Inlet Module for an Emissions Cleaning Module

TECHNICAL FIELD

The disclosure relates to an apparatus for use in cleaning of fluids emitted during the operation of combustion engines.

BACKGROUND

Engines, for example IC engines burning gasoline, diesel or biofuel, output various harmful substances which must be treated to meet current and future emissions legislation. Most commonly those substances comprise hydrocarbons (HC), carbon monoxides (CO), mono-nitrogen oxides (NO_x) and particulate matter, such as carbon (C), a constituent of soot. Some of those substances may be reduced by careful control of the operating conditions of the engine, but usually it is necessary to provide an emissions cleaning module downstream of the engine to treat at least some of those substances entrained in the exhaust gas. Various apparatus for reducing and/or eliminating constituents in emissions are known. For example, it is known to provide an oxidation device, such as a diesel oxidation catalyst, to reduce or to eliminate hydrocarbons (HC) and/or carbon monoxide (CO). Oxidation devices generally include a catalyst to convert those substances into carbon dioxide and water, which are significantly less harmful. As a further example, emissions cleaning modules may include filtration devices to restrict the particulates present in the exhaust gas from being output to atmosphere. The soot collected in the filtration device must later be removed to maintain the efficiency of the filtration device. The methods by which soot may be removed from the filtration device are well known in the art and may generally be referred to as regeneration which occurs at elevated temperatures. In addition, it is known to reduce or eliminate mono-nitrogen oxides (NO_x) in diesel combustion emissions by conversion to diatomic nitrogen (N₂) and water (H₂O) by catalytic reaction with chemicals such as ammonia (NH₃) entrained in the exhaust gas. Generally ammonia is not present in exhaust gas and must therefore be introduced upstream of a catalyst, typically by injecting a urea solution into the exhaust gas which decomposes into ammonia at sufficiently high temperatures.

By these methods, engine emissions can be cleaned, meaning that a proportion of the harmful substances which would otherwise be released to atmosphere are instead converted to carbon dioxide (CO₂), nitrogen (N₂) and water (H₂O).

To ensure most efficient operation of the emissions cleaning module it may be desirable to create a uniform flow of the exhaust gases within the conduits of the module. This may allow better operation of the stages within the module, such as an oxidation device. It has been found that the geometry of the exhaust gas pipework connected to the emissions cleaning module which supplies the exhaust gases may affect the uniformity of flow within the conduits. In turn, this may affect the efficient operation of the emissions cleaning module.

Against this background there is provided an inlet module for an emissions cleaning module for a diesel engine. There is also provided an emissions cleaning module comprising such an inlet module.

SUMMARY OF THE DISCLOSURE

The inlet module, for an emissions cleaning module of a combustion engine, may comprise:

• • an inlet for receiving exhaust gases from the combustion engine;
  • an outlet for directing said exhaust gases into an inlet of the emissions cleaning module; and
  • a flow distributor located in a flow path of the exhaust gases between the inlet and the outlet of the inlet module;
  • wherein the flow distributor comprises a plurality of apertures through which, in use, the exhaust gases pass.

The emissions cleaning module may comprise an inlet module as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 shows an emissions cleaning module to which can be connected an inlet module of the present disclosure;

FIG. 2 shows the emissions cleaning module of FIG. 1 from another angle showing the inlet module;

FIG. 3 shows an end view of the outside of the inlet module;

FIG. 4 shows a perspective view of the inside of the inlet module;

FIG. 5 shows an exploded perspective view of the inlet module of FIG. 4;

FIG. 6 shows a perspective view of a tubular member of the inlet module of FIG. 4;

FIG. 7 shows an arrangement of aperture zones of the tubular member of FIG. 4;

FIG. 8 shows aperture arrangements of the aperture zones of FIG. 7;

FIG. 9a shows a first exhaust pipe arrangement and FIGS. 9b and 9c show a comparison of flow uniformity in the emissions cleaning module when gas is supplied using that first exhaust pipe arrangement;

FIG. 10a shows a second exhaust pipe arrangement and FIGS. 10b and 10c show a comparison of flow uniformity in the emissions cleaning module when gas is supplied using that second exhaust pipe arrangement;

FIG. 11a shows a third exhaust pipe arrangement and FIG. 11 b and 119c show a comparison of flow uniformity in the emissions cleaning module when gas is supplied using that third exhaust pipe arrangement;

FIGS. 12 to 14 show a comparison of flow uniformity in the emissions cleaning module of FIGS. 1 and 2 when varying flow rate and gas temperature.

DETAILED DESCRIPTION

The present disclosure is directed to an inlet module 2 for use with an emissions cleaning module 1.

The emissions cleaning module 1 is illustrated in FIG. 1. The inlet module 2, suitable for use with the emissions cleaning module 1, is illustrated in FIG. 4, and is shown connected to the emissions cleaning module 1 in FIGS. 2 and 3.

The emissions cleaning module 1 may comprise a first conduit 10, a second conduit 20, a third conduit 30, and a support structure 40. The support structure 40 may comprise a first support member 50 and a second support member 60.

Each support member 50, 60 may be generally planar and may be of rigid material, for example metal.

The first, second and third conduits 10, 20, 30 may be elongate, having an axis of elongation, and may have substantially constant cross-section along the axis of elongation. The first, second and third conduits 10, 20, 30 may be substantially cylindrical.

The first conduit 10 may comprise a first end 11 providing an inlet to the conduit and a second end 12 providing an outlet to the conduit. The second conduit 20 may comprise a first end 21 providing an outlet to the conduit and a second end 22 providing an inlet to the conduit. The third conduit 30 may comprise a first end 31 providing and inlet to the conduit and a second end 32 providing an outlet to the conduit.

The conduits 10, 20, 30 may extend between the support members 50, 60. The conduits 10, 20, 30 may be generally substantially parallel. The first ends 11, 21, 31 of the first, second and third conduits 10, 20, 30 may be received in and may be shaped to correspond with first, second and third openings (not shown), respectively, of the first support member 50. The second ends 12, 22, 32 of the first, second and third conduits 10, 20, 30 may be received in and may be shaped to correspond with first, second and third openings (not shown), respectively, of the second support member 60. By this arrangement, lateral movement of the conduits may be restricted.

The conduits 10, 20, 30 may all be of substantially similar length. The first conduit 10 may have a first diameter, the second conduit 20 may have a second diameter and the third conduit 30 may have a third diameter. The second diameter may be smaller than the first and third diameters.

The first and second ends 11, 21, 31, 12, 22, 32 of the conduits 10, 20, 30 may be welded, adhered or otherwise secured to portions of the support members 50, 60 defining or surrounding the openings. Alternatively, first and second ends 11, 21, 31, 12, 22, 32 of the conduits 10, 20, 30 may abut the inner sides of the support members 50, 60 so as to overlie respective openings in the support members 50, 60.

The first, second and third conduits 10, 20, 30 and the first and second support members 50, 60 may be interconnected in a manner which restricts relative translational movement of those components. Instead or in addition, the first, second and third conduits 10, 20, 30 and the first and second support members 50, 60 may be interconnected in a manner which restricts rotational movement of one component with respect to another.

The first conduit 10 may be coupled to the second conduit 20 via a first end coupling 15 for fluidly connecting the outlet of the first conduit to the inlet of the second conduit. The first end coupling 15 may comprise an injector module 16. The second conduit 20 may be coupled to the third conduit 30 via a second end coupling 25 for fluidly connecting the outlet of the second conduit to the inlet of the third conduit. Each of the first and second end couplings may define, in combination with its respective support member, a flow path through which exhaust gas may pass between adjacent conduits.

The inlet module 2 may be connected to, or otherwise integrated with, the first end 11 of the first conduit 10 such that fluid may pass from the inlet module 2 into a first portion of the first conduit 10. The inlet module 2 may act to produce a more uniform flow of fluids, such as exhaust gases, across the cross-section of the first conduit 10. Alternatively, the inlet module 2 may be connected to, or otherwise be integrated with, the support member 50 and arranged over the first opening in that support member.

The inlet module 2 may comprise a housing 100 defining a cavity 101 in which may be arranged a flow distributor 106. The housing 100 may be in the form of an end cap which may comprise a closed end face 103 and a dependent side wall 104. Alternatively, the housing may be dome shaped. The end cap may be generally circular in cross section. An end of the end cap opposite the closed end face 103 may be open which may define an outlet 105 of the inlet module 2. A rim 107 of the side wall 104 may be provided with a fastening mechanism for connecting the inlet module 2 to the first end 11 of the first conduit 10 or to the support member 50. The fastening mechanism may be, for example, a threaded screw fit or a clamping mechanism. A sealing member may be provided interposed between the inlet module 2 and the first end 11 of the first conduit 10 which may help to provide a fluid tight seal between the inlet module and the first conduit 10.

Alternatively, the inlet module 2 may be integrated with the first end 11 by, for example, welding or by an interference push-fit.

The flow distributor 106 may comprise a tubular member 108 which may extend at least part way into or across the cavity 101 in the housing 100. The tubular member 108 may comprise an open first end 109. The first end 109 may itself define an inlet of the inlet module 2. Alternatively, and as illustrated, a shaped connector 110 may be provided which may be attached to the first end 109 of the tubular member. The shaped connector 110 may define the inlet 111 of the inlet module 2 and may be sized and shaped so as to be configured to be connected to an exhaust conduit or hose of a combustion engine.

The tubular member 108 may be arranged transverse to the end cap, as shown in FIGS. 4 and 5. The tubular member 108 may extend through a first side wall aperture 120 formed in the side wall 104 at one point of the end cap towards and into contact with an end piece 113 which may itself be received in a second side wall aperture 121 of the end cap at a point on an opposite side of the end cap. The end piece 113 may serve to close off an open second end 112 of the tubular member 118, opposite the open first end 109. The tubular member 108 may be spaced from the closed end face 103. The tubular member 108 may form a structural member which may serve to strengthen the end cap. Alternatively, the second end 112 may locate against an inner surface of the side wall and be secured in place to restrict relative movement of those parts.

The tubular member 108 may define a conduit within the tubular member 108 through which exhaust gases may flow in use. The tubular member 108 may be configured to have a substantially oval cross sectional shape in its transverse plane perpendicular to the elongate axis of the tubular member 108. This may allow for a smaller depth for the end cap.

The tubular member 108 may be formed from stamped and rolled stainless steel which may be welded to form a closed tubular section. Alternatively, it may be extruded or cast.

The tubular member 108 may comprise a first face 108a which may be directed towards the outlet 105 of the end cap and a second, opposed face 108b which may be directed towards the closed end face 103 of the end cap. The first and second faces may be connected by curved side sections 108c of the tubular member 108. The faces 108a and 108b may be flat or substantially flat.

The flow distributor 106 may comprise a plurality of apertures 114 through which, in use, the exhaust gases pass into the cavity 101. There may be provided a large plurality of apertures 114. The apertures 114 may be provided in the tubular member 108 and may be arranged into a plurality of zones having predefined aperture areas which may vary depending on the location of the zones. The number of apertures 114 in each zone, the size of apertures 114 in each zone and/or the spacing of apertures 114 in each zone may be varied so that the resistance to the passage of exhaust gases out of the flow distributor 106 may be configured to vary between zones.

In the illustrated embodiment of FIGS. 4 to 8, by way of example only, the apertures 114 are varied in terms of their number and/or spacing in each zone. As shown in FIGS. 7 and 8, three types of zone A, B, C may be provided.

A zone of type A may be provided with apertures 114a of diameter 5 mm, where the apertures 114a may be arranged in rows. The apertures 114a in each row may have a centre-to-centre spacing of 15 mm. The rows may have a spacing of 7.5 mm. Consequently, the percentage open area of the zone (defined as sum of the area of the apertures in the zone as a percentage of the total area of the zone) may be 17.5%. The zone of type A may present, relatively, a medium resistance to outflow of gas. The percentage open area of the zone may be 10 to 25%.

A zone of type B may be provided with apertures 114b of diameter 5 mm, where the apertures 114b may be arranged in rows. The apertures 114b in each row may have a centre-to-centre spacing of 15 mm. The rows may have a spacing of 15 mm. Consequently, the percentage open area of the zone may be 8.75%. The zone of type B may present, relatively, a high resistance to outflow of gas. The percentage open area of the zone may be 5 to 12%. The percentage open area of the zone of type B may be half that of the zone of type A.

A zone of type C may be provided with apertures 114c of diameter 5 mm, where the apertures 114c may be arranged in rows. The apertures 114c in each row may have a centre-to-centre spacing of 7.5 mm. The rows may have a spacing of 7.5 mm. Consequently, the percentage open area of the zone (defined as sum of the area of the apertures in the zone as a percentage of the total area of the zone) may be 35%. The zone of type C may present, relatively, a low resistance to outflow of gas. The percentage open area of the zone may be 20 to 50%. The percentage open area of the zone of type C may be twice that of the zone of type A.

The first face 108a of the tubular member 108 may be provided with a zone of type A nearest the first end 109 and a zone of type B nearest the second end 112. The zone of type A may extend approximately two-thirds of the length of the tubular member 108, while the zone of type B may extend approximately one-third of the length.

The second face 108b of the tubular member 108 may be provided with a zone of type C nearest the first end 109 and a zone of type A nearest the second end 112. The zone of type C may extend approximately two-thirds of the length of the tubular member 108, while the zone of type A may extend approximately one-third of the length.

Likewise, the curved side sections 108c of the tubular member 108 may be provided with a zone of type C nearest the first end 109 and a zone of type A nearest the second end 112. The zone of type C may extend approximately two-thirds of the length of the tubular member 108, while the zone of type A may extend approximately one-third of the length.

While not wishing to be bound by theory, it is thought that a more uniform flow may be obtained when the zone with the greatest percentage open area is positioned facing the closed end 103 of the end cap. This may allow for a greater percentage of the incoming flow of exhaust gases to be reflected off the closed end face 103 of the end cap which may allow for enhanced mixing and uniformity of the flow as it enters the inlet 11 of the first conduit 11 of the emissions cleaning module 1.

The inlet module 2 may act to produce a more uniform flow of fluids, such as exhaust gases, across the cross-section of the first conduit 10 as illustrated in FIGS. 9 to 14. The uniformity of gas flow across a cross-section of a conduit may be characterised by the Gamma Uniformity Index, γ:

γ

=

1

-

1

2



∑

i

=

1

n







v

i

-

v

_





A

i

v

_

·

A

where:

• • n is the number of channels in the substrate cross section
  • v_i is the velocity in channel i
  • v is mean velocity over the substrate cross section
  • A_i is the channel cross section area
  • A is the substrate cross section area

FIGS. 9a, 10a and 11a illustrate three different configurations of exhaust gas pipework 130 that may be connected to the shaped connector 110 of the inlet module 2. In FIG. 9a the connected pipework 130a is relatively straight, with only a slight dog-leg in the vicinity of the shaped connector 110. In FIG. 10a the connected pipework 130b comprises a 90 degree bend on approach to the shaped connector 110. In FIG. 11a the connected pipework 130c comprises two 90 degree bends on approach to the shaped connector 110.

FIGS. 9c, 10c and 11c illustrate the respective flow uniformity for the three configurations with a standard end cap with no flow distributor 106. FIGS. 9b, 10b and 11 b illustrate the respective flow uniformity for the three configurations with the inlet module 102 of the present disclosure in use. The Gamma Uniformity Indices are given in the table below:

Gamma Uniformity Index, γ

Configuration

Standard end cap

With inlet module 2

FIG.  9a

0.75

0.96

FIG. 10a

0.75

0.95

FIG. 11a

0.87

0.96

As can be seen, use of the inlet module 2 may advantageously significantly increase the uniformity of flow across the cross-section. It also, advantageously, may produce a highly uniform flow independent of the geometrically configuration of the upstream exhaust gas pipework 130.

As illustrated in FIGS. 12 to 14, use of the inlet module 2 may advantageously produce a highly uniform flow irrespective of the temperature and/or flow rate of the exhaust gases. The Gamma Uniformity Indices are given in the table below:

Temperature

Gamma

Flow rate

degrees

Uniformity Index

kg/hr

Celsius

γ

FIG. 12

1117.5

465

0.96

FIG. 13

1044

405

0.96

FIG. 14

714

513

0.97

As can be seen, use of the inlet module 2 may advantageously significantly increase the uniformity of flow across the cross-section even with varying temperature and flow rate of exhaust gases.

An outlet for fluid from the emissions cleaning module 1 may be provided at the second end 32 of the third conduit such that fluid may be released from the emissions cleaning module 1, perhaps into atmosphere. The outlet may comprise a flow distributor which may also be of the type shown in FIG. 4.

Within the fluid flow path of the emissions cleaning module 1 there may be located a diesel oxidation catalyst (DOC) module, a diesel particulate filter (DPF) module, an injector module, a mixer module, a selective catalyst reduction (SCR) module and an ammonia oxidation catalyst (AMOX) module.

The DOC module may be located in a first portion of the first conduit 10 towards the first, inlet, end 11 of the first conduit 10. The DPF module may be located in a second portion of the first conduit 10 towards the second, outlet, end 12 of the first conduit 10. The first end coupling 15 may provide a fluid flow path from the second end 12 of the first conduit 10 to the second end 22 of the second conduit 20. The first end coupling 15 may comprise the injector module 16.

A mixer module may be located in the second conduit 20. The mixer module may be configured to mix a fluid injected by the injector module 16 with a fluid arriving from the first conduit 10. The mixer module may comprise multiple features, such as interspersed fins, which may give rise to an even blend of the injected fluid with the fluid from the first conduit 10. The second end coupling 25 may provide a fluid flow path from the first end of the second conduit to the first end of the third conduit.

The SCR module may be located in a first portion of the third conduit 30 towards the first end 31 of the third conduit 30. The SCR module may comprise a catalyst surface intended to catalyse a reaction to occur between the two fluids mixed in the mixer module and output by the diffuser. The AMOX module may both be located in a second portion of the third conduit 30 towards the second end 32 of the third conduit 30. The AMOX module may comprise a catalyst which may catalyse a reaction of one or more of the products output from the SCR module.

The emissions cleaning module 1 may comprise one or more sensors for sensing one or more conditions in the emissions cleaning module 1, such as temperature or quantity of NO_x. Each sensor may penetrate a conduit 10, 20, 30 of the emissions cleaning module such that those elements of the sensor (i.e. electronic components) which need not be located within a volume to be sensed may be located on an exterior surface of the conduit 10, 20, 30. In this manner, sensitive elements of the sensors can be located away from high temperatures likely to occur inside the conduit. The sensors may be arranged such that those elements of the sensors located on the exterior surface of the third conduit may be distributed in a fashion which is diagonal to a line parallel to the elongate axis of the third conduit. This may allow for increased air flow so as to reduce damage to the sensors which might otherwise be caused due to heat.

In use, fluid, such as exhaust gases, may be supplied to the emissions cleaning module 1 via the inlet module 2.

The fluid may enter the inlet module 2 through the inlet 111 defined by the shaped connector 110. The fluid may then pass through the first end 109 of the tubular member and along the conduit defined by the tubular member 108. As the fluid passes along the conduit it may flow out through the apertures 114 into the cavity 101 of the end cap. From the cavity 101 the fluid may exit through the outlet 105 into the inlet of the first conduit 10. Due to the plurality of the zones of the tubular member 108, which may present different resistances to flow of the fluid exiting the tubular member 108, the flow distributor 106 may produce a more uniform flow of fluid into the first conduit 11. This may have the advantage that the fluid flow reaching the first and subsequent modules, for example the diesel oxidation catalyst (DOC) module and the diesel particulate filter (DPF) module, is more uniform. Consequently, a more efficient treatment of the fluid by those modules may be achieved.

Fluid may pass into the DOC module in the first portion of the first conduit 10. Prior to receipt at the inlet module 2, the pressure of the fluid may be controlled by a back pressure valve.

The DOC module may comprise one or more catalysts, such as palladium or platinum. These materials serve as catalysts to cause oxidation of hydrocarbons ([HC]) and carbon monoxide (CO) present in the fluid flow in order to produce carbon dioxide (CO₂) and water (H₂O). The catalysts may be distributed in a manner so as to maximise the surface area of catalyst material in order to increase effectiveness of the catalyst in catalysing reactions.

Fluid may flow from the DOC module to the DPF module which comprises features which are intended to prevent onward passage of carbon (C) in the form of soot. Carbon particles in the fluid may thus trapped in the filter. The filter may be regenerated through known regeneration techniques. These techniques may involve controlling one or more of the temperature of the fluid, the pressure of the fluid and the proportion of unburnt fuel in the fluid.

Fluid may pass from the DOC module into the injector module 16 located within the first end coupling 15. The injector module 16 may be associated with or attachable to a pump electronic tank unit (PETU). The pump electronic tank unit may comprise a tank for providing a reservoir for fluid to be injected by the injector. Such fluids may include urea or ammonia. The tank may comprise a lower portion having a first cross sectional area and an upper portion having a second cross sectional area. The second cross sectional area may be smaller than the first cross sectional area. The difference in cross sectional area between the first and second portions may provide for a volume to house additional components of the PETU. This may provide better protection than if components were simply attached to an otherwise external surface of the tank.

The PETU may further comprise a controller configured to control a volume of fluid to be injected from the tank by the injector. The controller may have as inputs, for example, temperature information and quantity of NO_x information which may be derived from sensors in the SCR module.

Fluid may pass from the injector module 16 into the mixer module located in the second conduit 20. The mixer module may comprise features for ensuring that the fluid originating from the first conduit 10 is well mixed with the fluid originating from the injector 16.

Fluid may pass from the injector module 16 into the SCR module located in the first portion of the third conduit via the second end coupling 25. The SCR module may comprise one or more catalysts through which the mixture of exhaust gas and urea/ammonia may flow. As the mixture passes over the surfaces of the catalyst a reaction may occur which converts the ammonia and NO_x to diatomic nitrogen (N₂) and water (H₂O).

Fluid may pass from the SCR module to the AMOX module located in the second portion of the third conduit 30. The AMOX module may comprise an oxidation catalyst which may cause residual ammonia present in the fluid exiting the SCR module to react to produce nitrogen (N₂) and water (H₂O).

Fluid may pass from the AMOX module to the emissions cleaning module outlet located at the second end 32 of the third conduit 30.

In the above, the flow distributor 106 has been described as a tubular member 108. Alternatively, the flow distributor 106 may take another geometric form, for example a wall or partition which may divide the cavity 101 of the inlet module 2 into two or more sections.

INDUSTRIAL APPLICABILITY

The present disclosure finds application in improving inlet flow of exhaust gases into an emissions cleaning module.