US20110219745A1 - Method and apparatus for gaseous mixing in a diesel exhaust system - Google Patents
Method and apparatus for gaseous mixing in a diesel exhaust system Download PDFInfo
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- US20110219745A1 US20110219745A1 US12/723,244 US72324410A US2011219745A1 US 20110219745 A1 US20110219745 A1 US 20110219745A1 US 72324410 A US72324410 A US 72324410A US 2011219745 A1 US2011219745 A1 US 2011219745A1
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- mixer
- exhaust stream
- injection tube
- chamber
- mixing device
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- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000002347 injection Methods 0.000 claims abstract description 54
- 239000007924 injection Substances 0.000 claims abstract description 54
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000003153 chemical reaction reagent Substances 0.000 claims abstract description 18
- 229910000069 nitrogen hydride Inorganic materials 0.000 claims abstract description 15
- 230000000694 effects Effects 0.000 claims abstract description 6
- 238000007599 discharging Methods 0.000 claims abstract description 5
- 229910021529 ammonia Inorganic materials 0.000 claims abstract description 4
- 239000003054 catalyst Substances 0.000 claims description 8
- 239000012530 fluid Substances 0.000 claims description 5
- 239000008240 homogeneous mixture Substances 0.000 claims description 5
- 238000004891 communication Methods 0.000 claims description 4
- 230000003647 oxidation Effects 0.000 claims description 3
- 238000007254 oxidation reaction Methods 0.000 claims description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 20
- 238000004806 packaging method and process Methods 0.000 description 7
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 3
- 239000004202 carbamide Substances 0.000 description 3
- 238000010531 catalytic reduction reaction Methods 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000009827 uniform distribution Methods 0.000 description 2
- 238000007792 addition Methods 0.000 description 1
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
Images
Classifications
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- 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
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2892—Exhaust flow directors or the like, e.g. upstream of catalytic device
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/20—Mixing gases with liquids
- B01F23/21—Mixing gases with liquids by introducing liquids into gaseous media
- B01F23/213—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids
- B01F23/2132—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids using nozzles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3131—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit with additional mixing means other than injector mixers, e.g. screens, baffles or rotating elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3132—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit by using two or more injector devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3133—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit characterised by the specific design of the injector
- B01F25/31332—Ring, torus, toroidal or coiled configurations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/40—Static mixers
- B01F25/42—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions
- B01F25/43—Mixing tubes, e.g. wherein the material is moved in a radial or partly reversed direction
- B01F25/431—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor
- B01F25/4316—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor the baffles being flat pieces of material, e.g. intermeshing, fixed to the wall or fixed on a central rod
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/40—Static mixers
- B01F25/42—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions
- B01F25/43—Mixing tubes, e.g. wherein the material is moved in a radial or partly reversed direction
- B01F25/431—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor
- B01F25/4317—Profiled elements, e.g. profiled blades, bars, pillars, columns or chevrons
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- 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
-
- 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
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- 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
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust 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
- F01N3/033—Exhaust 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 in combination with other devices
- F01N3/035—Exhaust 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 in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- 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
- F01N3/103—Oxidation catalysts for HC and CO only
-
- 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
- F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
- F01N3/106—Auxiliary oxidation catalysts
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- 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
- F01N2340/00—Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses
- F01N2340/02—Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses characterised by the distance of the apparatus to the engine, or the distance between two exhaust treating apparatuses
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- 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
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- 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
Definitions
- the present invention relates to an apparatus and method for treating and mixing diesel exhaust in a diesel exhaust system.
- the present invention provides methods and apparatus for injecting reagent into a diesel exhaust stream to reduce nitrogen oxides (NO x ) without increasing the packing space of the exhaust system.
- Diesel engines are efficient, durable and economical. Diesel exhaust, however, can harm both the environment and people. To reduce this harm, governments, such as the United States and the European Union, have proposed stricter diesel exhaust emission regulations. These environmental regulations require diesel engines to meet the same pollution emission standards as gasoline engines.
- a lean burning engine provides improved fuel efficiency by operating with an amount of oxygen in excess of the amount necessary for complete combustion of the fuel. Such engines are said to run “lean” or on a “lean mixture.”
- the increase in fuel efficiency is offset by the creation of undesirable pollution emissions in the form of nitrogen oxides (NO x ).
- NO x nitrogen oxides
- One method used to reduce NO x emissions from lean burn internal combustion engines is known as selective catalytic reduction.
- selective catalytic reduction involves injecting atomized urea into the exhaust stream of the engine in relation to one or more selected engine operational parameters and running the stream through a reactor containing a catalyst.
- selective catalytic reduction and the use of aqueous urea involve many disadvantages, including added packaging weight and added packaging length to the exhaust system, as well as the highly corrosiveness and poor lubricity of aqueous urea.
- a mixing device for a diesel exhaust system having a chamber, a mixer within the chamber, and an injection tube supported on the mixer within the chamber.
- the mixer is positioned within the chamber adjacent an inlet and includes a plurality of angled blades to effect turbulent flow in a diesel exhaust stream entering the chamber through the inlet.
- the injection tube includes a plurality of injection points (e.g., openings) for discharging a reagent into the exhaust stream.
- the injection tube is curved, and more specifically it is coiled with the injection points spread along the length of the tube in order to deliver reagent across a section of the chamber perpendicular to the exhaust stream flow.
- the disclosed method for mixing gaseous ammonia in a diesel exhaust system begins with a diesel exhaust stream from a diesel engine passing from the engine through a conduit in fluid communication with the engine.
- the exhaust stream is directed to flow through the conduit into a housing having a mixer, an injection tube and an exit disposed therein. Turbulent flow in the diesel exhaust stream is created within the housing as the stream passes through the mixer.
- a continuous injection of gaseous NH 3 from the injection tube into the diesel exhaust stream is made as the stream moves from the mixer toward the housing exit to create a treated homogenous exhaust stream.
- the treated exhaust stream is discharged through the housing exit.
- FIG. 1 is a schematic illustrating a typical mixer/injector device in a diesel exhaust system
- FIG. 2 is a schematic illustrating an embodiment of a mixer/NH 3 injection device of the present invention in a diesel exhaust system
- FIG. 3 is a schematic illustrating another embodiment of a mixer/NH 3 injection device of the present invention in a diesel exhaust system
- FIG. 4 is a front view of an embodiment of a mixer/NH 3 injection device.
- FIG. 5 is a perspective view of the mixer/NH 3 injection device of FIG. 4 .
- the exhaust treatment system 110 typically consists of, in downstream order, a diesel oxidation catalyst (DOC) 112 , a diesel particulate filter (DPF) 114 , a mixer/NH 3 treatment canister 116 , and a NO x slip catalyst (NSC) 118 .
- DOC diesel oxidation catalyst
- DPF diesel particulate filter
- NSC NO x slip catalyst
- the DOC 112 , DPF 114 and NSC 118 are additional exhaust treatment structures present in most diesel exhaust treatment systems and which form no part of the present system 10 . Such structures will be generally referenced herein and identified in the drawing figures but, as each of these additional exhaust treatment structures is commonly understood by those skilled in the art, a detailed discussion of each is avoided for the purpose of focusing discussion on the system 10 as set forth in the appended claims.
- the mixer/treatment canister 116 is shown to include a connection pipe 120 with an injector 122 at the upstream end where NH 3 —or an NH 3 containing reagent—is injected into a laminar diesel exhaust flow as it is discharged from the DOC 112 and DPF 114 .
- the ammonia/exhaust stream then passes through a mixer 124 to effect mixing of the NH 3 and the diesel exhaust.
- a substantial length of pipe 120 is needed to allow for adequate mixing of the two components before the flow enters the NSC 118 .
- the mixer/injector system adds packaging length and weight to the diesel exhaust system 100 which might otherwise be used for other after-treatment substrates.
- FIGS. 2-5 there is illustrated a mixer/NH 3 injection system, generally designated by the numeral 10 .
- the system 10 is shown in two distinct exhaust treatment configurations.
- FIG. 2 illustrates a configuration similar to that of FIG. 1 where the downstream order of components is DOC 12 , then DPF 14 and NSC 18 sandwiched about system 10 .
- FIG. 3 illustrates a configuration where the NSC 18 is on the DPF 14 —i.e., NO x slip catalyst on diesel particulate filter (NPF) 19 —sandwiching the system 10 with the DOC 12 .
- Other configurations may exist in which the system 10 is moved up or downstream in the exhaust flow.
- system 10 is comprised of a housing 20 defining a mixing chamber 25 , an injection tube 22 fed by an exterior injector boss 30 coupled to a supply (not shown), and a mixer 24 .
- FIGS. 2 and 3 illustrate the diameter of the housing 20 (approx. 12 inches (30.5 cm)) is substantially equal to that of the surrounding structures—e.g., DPF 14 and NSC 18 .
- FIGS. 4 and 5 illustrate a specific embodiment of a single-plane, coiled injection tube 22 .
- Injection tube 22 enters through the housing sidewall and begins a tortuous path to a center of the chamber 25 .
- the tube 22 includes a series of injection points 23 where reagent can be emitted into the chamber 25 .
- the injection points 23 are spaced along the tube 22 and, therefore, throughout a cross-section of the chamber 25 to provide a more uniform distribution of reagent throughout that cross-section of the mixing chamber 25 .
- the uniform distribution into the exhaust stream results in a more homogenous mixture of reagent and exhaust in a shorter mixing period.
- the tube 22 may be configured in several alternative shapes, including circular and serpentine, so long as a distribution of the injection points 23 throughout a cross-section of the chamber is provided.
- the injection points 23 comprise small openings in the tube 22 to allow discharge of the reagent from the tube 22 .
- the first opening has a very small diameter and successive opening diameters increase toward the tube end 27 —i.e., the smallest diameter openings are positioned at the beginning of the tube where the fluid pressure is the greatest.
- the purpose again, is to achieve even distribution of reagent across the entire cross-section of the mixing chamber 25 .
- exhaust flow mixer 24 is also shown in FIGS. 4 and 5 .
- the mixer 24 is comprised of a plurality of fixed blades 37 , four are shown, secured to one another at a midpoint and outwardly to and within a short section (approx. six inches (15.2 cm)) of the housing 20 .
- the blades 37 are angled from back to front as a way of imparting a turbulent flow to the substantially laminar exhaust flow entering system 10 . Though not shown, additional blade configurations are possible to achieve the desired turbulent exhaust flow for mixing.
- the mixer 24 supports the injection tube 22 . That is, the tube 22 , which is positioned on the downstream side of the mixer 24 , attaches to, by way of welds or any other suitable attachment means, each of the mixer blades 37 for simple structural support. Attachment may be achieved, for example, at the areas 39 where the tube 22 crosses each blade 37 .
- the securing of the coiled tube 22 alleviates damage which might otherwise be caused by the more violent vibration of the tube 22 during operation of the vehicle.
- Reagent e.g., gaseous NH 3
- injection points 23 immediately enters the turbulent diesel exhaust stream as it moves toward the chamber exit 35 ( FIGS. 2 and 3 ). A relatively short distance is needed to provide the necessary mixing time to create a homogonous reagent/diesel exhaust.
- the homogenous mixture is then exited from the mixing chamber 25 into one of either the NSC 18 ( FIG. 2 ) or the NPF 19 ( FIG. 3 ) for further treatment.
Abstract
Description
- The present invention relates to an apparatus and method for treating and mixing diesel exhaust in a diesel exhaust system. Particularly, the present invention provides methods and apparatus for injecting reagent into a diesel exhaust stream to reduce nitrogen oxides (NOx) without increasing the packing space of the exhaust system.
- Diesel engines are efficient, durable and economical. Diesel exhaust, however, can harm both the environment and people. To reduce this harm, governments, such as the United States and the European Union, have proposed stricter diesel exhaust emission regulations. These environmental regulations require diesel engines to meet the same pollution emission standards as gasoline engines.
- Typically, to meet such regulations and standards, systems require equipment additions and modifications. Additional equipment can often lead to additional weight and/or additional packaging length.
- For example, a lean burning engine provides improved fuel efficiency by operating with an amount of oxygen in excess of the amount necessary for complete combustion of the fuel. Such engines are said to run “lean” or on a “lean mixture.” However, the increase in fuel efficiency is offset by the creation of undesirable pollution emissions in the form of nitrogen oxides (NOx). One method used to reduce NOx emissions from lean burn internal combustion engines is known as selective catalytic reduction. When used to reduce NOx emissions from a diesel engine, selective catalytic reduction involves injecting atomized urea into the exhaust stream of the engine in relation to one or more selected engine operational parameters and running the stream through a reactor containing a catalyst. However, selective catalytic reduction and the use of aqueous urea involve many disadvantages, including added packaging weight and added packaging length to the exhaust system, as well as the highly corrosiveness and poor lubricity of aqueous urea.
- It would be advantageous to provide methods and apparatus for addressing the regulations and standards without adding weight or length to an already complex diesel exhaust system. Accordingly, it would be advantageous to provide methods and apparatus for injecting a NOx reducing reagent into the diesel exhaust stream of a lean burn engine where little or no added weight or packaging length is required. Further, it would be advantageous to provide a mixing system which creates a more homogenous mixture in a limited length. It would also be advantageous to provide an injector which is capable of distributing the reagent more uniformly throughout a cross-section of the treatment area. Accordingly, it would be advantageous to provide multiple injection points within a diesel exhaust stream.
- The methods and apparatus of the present invention provide the foregoing and other advantages.
- There is disclosed herein an improved diesel exhaust treatment system and method which avoid disadvantages of prior devices and methods, while affording additional structural and operating advantages.
- Generally speaking, a mixing device for a diesel exhaust system is disclosed having a chamber, a mixer within the chamber, and an injection tube supported on the mixer within the chamber. The mixer is positioned within the chamber adjacent an inlet and includes a plurality of angled blades to effect turbulent flow in a diesel exhaust stream entering the chamber through the inlet.
- In specific embodiments of the system, the injection tube includes a plurality of injection points (e.g., openings) for discharging a reagent into the exhaust stream. The injection tube is curved, and more specifically it is coiled with the injection points spread along the length of the tube in order to deliver reagent across a section of the chamber perpendicular to the exhaust stream flow.
- The disclosed method for mixing gaseous ammonia in a diesel exhaust system begins with a diesel exhaust stream from a diesel engine passing from the engine through a conduit in fluid communication with the engine. The exhaust stream is directed to flow through the conduit into a housing having a mixer, an injection tube and an exit disposed therein. Turbulent flow in the diesel exhaust stream is created within the housing as the stream passes through the mixer. A continuous injection of gaseous NH3 from the injection tube into the diesel exhaust stream is made as the stream moves from the mixer toward the housing exit to create a treated homogenous exhaust stream. Finally, the treated exhaust stream is discharged through the housing exit.
- These and other aspects of the invention may be understood more readily from the following description and the appended drawings.
- For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
-
FIG. 1 is a schematic illustrating a typical mixer/injector device in a diesel exhaust system; -
FIG. 2 is a schematic illustrating an embodiment of a mixer/NH3 injection device of the present invention in a diesel exhaust system; -
FIG. 3 is a schematic illustrating another embodiment of a mixer/NH3 injection device of the present invention in a diesel exhaust system; -
FIG. 4 is a front view of an embodiment of a mixer/NH3 injection device; and -
FIG. 5 is a perspective view of the mixer/NH3 injection device ofFIG. 4 . - While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated.
- Referring to
FIG. 1 , there is illustrated a typical mixer/injector device. Exhaust is discharged from thediesel engine 100, through conduit such as exhaust piping to anexhaust treatment system 110. Theexhaust treatment system 110 typically consists of, in downstream order, a diesel oxidation catalyst (DOC) 112, a diesel particulate filter (DPF) 114, a mixer/NH3 treatment canister 116, and a NOx slip catalyst (NSC) 118. TheDOC 112, DPF 114 andNSC 118 are additional exhaust treatment structures present in most diesel exhaust treatment systems and which form no part of thepresent system 10. Such structures will be generally referenced herein and identified in the drawing figures but, as each of these additional exhaust treatment structures is commonly understood by those skilled in the art, a detailed discussion of each is avoided for the purpose of focusing discussion on thesystem 10 as set forth in the appended claims. - The mixer/
treatment canister 116 is shown to include aconnection pipe 120 with aninjector 122 at the upstream end where NH3—or an NH3 containing reagent—is injected into a laminar diesel exhaust flow as it is discharged from theDOC 112 andDPF 114. The ammonia/exhaust stream then passes through amixer 124 to effect mixing of the NH3 and the diesel exhaust. A substantial length ofpipe 120 is needed to allow for adequate mixing of the two components before the flow enters theNSC 118. As such, the mixer/injector system adds packaging length and weight to thediesel exhaust system 100 which might otherwise be used for other after-treatment substrates. - Referring to
FIGS. 2-5 , there is illustrated a mixer/NH3 injection system, generally designated by thenumeral 10. Thesystem 10 is shown in two distinct exhaust treatment configurations.FIG. 2 illustrates a configuration similar to that ofFIG. 1 where the downstream order of components isDOC 12, thenDPF 14 andNSC 18 sandwiched aboutsystem 10. Alternatively,FIG. 3 illustrates a configuration where theNSC 18 is on theDPF 14—i.e., NOx slip catalyst on diesel particulate filter (NPF) 19—sandwiching thesystem 10 with theDOC 12. Other configurations may exist in which thesystem 10 is moved up or downstream in the exhaust flow. - Regardless of the specific configuration, it is clear from examination of
FIGS. 2 and 3 that the packaging space required forsystem 10 is substantially reduced from that required for a typical mixer/injector device 110 illustrated inFIG. 1 . - Generally speaking,
system 10 is comprised of ahousing 20 defining amixing chamber 25, aninjection tube 22 fed by anexterior injector boss 30 coupled to a supply (not shown), and amixer 24.FIGS. 2 and 3 illustrate the diameter of the housing 20 (approx. 12 inches (30.5 cm)) is substantially equal to that of the surrounding structures—e.g.,DPF 14 andNSC 18. By providing the larger diameter system housing 20 (vs. narrow connecting pipe 120), the need for reducers 123 (FIG. 1 ) is eliminated, further reducing the packaging size of the entire diesel exhaust treatment system. -
FIGS. 4 and 5 illustrate a specific embodiment of a single-plane, coiledinjection tube 22.Injection tube 22 enters through the housing sidewall and begins a tortuous path to a center of thechamber 25. Thetube 22 includes a series ofinjection points 23 where reagent can be emitted into thechamber 25. The injection points 23 are spaced along thetube 22 and, therefore, throughout a cross-section of thechamber 25 to provide a more uniform distribution of reagent throughout that cross-section of the mixingchamber 25. The uniform distribution into the exhaust stream results in a more homogenous mixture of reagent and exhaust in a shorter mixing period. - The
tube 22 may be configured in several alternative shapes, including circular and serpentine, so long as a distribution of the injection points 23 throughout a cross-section of the chamber is provided. Further, the injection points 23 comprise small openings in thetube 22 to allow discharge of the reagent from thetube 22. To effect a uniform or even discharge from all the injection points 23, the first opening has a very small diameter and successive opening diameters increase toward thetube end 27—i.e., the smallest diameter openings are positioned at the beginning of the tube where the fluid pressure is the greatest. The purpose, again, is to achieve even distribution of reagent across the entire cross-section of the mixingchamber 25. - Also shown in
FIGS. 4 and 5 , isexhaust flow mixer 24. Themixer 24 is comprised of a plurality of fixedblades 37, four are shown, secured to one another at a midpoint and outwardly to and within a short section (approx. six inches (15.2 cm)) of thehousing 20. Theblades 37 are angled from back to front as a way of imparting a turbulent flow to the substantially laminar exhaustflow entering system 10. Though not shown, additional blade configurations are possible to achieve the desired turbulent exhaust flow for mixing. - Another feature of the
mixer 24 is that it supports theinjection tube 22. That is, thetube 22, which is positioned on the downstream side of themixer 24, attaches to, by way of welds or any other suitable attachment means, each of themixer blades 37 for simple structural support. Attachment may be achieved, for example, at theareas 39 where thetube 22 crosses eachblade 37. The securing of the coiledtube 22 alleviates damage which might otherwise be caused by the more violent vibration of thetube 22 during operation of the vehicle. Reagent (e.g., gaseous NH3) discharged from injection points 23 immediately enters the turbulent diesel exhaust stream as it moves toward the chamber exit 35 (FIGS. 2 and 3 ). A relatively short distance is needed to provide the necessary mixing time to create a homogonous reagent/diesel exhaust. - The homogenous mixture is then exited from the mixing
chamber 25 into one of either the NSC 18 (FIG. 2 ) or the NPF 19 (FIG. 3 ) for further treatment. - The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
Claims (27)
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US12/723,244 US20110219745A1 (en) | 2010-03-12 | 2010-03-12 | Method and apparatus for gaseous mixing in a diesel exhaust system |
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US12/723,244 US20110219745A1 (en) | 2010-03-12 | 2010-03-12 | Method and apparatus for gaseous mixing in a diesel exhaust system |
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US12/723,244 Abandoned US20110219745A1 (en) | 2010-03-12 | 2010-03-12 | Method and apparatus for gaseous mixing in a diesel exhaust system |
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US10794252B1 (en) * | 2019-04-18 | 2020-10-06 | Faurecia Emissions Control Technologies, Usa, Llc | Direct spray exhaust mixer system |
US10883407B1 (en) * | 2019-07-26 | 2021-01-05 | Faurecia Emissions Control Technologies, Usa, Llc | Automotive aftertreatment system having a tubular injector |
US20210025311A1 (en) * | 2019-07-26 | 2021-01-28 | Faurecia Emissions Control Technologies, Usa, Llc | Automotive aftertreatment system having a tubular injector |
US11203966B1 (en) | 2020-09-30 | 2021-12-21 | Faurecia Emissions Control Technologies, Usa, Llc | Circular sampling device for an exhaust gas sensor |
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