CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines

Łukasz Jan Kapusta (), Bartosz Kaźmierski, Rohit Thokala, Łukasz Boruc, Jakub Bachanek, Rafał Rogóż, Łukasz Szabłowski (), Krzysztof Badyda, Andrzej Teodorczyk and Sebastian Jarosiński
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Łukasz Jan Kapusta: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Bartosz Kaźmierski: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Rohit Thokala: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Łukasz Boruc: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Jakub Bachanek: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Rafał Rogóż: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Łukasz Szabłowski: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Krzysztof Badyda: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Andrzej Teodorczyk: Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, Poland
Sebastian Jarosiński: Katcon Sp.z.o.o., 05-870 Błonie, Poland

Energies, 2025, vol. 18, issue 14, 1-24

Abstract: Combustion processes in compression ignition engines lead to the inevitable generation of nitrogen oxides, which cannot be limited to the currently desired levels just by optimising the in-cylinder processes. Therefore, simulation-based engine development needs to include all engine-related aspects which contribute to tailpipe emissions. Among them, the SCR (selective catalytic reduction) aftertreatment-related processes, such as urea–water solution injection, urea decomposition, mixing, NOx catalytic reduction, and deposits’ formation, are the most challenging, and require as much attention as the processes taking place inside the cylinder. Over the last decade, the urea-SCR aftertreatment systems have evolved from underfloor designs to close-coupled (to the engine) architecture, characterised by the short mixing length. Therefore, they need to be tailor-made for each application. This study presents the CFD-based development of a multi-platform SCR system with a short mixing length for mobile non-road applications, compliant with Stage V NRE-v/c-5 emission standard. It combines multiphase dispersed flow, including wall wetting and urea decomposition kinetic reaction modelling to account for the critical aspects of the SCR system operation. The baseline system’s design was characterised by the severe deposit formation near the mixer’s outlet, which was attributed to the intensive cooling in the mounting area. Moreover, as the simulations suggested, the spray was not appropriately mixed with the surrounding gas in its primary zone. The proposed measures to reduce the wall film formation needed to account for the multi-platform application (ranging from 56 to 130 kW) and large-scale production capability. The performed simulations led to the system design, providing excellent UWS–exhaust gas mixing without a solid deposit formation. The developed system was designed to be manufactured and implemented in large-scale series production.

Keywords: SCR selective catalytic reduction; urea-SCR aftertreatment; NOx nitrogen oxides; exhaust system; emission control; emission reduction; numerical simulations (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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