AFTERTREATMENT SYSTEM

Abstract

A post-treatment module (164; 180, 182; 200; 300; 400) for insertion into a sleeve (166) arranged in a post-treatment module (120), the post-treatment module (164) comprising: a substrate matrix (210), the substrate matrix (210) extending between a first end face (220) and a second end face (222); a jacket (230) mounted around the substrate matrix (210), the jacket (230) extending between a first edge (232) proximate the first end face (220) and a second edge (234) proximate the second end face (222), the jacket (230) having an overhanging extension (240) extending between the first edge (232) and the first end face (220); and a removal aid (250) arranged on an inner surface (242) of the overhanging extension (240), the removal aid (250) enabling the removal of the post-treatment module (164) from the sleeve (166).

Description

Technical area

[0001] This patent disclosure relates generally to an exhaust aftertreatment system for reducing emissions from power systems such as large internal combustion engines, and more specifically to a system in which catalysts or aftertreatment modules can be occasionally removed and serviced. State of the art

[0002] Power systems, particularly internal combustion engines such as diesel engines, gasoline engines and natural gas burning turbines, produce a number of by-products and emissions during operation, including nitrogen oxide emissions such as NO and NO2, which are sometimes referred to as NO xIn response to increased government regulations regarding such emissions, manufacturers of internal combustion engines have developed measures to reduce the amount or impact of nitrogen oxides produced by the combustion process. One method is a chemical process called selective catalytic reduction (SCR), which may be referred to as SCR. In the SCR process, a gaseous or liquid reductant is introduced into the exhaust system, where the reductant may mix with the exhaust gases, or it may be adsorbed onto a catalyst located within the exhaust system downstream of the internal combustion engine. A common reductant is urea, although other suitable substances such as ammonia can easily be used in the SCR process. The NO x-Impurities can react with the reducing agent and the catalyst in such a way that the NO x is converted into nitrogen (N2) and water (H2O).

[0003] The catalyst used in the SCR process may have an internal support structure or substrate matrix that has been treated or coated with an active material that supports the SCR conversion process. For example, the matrix may be made of metal or ceramic, or a combination, such as copper zeolite with a host material such as vanadium. In a large-scale application, multiple catalysts may be arranged in a common module or housing, as suggested, for example, in US 2009 / 0 113 709 A1, entitled "Method of Manufacturing Exhaust Aftertreatment Devices," which is incorporated herein by reference in its entirety. The application describes multiple monolithic substrates that may be encased in a supporting mat and inserted into a cylindrical housing for storage by a "soft stuffing" process.

[0004] Over time, the active material in SCR catalysts can be consumed or deactivated due to other processes in the exhaust gases, such as the accumulation of phosphorus or sulfur in the catalyst. Furthermore, the substrate matrix is ​​typically designed as a thin-walled grid or frame, which can be damaged. Accordingly, it may be necessary to occasionally remove the SCR catalysts from the exhaust system for repair or replacement. However, when multiple catalysts are contained within a housing or module, particularly in exhaust systems associated with large power systems, the removal and replacement of a single catalyst can be complicated.

[0005] US 4 628 689 A shows an exhaust system for the internal combustion engine of a motor vehicle, which comprises a die-cast housing made of an aluminum-magnesium-silicon alloy in the form of a box-shaped housing part provided with a removable cover allowing access to a replaceable rectangular cuboid-shaped filter cartridge which divides the housing into an intake chamber and an outlet chamber, each of which is connected to an expansion chamber and the tailpipe.

[0006] DE 10 2004 013 786 A1 teaches an exhaust aftertreatment system with an exhaust gas purification function and a silencer function, which is arranged in the exhaust system of a motor vehicle. It has a cuboid-shaped housing that accommodates several exhaust gas purification units, each with at least one catalytic and / or filtering function.

[0007] The present invention is directed to overcoming one or more of the problems or disadvantages associated with the prior art. Summary

[0008] The object of the present invention is achieved by an aftertreatment module according to claim 1 and by a method for maintaining an aftertreatment module according to claim 10. The subclaims relate to preferred embodiments of the invention.

[0009] The disclosure describes, in one aspect, a post-treatment module for insertion into a sleeve. The post-treatment module has a substrate matrix extending between a first surface or end face and a second surface or end face. A shell or sleeve is arranged around the substrate matrix. The sleeve can extend between a first edge near the first surface and a second edge near the second surface. The sleeve can also have an overhanging extension extending the first edge beyond the end face. To facilitate removal of the post-treatment module from the sleeve, the post-treatment module can have a removal aid arranged on an inner surface of the overhanging extension.

[0010] In another aspect, the disclosure describes a method of servicing an aftertreatment module, if necessary. The aftertreatment module includes at least one elongated sleeve extending between an upstream end and a downstream end along a longitudinal axis. The sleeve includes an axially aligned opening formed at the upstream end. The method includes placing a first aftertreatment module within the sleeve so that it is axially aligned along the longitudinal axis. The method further includes removing the first aftertreatment module from the sleeve by grasping a removal aid on the first aftertreatment module and removing the first SCR catalyst axially through the opening. Short description of the drawings Fig. 1 is a side elevational view of a power system including an internal combustion engine coupled to a generator and associated with a clean emissions module (CEM). Fig. Figure 2 is a perspective view of the emissions control module with the cover removed to illustrate the components within the module and the exhaust flow through the module. Fig. 3 is a perspective view of an SCR module used in the emission control module of the Fig. 2 and which comprises at least one sleeve which accommodates a plurality of SCR catalysts. Fig. 4 is a perspective view of an embodiment of an aftertreatment module, in particular an SCR catalyst, which has a removal aid in the form of a slot which is arranged in an overhanging extension of the outer shell of the SCR catalyst, wherein the substrate matrix is ​​shown in detail. Fig. 5 is a perspective view of the SCR catalyst of the Fig. 4, which is removed from the sleeve of an SCR module, shown in dashed lines, by means of a removal tool engaging the slot. Fig. 6 is a perspective view of another embodiment of a removal tool engaging diametrically opposed slots disposed on the SCR catalyst. Fig. 7 is a perspective view of another embodiment of the SCR catalyst having a removal aid in the form of a handle attached to clamps arranged on the overhanging extension, one clamp being shown in detail. Fig. 8 is a perspective view of another embodiment of the SCR catalyst having a removal aid in the form of a tab arranged on the overhanging extension and engageable by a removal tool. Detailed description

[0011] This disclosure relates generally to an exhaust aftertreatment system, and more particularly to selective catalytic reduction (SCR) catalysts adapted to be removed from such systems. Referring now to the drawings, in which similar reference numerals refer to similar elements, Fig. 1 illustrates a power system 100 that can generate energy through the combustion of fossil fuels or the like. The illustrated power system 100 may include an internal combustion engine 102, such as a diesel engine, operatively coupled to a generator 104 for electrical generation. The internal combustion engine 102 may have any number of cylinders, as will be appreciated by those skilled in the art. The internal combustion engine 102 and generator 104 may be mounted on a common support frame 106. The power system 100 may provide backup power on a site or permanent electrical power in locations where access to an electrical grid is limited or unavailable. Accordingly, the generator 104 and the internal combustion engine 102 may be scaled or sized to provide an appropriate number of watts and horsepower.It should be appreciated that the power system of the present disclosure, in other embodiments, may be used in other applications, such as gasoline-burning engines, natural gas turbines, and coal-burning systems. Furthermore, in addition to stationary applications, the present disclosure may be used in mobile applications, such as locomotives and marine engines.

[0012] To direct intake air into and exhaust gases out of the power system 100, the power system may include an air induction system 110 and an exhaust system 112. The air induction system 110 introduces air or an air-fuel mixture into the combustion chambers of the internal combustion engine 102 for combustion, and the exhaust system 112 includes an exhaust pipe or duct 114 in fluid communication with the combustion chambers to direct the exhaust gases produced by the combustion process to the atmosphere. To pressurize the intake air using the positive pressure of the exhaust gases, the power system 100 may include one or more turbochargers 116 operatively connected to the air induction system 110 and the exhaust system 112.

[0013] The exhaust system 112 may include components for treating or conditioning exhaust gases before they are expelled to the environment. For example, an exhaust aftertreatment system module 120 in the form of an emissions control module (CEM) may be downstream of the turbochargers 116 and in fluid communication with the exhaust system 112 to receive the exhaust gases expelled from the internal combustion engine 102. The aftertreatment module 120 may be configured as a separate unit that may be generally mounted on the power system 100, for example, above the generator 104, and may receive exhaust gases from the exhaust passage 114. By fabricating the aftertreatment module 120 as a separate modular unit, this configuration may be used with various sizes and configurations of the power system 100.The aftertreatment module 120 may be designed to treat, remove, or convert regulated emissions and other constituents in the exhaust gases.

[0014] With reference to Fig. 2, the aftertreatment module 120 may include a box-like housing 122 supported by a base structure 124 adapted to attach the aftertreatment module to the power system. The box-like housing 122 may include a forward-facing first wall 126, an opposite rearward-facing second wall 128, and respective third and fourth side walls 130, 132. However, it should be appreciated that terms such as front, rear, and side are for convenience only and should not be construed as limiting the scope of the claims. Additionally, an imaginary central module axis line 134 may be located between the front first wall 126 and the rear second wall 128 and located midway between the third and fourth side walls 130, 132. The housing 122 may be constructed of welded steel plates or sheet metal.

[0015] To receive the untreated exhaust gases in the aftertreatment module 120, one or more inlets 140 may be disposed through the first wall 126 of the housing 122 and may be coupled in fluid communication with the exhaust passage from the exhaust system. In the illustrated embodiment, the aftertreatment module 120 includes two inlets 140 generally parallel to each other and centrally located between the third and fourth sidewalls 130, 132 on either side of the module axis line 134 so that the incoming exhaust gases are directed toward the rear second wall 128. However, other embodiments of the aftertreatment module 120 may have different numbers and / or different positions of the inlets. To allow the exhaust gases to exit the aftertreatment module 120, two outlets 142 may also be disposed through the first wall 126 of the housing 122.Each of the outlets 142 may be parallel to the centrally aligned inlets 140 and disposed toward one of the respective third and fourth side walls 130, 132.

[0016] To treat or condition the exhaust gases, the housing 122 may include various types or styles of exhaust treatment devices through or past which the exhaust gases are directed. For example, and following the arrows, which may indicate exhaust flow through the aftertreatment module 120 to reduce the velocity of the incoming exhaust gases for treatment, the inlets 140 may each be communicatively associated with a flared, cone-shaped diffuser 144 mounted outside the first front wall 126. Each diffuser 144 may direct the exhaust gases to a dedicated diesel oxidation catalyst (DOC) 146 positioned adjacent the first wall 126 within the housing 122, which then directs the exhaust gases to a common collection passage 148 centrally aligned along the module axis line 134.The DOCs 146 may contain materials such as platinum group metals such as platinum or palladium, which can catalyze carbon monoxide and hydrocarbons in the exhaust gases to water and carbon dioxide according to the following possible reactions:. CO + ½ O2 = CO2 (1) [HC] + O2 = CO2 + H2O (2)

[0017] In order to further reduce emissions in exhaust gases and in particular to reduce nitrogen oxides such as NO and NO2, which are sometimes referred to as NO x To reduce the NOx emissions, the aftertreatment module may include an SCR system 150. In the SCR process, a gaseous or liquid reductant is introduced into the exhaust system and passed along with the exhaust gases through an SCR catalyst. The SCR catalyst may include materials that cause the exhaust gases to react with the reductant to reduce the NOx. xinto nitrogen (N2) and water (H2O). A common reducing agent is urea ((NH2)2CO), although other suitable substances such as ammonia (NH3) can easily be used in the SCR process. The reaction can take place according to the following general formula: NH3 + NO x = N2 + H2O (3)

[0018] With reference to Fig. 2, the SCR system 150 includes a reductant injector 152 positioned downstream of the collection passage 148 and upstream of a centrally aligned mixing passage 154 that directs the exhaust gases toward the rear second wall 128 of the housing 122. The reductant injector 152 may be in fluid communication with a storage tank or reservoir that stores the reductant and may periodically or continuously inject an amount of the reductant into the exhaust stream in a process sometimes referred to as dosing. The amount of reductant introduced may depend on the NO x-loading of the exhaust gases. The elongated mixing passage 154 uniformly mixes the reductant with the exhaust gases before they enter the downstream SCR catalyst. At the end of the mixing passage 154 near the second wall 128, a diffuser 156 may be disposed, which redirects the exhaust gas / reductant mixture toward the third and fourth sidewalls 130, 132 of the aftertreatment module 120. The third and fourth sidewalls 130, 132 may redirect the exhaust gas / reductant mixture generally back toward the front first wall 126.

[0019] To perform the SCR reaction process, the aftertreatment module 120 may include a first SCR module 160 disposed near the third sidewall 130 and a second SCR module 162 disposed near the fourth sidewall 132. The first and second SCR modules 160, 162 are oriented to receive the redirected exhaust gas / reductant mixture. With reference to Fig. 2 and Fig. 3, the first and second SCR modules 160, 162 may house a plurality of SCR catalysts 164, sometimes referred to as aftertreatment modules, within one or more sleeves 166. However, the term aftertreatment module may refer to a variety of different aftertreatment devices, of which SCR catalysts are merely a subset. The sleeves 166 may be generally elongated, tubular structures having an upstream end 168 and a downstream end 170 aligned along a longitudinal axis 172. In those embodiments that include more than one sleeve in the first and second SCR modules 160, 162, the sleeves may be supported within a bracket or frame 174.The frame 174 may be oriented such that the upstream ends 168 are directed toward the respective third and fourth sidewalls 130, 132, and the downstream ends 170 communicate with a central region 175 of the aftertreatment module 120 that generally surrounds but is fluidly separated from the mixing passage 154. The central region 175 directs the treated exhaust gases forward to the outlets 142 disposed through the front first wall 126. In various embodiments, one or more exhaust treatment devices may be disposed within the aftertreatment module 120, such as diesel particulate filters 178 for soot removal.

[0020] With reference to Fig. 3, the upstream end 168 of each sleeve may remain open and unobstructed to receive the SCR catalysts 164 within the sleeves 166. As shown in the illustrated embodiment, the catalysts 164 and the sleeves 166 may have corresponding cylindrical shapes, although in other embodiments, it will be appreciated that the sleeves and catalysts may have other suitable corresponding shapes. The catalysts 164 may be aligned along the longitudinal axis 172 and slidably inserted into the sleeves 166. The catalysts 164 may be flow-through devices so that the exhaust gas / reductant mixture can pass through them.In those embodiments, where multiple catalysts 164 are housed in each sleeve 166, the insertion process may include a first catalyst 180 and a second catalyst 182 being inserted in such a sequence that the first catalyst is directed toward the upstream end 168 and the second catalyst is directed toward the downstream end 170. In the illustrated embodiment, a third catalyst 184 may be inserted between the upstream first catalyst 180 and the downstream second catalyst 182. The catalysts may have the same or different axial lengths.

[0021] To facilitate the insertion and removal of the catalysts, a gap of 2-3 mm may exist between portions of the catalysts 164 and the sleeve. Furthermore, to prevent leakage of the exhaust gas / reductant mixture through the SCR module, the catalysts 164 and the sleeves 166 may be adapted to form a sealing connection with each other along at least a portion of their mating peripheries. For example, one or more protruding ribs 188 may protrude radially around the periphery of the catalysts 164, which may form a seal with the inner periphery of the sleeves 166. To gain access into the SCR modules 160, 162 for insertion or removal of the catalysts 164, a removable access panel 176 may be disposed in the respective third and fourth side walls 130, 132 of the housing 122.

[0022] As described above, SCR catalysts can become less effective due to the deposition of phosphorus, sulfur, and other materials from the exhaust gases on the active areas of the catalysts. Furthermore, the internal structure of the catalyst could be damaged, preventing flow through it, or the seal between the catalyst and the sleeve could fail, allowing exhaust gases to escape untreated through the SCR module. It may therefore be necessary to remove and replace the SCR catalysts from the SCR module. As stated in the Fig. 3, however, the orientation and order of insertion of the catalysts 164 may make removal of the catalysts from the sleeves difficult. For example, the second catalyst 182 may be inserted deeply into the sleeve 166 from the upstream end 168, making its removal more complicated. Similarly, the matching size and shape and sealing engagement of the first catalyst 180 and the sleeve 166 may make it difficult to grasp or secure the first catalyst. In some embodiments, the catalysts may be relatively heavy, for example, between 13 and 17 kilograms each, further complicating their removal. Accordingly, the catalysts 164 may be provided with a removal aid to assist their removal and removal from the sleeves 166.

[0023] With reference to Fig. 4 illustrates an embodiment of an SCR catalyst 200 of the type for use with the described SCR module, which includes a removal aid to assist in removing the catalyst from the sleeve 166. To support the catalytic material, the catalyst 200 may include an internal substrate matrix 210 made from a triangular grid, a honeycomb grid, a metal mesh substrate, or a similar thin-walled support structure 212, onto which the catalytic material or catalytic coating 214 may be deposited. Such support structure configurations allow the exhaust gas / reductant mixture to enter and pass through the catalyst. Any suitable material may be used for the support structure 212, including, for example, ceramics, titanium oxide, or copper zeolite.Catalytic coatings 214 that initiate the SCR reaction can include various types of metals, such as vanadium, molybdenum, and tungsten. The catalytic coating 214 can be deposited on the support structure 212 using any suitable method, including, for example, chemical vapor deposition (CVD), adsorption, powder coating, spraying, etc. In other embodiments, instead of having separate support structures and catalytic coatings, which are often used to reduce material costs, the substrate matrix can be composed entirely of a catalytic material.In the illustrated embodiment, the substrate matrix 210 has a generally cylindrical shape and extends between a first circular end surface 220 and a second circular end surface 222 to define a first length 224, however, in other embodiments, different shapes may be applied to the substrate matrix, e.g., square, rectangular, etc. For example only, the first length may be approximately 17.78 (7 inches).

[0024] To protect the support structure 212, a tubular shell or sleeve 230 may be disposed generally around the substrate matrix 210. The tubular shell 230 may be made of a thicker or stiffer material than the thin-walled support structure 212, such as aluminum or steel. For example, the shell may be approximately 1.2 mm thick to provide sufficient structural rigidity to the catalyst. The tubular shell 230 may have a shape corresponding to that of the substrate matrix 210, which is generally cylindrical in the illustrated embodiment. The cylindrical shell 230 may therefore extend between a first annular edge 232 and a second annular edge 234. However, in other embodiments, the shell and its first and second edges may have other shapes.The shroud may have a second length 236 sandwiched between the first edge 232 and the second edge 234 that is slightly greater than the first length 224 of the substrate matrix 210. For example only, the second length 236 may be approximately 20.32 cm (8 inches). Accordingly, when disposed around the shorter substrate matrix 210, the shroud 230 may have an overhanging extension 240 that extends at least beyond the first end surface 220 of the substrate matrix, such that the overhanging extension offsets the first edge 232 a certain distance beyond the first end surface. For the examples given above, the overhanging extension 240 may be on the order of 2.54 cm (one inch), although the disclosure is not so limited.In the illustrated embodiment, the overhanging extension 240 curves with the circular first edge 232 and includes a cylindrical inner surface 242 extending between the first edge and the first end face 220 of the substrate matrix 210.

[0025] To facilitate removal of the illustrated embodiment of the catalyst 200 from the canisters of the SCR module, the removal aid 250 may be located on the inner surface 242 of the overhanging extension 240, a location generally accessible from outside the first edge 232. In the illustrated embodiment, the removal aid 250 may be an elongated, relatively narrow slot 252 disposed along the overhanging extension 240 and located generally midway between the first edge 232 and the first end face 220 of the substrate matrix 210. The slot 252 may have any suitable dimensions relative to the catalyst 200. For example, if the overhanging extension 240 is approximately 2.54 cm (one inch) long, then the slot 252 may have a width of, for example, 31.75 mm (0.125 inches).The slot 252 may extend in a radial direction around a portion of the circumference of the annular inner surface 242, and the arc length 256 of the slot 252 may be approximately 5% to 10% of the circumferential length of the catalyst 200. For example, if the catalyst 200 has a diameter of approximately 35.56 cm (14 inches), as indicated by arrow 254, then the circumferential length will be approximately 111.76 cm (44 inches), and the arc length 256 of the slot may be approximately 5.59 cm to 11.18 cm (2.2 to 4.4 inches). In addition, although the arc length 256 shown in FIG. Fig. 4 shows two opposing slots 252 disposed in the overhanging extension 240, in other embodiments any suitable number of slots may be present. The slots may extend completely through the overhanging extension or may be partially recessed into the extension. To form the slot 252, in various embodiments, the slot may be either punched or laser cut into the shell 230, either before or after the shell has been applied around the substrate matrix 210. Potential advantages of laser cutting include a smoother edge and that the cutting is less likely to damage or deform the overhanging extension, particularly if the process of forming the slot is performed after the shell has already been applied around the substrate matrix.

[0026] With reference to Fig. 5, the SCR catalyst 200 may be housed in a sleeve 166 of the first SCR module 160 such that the overhanging extension 240 is oriented toward the upstream end 168 of the sleeve. To remove the SCR catalyst 200 from the sleeve 166, the slot 252 may engage a suitable removal tool 260 inserted through the upstream end 168. To engage the slot 252, the removal tool 260 may be a generally L-shaped bracket having a hook 262 at the end thereof, which protrudes at a right angle from the end of an elongated arm 264 such that the hook may be inserted into or received within the slot. The L-shaped removal tool may be fabricated from a stamped, elongated blank of sheet metal or plate.Once the removal tool engages the slot 252, the catalyst 200 can be pulled out of the sleeve 166 through the upstream end 168.

[0027] With reference to Fig. 6, another embodiment of a removal tool 270 is shown that can engage diametrically opposed slots 252 disposed on the SCR catalyst 200. In this embodiment, the removal tool 270 may resemble inverted pliers, having first and second articulated arms 272, 274 that are pivotally connected to each other at a pivot point 276. A ledge-like rib 282 may be located at the opposite first and second distal ends 278, 280 of the respective first and second arms 272, 274. Handles may be formed at the opposite proximal ends of the first and second arms 272, 274. Moving the handles of the first and second arms 272, 274 toward each other causes the first and second distal ends 278, 280 to move apart.Accordingly, when the first and second distal ends 278, 280 are placed within the perimeter defined by the overhanging extension 240, the first and second distal ends can be moved apart so that the ribs 282 formed thereon can be received in and engaged with the diametrically opposed slots 252.

[0028] With reference to Fig. 7 shows another embodiment of an SCR catalyst 300 having a removal aid 350 in the form of a handle 352. The illustrated SCR catalyst 300 may have the same basic structure as described above, including a substrate matrix 310 with a protective tubular shell 330 mounted around the substrate matrix, which extends between a first edge 332 and a second edge 334. The substrate matrix and the shell may have any suitable shape, including cylindrical, as illustrated. The tubular shell 330 may have an overhanging extension 340 spacing the shell first edge 332 from the forward-facing first end surface 320 of the substrate matrix 310. The overhanging extension 340 thereby defines an accessible inner peripheral surface 342.To secure the handle 352 to the catalytic converter, a first bracket 360 and a second bracket 362 may be mounted on the inner surface 342 of the overhanging extension 340. Referring to the detailed view, the first and second brackets 360, 362 may be formed of stamped metal with a stepped surface 364 supported between two depending legs of the bracket 366 and a circular hole 368 disposed through the stepped surface. When mounted on the inner surface 342 of the overhanging extension 340, the first and second brackets 360, 362 may be disposed substantially diametrically opposite each other. The first and second brackets 360, 362 may be attached to the shell 330 by any suitable method, such as welding, riveting, or fasteners.

[0029] To form the handle 352, an elongated rod may be bent or formed into an arcuate or curved shape having a first leg 370 and a second leg 372, with the handle located at the center thereof at an apex 374. In the illustrated embodiment, the apex 374 may be configured as a straight handle. To attach the handle 352 to the catalytic converter 300 using the first and second clips 360, 362, respective first and second pin-shaped ends 376, 378 may be formed or attached to the opposite distal ends of the first and second legs 370, 372. The handle 352 is thus supported across the diameter of the circular first edge 332.The first and second pin-shaped ends 376, 378 may have a size and shape corresponding to the circular holes 368 formed in the first and second brackets 360, 362 so that they can be insertedly received in the holes.

[0030] In one embodiment, the first and second pin-shaped ends 376, 378 may form a journal bearing with the holes 368 to rotate or pivot the handle 352 relative to the catalyst 300. As shown in Fig. As shown in Figure 7, the handle 352 can be pivoted so that it is perpendicular to the SCR catalyst 300 to pull the catalyst out of the sleeves. Furthermore, the curved shape of the handle 352 can be sized such that it can be placed or accommodated within the perimeter of the overhanging extension 340 when pivoted adjacent to the first end face 320 of the substrate matrix 310. Accordingly, multiple catalysts can be lined up and stacked adjacent to one another in the sleeves without the handles interfering with this. In other embodiments, to achieve the same positive result, the handle 352 can be removed from the catalytic converter 300 by moving or pushing the first and second legs 370, 372 toward each other so that the first and second pin-shaped ends 376, 378 are removed and released from the corresponding holes 368 in the first and second brackets 360, 362.The handle can optionally be reattached if necessary to remove the catalytic converter.

[0031] With reference to Fig. 8 shows a further embodiment of the SCR catalyst 400, which is equipped with a variation of the removal aid 450 for removing the catalyst from the sleeve of an SCR module. The catalyst 400 can include a substrate matrix 410 having first and second opposing end faces 420, 422, which is surrounded by a tubular shell 430 extending between a first edge 432 and a second edge 434. The shell 430 can form an overhanging extension 440 extending from the first edge 432 to the first end face 420 of the substrate matrix 410. The removal aid 450 can be in the form of a pocket-like driver 452 arranged on the cylindrical inner surface 442 of the overhanging extension 440. In various embodiments, a plurality of pocket-like drivers 452 may be arranged on the cylindrical inner surface 442.The driver 452 may extend outwardly from the inner surface 442 and may define an inner pocket accessible through a lip 454 facing away from the first edge 432 and toward the first end face 420 of the substrate matrix 410. To engage the driver 452, the removal tool 460 may include a hook 462 attached to a distal end of an elongated rod or handle 464, which may be partially hooked around the lip 454 and partially received within the inner pocket. Pulling the removal tool in a particular direction will accordingly pull the SCR catalyst in that direction. Industrial applicability

[0032] The present disclosure is applicable to the removal of aftertreatment modules or units housed in large-scale aftertreatment modules when the aftertreatment modules require maintenance. Although the disclosure particularly describes SCR catalysts, the disclosure may relate to other aftertreatment devices, such as diesel oxidation catalysts (DOCs) and / or diesel particulate filters (DPFs), sometimes also referred to as modules. Again, with reference to the Fig. 2 and Fig. 3, to access the catalysts, an operator may remove the access panel 176 that is proximate to the respective first or second SCR modules 160, 162 within the aftertreatment system 120. Using an elongated tool, the operator may reach through the access panel and insert the tool into the open upstream end 168 of the elongated sleeves 166 bundled together in the SCR module 160, 162. The removal tool may engage a removal aid mounted on the catalyst in one of the ways previously described. For example, in the embodiment where the removal aid is a slot 252, the removal tool may engage the slot and be retracted to pull the catalyst from the sleeve 166.In those embodiments in which the removal aid is a handle, the removal tool can be a hook that is inserted into the open upstream end of the sleeves 166 to hook onto the handle. Alternatively, the operator can insert their arm into the sleeves to grasp the handle with their hand.

[0033] This disclosure is particularly suitable for the removal of a plurality of the catalysts 164 which are housed in an axially aligned manner within the same elongated sleeve 166 of the SCR module 160, 162. With reference to Fig. 3, it can be appreciated that the second catalyst 182, located deep within the sleeve 166 toward the downstream end 170, can be satisfactorily reached with the elongated removal tool. Accordingly, the disclosure enables the orderly insertion and / or removal of multiple SCR catalysts 164 located at various distances from the upstream end 168 of the sleeve 166. Furthermore, referring now, for example, to Fig.4, the removal aid 250 generally does not interfere with adjacent catalysts that are axially inserted directly thereafter into the same sleeve because it is disposed on the inner surface 242 of the overhanging extension 240, even in those embodiments in which the removal aid is a pivoting handle. Furthermore, positioning the removal aid within the overhanging extension helps ensure that it does not interfere with the sleeve surrounding the catalyst. In certain embodiments, the removal tool can also assist in inserting new SCR catalysts into the sleeves for replacement after the spent SCR catalysts have been removed.

[0034] It should be noted that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to refer to the particular example being described at that time and are not intended to imply any further limitation on the scope of the disclosure. Any mention of emphasis or derogation regarding particular features is intended to indicate a lack of preference for the features in question, but in no way to exclude them entirely from the scope of the disclosure unless otherwise indicated.

[0035] The specification of value ranges herein is intended merely as a shorthand method for referring to each value falling within the range individually, unless otherwise indicated, and each individual value is included in the description as if it were individually specified herein. All methods described herein may be performed in any suitable sequence, unless otherwise indicated herein or otherwise clearly contradicted by the context.

[0036] Reference symbols used in the claims 120 post-treatment module 164, 180, 182, 200, 300, 400 post-treatment modules 166 sleeve 168 above end 170 below end 172 Longitudinal axis 210 Substrate matrix 220 first frontal surface 222 second frontal surface 230 coat 232 first edge 234 second edge 240, 340, 440 overhanging extensions 242, 342, 442 inner surfaces 250, 350, 450 removal aids 252 slot 260, 460 4 removal tools 352 handle 360 first bracket 362 second bracket 368 first and second hole 376 first pin-shaped end 378 second pin-shaped end 370 first leg 372 second leg 374 vertex 452 carriers 462 hooks

Claims

[1] A post-treatment module (164; 180, 182; 200; 300; 400) for insertion into a sleeve (166) arranged in a post-treatment module (120), the post-treatment module (164) comprising: a substrate matrix (210), the substrate matrix (210) extending between a first end face (220) and a second end face (222); a jacket (230) mounted around the substrate matrix (210), the jacket (230) extending between a first edge (232) proximate the first end face (220) and a second edge (234) proximate the second end face (222), the jacket (230) having an overhanging extension (240) extending between the first edge (232) and the first end face (220); and a removal aid (250) arranged on an inner surface (242) of the overhanging extension (240), the removal aid (250) enabling the removal of the post-treatment module (164) from the sleeve (166). [2] The aftertreatment module (200) according to claim 1, wherein the removal aid (250) is a slot (252) arranged on the inner surface (242) of the overhanging extension (240), the slot (252) being adapted to engage a removal tool (260). [3] The aftertreatment module (300) of claim 1, wherein the removal aid (350) includes a handle (352) extending generally diametrically across the overhanging extension (340). [4] The post-treatment module (300) according to claim 3, wherein the removal aid (350) further comprises a first clamp (360) and a second clamp (362) arranged on the inner surface (342) of the overhanging extension (340), the first and second clamps (360, 362) being diametrically opposed to each other. [5] The aftertreatment module (300) according to claim 4, wherein the handle (352) has a first pin-shaped end (376) received in a first hole (368) arranged in the first bracket (360) and a second pin-shaped end (378) received in a second hole (368) arranged in the second bracket (362); and wherein the handle (352) is articulated with respect to the aftertreatment module (300) by pivoting the first and second pin-shaped ends (376, 378) in the respective first and second holes (368). [6] The aftertreatment module (300) of claim 5, wherein the handle (352) is shaped to form an elongated rod having a curved portion extending between the first and second pin-shaped ends (376, 378), the curved portion having a first leg (370) and a second leg (372) each extending between an apex (374) of the handle (352) to the first and second pin-shaped ends (376, 378). [7] The aftertreatment module (300) according to claim 6, wherein the handle (352) is removable by moving the first and second legs (370, 372) towards each other to remove the first and second pin-shaped ends (376, 378) from the corresponding first and second holes (368). [8] The aftertreatment module (400) according to claim 1, wherein the removal aid (450) comprises a driver (452) arranged on and extending inwardly from an inner surface (442) of the overhanging extension (440), the driver (452) being adapted to engage a hook (462) arranged on a removal tool (460). [9] The post-treatment module (200) according to claim 1, wherein the substrate matrix (210) has a cylindrical shape, the shell (230) is tubular and is arranged around the cylindrical shape of the substrate matrix (210), and wherein the first edge (232) and the second edge (234) are annular. [10] A method of servicing an aftertreatment module (120), comprising: Providing an aftertreatment module (120) having at least one elongated sleeve (166) extending between an upstream end (168) and a downstream end (170) along a longitudinal axis (172), the at least one sleeve (166) having an axially aligned opening formed at the upstream end (168); Housing a first aftertreatment module (180) in the at least one sleeve (166), the first aftertreatment module (180) being generally axially aligned along the longitudinal axis (172); removing the first aftertreatment module (180) from the at least one sleeve (166) by engaging a removal aid (250) on the first aftertreatment module (180), and Removing the first post-treatment module (180) axially through the opening of the at least one sleeve (166). [11] The method according to claim 10, wherein the first aftertreatment module (180) is arranged towards the upstream end (168) of the at least one sleeve (166), the method further comprising: Including a second aftertreatment module (182) disposed toward the downstream end (170) of the at least one sleeve (166), the second aftertreatment module (182) being generally axially aligned along the longitudinal axis (172); and Removing the second aftertreatment module (182) from the at least one sleeve (166) by engaging a removal aid (250) on the second aftertreatment module (182), and removing the second aftertreatment module (182) axially through the opening of the at least one sleeve (166).

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