CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines
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...
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2025-07-01
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| Series: | Energies |
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| Online Access: | https://www.mdpi.com/1996-1073/18/14/3697 |
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| author | Łukasz Jan Kapusta Bartosz Kaźmierski Rohit Thokala Łukasz Boruc Jakub Bachanek Rafał Rogóż Łukasz Szabłowski Krzysztof Badyda Andrzej Teodorczyk Sebastian Jarosiński |
| author_facet | Łukasz Jan Kapusta Bartosz Kaźmierski Rohit Thokala Łukasz Boruc Jakub Bachanek Rafał Rogóż Łukasz Szabłowski Krzysztof Badyda Andrzej Teodorczyk Sebastian Jarosiński |
| author_sort | Łukasz Jan Kapusta |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-fe3cc2d99cf541b7bd85a3e63d371c75 |
| institution | Kabale University |
| issn | 1996-1073 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj-art-fe3cc2d99cf541b7bd85a3e63d371c752025-08-20T03:36:19ZengMDPI AGEnergies1996-10732025-07-011814369710.3390/en18143697CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition EnginesŁukasz Jan Kapusta0Bartosz Kaźmierski1Rohit Thokala2Łukasz Boruc3Jakub Bachanek4Rafał Rogóż5Łukasz Szabłowski6Krzysztof Badyda7Andrzej Teodorczyk8Sebastian Jarosiński9Faculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandFaculty of Power and Aeronautical Engineering, Institute of Heat Engineering, Warsaw University of Technology, 00-661 Warszawa, PolandKatcon Sp.z.o.o., 05-870 Błonie, PolandCombustion 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.https://www.mdpi.com/1996-1073/18/14/3697SCR selective catalytic reductionurea-SCR aftertreatmentNOx nitrogen oxidesexhaust systememission controlemission reduction |
| spellingShingle | Łukasz Jan Kapusta Bartosz Kaźmierski Rohit Thokala Łukasz Boruc Jakub Bachanek Rafał Rogóż Łukasz Szabłowski Krzysztof Badyda Andrzej Teodorczyk Sebastian Jarosiński CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines Energies SCR selective catalytic reduction urea-SCR aftertreatment NOx nitrogen oxides exhaust system emission control emission reduction |
| title | CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines |
| title_full | CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines |
| title_fullStr | CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines |
| title_full_unstemmed | CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines |
| title_short | CFD Simulation-Based Development of a Multi-Platform SCR Aftertreatment System for Heavy-Duty Compression Ignition Engines |
| title_sort | cfd simulation based development of a multi platform scr aftertreatment system for heavy duty compression ignition engines |
| topic | SCR selective catalytic reduction urea-SCR aftertreatment NOx nitrogen oxides exhaust system emission control emission reduction |
| url | https://www.mdpi.com/1996-1073/18/14/3697 |
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