Variable Porosity Diffuser Plate for SCR Exhaust Distribution
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Solution Overview
Problem
Traditional vertical SCR designs face challenges in evenly distributing exhaust mass flow and reductant vapor across SCR catalysts due to space constraints and limitations in assembling multiple stages of catalysts, with existing solutions failing to effectively address these issues.
Innovation Solution
A diffuser plate with a variable degree of porosity, featuring a first section with a higher porosity than a second section, is positioned downstream of the inlet port and upstream of the SCR catalysts to evenly distribute the composition of engine exhaust mixed with reductant across multiple SCR catalysts, aiding in assembly by providing a strength-enhanced, modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vertical SCR designs are used, then the aftertreatment system can be implemented, but even distribution of exhaust mass flow and reductant vapor across SCR catalysts cannot be achieved due to space constraints
Solution Approach 1:
The patent employs a diffuser plate with controlled porosity to achieve even distribution of exhaust mass flow and reductant vapor. The porous structure allows uniform flow through the plate while maintaining compact dimensions, resolving the contradiction between distribution quality and space requirements.
Solution Approach 2:
The diffuser plate's porosity parameter is specifically optimized to balance flow distribution effectiveness with compact system volume. By adjusting the porosity parameter, the design achieves uniform exhaust and reductant vapor distribution across catalysts without requiring excessive space.
2Ease of operation
If traditional vertical SCR designs are used, then the aftertreatment system can be implemented, but convenient aid for assembling multiple stages of SCR catalysts is not provided
Solution Approach 1:
The diffuser plate serves multiple functions: it distributes exhaust flow, distributes reductant vapor, and provides structural support for catalyst assembly. This multi-functionality simplifies the overall assembly structure and improves ease of assembly while maintaining effective SCR operation.
Solution Approach 2:
The diffuser plate acts as an intermediary component between the exhaust inlet and catalyst stages, providing a standardized interface that facilitates convenient assembly of multiple catalyst stages. This intermediary structure simplifies the assembly process compared to direct catalyst mounting.
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
The diffuser plate ensures uniform distribution of exhaust flow and reductant vapor across SCR catalysts, enhancing the efficiency of the SCR process and facilitating the assembly of multiple stages within the aftertreatment module.
Implementation Method 1
The diffuser plate may include a first section including a first degree of porosity and a second section including a second degree of porosity
Data Source
AI summary
An aftertreatment module may include a housing with an inlet port and an outlet port. A selective catalytic reduction catalyst may be disposed between the inlet port and the outlet port. A diffuser plate may be disposed downstream of the inlet port and upstream of the selective catalytic reduction catalysts. The diffuser plate may include a first section including a first degree of porosity and a second section including a second degree of porosity. The first degree of porosity may be greater than the second degree of porosity.