The present disclosure relates generally to a emissions system mounting device and, more particularly, to an emissions system mounting device which includes at least one device configured to mix reductant into a flow of exhaust.
Conventional diesel powered systems for engines, factories, and power plants produce emissions that contain a variety of pollutants. These pollutants may include, for example, particulate matter (e.g., soot), nitrogen oxides (NOx), and sulfur compounds. Due to heightened environmental concerns, engine exhaust emission standards have become increasingly stringent. In order to comply with emission standards, machine manufactures have developed and implemented a variety of exhaust treatment components to reduce pollutants in exhaust gas prior to the exhaust gas being released into the atmosphere. The exhaust treatment components may include, for example, a diesel particulate filter, a selective catalytic reduction device, a diesel oxidation catalyst, a fuel-fired burner for regeneration of the diesel particulate filter, a muffler, and other similar components.
Frequently these exhaust treatment components, including their associated sensors and electronics, are mounted individually in an exhaust system within the available space using individual brackets. However, due to the increasing complexity and number of exhaust treatment components and the small amount of available space, mounting and interconnecting exhaust treatment components has proven difficult.
One method for combining exhaust treatment devices in a casing is disclosed in U.S. Patent Publication No. 2006/0264296 (the '296 publication) to Theis. Specifically, the '296 publication discloses a casing that supports a first lean NOx trap (LNT), a second LNT, and a selective catalytic reduction (SCR) device. The casing also supports a first port for introducing an exotherm generating agent and a second port for introducing a reducing agent. The second port is located upstream of the SCR. The reducing agent may be introduced from the second port into the exhaust flow in order to precondition the SCR. In addition, there may be a gap between the LNT and the SCR to facilitate mixing.
Although the system of the '296 publication may disclose a casing with both an LNT and an SCR for remediating emissions, the '296 system may have limitations. For example, the '296 system may only achieve limited mixing of the reductant with the exhaust flow, potentially resulting in poor NOx reduction.
The disclosed device is directed to overcoming one or more of the problems set forth above.
In one aspect, the present disclosure is directed to an emissions control system. The emissions control system may include a first exhaust treatment device. The emissions control system may also include an end cap defining a mixing chamber connected to an end of the first exhaust treatment device. The mixing chamber may be configured to promote mixing between a flow of exhaust received from the first exhaust treatment device and a reductant. The emissions control system may further include a second exhaust treatment device configured to receive the flow of exhaust and reductant after it passes through the mixing chamber.
In another aspect, the present disclosure is directed to another emissions control system. The emissions control system may include a first bracket and a second bracket coupled to the first bracket. The emissions control system may also include a first exhaust treatment device supported by the first bracket and the second bracket. The emissions control system may further include a second exhaust treatment device supported by the first bracket and the second bracket. The emissions control system may also include a conduit having a static mixer. The conduit may be supported by the first bracket and the second bracket. The conduit, the first exhaust treatment device, and the second exhaust treatment device may be fluidly communicated via one or more connectors. The one or more connectors may connect the first exhaust treatment device, the second exhaust treatment device, and the conduit in a side-by-side orientation.
In a further aspect, the present disclosure may be directed at another emissions control system. The emissions control system may include a mount. The emissions control system may also include a diesel particulate filter supported by the mount. The emissions control system may further include at least one of a lean NOx trap or a selective catalytic reduction device supported by the mount. The emissions control system may also include an end cap defining a mixing chamber connected to an end of the diesel particulate filter. The mixing chamber may be configured receive a flow of exhaust from the diesel particulate filter and an injected reductant.
Exhaust system 14 may direct exhaust from power source 12 via an exhaust conduit 23 to an emissions control system 16. After passing through emissions control system 16, the exhaust may be directed to the atmosphere. Emissions control system 16 of exhaust system 14 may be configured to monitor, control, and/or modify exhaust emissions. Emissions control system 16 may include one or more exhaust treatment devices 22, electronics 24 associated with the exhaust treatment devices 22, and a mount 26.
Exhaust treatment devices 22 may be devices configured to reduce emissions of harmful gasses, particulate matter, and/or noise emitted from power source 12. Each exhaust treatment device 22 may embody, for example a diesel oxidation catalyst (DOC), a particulate filter (PF or DPF), a selective catalytic reduction (SCR) device, a lean NOx trap (LNT), a muffler, a regeneration device, a reductant mixing device, or any other exhaust treatment device known in the art. It is contemplated that each exhaust treatment device 22 may also comprise a combination of exhaust treatment devices, such as, for example, a combination of a DOC and a DPF; a combination of a catalyst and a DPF (i.e., a CDPF); a combination of a DOC, a DPF, and an SCR; or other combinations known in the art.
Electronics 24 may be configured to monitor and/or control operation of exhaust treatment devices 22. Electronics 24 may include one or more electronic devices, such as, for example, sensors, microprocessors, power supply circuitry, signal conditioning circuitry, actuator driving circuitry, solenoids, relays, electronic valves, coils, and/or other types of electronics and circuitry known in the art. For example, electronics 24 may include a microprocessor and other electronic hardware configured to control injection of a reductant into one of exhaust treatment devices 22 (e.g., reductant for SCR or LNT). Electronics 24 may also include a microprocessor and other electronic hardware configured to control a regeneration process for one of exhaust treatment devices 22 (e.g., regeneration of DPF).
As shown in
Each of first and second brackets 28 and 30 may include a first support surface 34. First support surface 34 of first bracket 28 and first support surface 34 of second bracket 30 may be configured to support each end of a first exhaust treatment device 36. Each of first and second brackets 28 and 30 may also include a second support surface 38. Second support surface 38 of first bracket 28 and second support surface 38 of second bracket 30 may be configured to support each end of a second exhaust treatment device 40. In addition to connecting first and second brackets 28 and 30, one or more of cross members 32 may be configured to support a middle portion of first exhaust treatment device 36 and/or second exhaust treatment device 40.
It is contemplated that a geometry of first support surface 34 may be shaped to match an outer geometry of first exhaust treatment device 36 and a geometry of second support surface 38 may be shaped to match an outer geometry of second exhaust treatment device 40. For example, when first and second exhaust treatment devices 36 and 40 are shaped as canisters, first and second support surfaces 34 and 38 may have generally arcuate surfaces with substantially the same radii of curvature as first and second exhaust treatment devices 36 and 40, respectively.
As seen in
Returning to
Mount 26 may also include a first aperture 42 in first bracket 28 and a second aperture 44 in second bracket 30. Each of first and second apertures 42 and 44 may include a third support surface 49. Third support surface 49 of first aperture 42 and third support surface 49 of second aperture 44 may be configured to support, for example, each end of a third exhaust treatment device 46.
It should be noted that first support surfaces 34, second support surfaces 38, and third support surfaces 49 may be located to allow for first, second, and third exhaust treatment devices, 36, 40, and 46, respectively, to be positioned in a compact, side-by-side, parallel orientation. For example, an axis A1 of first support surfaces 34, an axis A2 of second support surfaces 38, and an axis A3 of third support surfaces 49 may all be parallel. It is contemplated that mount 26 may be configured to allow for easy access and removal of each exhaust treatment device 22.
In an exemplary embodiment of emissions control system 16, first exhaust treatment device 36 may embody a diesel particulate filter, second exhaust treatment device 40 may embody a muffler, and third exhaust treatment device 46 may embody a mixing conduit 54. Mount 26 may also support or house a fourth exhaust treatment device 51 (see
Referring to
First and second connector 56 and 58 may embody, for example, elbow-type connectors. Specifically, first and second connector 56 and 58 may embody cobra-head connectors where a base portion 60 of first and second connectors 56 and 58 is wider than a terminal portion 62. Base portion 60 may have a substantially oval or elliptical shape while terminal portion 62 may have a substantially cylindrical shape to allow terminal portion 62 to mate with mixing conduit 54. It is contemplated that first and second connectors 56 and 58 may be formed integrally with first and second exhaust treatment devices 36 and 40, respectively. Alternatively, first and second connectors 56 and 58 may attach to first and second exhaust treatment devices 36 and 40, respectively, using mechanical fastening, welding, brazing, or any other appropriate fastening method. First and second connectors 56 and 58 may have a simple 90 degree bend or a curved bend.
Mixing conduit 54 may include an internal mixing device 63 (see
It is contemplated that with respect to the embodiment of emissions control system 16 and mount 26 depicted in
As shown in
Double end cap 70 may include a tumble mixer 71 located between first mixing chamber 73 and second mixing chamber 75. Similar to tumble flow generator 68, tumble mixer 71 may include a plurality of flow deflectors 79. Flow deflectors 79 of tumble mixer 71 may embody, for example, channels, baffles, or vanes configured to promote mixing of the reductant with the flow of exhaust and disperse the mixed exhaust and reductant into second mixing chamber 75. Flow deflectors 79 may be angled at any appropriate angle between 30° and 75°, and more specifically, at approximately 45°.
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Injector 74 may be a fluid injector configured to inject a reductant for dosing second exhaust treatment device 40. Injector 74 may embody any type of fluid injector known in the art. Injector 74 may fluidly communicate with fluid source 76 (e.g., a supply tank) to provide for repeated injections of reductant. The reductant may be, for example, gaseous ammonia, ammonia in aqueous solution, aqueous urea, ammonia from an ammonia generator, diesel fuel, or any other appropriate reductant known in the art. Injector 74 may be located upstream of second exhaust treatment device 40.
Referring to
Referring to
In some embodiments, injection system 72 may include a plurality of injectors 74 for injecting reductant. For example, the plurality of injectors 74 may be located radially around a perimeter of first connector 56, mixing conduit 54, end cap 64, or double end cap 70.
Controller 78 may be a device configured to control injector(s) 74. Controller 78 may embody a general machine microprocessor capable of controlling numerous machine functions. Controller 78 may include a memory, a storage device, a processor, and components known in the art. Various other circuits may be associated with controller 78, such as power supply circuitry, signal conditioning circuitry, data acquisition circuitry, signal output circuitry, signal amplification circuitry, and other types of circuitry known in the art. Controller 78 may be configured to selectively actuate injector 74 in order to dose second exhaust treatment device 40. It is contemplated that controller 78 may communicate with and actuate injector 74 based on input from one or more sensors (not shown), such as, for example, an NOx sensor, an ammonia sensor, a flow speed sensor, a pressure sensor, a temperature sensor, and other sensors known in the art.
The disclosed emissions control system may be applicable to any power system. The disclosed emissions control system may provide enhanced mixing of reductant for use with exhaust treatment devices. Operation of the disclosed power system will now be described.
Referring to
Referring to
In the embodiment shown in
It is contemplated that first and second connectors 56 and 58 may reverse a direction of fluid flow. In other words, a flow direction of the flow of exhaust may be reversed as the flow of exhaust passes from first exhaust treatment device 36, through first connector 56, and into mixing conduit 54. The flow direction of the flow of exhaust may be reversed again as the flow of exhaust passes from mixing conduit 54, through second connector 58, and into second exhaust treatment device 40. The two reversals of flow direction may create an “S” shaped flow path between first exhaust treatment device 36, third exhaust treatment device 46 (e.g., mixing conduit 54), and second exhaust treatment device 40. It is also contemplated that in some embodiments, the flow of exhaust may pass through fourth exhaust treatment device 51 (e.g., a regeneration device) prior to entering first exhaust treatment device 36.
The disclosed emissions control system may be applicable to any power system. The disclosed mount may provide a compact structure for mounting exhaust treatment devices in a power system, thus preserving space for other power system components. Additionally, the “S” shaped flow path created by the side-by-side exhaust treatment devices may reduce the overall length and size of the exhaust treatment system. Also, the disclosed mixing devices may ensure proper mixing and dispersion of the reductant into the exhaust gas before the exhaust gas reaches a downstream exhaust treatment device, thus improving performance of the disclosed emissions control system.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed emissions control system. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed emissions control system. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims.