Integrated Dosing Tank Filter for SCR System Cost Reduction
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Solution Overview
Problem
Current filtration methods in SCR systems for reducing NOx emissions are costly due to frequent filter replacements and the need for additional heating elements to prevent freezing, which increases manufacturing and maintenance expenses.
Innovation Solution
A filtration system with a dosing tank containing a filter media, such as polymeric melt-blown microfilaments, that filters the dosing fluid before it enters or exits the tank, eliminating the need for separate heaters and reducing the frequency of filter replacements by integrating the filter within the tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If paper filters are used in SCR systems to filter dosing fluid, then contamination is reduced, but manufacturing cost and maintenance cost increase due to frequent filter replacement
Solution Approach 1:
The filter media is integrated directly into the dosing tank structure, combining the storage function and filtration function into a single component. This eliminates the need for separate filter housings and reduces the number of parts, thereby lowering manufacturing costs while maintaining filtration effectiveness.
Solution Approach 2:
The dosing tank is designed to serve multiple functions: storing dosing fluid, filtering contaminants, and preventing freezing through integrated heating elements. This multi-functionality reduces the overall system complexity and manufacturing cost compared to using separate components for each function.
2Reliability
If paper filters are used in SCR systems to filter dosing fluid, then contamination is reduced, but maintenance cost increases due to regular filter replacement or cleaning
Solution Approach 1:
The filter media is permanently integrated into the dosing tank structure, eliminating the need for separate filter assemblies that require removal, replacement, or cleaning. This integration reduces maintenance operations and associated costs while maintaining continuous filtration capability.
Solution Approach 2:
The filter media is designed to be self-cleaning through the recirculation system, which flushes contaminants away from the filter during normal operation. This self-maintaining feature eliminates the need for manual filter cleaning or replacement, significantly reducing maintenance costs.
3Reliability
If heaters are added to filter housings to prevent freezing in cold temperatures, then dosing fluid flow is maintained, but manufacturing cost increases
Solution Approach 1:
Heating elements are integrated directly into the dosing tank structure rather than being added as separate components to external filter housings. This integration eliminates the need for additional filter housing modifications and reduces manufacturing cost while ensuring the dosing fluid remains above freezing temperature.
Solution Approach 2:
The dosing tank is designed to serve multiple functions: storing dosing fluid, filtering contaminants, and preventing freezing through integrated heating elements. This multi-functionality reduces the overall system complexity and manufacturing cost compared to using separate components for each function.
4Device complexity
If dosing fluid is allowed to settle in filter housing in cold temperatures, then the system is simpler, but the dosing fluid freezes and damages the SCR system
Solution Approach 1:
The filter media is integrated directly into the dosing tank structure, eliminating separate filter housings where fluid could settle and freeze. This integration maintains system simplicity while preventing freezing damage by ensuring continuous fluid circulation through the heated tank.
Solution Approach 2:
The recirculation system continuously circulates dosing fluid through the tank, preventing settlement and freezing without requiring complex additional components. This self-circulating feature maintains reliability while keeping the system relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces operational and manufacturing costs by integrating the filter within the dosing tank, preventing contamination and freezing issues, thereby enhancing the efficiency and cost-effectiveness of the SCR system.
Implementation Method 1
A filter is provided with a plurality of modules configured to functionally execute the necessary steps of filtering dosing fluid
Implementation Method 2
vehicles with SCR systems operating in cold temperatures often include heaters in the filter housings of the SCR system
Data Source
AI summary
An apparatus, system, and method are disclosed for a filter for filtering a dosing fluid in an exhaust aftertreatment system. The filter may comprise a dosing tank configured to contain a dosing fluid, a filter media disposed within the dosing tank, and a support structure supporting the filter media to form a pathway for a flow of dosing fluid. Beneficially, the apparatus, system, and method of the present invention reduce the cost of operation and manufacture of the SCR system.