direction and intermixes
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Abstract

本发明涉及柴油机排放流体的混合，具体涉及用在排放气体后处理装置中使用的罐组件，包括限定圆柱形轴线、径向方向和圆周方向的圆柱形壳体、顶端和底端。流量管插入到圆柱形壳体的顶端中并在到达圆柱形壳体的底端之前终止，从而限定流量管的出口。包括关于圆柱形轴线对称的环形形状并限定混合碗状槽的混合碗状构件固定地附接在圆柱形壳体的底端处。

Description

柴油机排放流体的混合
技术领域
本发明大致涉及用来处理排放流体以减少有害排放物的罐组件。更明确地，本发明涉及一种罐组件，其使用罐组件底部处的混合碗状构件来减小用于减少有害排放物的后处理装置的尺寸和复杂性。
背景技术
内燃发动机通常用在各种行业中以为机器和设备提供动力。使用这种机器和设备的行业的示例包括海运业、动土业、建筑业，采矿业、机车业以及农耕业等。在某些市场和细分市场中，使用了汽油或柴油燃料动力发动机。这些发动机经常发出不期望的排放物，诸如微粒物质和NOx。采用各种技术来减少这些排放物的诸如罐(CAN)组件的后处理装置在本领域中也是熟知的。然而，这些熟知的后处理装置却受各种缺陷困扰。
首先，许多现有的后处理装置是复杂的，而且包括许多部件，诸如挡板和翅片，其设置在罐组件的入口流量管中以促进将排放处理流体(诸如柴油机排放流体(DEF))混合到排放气体流中，从而有效地减少排放物。如果将柴油机排放流体混合到排放气体流中是不充分的，则可能不会实现期望的排放物减少并且/或者柴油机排放流体可能会在罐组件的各部分上冷凝并结晶。这可能要求罐组件是清洁的或者在罐组件上进行其它维护。这可能会是高成本且耗时的。因此，有效地混合带有排放气体的柴油机排放流体的需要是所需的。
其次，使用这种挡板和翅片对制造而言可能是高成本的。当成本引起相当大的关注时，使用诸如挡板和翅片的复杂特点是不可行的。在传统上低成本的国家中，当排放物标准不太严格时，可能会忽略这种特点或者可能会完全忽略后处理。然而，即使在低成本的国家中，现在对排放物影响的意识也日益增加，因此更容易制造且低成本的提供排放气体后处理的方法和装置正在变得必不可少。更明确地，这种低成本国家中的排放物标准正在变得更加严格，从而使提供低成本的后处理是必不可少的。
第三，由后处理装置占用的空间可能比一些应用中所期望的空间更大。减少后处理装置占用的空间可能会允许有诸如发动机等的其它系统的改进或添加。因此，减小诸如罐组件的后处理装置的尺寸可能是有用的。
Frederiksen等人的美国专利6,312,650示出了用来清洁排放气体的消音器或罐组件。罐组件包括连接到排放入口管(2)和排放出口管(3)的气密外壳(1)，并且含有至少两个隔音室(4i、4ii)和诸如催化剂或颗粒过滤器的一个或多个整体式主体(5)，排放气体在纵向通道或孔隙中在流动方向上通过其流动，以及一个或多个管道或通道(6、7)，至少一个管道或通道穿透一个或多个整体式主体(5)并将排放气体引导到与整体式主体(5)的通道或孔隙中的流动方向相对的流动方向上，并且至少一个管道或通道(6、7)连接至少两个隔音室(4i、4ii)。大致的流动方向优选地在基本上紧接穿透的整体式主体(5)的上游和在基本上紧接或者相同的整体式主体(5)或者另一穿透的整体式主体的下游是相对的。用于催化还原NOx的固体活性颗粒或者含有尿素和/或氨水的水溶液的液体喷雾(其对于催化还原NOx而言是活性的)可以喷射到排放气体中以冲击涂敷在所设置的挡板(13)、端盖(11、12)或流动元件上催化层(35、36)，从而所述颗粒和/或液滴冲击在其上。
如能够看到的那样，Frederiksen等人的设计没有解决一些诸如具有减小的尺寸和复杂性的当前市场需求，而仍确保了将充足的柴油机排放流体充分地混合到由柴油发动机等所产生的排放气体流中。因此，期望的是开发一种后处理装置，其具有减小的尺寸和复杂性，并同时比尚已设计的后处理装置将柴油机排放流体或其它排放气体处理流体充分地混合到排放气体流中。
发明内容
根据本发明的实施例用于排放气体后处理装置的罐组件包括限定圆柱形轴线、径向方向和圆周方向的圆柱形壳体、顶端、底端以及顶端与底端之间的内部。流量管插入到圆柱形壳体的顶端中并在到达圆柱形壳体的底端之前终止，从而限定流量管的出口。包括关于圆柱形轴线对称的环形形状并限定与圆柱形壳体的内部流体连通的混合碗状槽的混合碗状构件固定地附接在圆柱形壳体的底端处，并且流量管的出口径向地定位在混合碗状槽上方并远离混合碗状构件轴向地间隔开。
根据本发明的实施例的罐组件包括限定圆柱形轴线、径向方向和圆周方向的圆柱形壳体、顶端、底端以及顶端和底端之间的内部。还设置了混合碗状构件，其包括关于圆柱形轴线对称的环形形状并且其限定具有朝向圆柱形壳体内部的分流器的混合碗状槽，混合碗状构件固定地附接在圆柱形壳体的底端处，并且分流器径向地居中。
根据本发明的实施例的混合碗状构件包括限定径向方向、轴向方向和圆周方向的大致圆柱形主体，并且包括顶部轴向表面、底部轴向表面和外部圆柱形表面。顶部轴向表面限定混合碗状槽，其包括径向地居中的分流器。
附图说明
图1是根据本发明的实施例的在组件底部处具有混合碗状的罐(CAN)组件的示意图，其显示了在罐组件的顶部附近将柴油机排放流体喷射到柴油机排放气体流中。
图2是类似于图1的罐组件的罐(CAN)组件的示意图，其显示了在罐组件的顶部附近在喷射柴油机排放流体的相对处喷射增压空气。
图3是设置在图1和图2的罐组件底部处的混合碗状构件的放大侧截面图，其更清晰地显示了附接到罐组件壳体的混合碗状构件的混合碗状几何形状。
图4是从罐组件中移除的图3的混合碗状构件的透视图。
图5是图4的混合碗状构件的侧截面图。
具体实施方式
现在将对本发明的实施例做出在细节上参考，而且其示例示出在附图中。只要有可能，贯穿整个附图将使用相同的参考标号来指示相同或相似的部分。在一些情况下，参考标号将在此说明书中指示，并且附图将显示后面跟随字母的参考标号，例如100a、100b或诸如100'、100”等的主指示符。将要理解的是紧接在参考标号之后使用字母或上撇号指示这些特点是相似形状的并具有与几何形状关于对称平面成镜像的情况通常那样相似的功能。为了易于在此说明书中解释，字母或上撇号通常将不包括在本文中，但可以显示在附图中以指示此书面说明书内所讨论的特点的重复。
现在将根据本发明来描述罐组件或与排放气体后处理装置或其它化学过程一起使用的罐组件以及相关的混合碗状构件的各种实施例。虽然许多实施例涉及使用具有柴油机排放气体的柴油机排放流体，但是其它实施例可以涉及与使用天然气共混物或甲烷气体共混物作为燃料等相关的排放。
参见图1和图2，现在将讨论用在排放气体后处理装置中的罐组件。罐组件100可以包括限定圆柱形轴线104、径向方向106和圆周方向108的圆柱形壳体102、顶端110和底端112。流量管114可以插入到圆柱形壳体102的顶端110中并在圆柱形壳体102的底端112不远处终止，从而限定流量管114的出口116。在许多实施例中，流量管114具有圆柱形环形形状，其类似于圆柱形壳体102的形状并可以与其是同心的。可以设置混合碗状构件118，其包括关于圆柱形轴线104对称的环形形状并且其限定混合碗状槽120。混合碗状构件118附接在圆柱形壳体102的底端112处，并且流量管114的出口116径向地定位在混合碗状槽120上方并轴向地远离混合碗状构件118间隔开，从而产生混合碗状构件118与流量管114之间的径向流动路径122。
由于此设置，排放气体和排放气体处理流体共混物可以流过流量管114并冲击在混合碗状槽120上，从而改进诸如柴油机排放流体的排放气体处理流体与排放气体的混合或扩散。在图1和图2中明确显示的实施例中，流量管114限定轴向地设置在圆柱形壳体102的顶端110外侧的入口124，并且排放气体处理液体喷射点126设置在圆柱形壳体102的顶端110邻近处。在诸如图2中所示的一些实施例中，提供了增压空气喷射点128，其轴向地设置在排放气体处理液喷射点126径向地相对的圆柱形壳体102的顶端110外侧。这可以辅助于将排放气体处理液初始混合到排放气体中，因此排放气体处理液在到达混合碗状构件118之前不太可能在流量管114中冷凝。
改进湍流或流速的任何物质都可以改进排放气体处理液在排放气体流中的初始混合，因此在流量管114中不需要翅片、挡板和其它装置，从而降低了罐组件100的成本和复杂性。为了此目的，可以对各个变量进行优化以实现期望的结果，这些变量包括排放气体处理液的喷射角度130、增压空气的喷射角度132、流量管114的直径134、流量管114的有效轴向长度136等。在一些实施例中，流量管114的直径134可以在1英寸至3英寸的范围内，并且流量管114从喷射点126的长度136可以在9英寸至27英寸的范围内。排放气体处理液与轴向方向104形成的喷射角度130可以是20度至80度，并且在一些实施例中可以是大约30度至60度。增压空气的喷射角度132可以具有类似的范围并可以以相似的方式来测量。也可以对排放气体处理液的液滴尺寸进行优化以改进初始混合。更小的液滴自然可以更好地混合。
如根据应用所需要或所期望的那样，可以改变本文中所讨论的任何尺寸、角度或比率。在一些实施例(例如使用诸如具有容量为27/32升的那些大型发动机的海运业应用)中，流量管的直径可以是5英寸、6英寸或更大。流量管的长度可以与总后处理槽需要的一样长(基于性能和包装限制)。(柴油机排放流体和增压空气两者的)喷射角度也可以修改成如其与性能/包装要求有关的任何角度。
混合过程可以具有两个阶段。第一初始混合阶段可以在流量管中发生并只需要充分至避免冷凝。当流动冲击到混合碗状构件的槽上时发生第二混合阶段，从而最大化减少排放物的有效性。
如图1和图2所示，圆柱形壳体102限定沿圆柱形壳体102的圆周表面138所设置的圆周表面138和出口140。可以提供直径上相对的出口140、140'。另外，罐组件100可以进一步包括设置在流量管114周围的圆柱形壳体102中的至少一个环形形状的后处理装置142。至少一个环形形状的后处理装置142可以包括以下的一个：柴油机氧化催化器(DOC)、柴油机微粒过滤器(DPF)、选择性催化还原器(SCR)、以及氨气氧化催化器(AMOX)。
在更进一步的实施例中，圆柱形壳体102也可以具有大于27英寸的长度范围和大于9英寸的直径。例如，直径在一些实施例中可以是大约14英寸。再次，可以如在其它应用中所需要或所期望的那样来改变本文中所讨论的任何尺寸、角度或比率。
由于所有这些各种特征，所以罐组件100可以占用较少的空间，由于缺少翅片和挡板而不那么复杂，并且比其它先前熟知的罐组件或其它类似的排放气体后处理装置不那么高成本。罐组件100的期望外侧尺寸可以表示如下。在一些实施例中，圆柱形壳体102可以限定9英寸至27英寸的范围内的轴向长度144和3英寸到9英寸的范围内的直径146。长度144与直径146的相关宽高比可以在3：1至9：1的范围内。
图1和图2的罐组件100的运行可以如下来描述。排放气体进入流量管114的入口124并轴向地流动，直到它到达排放气体处理液喷射点126和增压空气喷射点128(如果提供的话)。然后，将诸如柴油机排放流体的排放气体处理液喷射到排放气体中，从而与其初始混合。任选地，也可以喷射增压空气以产生湍流，从而增强此混合。这些喷射点126、128可以如图1和图2中所示位于流量管114中的圆柱形壳体102外侧，或者在其它实施例中在流量管中的圆柱形壳体内侧。初始混合的排放气体和排放气体处理液然后沿流量管114轴向地向下流出出口116，并冲击在混合碗状构件118上以如前所述进行更完全的混合。
更具体地，共混物进入混合碗状构件118的混合碗状槽120，从而改进排放气体处理液到排放气体中的扩散或混合。然后，通过混合碗状槽120将共混物重定向到限定在流量管114和圆柱形壳体102之间的环形形状通路148直到它到达辅助后处理装置142(如果提供的话)，以进一步增强对排放气体的清洁或其它处理。一旦已完全地对排放气体进行处理，它就会从出口排出并最终通到大气。
现在参照图3，罐组件200可以包括限定圆柱形轴线104、径向方向106和圆周方向108的圆柱形壳体102、顶端110(参见图1和图2)和底端112。也可以提供混合碗状构件118、300，其包括关于圆柱形轴线104对称的环形形状并且其限定混合碗状槽120、302并包括分流器304。混合碗状构件300可以附接在圆柱形壳体102的底端112处并且分流器304可以关于圆柱形壳体102径向地居中。
对于图3中所示的实施例而言，分流器304是突出部306，但考虑的是分流器304在其它实施例中可以是凹陷物。突出部306可以包括峰308和锥形表面310，锥形表面310远离峰308倾斜，从而在混合碗状槽302的轴向底端312附近处终止。由于分流器304的此构造，诸如废气与排放气体处理液的混合物的任何流体可以通过突出部306的峰308来分流，其沿锥形表面310向下发送混合物的分流到增强混合的涡流槽。
如图3中所示，混合碗状构件300包括大致圆柱形形状，其插入到圆柱形壳体102的底端112中。混合碗状构件300可以焊接到圆柱形壳体102上。插头焊接或缝焊接是可能的。圆柱形壳体102可以限定第一轴向长度144(参见图1或图2)，并且混合碗状构件300可以限定第二轴向长度314，并且第一轴向长度144与第二轴向长度314的比率可以在8：1到20：1的范围内。圆柱形壳体或流量管可以包括不锈钢或任何其它适当耐用且耐腐蚀的材料(例如钛)。
如本文中所用，“弓形的”包括任何不直的形状，其包括径向的、椭圆型的、多项式的等。术语“共混物”也可以类似地来理解。
现在参照图4和图5，对于本文中提到的任何目的而言可以设置混合碗状构件300以与罐组件100或罐子组件200一起使用。混合碗状构件300可以包括限定径向方向316、轴向方向318和周向方向320的大致圆柱形主体。该主体也可以具有顶部轴向表面322、底部轴向表面324和外部圆柱形表面326。顶部轴向表面322限定混合碗状槽302，其包括径向地居中的分流器304。分流器304可以采取任何适当的形式，其包括凹陷物或突出部306。
如图3至图5中所示，分流器304是包括峰308的突出部306，峰308甚至与顶部轴向表面322一起轴向地终止。这可能不是其它实施例中的情况。例如，突出部可以轴向地延伸超过顶部轴向表面，因此突出部更靠近于流量管以提供更加渐进的流动分流。突出部306可以包括倾斜的锥形表面310，其在轴向地在混合碗状槽302的底部轴向末端312邻近处终止。该主体可以进一步限定底部弓形表面328和内侧圆柱形表面330，底部弓形表面328限定混合碗状槽302的底部轴向末端312，并且内部圆柱形表面330从底部弓形表面328朝向顶部轴向表面322来引导。顶部弓形共混物332可以从内侧圆柱形表面330过渡到顶部轴向表面322，并且引入表面334(诸如倒角)可以从顶部轴向表面322连接或延伸到外部圆柱形表面326。引入表面334(诸如倒角)可以便于将混合碗状构件插入到壳体中。
外部圆柱形表面326可以限定直径336，并且该主体可以限定从顶部轴向表面322到底部轴向表面324所测的轴向长度314。轴向长度314与直径336的比率可以在3：1至8：1的范围内。而且，从混合碗状槽302的顶部轴向表面322到其底部轴向末端312所测的槽302的轴向深度338可以是主体的轴向长度314的大约40％至60％。此构造可以辅助于最小化罐组件或罐子组件的尺寸，并同时也促进使朝向流量管与壳体之间发现的环形形状流动路径的流动混合和重定向。
混合碗状构件300的主体可以包括不锈钢或任何其它适当耐用且耐腐蚀的材料。例如，可以使用316不锈钢、400不锈钢、420不锈钢、439不锈钢、440不锈钢、441不锈钢等。也可以使用钛，但其可能成本过高。该主体可以由钢板制成，然后使用车削、铣削和/或放电加工过程进行机械加工。或者，该主体可以进行铸造然后机械加工。制造混合碗状构件的其它方法也考虑在本发明的范围内。
工业实用性
在实践中，根据本文中所述的任一实施例的混合碗状构件、罐子组件和/或罐组件可以如在售后市场或OEM(原始设备制造商)背景中所需要或所期望的那样来提供、销售、制造并购买等。例如，混合碗状构件、罐子组件或罐组件可以用来翻新本领域中已经现有的发动机排放系统，或者可以与发动机/排放系统或在该件设备的第一销售点处使用该发动机或排放系统的一件设备一起销售。
如本文中前面在或售后市场或OEM背景中所提及的那样，其它的化学混合应用也可以受益于使用混合碗状构件、罐子组件和/或罐组件的各种实施例。
将理解到的是前述说明书提供了公开的组件和工艺的示例。然而，考虑的是本发明的其它实施方式可以在细节上与前述的示例不同。对本发明或其示例的所有参考文献旨在参考在那点处正在讨论的具体示例，并且不旨在更大致暗示关于本发明范围的任何限制。除非另有指示，否则关于某些特点的差分和贬低的所有语言旨在指示缺乏对这些特点的偏好，但不是将这些完全排除在本发明的范围之外。
除非本文中另有指示，否则本文中数值范围的引用仅仅旨在用作单个地指代落在该的范围内的每个单独值的简写方法，并且每个单独值如同其在本文中单个地引用一样来并入本说明书中。
对本领域技术人员将显而易见的是，在不脱离本发明的范围或精神的情况下，可以对如本文中所讨论的装置和组装方法的实施例做出各种修改和变型。考虑到本文中所公开的各种实施例的详述和实践，本发明的其它实施例对本领域技术人员将是显而易见的。例如，一些设备可以不同于本文中已描述的设备来构造并运行并可以省略任何方法的某些步骤，以与已明确地提及的顺序不同的顺序来进行，或者在某些情况下同时地或者以子步骤的方式来进行。此外，可以对各种实施例的某些方面或特点做出变型或修改以产生进一步的实施例，并且各种实施例的特点和方面可以添加到或替换为其它实施例的其它特点或方面以便提供更进一步的实施例。
因此，如由适用法律所允许的那样，本发明包括本文所附的权利要求书中所引主题的所有修改和等同物。此外，除非本文中另有指示或者除非与上下文明显地矛盾，否则本发明涵盖了上述元件在其所有可能变型中的任何组合。

Claims (10)

1.一种用于排放气体后处理装置的罐组件，所述罐组件包括：
限定圆柱形轴线、径向方向和圆周方向的圆柱形壳体、顶端、底端以及所述顶端和所述底端之间的内部；
流量管，其插入到所述圆柱形壳体的所述顶端中并在到达所述圆柱形壳体的所述底端之前终止，从而限定所述流量管的出口；和
混合碗状构件，其包括关于所述圆柱形轴线对称的环形形状并限定与所述圆柱形壳体的所述内部流体连通的混合碗状槽，所述混合碗状构件固定地附接在所述圆柱形壳体的所述底端，并且所述流量管的所述出口径向地定位在所述混合碗状槽上方并远离所述混合碗状构件轴向地间隔开。
2.根据权利要求1所述的罐组件，其中所述流量管限定轴向地设置在所述圆柱形壳体的所述顶端外侧的入口，并且排放气体处理液体喷射点设置在所述圆柱形壳体的所述顶端的邻近处。
3.根据权利要求2所述的罐组件，其进一步包括增压空气喷射点，所述增压空气喷射点轴向地设置在与所述排放气体处理液注入点径向地相对的所述圆柱形壳体的所述顶端外侧。
4.根据权利要求1所述的罐组件，其中所述圆柱形壳体沿着所述圆柱形壳体的所述圆周表面限定圆周表面和出口点。
5.根据权利要求4所述的罐组件，其进一步包括设置在所述流量管周围的所述圆柱形壳体中的至少一个环形形状的后处理装置。
6.根据权利要求5所述的罐组件，其中所述至少一个环形形状的后处理装置包括以下的一个：柴油机氧化催化器、柴油机微粒过滤器、选择性催化还原器以及氨氧化催化器。
7.根据权利要求1所述的罐组件，其中所述圆柱形壳体限定9英寸至27英寸的范围内的轴向长度和3英寸至9英寸的范围内的直径。
8.一种用在排放气体后处理装置中的罐子组件，所述罐子组件包括：
限定圆柱形轴线、径向方向和圆周方向的圆柱形壳体、顶端、底端以及所述顶端和所述底端之间的内部；和
混合碗状构件，其包括关于所述圆柱形轴线对称的环形形状并限定混合碗状槽，且其包括朝向所述圆柱形壳体的所述内部的分流器，所述混合碗状构件固定地附接在所述圆柱形壳体的所述底端处，并且所述分流器径向地居中。
9.根据权利要求8所述的罐子组件，其中所述分流器是突出部，并且所述突出部包括峰和远离所述峰而倾斜的锥形表面，并且所述混合碗状槽限定轴向底部末端，并且所述锥形表面在所述混合碗状槽的所述轴向底部末端的邻近处终止。
10.根据权利要求9所述的罐子组件，其中所述混合碗状构件包括大致圆柱形形状，其插入到所述圆柱形壳体的所述底端中，并且所述圆柱形壳体限定第一轴向长度，并且所述混合碗状构件限定第二轴向长度，并且所述第一轴向长度与所述第二轴向长度的比率在8:1至20:1的范围内。
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