1. Development of an exhaust after-treatment device to improve the low temperature NOx reduction efficiency
- Author
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Maizak, David
- Abstract
The objective of this thesis is the development of an exhaust gas system concept for diesel engines that meets the present and future challenges of exhaust gas aftertreatment of nitrogen oxides at low exhaust gas temperatures. Previous studies on this topic have mainly focused on the optimisation of the currently used exhaust gas aftertreatment systems. This thesis starts one step earlier. In the first part of this thesis – the concept development phase – the objectives and boundary conditions for the development of an exhaust gas system for low temperatures will be established. The result will show that the efficiency of the exhaust gas aftertreatment at low exhaust temperatures, as well as in the entire engine map range, depends in particular on the provision of reducers (substances required for the conversion of NOX into N2) and on the homogeneity of these reducers on the SCR catalyst. Based on these results, the physical principles with which the reducers can be optimally provided for the conversion process will be investigated. Three principles will be identified: Process before injection, Process during injection, and Process after injection. In the following step, these established principles will be discussed in terms of advantages and disadvantages, which will then be compiled by means of a literature search and evaluated using VDI guideline 2225. The result will show that the introduction of the reducers on the basis of the process during injection (using a heated injector) is the most suitable solution. Based on this finding, the components of the exhaust gas system relevant for the adaption of the heated injection (injector, mixer and mixing section) will be identified. In a further analysis stage, it will be investigated and determined which configuration of these components (e.g. exhaust gas system near the engine or underbody system) will be used for the following test series. Subsequently, these components will be modified for the heated injection process. The exhaust gas concept system will then be designed in CAD. Finally, the concept system will be built in hardware. The second part of the thesis – the experimental phase – will comprise several test series on different test benches. The thermodynamic principles and boundary conditions of the heated spray process will be identified and the required parameters for the test bench trials will be derived. Subsequently, in an initial test series, the heated injector will be measured on an optical test bench. The aim will be to determine the fundamental spray properties, to validate the previously identified parameters, and to compare the test results to the literature. During this series of tests, the required parameters for the subsequent test series on the engine test bench will also be determined. The result will be that the expected spray behaviour will be achieved and a fine spray will be produced, which also shows an increasing gas content with increasing injection temperature. The subsequent test series on the engine test bench will cover the entire concept exhaust gas system. The aim of these test series will be to analyse the factors that determine the efficiency of the exhaust gas system, as identified in the first part of this thesis. These are the provision of reducers, which can be measured by the degree of conversion of the nitrogen oxides, and the distribution uniformity of the reducers on the SCR catalyst. Relevant effects such as the formation of solid deposits will also be investigated and discussed. Furthermore, the result of the second part of the thesis will include pinpointing the challenges of the new method, which can be briefly described as spray drift effects. In the third part of the thesis, the challenges identified in the second part will be addressed and solution proposals will be developed. Based on the methodical development process, a concept of an exhaust gas system optimised to meet the previously identified challenges will be developed. For this purpose, different design possibilities of the concept exhaust gas system will be developed, analysed, and evaluated. The result of this concept study will then first be designed in CAD. This will be followed by comprehensive flow-engineering studies based on CFD. The aim of these flow mechanical investigations will be to identify and discuss the central flow mechanical effects of the exhaust gas system spray interaction. For this reason, only the heated spray in the concept exhaust gas system without a mixer will be investigated in the first step. The result will show that spray drift effects also take a central role here. Based on these findings, basic mixer concepts will be developed. The flow mechanical effects that occur will again be analysed and discussed here as well, and optimisation potential will be deduced from them. In summary, the results of the thesis are the legal, design, and flow-mechanical boundary conditions for the development of an innovative but close-to-production exhaust gas system.
- Published
- 2020