WO2015020819A1 - Module de pulvérisation d'écoulement axial - Google Patents

Module de pulvérisation d'écoulement axial Download PDF

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Publication number
WO2015020819A1
WO2015020819A1 PCT/US2014/048374 US2014048374W WO2015020819A1 WO 2015020819 A1 WO2015020819 A1 WO 2015020819A1 US 2014048374 W US2014048374 W US 2014048374W WO 2015020819 A1 WO2015020819 A1 WO 2015020819A1
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WO
WIPO (PCT)
Prior art keywords
exhaust
exhaust treatment
treatment component
flow
reversing device
Prior art date
Application number
PCT/US2014/048374
Other languages
English (en)
Inventor
John Stanavich
Megan Wikaryasz
Rick Thompson
Original Assignee
Tenneco Automotive Operating Company Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US13/958,955 external-priority patent/US9314750B2/en
Application filed by Tenneco Automotive Operating Company Inc. filed Critical Tenneco Automotive Operating Company Inc.
Priority to KR1020167005610A priority Critical patent/KR101780341B1/ko
Priority to JP2016530094A priority patent/JP2016525648A/ja
Priority to CN201480044809.2A priority patent/CN105452624B/zh
Priority to DE112014003600.5T priority patent/DE112014003600T5/de
Publication of WO2015020819A1 publication Critical patent/WO2015020819A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • 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
    • F01N3/18—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 methods of operation; Control
    • F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00—Combination 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
    • F01N2240/20—Combination 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/14—Arrangements for the supply of substances, e.g. conduits
    • F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present disclosure relates to an exhaust after-treatment system including an exhaust gas mixing device.
  • Exhaust after-treatment systems may dose a reagent exhaust treatment fluid into the exhaust stream before the exhaust stream passes through various exhaust after-treatment components.
  • a urea exhaust treatment fluid for example, may be dosed into the exhaust stream before the exhaust passes through a selective catalytic reduction (SCR) catalyst.
  • SCR selective catalytic reduction
  • the present disclosure provides an exhaust treatment component for treating an engine exhaust including a housing including an inlet and an outlet.
  • a mixing device is located within the housing between the inlet and the outlet, and the mixing device includes a shell communicating with the outlet, a decomposition tube having a first end and a second end, and a flow reversing device disposed proximate the second end.
  • the first end extends from the shell and is configured to receive the exhaust from the inlet, and is configured to receive a reagent exhaust treatment fluid.
  • the second end is positioned within the shell.
  • the flow reversing device is configured to direct a mixture of the exhaust and reagent exhaust treatment fluid in predetermined directions into the shell, the flow reversing device reverses a flow direction of the exhaust back towards the first end of the decomposition tube.
  • Figure 1 is a schematic representation of an exhaust system according to a principle of the present disclosure
  • Figure 2 is a perspective view of an exhaust treatment component according to a principle of the present disclosure
  • Figure 3 is a side-perspective view of the exhaust treatment component illustrated in Figure 2;
  • Figure 4 is a front-perspective view of the exhaust treatment component illustrated in Figure 2;
  • Figure 5 is a cross-sectional view along line 5-5 in Figure 4;
  • Figure 6 is a cross-sectional view along line 6-6 in Figure 4;
  • Figure 7 is a perspective view of a mixing assembly according to a first exemplary embodiment of the present disclosure.
  • Figure 8 is an exploded perspective view of the mixing assembly illustrated in Figure 7;
  • Figure 9 is a cross-sectional view of the mixing assembly illustrated in Figure 7;
  • Figure 10 is a perspective view of a mixing assembly according to a second exemplary embodiment of the present disclosure.
  • Figure 1 1 is a perspective view of a flow-reversing device and dispersion device of the mixing assembly illustrated in Figure 10;
  • Figure 12 is a perspective view of the dispersion device illustrated in Figure 1 1 in an assembled state
  • Figure 13 is another perspective view of the dispersion device illustrated in Figure 1 1 in an un-assembled state
  • Figure 14 is a perspective view of a mixing assembly according to a third exemplary embodiment of the present disclosure.
  • Figure 15 is a perspective view of a flow-reversing device and dispersion device of the mixing assembly illustrated in Figure 14;
  • Figure 16 is a perspective view of the dispersion device illustrated in Figure 15;
  • Figure 17 is a perspective view of a mixing assembly according to a fourth exemplary embodiment of the present disclosure.
  • Figure 18 is a partial-perspective view of the mixing assembly illustrated in Figure 17;
  • Figure 19 is a perspective cross-sectional view of Figure 17;
  • Figure 20 is a perspective view of a mixing assembly according to a fifth exemplary embodiment of the present disclosure.
  • Figure 21 is an exploded perspective view of the mixing assembly illustrated in Figure 10;
  • Figure 22 is a perspective view of an exhaust treatment component according to a principle of the present disclosure.
  • Figure 23 is a cross-sectional view of the exhaust treatment component illustrated in Figure 22;
  • Figure 24 is a perspective view of an exhaust after-treatment system according to a principle of the present disclosure.
  • Figure 25 is a perspective view of an exhaust treatment component that forms part of the exhaust after-treatment system illustrated in Figure 24;
  • Figure 26 is another perspective view of the exhaust treatment component illustrated in Figure 25;
  • Figure 27 is a top-perspective view of the exhaust treatment component illustrated in Figure 25;
  • Figure 28 is a side-perspective view of the exhaust treatment component illustrated in Figure 25;
  • Figure 29 is a cross-sectional perspective view of the exhaust treatment component illustrated in Figure 25;
  • Figure 30 is a cross-sectional view of the exhaust treatment component illustrated in Figure 25;
  • Figure 31 is a side-perspective view of an exhaust treatment component according to a principle of the present disclosure.
  • Figure 32 is a cross-sectional view of the exhaust treatment component illustrated in Figure 31 .
  • FIG. 1 schematically illustrates an exhaust system 10 according to the present disclosure.
  • Exhaust system 10 can include at least an engine 12 in communication with a fuel source (not shown) that, once consumed, will produce exhaust gases that are discharged into an exhaust passage 14 having an exhaust after-treatment system 16. Downstream from engine 12 can be disposed a pair of exhaust treatment components 18 and 20, which can include catalyst-coated substrates or filters 22 and 24.
  • Catalyst- coated substrates or filters 22 and 24 can be any combination of a diesel particulate filter (DPF), a diesel oxidation catalyst (DOC), a selective catalytic reduction (SCR) component, a lean NO x catalyst, an ammonia slip catalyst, or any other type of exhaust treatment device known to one skilled in the art. If a DPF is used, it may be catalyst-coated.
  • DPF diesel particulate filter
  • DOC diesel oxidation catalyst
  • SCR selective catalytic reduction
  • exhaust after- treatment system 16 can further include components such as a thermal enhancement device or burner 26 to increase a temperature of the exhaust gases passing through exhaust passage 14. Increasing the temperature of the exhaust gas is favorable to achieve light-off of the catalyst in the exhaust treatment component 18 in cold-weather conditions and upon start-up of engine 12, as well as initiate regeneration of the exhaust treatment component 18 when the exhaust treatment substrate 22 or 24 is a DPF.
  • a thermal enhancement device or burner 26 to increase a temperature of the exhaust gases passing through exhaust passage 14. Increasing the temperature of the exhaust gas is favorable to achieve light-off of the catalyst in the exhaust treatment component 18 in cold-weather conditions and upon start-up of engine 12, as well as initiate regeneration of the exhaust treatment component 18 when the exhaust treatment substrate 22 or 24 is a DPF.
  • exhaust after-treatment system 16 can include a dosing module 28 for periodically dosing an exhaust treatment fluid into the exhaust stream.
  • dosing module 28 can be located upstream of exhaust treatment component 18, and is operable to inject an exhaust treatment fluid into the exhaust stream.
  • dosing module 28 is in fluid communication with a reagent tank 30 and a pump 32 by way of inlet line 34 to dose an exhaust treatment fluid such as diesel fuel or urea into the exhaust passage 14 upstream of exhaust treatment components 18 and 20.
  • Dosing module 28 can also be in communication with reagent tank 30 via return line 36. Return line 36 allows for any exhaust treatment fluid not dosed into the exhaust stream to be returned to reagent tank 30.
  • dosing module 28 can be configured to include a cooling jacket that passes a coolant around dosing module 28 to cool it.
  • the amount of exhaust treatment fluid required to effectively treat the exhaust stream may vary with load, engine speed, exhaust gas temperature, exhaust gas flow, engine fuel injection timing, desired NO x reduction, barometric pressure, relative humidity, EGR rate and engine coolant temperature.
  • a NO x sensor or meter 38 may be positioned downstream from exhaust treatment component 18. NO x sensor 38 is operable to output a signal indicative of the exhaust NO x content to an engine control unit 40. All or some of the engine operating parameters may be supplied from engine control unit 40 via the engine/vehicle databus to a reagent electronic dosing controller 42. The reagent electronic dosing controller 42 could also be included as part of the engine control unit 40.
  • Exhaust gas temperature, exhaust gas flow and exhaust back pressure and other vehicle operating parameters may be measured by respective sensors, as indicated in Figure 1 .
  • the amount of exhaust treatment fluid required to effectively treat the exhaust stream can also be dependent on the size of the engine 12.
  • large-scale diesel engines used in locomotives, marine applications, and stationary applications can have exhaust flow rates that exceed the capacity of a single dosing module 28. Accordingly, although only a single dosing module 28 is illustrated for dosing exhaust treatment fluid, it should be understood that multiple dosing modules 28 for reagent injection are contemplated by the present disclosure.
  • exhaust treatment components 18 and 20 are illustrated. As best shown in Figure 2, exhaust treatment components 18 and 20 are arranged parallel to one another. It should be understood, however, that exhaust treatment components 18 and 20 can be arranged substantially co-axially, without departing from the scope of the present disclosure.
  • Exhaust treatment component 18 may include a housing 44, an inlet 46, and an outlet 48.
  • Inlet 46 may be in communication with exhaust passage 14, and outlet 48 may be in communication with exhaust treatment component 20.
  • outlet 48 is illustrated as being directly connected to exhaust treatment component 20, it should be understood that an additional conduit (not shown) may be positioned between outlet 48 and exhaust treatment component 20.
  • the additional conduit can be non-linear such that the flow of exhaust through the conduit must turn before entering exhaust treatment component 20.
  • Housing 44 can be cylindrically-shaped and may include a first section 50 supporting a DOC 52, and a second section 54 supporting DPF 56.
  • DOC 52 is illustrated as being upstream of DPF 56, it should be understood that DPF 56 can be positioned upstream of DOC 52 without departing from the scope of the present disclosure.
  • Opposing ends of housing 44 can include end caps 58 and 60 to hermetically seal housing 44. End caps 58 and 60 can be slip-fit and welded to first and second sections 50 and 54, respectively. First and second sections 50 and 54 may be secured by clamps 62. The use of clamps 62 allows for easy removal of DOC 52 or DPF 56 for maintenance, cleaning, or replacement of these components. Exhaust from exhaust passage 14 will enter inlet 46, pass through DOC 52 and DPF 56, and exit outlet 48 before entering exhaust treatment component 20.
  • Exhaust treatment component 20 is substantially similar to exhaust treatment component 18.
  • exhaust treatment component 20 may include a housing 64, an inlet 66, and an outlet 68.
  • Inlet 66 communicates with outlet 48 of exhaust treatment component 18, and outlet 68 may be in communication with a downstream section of exhaust passage 14.
  • Housing 64 can be cylindrically-shaped and may support an SCR 70 and ammonia slip catalyst 72. SCR is preferably located upstream of ammonia slip catalyst 72. Opposing ends of housing 64 can include end caps 74 and 76 to hermetically seal housing 64. End caps 74 and 76 can be slip-fit and welded to housing 64. Alternatively, end caps 74 and 76 can be secured to housing 64 by clamps (not shown). Exhaust from outlet 48 of exhaust treatment component 18 will enter inlet 66, pass through SCR 70 and ammonia slip catalyst 72, and exit outlet 68 before entering the downstream section of exhaust passage 14.
  • Dosing module 28 may be positioned on end cap 74 at a location proximate inlet 66. Dosing module 28 is operable to inject a reductant such as a urea exhaust treatment fluid into the exhaust stream before the exhaust stream passes through SCR 70. A sufficient intermingling of the exhaust and exhaust treatment fluid should occur to optimize the removal of NO x from the exhaust stream during as the mixture passes through SCR 70.
  • a mixing assembly 80 may be positioned downstream from inlet 66 and upstream of SCR 70. Mixing assembly 80 is positioned proximate dosing module 28 such that dosing module 28 may dose the urea exhaust treatment fluid directly into mixing assembly 80 where it may intermingle with the exhaust stream.
  • FIGS 7-9 illustrate a first exemplary embodiment of mixing assembly 80.
  • Mixing assembly 80 includes a decomposition tube 82 including a first end portion 84 that may be secured to end cap 74 and a second end portion 86 that is positioned proximate SCR 70.
  • Decomposition tube 82 may be substantially cylindrical, with a radially expanded portion 88 positioned between the first and second end portions 84 and 86.
  • Radially expanded portion 88 includes a conically-expanding portion 90 that expands the decomposition tube 82, a cylindrical portion 92 downstream from the conically-expanding portion 90 having a diameter that is greater than that of first and second end portions 84 and 86, and a conically-narrowing portion 94 that narrows decomposition tube 82. It should be understood that first and second end portions 84 and 86 may have different diameters, without departing from the scope of the present disclosure. It should also be understood that the present disclosure does not require conically-narrowing portion 94. That is, radially expanded portion 88 may extend over the entire length of second end portion 86.
  • First end portion 84 may be perforated such that first end portion 84 includes a plurality of first perforations 96.
  • First perforations 96 can vary in size around the circumference of first end portion 84, and assist in creating turbulence and increasing a velocity of the exhaust stream as it enters decomposition tube 82.
  • a perforated collar 98 including a plurality of second perforations formed as elongate slots 100 may be positioned around and secured to first end portion 84.
  • Perforated collar 98 includes a cylindrical portion 102 having a diameter greater than that of first end portion 84.
  • Cylindrical portion 102 radially narrows into an axially-extending flange 104 that may be fixedly coupled to decomposition tube 82 at a position proximate radially expanded portion 88 by welding, brazing, or any other secure attachment method known to one skilled in the art.
  • Elongate slots 100 may be dimensioned larger than first perforations 96. Elongate slots 100 can be oriented in various directions including directions parallel with an axis of decomposition tube 82, and directions arranged orthogonal to the axis of decomposition tube 82. It should be understood, however, that each elongate slot 100 can be oriented in the same direction without departing from the scope of the present disclosure. Similar to first perforations 96, elongate slots 100 assist in creating turbulence and increasing a velocity of the exhaust stream as it enters decomposition tube 82. [0055] Mixing assembly 80 includes a flow reversing device 106 at second end portion 86.
  • Flow reversing device 106 may be fixed to second end portion 86, or may be supported by a baffle (not shown) that secures flow reversing device 106 to end cap 74 at a position proximate terminal edge 108 of second end portion 86.
  • Flow reversing device 106 is a substantially cup-shaped member 1 10 having a central bulge 1 12 formed therein.
  • Flow reversing device 106 has a diameter greater than that of second end portion 86 of decomposition tube 82 such that as the exhaust flow enters the cup-shaped member 1 10, the exhaust flow will be forced to flow in a reverse direction back toward inlet 66 of housing 64. The reversing of the exhaust flow assists in intermingling of the reagent exhaust treatment fluid and the exhaust stream before the exhaust stream reaches SCR 70.
  • Flow reversing device 106 may include a plurality of deflecting members 1 14 to further assist in intermingling the reagent exhaust treatment fluid and the exhaust stream.
  • Deflecting members 1 14 may be formed as a plurality of vanes that extend radially inward from an inner surface 1 16 of outer wall 1 18 of flow reversing device 106.
  • vanes 1 14 may also be angled relative to an axis of decomposition tube 82 to further direct the exhaust flow as it exits flow reversing device 106.
  • Vanes 1 14 may be planar members, or may be slightly curved.
  • mixing assembly 80 may be arranged in a direction orthogonal to an axis of inlet 66.
  • the exhaust stream therefore, will enter mixing assembly 80 orthogonally before being directed toward SCR 70.
  • a velocity of the exhaust stream may increase and the flow of the exhaust stream will become tortuous due to first and second perforations 96 and 100.
  • the flow may tend to stay along the axis of the decomposition tube 82.
  • the velocity of the exhaust stream may slow, the velocity only slows to a minimal extent that ensures satisfactory intermingling of the exhaust and reagent exhaust treatment fluid.
  • radially expanded portion 88 diffuses the turbulence in the exhaust flow created by perforations 96 and 100, which aids in minimizing any potential loss in velocity.
  • Table 1 summarizes the peak velocity of the exhaust stream at various regions within exhaust treatment component 20.
  • the exhaust may have a peak velocity of 84 m/s (Region A).
  • the velocity may increase (Region B).
  • the increase in velocity at region B creates a large velocity differential between a velocity of the exhaust treatment fluid injected by dosing module 28 and the exhaust gas flowing through perforations 96 and 100.
  • the velocity differential of the bulk exhaust flow results in aerodynamic forces greater than the surface tension characteristic of the exhaust treatment fluid, which leads to droplet breakup and atomization of the exhaust treatment fluid.
  • the exhaust may slightly slow (Regions C and D). As the exhaust exits radially expanded portion and enters flow reversing device 106, the velocity may then increase (Regions E and F). The exhaust velocity may then decrease as the exhaust reaches SCR 70 (Region G). Because the exhaust velocity increases at a location (Region B) where the exhaust treatment fluid is dosed into the exhaust stream, and increases as it exits flow reversing device 106, the exhaust and exhaust treatment fluid can be sufficiently intermingled to ensure satisfactory atomization of the exhaust treatment fluid.
  • zones 120 of low velocity flow are present at positions adjacent inner walls 122 of decomposition tube 82 ( Figure 9). These zones 120 surround the exhaust stream as it passes through radially expanded portion 88, and assist in preventing wetting of inner walls 122 with the reagent exhaust treatment fluid. The prevention of the inner walls 122 being wetted prevents, or at least substantially minimizes, the build-up of solid urea deposits on the inner walls 122.
  • Mixing assembly 200 is similar to mixing assembly 80 illustrated in Figures 7 to 9. Description of components that are common to each assembly, therefore, is omitted herein for clarity.
  • Mixing assembly 200 includes deflecting device 202 including a plurality of deflecting members 204. As best shown in Figure 13, deflecting device 202 may be formed from an elongate strip 206 of metal such as aluminum, steel, titanium, or any other material known to one skilled in the art.
  • Deflecting members 204 are integral (i.e., unitary) with elongate strip 206 and are formed as planar tabs that are bent radially outward from elongate strip 206 from a plurality of cut-outs 208 formed in elongate strip 206. [0063] Deflecting members 204 may be designed to function in a manner similar to vanes 1 14. In this regard, as the exhaust flow exits flow reversing device 106, the exhaust will be directed by deflecting members 204, which will assist in further intermingling of the exhaust and reagent exhaust treatment fluid. As best shown in Figures 12 and 13, cut-outs 208 are angled relative to a length of elongate strip 206.
  • deflecting members 204 When deflecting members 204 are bent outward from elongate strip 206, deflecting members 204 will also be angled relative to an axis of mixing assembly 200, which may be used to direct the exhaust flow in predetermined directions upon exiting flow reversing device 106.
  • Deflecting members 204 may have a length that is substantially equal to a distance between second end portion 86 of decomposition tube 82 and outer wall 1 18 of flow reversing device 106. Alternatively, deflecting members 204 may have a length that is less than the distance between second end portion 86 and outer wall 1 18. In another alternative, deflecting members 204 may each have a terminal projection 210 that provides deflecting members 204 with a length that is greater than the distance between second end portion 86 and outer wall 1 18. Terminal projection 210 may then abut a terminal end 212 of outer wall 1 18 of flow reversing device 106, which assists in positioning deflecting device 202 relative to flow reversing device 106. Terminal projections 210 may also assist in securing deflecting device 202 to flow reversing device 106, by providing a location to weld, braze, or secure each tab to flow reversing device 106, if desired.
  • Mixing assembly 300 is substantially similar to mixing assembly 80 illustrated in Figures 7 to 9. Description of components that are common to each assembly, therefore, is omitted herein for clarity. Although collar 98 is not illustrated in Figure 14, it should be understood that mixing assembly 300 may include collar 98.
  • Mixing assembly 300 includes deflecting device 302 including a plurality of deflecting members 304. As best shown in Figure 15, deflecting device 302 may be formed from an annular ring 306 of metal such as aluminum, steel, titanium, or any other material known to one skilled in the art.
  • Deflecting members 304 are integral (i.e., unitary) with annular ring 306 and are formed as planar tabs that may be bent axially outward from annular ring from a plurality of cut-outs 308 formed in annular ring 306. Although deflecting members 304 are illustrated as being bent in a direction toward an interior 310 of flow reversing device 106, it should be understood that deflecting members 304 can be bent in a direction away from interior 310.
  • Deflecting members 304 may be designed to function in a manner similar to vanes 1 14. In this regard, as the exhaust flow exits flow reversing device 106, the exhaust will be directed by deflecting members 304, which will assist in further intermingling of the exhaust and reagent exhaust treatment fluid. Deflecting members 304 may also be angled relative to an axis of mixing assembly 300, which may be used to direct the exhaust flow in predetermined directions upon exiting flow reversing device 106.
  • Inner ring 312 may be used to secure deflecting device 302 to second end portion 86 of decomposition tube 82 by welding, brazing, or any other fixing method known in any manner known to one skilled in the art.
  • Deflecting device 302 may also include an axially-extending flange 316 that extends outward from outer ring 314.
  • Axially-extending flange 316 may correspond to terminal end 212 of flow reversing device 106 ( Figure 1 1 ), and overlap terminal end 212 such that axially-extending flange 316 may be secured to flow reversing device 106 by welding, brazing, or any other attachment method known.
  • Mixing assembly 400 is similar to mixing assembly 80 illustrated in Figures 7 to 9. Description of components that are common to each assembly, therefore, is omitted herein for clarity.
  • Mixing assembly 400 includes flow reversing device 106 at second end portion 86, which is a substantially cup- shaped member having a central bulge formed therein.
  • mixing assembly 400 may include a flow-dispersing cap 402 coupled between flow reversing device 106 and decomposition tube 82.
  • Flow-dispersing cap 402 includes a first axially-extending lip 404 that couples flow-dispersing cap 402 to flow reversing device 106, and a second axially-extending lip 406 that couples flow-dispersing cap 402 to decomposition tube 82. Between axially-extending lips 404 and 406 is a perforated conically-shaped ring 408 having a plurality of through-holes 410. Similar to first and second perforations 96 and 100, through-holes 410 assist in creating turbulence and increasing a velocity of the exhaust stream as it exits flow reversing device 106. Through-holes 410 can be sized and shaped in any manner desired.
  • Conically-shaped ring 408 can include a first portion 412 adjacent first axially-extending lip 404, and a second portion 414 adjacent second axially-extending lip 406.
  • a diverter ring 416 may be positioned between second portion 414 and decomposition tube 82.
  • diverter ring 416 includes a cylindrical portion 418 coupled to decomposition tube 82, and an angled flange 420 extending away from cylindrical portion 418 between decomposition tube 82 and conically-shaped ring 408.
  • Angled flange 420 may be positioned at any angle desired to further assist in diverting flow out from mixing assembly 400.
  • angled flange may be angled relative to cylindrical portion 418 in the range of 25 to 75 degrees, preferably in the range of 35 to 65 degrees, and most preferably at an angle of degrees.
  • Mixing assembly 500 is substantially similar to mixing assembly 80 illustrated in Figures 7 to 9. Description of components that are common to each assembly, therefore, is omitted herein for clarity.
  • Mixing assembly 500 includes flow reversing device 502 at second end portion 86 of decomposition tube 82, which is a substantially cup-shaped member having a central bulge 503 formed therein.
  • Flow reversing device 502 may include a plurality of flow deflecting members 504 formed in an outer wall 506 thereof.
  • Deflecting members 504 are integral (i.e., unitary) with flow reversing device 502 and are formed as planar tabs that are that are bent radially outward from outer wall 506 from a plurality of cut-outs 508 formed in outer wall 506. Deflecting members 504 may be designed to function in a manner similar to vanes 1 14. In this regard, as the exhaust flow exits flow reversing device 502 through cut-outs 508, the exhaust flow will become turbulent and deflected by deflecting members 504, which will assist in further intermingling of the exhaust and reagent exhaust treatment fluid.
  • Mixing assembly 500 may further include a dispersing ring 510 positioned between a terminal end 512 of flow reversing device 502 and decomposition tube 82.
  • Dispersing ring 510 may be formed from an annular ring 514 of metal such as aluminum, steel, titanium, or any other material known to one skilled in the art.
  • a cylindrical flange 516 may extend axially away from annular ring 514. Cylindrical flange 516 may be welded, brazed, or secured in any manner known, to decomposition tube 82.
  • Annular ring 514 includes a plurality of scallop-shaped recesses 518 formed therein. Recesses 518 serve as exit ports to allow the exhaust stream to exit mixing assembly 500.
  • the exhaust stream may exit through cut-outs 508, or may exit through recesses 518.
  • Adjacent recesses 518 may be separated by a land portion 520 of the annular ring 514.
  • a terminal end 522 of each land portion 520 located opposite to cylindrical flange 516 may be bent in the axial direction to provide an abutment surface that can position dispersing ring 510 relative to flow reversing device 502 before dispersing ring 510 is secured to decomposition tube 82.
  • the flow direction of the exhaust stream will be reversed back toward inlet 66.
  • the exhaust may exit through cut-outs 508 and be deflected in a desired direction by deflecting members 504, or the exhaust stream may exit through recesses 518 formed in dispersing ring 510. Regardless of the location at which the exhaust stream exits mixing assembly 500, the exhaust stream is further intermingled with the reagent exhaust treatment fluid before flowing toward SCR 70.
  • each mixing assembly has been described relative to use in an exhaust treatment component 20 including a single SCR 70, the present disclosure should not be limited thereto.
  • mixing assemblies can be used in an exhaust treatment component 20 having a pair of SCRs 70.
  • Figure 22 illustrates a pair of exhaust treatment components 18 and 20, arranged in parallel.
  • Exhaust treatment component 18 is similar to the previously-described embodiments so description thereof will be omitted.
  • Exhaust treatment component 20 includes mixing assembly 80 (or any other mixing assembly described above) for intermingling exhaust treatment fluid dosed into the exhaust stream by dosing module 28.
  • Exhaust treatment component 20 includes a pair of housings 600 in communication with a pair of end caps 602 and 604. End caps 602 and 604 may be secured to housings 600 by welding, or may be secured to housings 600 by clamps (not shown).
  • Mixing assembly 80 and dosing module 28 are secured in a conduit 606 that provides communication between exhaust treatment component 18 and exhaust treatment component 20.
  • Conduit 606 may include a first portion 608 and a second portion 610 each including a flange 612 and 614, respectively, that may be secured by welding, or by a clamp (not shown).
  • Each housing 600 supports a plurality of exhaust treatment component substrates 618, which may be a combination of SCRs, ammonia slip catalysts, and filters for treating the mixture of exhaust and exhaust treatment fluid.
  • the urea exhaust treatment fluid may be dosed directly into mixing assembly 80 by dosing module 28.
  • the exhaust treatment fluid and exhaust stream will be sufficiently intermingled before passing through exhaust treatment component substrates 618.
  • Mixing assembly 80 may include deflecting members or vanes 1 14 to assist in intermingling the exhaust and exhaust treatment fluid. Because a pair of housings 600 each including exhaust treatment component substrates 618 is used in the exemplary embodiment, vanes 1 14 may be positioned within flow reversing device 106 to ensure that a substantially equal amount of the exhaust stream is directed to each housing 600. That is, it should be understood that deflecting members 1 14 (and the deflecting members in each exemplary embodiment) can be oriented and positioned to direct the exhaust in the desired direction. In this manner, the exhaust can be properly treated by exhaust treatment component substrates 618.
  • exhaust treatment assembly 700 including exhaust treatment components 702 and 704 is illustrated. As best shown in Figure 24, exhaust treatment components 702 and 704 are arranged parallel to one another. It should be understood, however, that exhaust treatment components 702 and 704 can be arranged substantially co- axially, without departing from the scope of the present disclosure.
  • Exhaust treatment component 702 may include a housing 706, an inlet 708, and an outlet 710. Inlet 708 may be in communication with exhaust passage 14, and outlet 710 may be in communication with exhaust treatment component 704. Although outlet 710 is illustrated as being directly connected to exhaust treatment component 704, it should be understood that an additional conduit (not shown) may be positioned between outlet 710 and exhaust treatment component 704. The additional conduit can be non-linear such that the flow of exhaust through the conduit must turn before entering exhaust treatment component 704.
  • Housing 706 can be cylindrically-shaped and may include a first section 712 supporting a DOC 714, and a second section 716 supporting a mixing assembly 718 ( Figures 29 and 30).
  • DOC 714 may be replaced by for example, a DPF or catalyst-coated DPF without departing from the scope of the present disclosure.
  • Opposing ends of housing 706 can include end caps 720 and 722 to hermetically seal housing 706. End caps 720 and 722 can be slip-fit and welded to first and second sections 712 and 716, respectively.
  • First and second sections 712 and 716 may be secured by a clamp 724. Alternatively, first and second sections 712 and 716 may be slip fit or welded, without departing from the scope of the present disclosure.
  • clamp 724 allows for easy removal of DOC 714 or mixing assembly 718 for maintenance, cleaning, or replacement of these components.
  • a perforated baffle 725 may be positioned immediately downstream from inlet 708 and upstream for DOC 714. Exhaust from exhaust passage 14 will enter inlet 708, pass through perforated baffle 725, DOC 714, and mixing assembly 718, and exit outlet 710 before entering exhaust treatment component 704.
  • Exhaust treatment component 704 is substantially similar to exhaust treatment component 702.
  • exhaust treatment component 704 may include a housing 726, an inlet 728, and an outlet 730.
  • Inlet 728 communicates with outlet 710 of exhaust treatment component 702, and outlet 730 may be in communication with a downstream section of exhaust passage 14.
  • Housing 726 can be cylindrically-shaped and may support an
  • SCR 732 and ammonia slip catalyst 734 are preferably located upstream of ammonia slip catalyst 734.
  • Opposing ends of housing 726 can include end caps 736 and 738 to hermetically seal housing 726. End caps 736 and 738 can be slip-fit and welded to housing 726. Alternatively, end caps 736 and 738 can be secured to housing 726 by clamps (not shown). Exhaust from outlet 710 of exhaust treatment component 702 will enter inlet 728, pass through SCR 732 and ammonia slip catalyst 734, and exit outlet 730 before entering the downstream section of exhaust passage 14.
  • Dosing module 28 may be positioned on end cap 722 at a location proximate outlet 710. As in previously described embodiments, dosing module 28 is operable to inject a reductant such as a urea exhaust treatment fluid into the exhaust stream before the exhaust stream passes through SCR 732. A sufficient intermingling of the exhaust and exhaust treatment fluid should occur to optimize the removal of NO x from the exhaust stream before the mixture passes through SCR 732. To assist in intermingling of the exhaust stream and the urea exhaust treatment fluid, mixing assembly 718 may be positioned downstream from DOC 714 and upstream of SCR 732. Mixing assembly 718 is positioned proximate dosing module 28 such that dosing module 28 may dose the urea exhaust treatment fluid directly into mixing assembly 718 where it may intermingle with the exhaust stream.
  • a reductant such as a urea exhaust treatment fluid
  • FIGS 29 and 30 best illustrate mixing assembly 718. Similar to previously described embodiments, mixing assembly 718 includes a decomposition tube 82 including first end portion 84 that may be secured to end cap 722 and second end portion 86 that is positioned proximate DOC 714. Decomposition tube 82 may be substantially cylindrical, with radially expanded portion 88 positioned between the first and second end portions 84 and 86. A flow reversing device 740 at second end portion 86. In addition to decomposition tube 82 being fixed to end cap 722, mixing assembly 718 may be supported within housing 706 by a perforated support plate 742.
  • Support plate 742 includes an annular central portion 744 surrounding an aperture 746 defined by an axially extending flange 748 that is fixed to decomposition tube 82.
  • An annular outer portion 750 of support plate 742 includes a plurality of through-holes 752 for allowing the exhaust to flow therethrough.
  • Outer portion 750 also includes an axially-extending flange 754 for fixing support plate 742 to housing 706.
  • An axially-extending shoulder portion 756 may be positioned between the annular central portion 744 and annular outer portion 750.
  • Shoulder portion 756 provides a mounting surface for a cylindrical shell 758 of mixing assembly 718.
  • Shell 758 includes a proximal end 760 fixed to shoulder portion 756 and a distal end 762 fixed to flow reversing device 740.
  • a radially extending mounting flange 764 receives an end 766 of outlet 710.
  • mixing assembly 718 may cup-shaped nose 768 fixed to an outer surface 770 of flow-reversing device 740.
  • Cup-shaped nose 768 may include a conical, hemispherical, or ellipsoid outer surface 772 that, upon contact by the exhaust, directs the exhaust around mixing assembly 718.
  • Cup-shaped nose 768 may also have a concave surface relative to the direction of the exhaust.
  • cup-shaped nose 768 may have raised or recessed features (e.g., bumps or dimples, not shown) formed on outer surface 772.
  • cup-shaped nose 768 is illustrated as being fixed to flow- reversing device 740, it should be understood that cup-shaped nose 768 can be supported by a support plate (not shown) at a position proximate flow-reversing device 740.
  • a support plate similar to support plate 742 having through-holes 752 to allow for exhaust flow may be used, with annular central portion 744 defining cup-shaped nose 768 rather than aperture 746.
  • the exhaust After passing around mixing assembly 718, the exhaust will pass through through-holes 752 of support plate 742. After passing through support plate 742, the exhaust may enter mixing assembly 718 through perforations 96 and 100. To assist in feeding the exhaust gas into mixing assembly 718, end cap 722 may define curved surfaces (i.e., similar to flow- reversing device 740, not shown) that direct the exhaust into mixing assembly 718.
  • end cap 722 may define curved surfaces (i.e., similar to flow- reversing device 740, not shown) that direct the exhaust into mixing assembly 718.
  • the exhaust treatment fluid e.g., urea
  • the exhaust will be directed in a reverse direction by flow reversing device 740 into shell 758. The exhaust may then exit shell 758 through outlet 710 and enter exhaust treatment component 704 where SCR 732 and ammonia slip catalyst 734 are located.
  • the exhaust flow will be forced to reverse direction within exhaust treatment component 702 twice. That is, the exhaust flow will firstly reverse direction as it enters mixing assembly 718, and the exhaust will secondly reverse direction due to contact with flow- reversing device 740. Due to the exhaust flow reversing in direction twice as it travels through exhaust treatment component 702, the exhaust flow will become tortuous, which increases the ability to intermingle the exhaust treatment fluid with the exhaust before the exhaust enters SCR 732. Due to the increased intermingling of the exhaust treatment fluid and the exhaust, the efficacy of SCR 732 in removing NO x from the exhaust can be increased.
  • flow-reversing device 740 may include deflecting members such as vanes 1 14.
  • any of mixing assemblies 200, 300, 400, and 500 may be used in exhaust treatment component 702 without departing from the scope of the present disclosure.
  • Exhaust treatment component 800 includes a housing 802, an inlet 804, and an outlet 806.
  • Housing 802 may include an inner shell 807 and an outer shell 808.
  • An insulating material 810 may be disposed between inner shell 806 and outer shell 808.
  • Inlet 804 may be coupled to exhaust passage 14, and includes an inner cone 812 and an outer cone 814.
  • Insulating material 810 may be disposed between inner cone 812 and outer cone 814.
  • Inner cone 812 may be fixed to inner shell 807, and outer cone 814 may be fixed to outer shell 808.
  • Inner cone 812 may first be fixed to outer cone 814, and then inlet 804 may be fixed to inner and outer shells 807 and 808.
  • Outlet 806 may include an outer sleeve 816 fixed to outer shell 808, and an inner sleeve 818.
  • Inner sleeve 818 may be constructed of one or more sections that are hermetically sealed.
  • Insulating material 810 may be disposed between inner sleeve 818 and outer sleeve 816.
  • Outlet 806 may extend radially outward from housing 802, while inlet 804 may be co-axial with housing 802.
  • An end cap 820 may be coupled to housing 802 at an end of housing 802 opposite to inlet 804.
  • Dosing module 28 may be positioned on end cap 820 (or on an additional flange (not shown) at a location proximate outlet 806.
  • dosing module 28 is operable to inject a reductant such as a urea exhaust treatment fluid into the exhaust stream before the exhaust stream passes through an SCR (not shown).
  • SCR an additional flange
  • a sufficient intermingling of the exhaust and exhaust treatment fluid should occur to optimize the removal of NO x from the exhaust stream before the mixture passes through the SCR.
  • mixing assembly 718 may be positioned between inlet 804 and outlet 806.
  • Mixing assembly 718 is positioned proximate dosing module 28 such that dosing module 28 may dose the exhaust treatment fluid directly into mixing assembly 718 where it may intermingle with the exhaust stream.
  • FIG 32 best illustrates mixing assembly 718 within exhaust treatment component 800.
  • Mixing assembly 718 includes a decomposition tube 82 including first end portion 84 that may be secured to end cap 820 and second end portion 86 that is positioned proximate inlet 804. The exhaust flow will enter inlet 804 and approach mixing assembly 718.
  • mixing assembly 718 may include cup-shaped nose 768 fixed to an outer surface 770 of flow-reversing device 740.
  • Cup-shaped nose 768 may include a conical, hemispherical, or ellipsoid outer surface 772 that, upon contact by the exhaust, directs the exhaust around mixing assembly 718.
  • Cup-shaped nose 768 may also have a concave surface relative to the direction of the exhaust.
  • cup-shaped nose 768 may have raised or recessed features (e.g., bumps or dimples, not shown) formed on outer surface 772.
  • the exhaust After passing around mixing assembly 718, the exhaust will pass through through- holes 752 of support plate 742. After passing through support plate 742, the exhaust may enter mixing assembly 718 through perforations 96.
  • mixing assembly 718 is illustrated in Figure 32 as not including perforated collar 98, it should be understood that the illustrated embodiment may include perforated collar 98 without departing from the scope of the present disclosure.
  • the exhaust flow After entering decomposition tube 82, the exhaust flow will be exposed to the exhaust treatment fluid (e.g., urea) dosed into mixing assembly 718 by dosing module 28. As the exhaust flows through decomposition tube 82, the exhaust will be directed in a reverse direction by flow reversing device 740 into shell 758. The exhaust may then exit shell 758 through outlet 806 and enter another exhaust treatment component (e.g., exhaust treatment component illustrated in Figure 24) where an SCR may be located.
  • the exhaust treatment fluid e.g., urea
  • flow-reversing device 740 may include deflecting members such as vanes 1 14.
  • any of mixing assemblies 200, 300, 400, and 500 may be used in exhaust treatment component 800 without departing from the scope of the present disclosure.
  • the exhaust flow will be forced to reverse direction within exhaust treatment component 800 twice. That is, the exhaust flow will firstly reverse direction as it enters mixing assembly 718, and the exhaust will secondly reverse direction due to contact with flow- reversing device 740.
  • exhaust flow Due to the exhaust flow reversing in direction twice as it travels through exhaust treatment component 800, the exhaust flow will become tortuous, which increases the ability to intermingle the exhaust treatment fluid with the exhaust before the exhaust enters an SCR. Due to the increased intermingling of the exhaust treatment fluid and the exhaust, the efficacy of the SCR in removing NO x from the exhaust can be increased.
  • exhaust treatment component 800 does not include a DOC, DPF, SCR, or some other type of exhaust treatment substrate. Without any of these devices, component 800 may be made to be compact. Such a design allows for existing exhaust after- treatment systems including an SCR to be retro-fit with component 800 to assist in increasing intermingling of the exhaust and urea exhaust treatment fluid.
  • inlet 708 illustrated in Figure 24 is illustrated as having a 90 degree bend
  • the present disclosure contemplates a co-axial inlet like that illustrated in Figure 31 (i.e., inlet 804) or a radially-positioned inlet like inlet 728.
  • outlet 710 may be replaced by a co-axial outlet (similar to co-axial inlet 804) or an outlet having a 90 degree bend (similar to inlet 708). Similar modifications may made in component 800, without departing from the scope of the present disclosure.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

L'invention porte sur un élément de traitement d'échappement pour traiter un échappement de moteur, lequel élément comprend un boîtier comprenant une entrée et une sortie. Un dispositif de mélange est disposé à l'intérieur du boîtier entre l'entrée et la sortie, et le dispositif de mélange comprend une enceinte communiquant avec la sortie, un tube de décomposition ayant une première extrémité et une seconde extrémité, et un dispositif d'inversion d'écoulement disposé à proximité de la seconde extrémité. La première extrémité s'étend à partir de l'enceinte et est configurée de façon à recevoir l'échappement à partir de l'entrée, et est configurée de façon à recevoir un fluide de traitement d'échappement réactif. La seconde extrémité est positionnée à l'intérieur de l'enceinte. Le dispositif d'inversion d'écoulement est configuré de façon à diriger un mélange de l'échappement et du fluide de traitement d'échappement réactif dans des directions prédéterminées à l'intérieur de l'enceinte, et le dispositif d'inversion d'écoulement inverse une direction d'écoulement de l'échappement de façon à le renvoyer vers la première extrémité du tube de décomposition.
PCT/US2014/048374 2013-08-05 2014-07-28 Module de pulvérisation d'écoulement axial WO2015020819A1 (fr)

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KR1020167005610A KR101780341B1 (ko) 2013-08-05 2014-07-28 축류 분무 모듈
JP2016530094A JP2016525648A (ja) 2013-08-05 2014-07-28 軸流噴霧化モジュール
CN201480044809.2A CN105452624B (zh) 2013-08-05 2014-07-28 轴流式雾化模块
DE112014003600.5T DE112014003600T5 (de) 2013-08-05 2014-07-28 Axialflusszerstäubungsmodul

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US13/958,955 US9314750B2 (en) 2013-05-07 2013-08-05 Axial flow atomization module

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US10100700B2 (en) * 2015-06-29 2018-10-16 Tenneco Automotive Operating Company Inc. Cantilevered flow distributing apparatus
CN205779158U (zh) * 2016-07-08 2016-12-07 天纳克（苏州）排放系统有限公司 尾气后处理装置
EP4069954A4 (fr) * 2019-12-03 2023-08-09 Cummins Emission Solutions Inc. Système de distribution de réducteur pour système de post-traitement de gaz d'échappement

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KR101780341B1 (ko) 2017-09-21
JP2016525648A (ja) 2016-08-25
KR20160038051A (ko) 2016-04-06
CN105452624A (zh) 2016-03-30
DE112014003600T5 (de) 2016-05-25
CN105452624B (zh) 2018-05-04

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