SCR-catalyst utilisation and mixing comparison using a novel biomimetic flash-boiling injector

NOx pollution from Diesel engines causes over 10 000 premature deaths annually and the trend is increasing. In order to decrease this growing global problem, exhaust after-treatment systems for Diesel engines have to be improved. The most common SCR systems in the market place inject an aqueous Urea solution, DEF that evaporates prior the catalytic surface of the SCR-catalyst. Due to a catalytic reaction within the catalyst, NOx is converted nominally into Nitrogen and Water. Currently, the evaporative process is enhanced by aggressive mixer plates and long flow paths; these, negatively, create extra exhaust back pressure and cool the exhaust gases decreasing engine and catalyst efficiency. To achieve future emission legislation targets SCR efficiency has to be improved especially under low catalyst temperature conditions, plus Ammonia slip has to be avoided as it is now legislated against. Swedish Biomimetic’s novel µMistR platform technology, inspired by the Bombardier Beetle, injects a hot, effervescent, finely atomised, highly dispersed spray plume of DEF into the exhaust stream. This is achieved by raising the temperature of the DEF, in a closed volume, above its saturated vapour pressure. The DEF is then rapidly released creating effervescent atomisation. This study investigates a back to back study of the evaporating and mixing behaviour of the µMistR injector and a class leading DEF injector. The test conditions are with and without a mixer plate and the use of two different flow path designs. Spray distribution across the face of the catalyst is assessed by measuring NOx conversion whilst Ammonia slip is also measured post catalyst. This report describes how the novel µMistR injector significantly increases NOx conversion and catalyst surface usage whilst considerably reducing Ammonia slip.