US20100186382A1 - Emissions system mounting device with reductant mixing - Google Patents

Emissions system mounting device with reductant mixing Download PDF

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Publication number
US20100186382A1
US20100186382A1 US12320423 US32042309A US2010186382A1 US 20100186382 A1 US20100186382 A1 US 20100186382A1 US 12320423 US12320423 US 12320423 US 32042309 A US32042309 A US 32042309A US 2010186382 A1 US2010186382 A1 US 2010186382A1
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Patent type
Prior art keywords
treatment device
exhaust treatment
control system
exhaust
emissions control
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12320423
Inventor
Eric Lee Schroeder
Jinhui Sun
Yuxiang Gu
Amarnath Nelli
Paul Frederick Olsen
Jack Albert Merchant
Stephan D. Roozenboom
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Caterpillar Inc
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Caterpillar Inc
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/025Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/18Exhaust 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 methods of operation; Control
    • F01N3/20Exhaust 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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066Selective catalytic reduction [SCR]
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/20Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a flow director or deflector
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00Adding substances to exhaust gases
    • F01N2610/08Adding substances to exhaust gases with prior mixing of the substances with a gas, e.g. air
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0821Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with particulate filters
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0871Regulation of absorbents or adsorbents, e.g. purging
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/20Exhaust after-treatment
    • Y02T10/24Selective Catalytic Reactors for reduction in oxygen rich atmosphere

Abstract

An emissions control system is disclosed. The emissions control system may have a first exhaust treatment device. The emissions control system may also have an end cap defining a mixing chamber connected to an end of the first exhaust treatment device. The mixing chamber may be configured to promote mixing between a flow of exhaust received from the first exhaust treatment device and a reductant. The emissions control system may further have a second exhaust treatment device configured to receive the flow of exhaust and reductant after it passes through the mixing chamber.

Description

    TECHNICAL FIELD
  • The present disclosure relates generally to a emissions system mounting device and, more particularly, to an emissions system mounting device which includes at least one device configured to mix reductant into a flow of exhaust.
  • BACKGROUND
  • Conventional diesel powered systems for engines, factories, and power plants produce emissions that contain a variety of pollutants. These pollutants may include, for example, particulate matter (e.g., soot), nitrogen oxides (NOx), and sulfur compounds. Due to heightened environmental concerns, engine exhaust emission standards have become increasingly stringent. In order to comply with emission standards, machine manufactures have developed and implemented a variety of exhaust treatment components to reduce pollutants in exhaust gas prior to the exhaust gas being released into the atmosphere. The exhaust treatment components may include, for example, a diesel particulate filter, a selective catalytic reduction device, a diesel oxidation catalyst, a fuel-fired burner for regeneration of the diesel particulate filter, a muffler, and other similar components.
  • Frequently these exhaust treatment components, including their associated sensors and electronics, are mounted individually in an exhaust system within the available space using individual brackets. However, due to the increasing complexity and number of exhaust treatment components and the small amount of available space, mounting and interconnecting exhaust treatment components has proven difficult.
  • One method for combining exhaust treatment devices in a casing is disclosed in U.S. Patent Publication No. 2006/0264296 (the '296 publication) to Theis. Specifically, the '296 publication discloses a casing that supports a first lean NOx trap (LNT), a second LNT, and a selective catalytic reduction (SCR) device. The casing also supports a first port for introducing an exotherm generating agent and a second port for introducing a reducing agent. The second port is located upstream of the SCR. The reducing agent may be introduced from the second port into the exhaust flow in order to precondition the SCR. In addition, there may be a gap between the LNT and the SCR to facilitate mixing.
  • Although the system of the '296 publication may disclose a casing with both an LNT and an SCR for remediating emissions, the '296 system may have limitations. For example, the '296 system may only achieve limited mixing of the reductant with the exhaust flow, potentially resulting in poor NOx reduction.
  • The disclosed device is directed to overcoming one or more of the problems set forth above.
  • SUMMARY OF THE DISCLOSURE
  • In one aspect, the present disclosure is directed to an emissions control system. The emissions control system may include a first exhaust treatment device. The emissions control system may also include an end cap defining a mixing chamber connected to an end of the first exhaust treatment device. The mixing chamber may be configured to promote mixing between a flow of exhaust received from the first exhaust treatment device and a reductant. The emissions control system may further include a second exhaust treatment device configured to receive the flow of exhaust and reductant after it passes through the mixing chamber.
  • In another aspect, the present disclosure is directed to another emissions control system. The emissions control system may include a first bracket and a second bracket coupled to the first bracket. The emissions control system may also include a first exhaust treatment device supported by the first bracket and the second bracket. The emissions control system may further include a second exhaust treatment device supported by the first bracket and the second bracket. The emissions control system may also include a conduit having a static mixer. The conduit may be supported by the first bracket and the second bracket. The conduit, the first exhaust treatment device, and the second exhaust treatment device may be fluidly communicated via one or more connectors. The one or more connectors may connect the first exhaust treatment device, the second exhaust treatment device, and the conduit in a side-by-side orientation.
  • In a further aspect, the present disclosure may be directed at another emissions control system. The emissions control system may include a mount. The emissions control system may also include a diesel particulate filter supported by the mount. The emissions control system may further include at least one of a lean NOx trap or a selective catalytic reduction device supported by the mount. The emissions control system may also include an end cap defining a mixing chamber connected to an end of the diesel particulate filter. The mixing chamber may be configured receive a flow of exhaust from the diesel particulate filter and an injected reductant.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a diagrammatic illustration of an exemplary disclosed power system including an emissions control system;
  • FIG. 2 is a diagrammatic illustration of an exemplary mount that may be used with the emissions control system FIG. 1;
  • FIG. 3 is a diagrammatic illustration of an exemplary emissions control system with an extension sleeve;
  • FIG. 4 is a diagrammatic illustration of another embodiment of an emissions control system;
  • FIG. 5 is a diagrammatic illustration of an exemplary exhaust treatment device with an end cap;
  • FIG. 6 is another view of the end cap of FIG. 5;
  • FIG. 7 is a diagrammatic illustration of an emissions control system including a double end cap;
  • FIG. 8 is a schematic illustration of an exemplary disclosed power system including an emissions control system;
  • FIG. 9 is another schematic illustration of an exemplary disclosed power system including an emissions control system with an end cap; and
  • FIG. 10 is a further schematic illustration of an exemplary disclosed power system including an emissions control system with a double end cap.
  • DETAILED DESCRIPTION
  • FIG. 1 illustrates a diagrammatic representation of a power system 10, which may include a power source 12 and an exhaust system 14. Power source 12 may embody a combustion engine, such as, for example, a diesel engine, a gasoline engine, a gaseous fuel-powered engine (e.g., a natural gas engine), or any other type of combustion engine known to one skilled in the art. Power source 12 may have a plurality of combustion chambers (not shown) that convert potential chemical energy (usually in the form of a combustible gas) into useful mechanical work. It is also considered that power source 12 may embody a furnace or a similar device. Power source 12 may receive air from an air cleaner 15 which fluidly communicates with power source 12 via intake 17. Power source 12 may output a flow of exhaust via an exhaust conduit 23.
  • Exhaust system 14 may direct exhaust from power source 12 via an exhaust conduit 23 to an emissions control system 16. After passing through emissions control system 16, the exhaust may be directed to the atmosphere. Emissions control system 16 of exhaust system 14 may be configured to monitor, control, and/or modify exhaust emissions. Emissions control system 16 may include one or more exhaust treatment devices 22, electronics 24 associated with the exhaust treatment devices 22, and a mount 26.
  • Exhaust treatment devices 22 may be devices configured to reduce emissions of harmful gasses, particulate matter, and/or noise emitted from power source 12. Each exhaust treatment device 22 may embody, for example a diesel oxidation catalyst (DOC), a particulate filter (PF or DPF), a selective catalytic reduction (SCR) device, a lean NOx trap (LNT), a muffler, a regeneration device, a reductant mixing device, or any other exhaust treatment device known in the art. It is contemplated that each exhaust treatment device 22 may also comprise a combination of exhaust treatment devices, such as, for example, a combination of a DOC and a DPF; a combination of a catalyst and a DPF (i.e., a CDPF); a combination of a DOC, a DPF, and an SCR; or other combinations known in the art.
  • Electronics 24 may be configured to monitor and/or control operation of exhaust treatment devices 22. Electronics 24 may include one or more electronic devices, such as, for example, sensors, microprocessors, power supply circuitry, signal conditioning circuitry, actuator driving circuitry, solenoids, relays, electronic valves, coils, and/or other types of electronics and circuitry known in the art. For example, electronics 24 may include a microprocessor and other electronic hardware configured to control injection of a reductant into one of exhaust treatment devices 22 (e.g., reductant for SCR or LNT). Electronics 24 may also include a microprocessor and other electronic hardware configured to control a regeneration process for one of exhaust treatment devices 22 (e.g., regeneration of DPF).
  • As shown in FIG. 2, mount 26 may be a device configured to support multiple exhaust treatment devices 22 using a single structure. Specifically, mount 26 may be configured to secure exhaust treatment devices 22 in a compact configuration. Mount 26 may include a first bracket 28 and a second bracket 30. First bracket 28 and second bracket 30 may be oriented parallel but spaced apart from each other. First bracket 28 may be coupled to second bracket 30 using one or more rigid cross members 32. Cross members 32 may attach to first and second brackets 28 and 30 via mechanical fasteners (e.g., bolts, screws, rivets, etc.), welding, brazing, or any other joining process known in the art. Alternatively, first bracket 28, second bracket 30, and cross members 32 may be formed using a single casting.
  • Each of first and second brackets 28 and 30 may include a first support surface 34. First support surface 34 of first bracket 28 and first support surface 34 of second bracket 30 may be configured to support each end of a first exhaust treatment device 36. Each of first and second brackets 28 and 30 may also include a second support surface 38. Second support surface 38 of first bracket 28 and second support surface 38 of second bracket 30 may be configured to support each end of a second exhaust treatment device 40. In addition to connecting first and second brackets 28 and 30, one or more of cross members 32 may be configured to support a middle portion of first exhaust treatment device 36 and/or second exhaust treatment device 40.
  • It is contemplated that a geometry of first support surface 34 may be shaped to match an outer geometry of first exhaust treatment device 36 and a geometry of second support surface 38 may be shaped to match an outer geometry of second exhaust treatment device 40. For example, when first and second exhaust treatment devices 36 and 40 are shaped as canisters, first and second support surfaces 34 and 38 may have generally arcuate surfaces with substantially the same radii of curvature as first and second exhaust treatment devices 36 and 40, respectively.
  • As seen in FIGS. 1 and 3, one or more bands 47 may pass over exhaust treatment devices 22 and secure exhaust treatment devices 22 to mount 26. In some embodiments, as seen in FIG. 3, one or more of exhaust treatment devices 22 may include an extension sleeve 52. Extension sleeve 52 may at least partially slide over or abut an end of exhaust treatment device 22. It is contemplated that extension sleeve 52 may be composed of, for example, steel, aluminum, iron, alloys, composites, or other materials known in the art. Extension sleeve 52 may be bolted, welded, or otherwise formed or attached to the end of exhaust treatment device 22. It is contemplated that extension sleeve 52 may extend the surface area of a given exhaust treatment device 22 such that a band 47 may pass around extension sleeve 52 and secure the given exhaust treatment device 22 to mount 26.
  • Returning to FIG. 2, mount 26 may include a base portion 48 with one or more footings 50. Specifically, each of first and second brackets 28 and 30 may include, for example, at least two footings 50. Each footing 50 may be configured to mount to power source 12 or another frame or structure (not shown) within power system 10.
  • Mount 26 may also include a first aperture 42 in first bracket 28 and a second aperture 44 in second bracket 30. Each of first and second apertures 42 and 44 may include a third support surface 49. Third support surface 49 of first aperture 42 and third support surface 49 of second aperture 44 may be configured to support, for example, each end of a third exhaust treatment device 46.
  • It should be noted that first support surfaces 34, second support surfaces 38, and third support surfaces 49 may be located to allow for first, second, and third exhaust treatment devices, 36, 40, and 46, respectively, to be positioned in a compact, side-by-side, parallel orientation. For example, an axis A1 of first support surfaces 34, an axis A2 of second support surfaces 38, and an axis A3 of third support surfaces 49 may all be parallel. It is contemplated that mount 26 may be configured to allow for easy access and removal of each exhaust treatment device 22.
  • In an exemplary embodiment of emissions control system 16, first exhaust treatment device 36 may embody a diesel particulate filter, second exhaust treatment device 40 may embody a muffler, and third exhaust treatment device 46 may embody a mixing conduit 54. Mount 26 may also support or house a fourth exhaust treatment device 51 (see FIGS. 1 and 4). Fourth exhaust treatment device 51 may embody, for example, a regeneration device, such as a fuel-fired burner. Fourth exhaust treatment device 51 may be configured to inject fuel and ignite the injected fuel in order to heat the exhaust flow received from power source 12 via exhaust conduit 23.
  • Referring to FIG. 4, mixing conduit 54 may be a substantially tubular member configured to convey a flow of exhaust and promote mixing of reductant with the flow of exhaust. Mixing conduit 54 may be cylindrical or have any other appropriate cross-sectional shape. Mixing conduit 54 may fluidly connect first exhaust treatment device 36 with second exhaust treatment device 40. Specifically, mixing conduit 54 may connect to first exhaust treatment device 36 via a first connector 56 and connect to second exhaust treatment device 40 via a second connector 58.
  • First and second connector 56 and 58 may embody, for example, elbow-type connectors. Specifically, first and second connector 56 and 58 may embody cobra-head connectors where a base portion 60 of first and second connectors 56 and 58 is wider than a terminal portion 62. Base portion 60 may have a substantially oval or elliptical shape while terminal portion 62 may have a substantially cylindrical shape to allow terminal portion 62 to mate with mixing conduit 54. It is contemplated that first and second connectors 56 and 58 may be formed integrally with first and second exhaust treatment devices 36 and 40, respectively. Alternatively, first and second connectors 56 and 58 may attach to first and second exhaust treatment devices 36 and 40, respectively, using mechanical fastening, welding, brazing, or any other appropriate fastening method. First and second connectors 56 and 58 may have a simple 90 degree bend or a curved bend.
  • Mixing conduit 54 may include an internal mixing device 63 (see FIGS. 8 and 9) configured to disperse or mix reductant into the flow of exhaust as the flow of exhaust passes through mixing conduit 54. Mixing device 63 may be located at any position along a length of mixing conduit 54 and may embody, for example, a static mixer, such as a mixing plate, mixing vanes, baffles, or other types of static mixers known in the art. Mixing device 63 may alternatively embody a rotatable mixing device 63. In some embodiments, mixing conduit 54 may include a plurality of mixing devices 63 located along the length of mixing conduit 54. Mixing device 63 may also embody turbulators located along an interior surface of mixing conduit 54.
  • It is contemplated that with respect to the embodiment of emissions control system 16 and mount 26 depicted in FIG. 4, first and second apertures 42 and 44 of mount 26 may be omitted and mixing conduit 54 may be secured only with first and second connectors 56 and 58. In other respects, the embodiment of FIG. 4 may be similar to other embodiments of emissions control system 16 described herein.
  • As shown in FIG. 5, emissions control system 16 may include an end cap 64. End cap 64 may couple to or be formed integrally with a downstream end of first exhaust treatment device 36. End cap 64 may be an device configured to promote mixing of injected reductant with the flow of exhaust within a mixing chamber 66. End cap 64 may include a tumble flow generator 68 configured to create rotational flow within mixing chamber 66. Tumble flow generator 68 may include, for example, a plurality of flow deflectors 69 (also see FIG. 6) positioned to redirect the flow of exhaust as it exits first exhaust treatment device 36 and enters end cap 64. Specifically, flow deflectors 69 may embody channels, baffles, or vanes angled such that the flow of exhaust is redirected toward walls 67 of mixing chamber 66 as the flow of exhaust enters mixing chamber 66. The angle of flow deflectors 69 may be between 30° and 75°, and more specifically, approximately 60°. It is contemplated that tumble flow generator 68 may increase the dispersion of the reductant in the flow of exhaust and help prevent reductant droplets from forming on walls 67 of mixing chamber 66.
  • FIG. 7 depicts a further alternative embodiment of emissions control system 16. In the embodiment of FIG. 7, mixing conduit 54 may be omitted and replaced with a double end cap 70. A first end of double end cap 70 may couple to the downstream end of first exhaust treatment device 36 and a second end of double end cap 70 may couple to an upstream end of second exhaust treatment device 40. Double end cap 70 may define a first mixing chamber 73 associated with the downstream end of first exhaust treatment device 36 and a second mixing chamber 75 associated with the upstream end of second exhaust treatment device 40. Double end cap 70 may include a tumble flow generator 68 that is substantially the same as tumble flow generator 68 in the embodiment of FIGS. 4 and 5.
  • Double end cap 70 may include a tumble mixer 71 located between first mixing chamber 73 and second mixing chamber 75. Similar to tumble flow generator 68, tumble mixer 71 may include a plurality of flow deflectors 79. Flow deflectors 79 of tumble mixer 71 may embody, for example, channels, baffles, or vanes configured to promote mixing of the reductant with the flow of exhaust and disperse the mixed exhaust and reductant into second mixing chamber 75. Flow deflectors 79 may be angled at any appropriate angle between 30° and 75°, and more specifically, at approximately 45°.
  • As shown in FIG. 8, emissions control system 16 may include an injection system 72 to selectively inject reductant into the flow of exhaust. Injection system 72 may include, for example, an injector 74, a fluid source 76, and a controller 78.
  • Injector 74 may be a fluid injector configured to inject a reductant for dosing second exhaust treatment device 40. Injector 74 may embody any type of fluid injector known in the art. Injector 74 may fluidly communicate with fluid source 76 (e.g., a supply tank) to provide for repeated injections of reductant. The reductant may be, for example, gaseous ammonia, ammonia in aqueous solution, aqueous urea, ammonia from an ammonia generator, diesel fuel, or any other appropriate reductant known in the art. Injector 74 may be located upstream of second exhaust treatment device 40.
  • Referring to FIG. 8, (representing an embodiment of exhaust system 14 that omits end cap 64), injector 74 may be located downstream of the first exhaust treatment device 36. For example, injector 74 may be located at first connector 56. In this embodiment, injector 74 may be housed within or attached to first connector 56 such that injector 74 injects reductant along a center axis A4 of mixing conduit 54. Injector 74 may also be configured to inject slightly off of center axis A4 to account for the momentum of the flow of exhaust, such that the injected reductant ends up in the center of mixing conduit 54 as it flows down mixing conduit 54.
  • Referring to FIG. 9 (representing an embodiment of exhaust system 14 that includes end cap 64), injector 74 may be configured to inject reductant into mixing chamber 66. Injector 74 may be connected to wall 67 of end cap 64 opposing first connector 56. When actuated, injector 74 may inject the reductant across the flow of exhaust exiting tumble flow generator 68 and towards first connector 56.
  • In some embodiments, injection system 72 may include a plurality of injectors 74 for injecting reductant. For example, the plurality of injectors 74 may be located radially around a perimeter of first connector 56, mixing conduit 54, end cap 64, or double end cap 70.
  • Controller 78 may be a device configured to control injector(s) 74. Controller 78 may embody a general machine microprocessor capable of controlling numerous machine functions. Controller 78 may include a memory, a storage device, a processor, and components known in the art. Various other circuits may be associated with controller 78, such as power supply circuitry, signal conditioning circuitry, data acquisition circuitry, signal output circuitry, signal amplification circuitry, and other types of circuitry known in the art. Controller 78 may be configured to selectively actuate injector 74 in order to dose second exhaust treatment device 40. It is contemplated that controller 78 may communicate with and actuate injector 74 based on input from one or more sensors (not shown), such as, for example, an NOx sensor, an ammonia sensor, a flow speed sensor, a pressure sensor, a temperature sensor, and other sensors known in the art.
  • INDUSTRIAL APPLICABILITY
  • The disclosed emissions control system may be applicable to any power system. The disclosed emissions control system may provide enhanced mixing of reductant for use with exhaust treatment devices. Operation of the disclosed power system will now be described.
  • Referring to FIG. 8, air may be drawn into power source 12 for combustion via intake 17. Fuel and air may be combusted to produce a mechanical work output and an exhaust flow. The exhaust flow may contain a complex mixture of air pollutants composed of gases and particulate matter. The exhaust flow may be directed from power source 12 via exhaust conduit 23 to exhaust treatment devices 22. The exhaust flow may pass through first exhaust treatment device 36 and enter reductant mixing conduit 54 through first connector 56. Injector 74 may inject reductant into the exhaust flow as it enters mixing conduit 54. As the exhaust flow and reductant pass through mixing conduit 54, mixing device 63 may mix and disperse the reductant into the flow of exhaust. The flow of exhaust and reductant mixture may then pass through second connector 58 into second exhaust treatment device 40. It is contemplated that the second exhaust treatment device 40 may include, for example, an SCR catalyst or an LNT. While inside of second exhaust treatment device 40 the exhaust gas may undergo a pollutant reducing reaction. The flow of exhaust may then be released into the atmosphere.
  • Referring to FIG. 9, as described above, air and fuel may be drawn into power source 12 and combusted to produce a mechanical work output and an exhaust flow. The exhaust flow may be directed from power source 12 via exhaust conduit 23 to exhaust treatment devices 22. The exhaust flow may pass through first exhaust treatment device 36. After passing through first exhaust treatment device 36, the exhaust may pass through tumble flow generator 68, thus creating rotational flow as the flow of exhaust enters mixing chamber 66. Injector 74 may then inject reductant into the exhaust flow as it enters mixing chamber 66. The rotational flow of the exhaust in mixing chamber 66 may facilitate mixing of the reductant into the flow of exhaust. The reductant and exhaust mixture may then exit mixing chamber 66 and enter mixing conduit 54. As the exhaust flow and reductant pass through mixing conduit 54, mixing device 63 may further mix and disperse the reductant into the flow of exhaust (it is contemplated, however, that in some embodiments, mixing device 63 may be omitted). The flow of exhaust and reductant mixture may then pass through second connector 58 into second exhaust treatment device 40. While inside of second exhaust treatment device 40 the exhaust gas may undergo a pollutant reducing reaction. The flow of exhaust may then be released into the atmosphere.
  • In the embodiment shown in FIG. 10, emissions control system 16 may include a double end cap 70. As described above, air and fuel may be drawn into power source 12 and combusted to produce a mechanical work output and an exhaust flow. The exhaust flow may be directed from power source 12 via exhaust conduit 23 to exhaust treatment devices 22. The exhaust flow may pass through first exhaust treatment device 36. After passing through first exhaust treatment device 36, the exhaust may pass through tumble flow generator 68, thus creating rotational flow as the flow of exhaust enters first mixing chamber 73 of double end cap 70. Injector 74 may then inject reductant into the exhaust flow as it enters first mixing chamber 73. The rotational flow of the exhaust in first mixing chamber 73 may facilitate mixing of the reductant into the flow of exhaust. The reductant and exhaust mixture may pass through tumble mixer 71, thus further mixing and dispersing the reductant into the flow of exhaust as it enters into second mixing chamber 75. The flow of exhaust and reductant mixture may then pass into second exhaust treatment device 40. While inside of second exhaust treatment device 40 the exhaust gas may undergo a pollutant reducing reaction. The flow of exhaust may then be released into the atmosphere. In all other respects, the operation of power system 10 shown in FIG. 10 may be substantially the same as that of FIGS. 8 and 9.
  • It is contemplated that first and second connectors 56 and 58 may reverse a direction of fluid flow. In other words, a flow direction of the flow of exhaust may be reversed as the flow of exhaust passes from first exhaust treatment device 36, through first connector 56, and into mixing conduit 54. The flow direction of the flow of exhaust may be reversed again as the flow of exhaust passes from mixing conduit 54, through second connector 58, and into second exhaust treatment device 40. The two reversals of flow direction may create an “S” shaped flow path between first exhaust treatment device 36, third exhaust treatment device 46 (e.g., mixing conduit 54), and second exhaust treatment device 40. It is also contemplated that in some embodiments, the flow of exhaust may pass through fourth exhaust treatment device 51 (e.g., a regeneration device) prior to entering first exhaust treatment device 36.
  • The disclosed emissions control system may be applicable to any power system. The disclosed mount may provide a compact structure for mounting exhaust treatment devices in a power system, thus preserving space for other power system components. Additionally, the “S” shaped flow path created by the side-by-side exhaust treatment devices may reduce the overall length and size of the exhaust treatment system. Also, the disclosed mixing devices may ensure proper mixing and dispersion of the reductant into the exhaust gas before the exhaust gas reaches a downstream exhaust treatment device, thus improving performance of the disclosed emissions control system.
  • It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed emissions control system. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed emissions control system. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims.

Claims (20)

  1. 1. An emissions control system, comprising:
    a first exhaust treatment device;
    an end cap defining a mixing chamber connected to an end of the first exhaust treatment device, the mixing chamber being configured to promote mixing between a flow of exhaust received from the first exhaust treatment device and a reductant; and
    a second exhaust treatment device configured to receive the flow of exhaust and reductant after it passes through the mixing chamber.
  2. 2. The emissions control system of claim 1, wherein the end cap further includes a tumble flow generator situated between the first exhaust treatment device and the mixing chamber.
  3. 3. The emissions control system of claim 2, wherein the tumble flow generator includes a plurality of flow deflectors, each flow deflector being angled at between 30 and 75 degrees.
  4. 4. The emissions control system of claim 2, further including an injector located in the end cap, the injector being configured to inject the reductant.
  5. 5. The emissions control system of claim 1, further including a mixing conduit, the mixing conduit, the first exhaust treatment device, and the second exhaust treatment device being fluidly communicated via one or more connectors, the one or more connectors connecting the first exhaust treatment device, the second exhaust treatment device, and the mixing conduit in a side-by-side orientation, the mixing conduit including a static mixer.
  6. 6. The emissions control system of claim 1, wherein the end cap is a double end cap, a first end of the double end cap connecting to the first exhaust treatment device and a second end of the double end cap connecting to the second exhaust treatment device, the double end cap including a tumble mixer.
  7. 7. The emissions control system of claim 1, wherein the first exhaust treatment device is a particulate filter and the second exhaust treatment device is at least one of a selective catalytic reduction device or a lean NOx trap.
  8. 8. The emissions control system of claim 1, further including:
    a first bracket; and
    a second bracket coupled to the first bracket, wherein the first exhaust treatment device and the second exhaust treatment device are supported by the first and second brackets.
  9. 9. An emissions control system, comprising:
    a first bracket;
    a second bracket coupled to the first bracket;
    a first exhaust treatment device supported by the first bracket and the second bracket;
    a second exhaust treatment device supported by the first bracket and the second bracket; and
    a conduit having a static mixer, the conduit being supported by the first bracket and the second bracket, wherein the conduit, the first exhaust treatment device, and the second exhaust treatment device are fluidly communicated via one or more connectors, the one or more connectors connecting the first exhaust treatment device, the second exhaust treatment device, and the conduit in a side-by-side orientation.
  10. 10. The emissions control system of claim 9, wherein the static mixer includes at least one of a mixing plate, baffles, or vanes.
  11. 11. The emissions control system of claim 9, further including an end cap with a mixing chamber, the end cap being coupled to the first exhaust treatment device.
  12. 12. The emissions control system of claim 11, wherein the end cap further includes a tumble flow generator situated between the first exhaust treatment device and the mixing chamber.
  13. 13. The emissions control system of claim 12, wherein the tumble flow generator includes a plurality of flow deflectors, each flow deflector being angled at between 30 and 75 degrees.
  14. 14. The emissions control system of claim 11, further including an injector located in the end cap, the injector being configured to inject a reductant.
  15. 15. The emissions control system of claim 9, further including
    a connector configured to fluidly communicate the first exhaust treatment device with the conduit; and
    an injector located in the connector, the injector being configured to inject reductant.
  16. 16. The emissions control system of claim 15, wherein the connector embodies elbow-type or cobra-head connectors.
  17. 17. The emissions control system of claim 15, wherein the injector is configured to inject along an axis of the conduit.
  18. 18. The emissions control system of claim 15, wherein the first exhaust treatment device is a particulate filter and the second exhaust treatment device at least one of a selective catalytic reduction device or a lean NOx trap.
  19. 19. An emissions control system, comprising:
    a mount;
    a diesel particulate filter supported by the mount;
    at least one of a lean NOx trap or a selective catalytic reduction device supported by the mount;
    an end cap defining a mixing chamber connected to an end of the diesel particulate filter, the mixing chamber being configured to receive a flow of exhaust from the diesel particulate filter and an injected reductant.
  20. 20. The emissions control system of claim 19, wherein the end cap further includes a tumble flow generator situated between the first exhaust treatment device and the mixing chamber.
US12320423 2009-01-26 2009-01-26 Emissions system mounting device with reductant mixing Abandoned US20100186382A1 (en)

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US12320423 US20100186382A1 (en) 2009-01-26 2009-01-26 Emissions system mounting device with reductant mixing
DE201011000852 DE112010000852T5 (en) 2009-01-26 2010-01-26 Fastening device for an emission system with reducing agents admixture
CN 201080005485 CN102292526A (en) 2009-01-26 2010-01-26 Emissions system with a reducing agent of the mounting device
PCT/US2010/022064 WO2010085786A3 (en) 2009-01-26 2010-01-26 Emissions system mounting device with reductant mixing

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CN (1) CN102292526A (en)
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WO2010085786A3 (en) 2010-11-25 application
WO2010085786A2 (en) 2010-07-29 application
CN102292526A (en) 2011-12-21 application

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