초록 ▼

A means for increasing the robustness of a SCR after-treatment system is provided. Specifically, a hydrolysis catalyst coating is applied to multiple surfaces within a decomposition reactor to aid in urea and urea based deposit decomposition and mitigation of urea based deposits. The reactor include

A means for increasing the robustness of a SCR after-treatment system is provided. Specifically, a hydrolysis catalyst coating is applied to multiple surfaces within a decomposition reactor to aid in urea and urea based deposit decomposition and mitigation of urea based deposits. The reactor includes an injector mount attached to a middle tube portion, an inlet tube, an outlet tube and a mixer. A hydrolysis catalyst coating is applied to an inner surface of the injector mount, an inner surface of the middle tube portion, an inner surface of the outlet tube and an outer edge of the mixer. The hydrolysis catalyst coating is capable of decomposing urea and urea based deposits that comes in contact with the hydrolysis catalyst coating and mitigates the formation of urea based deposits.

대표청구항 ▼

1. A reductant decomposition reactor capable of decomposing urea and urea based deposits and mitigating the formation of urea based deposits comprising: an injector mount attached to a middle tube portion, the injector mount capable of introducing urea into the reactor;an inlet tube disposed at a fi

1. A reductant decomposition reactor capable of decomposing urea and urea based deposits and mitigating the formation of urea based deposits comprising: an injector mount attached to a middle tube portion, the injector mount capable of introducing urea into the reactor;an inlet tube disposed at a first end of the middle tube portion that is configured to connect to a first portion of an exhaust system;an outlet tube disposed at a second end of the middle tube portion that is configured to connect to a second portion of the exhaust system;a mixer disposed at a second end of the middle tube portion adjacent to the outlet tube that is configured to decompose the urea introduced into the reactor via the injector mount;a metallic skirt with a hydrolysis catalyst coating applied to a portion of the skirt and attached to an inner surface of the injector mount using a post adjacent to an injector port of the injector mount, the skirt having an opening at a back end of the skirt in the injector mount, the opening configured to force the injected urea into the middle tube portion and the skirt configured to prevent the injected urea from traveling back into the injector port;wherein a portion of the inner surface of the injector mount, a portion of an inner surface of the middle tube portion, a portion of an inner surface of the outlet tube and a portion of an outer edge of the mixer have the hydrolysis catalyst coating applied thereto that is capable of decomposing urea and urea based deposits that come in contact with the hydrolysis catalyst coating and mitigates the formation of urea based deposits. 2. The reactor of claim 1, wherein the skirt extends to a back end of an injector chamber of the injector mount substantially toward a top portion of the middle tube portion. 3. The reactor of claim 1, wherein the hydrolysis catalyst coating comprises a metal oxide, zeolite or a combination of both metal oxide and zeolite. 4. The reactor of claim 3, wherein if the hydrolysis catalyst coating comprises the metal oxide or the combination of the metal oxide and the zeolite, the metal oxide is titania. 5. The reactor of claim 3, wherein if the hydrolysis catalyst coating comprises the metal oxide or the combination of the metal oxide and the zeolite, the metal oxide is aluminum-oxide or cerium-oxide. 6. The reactor of claim 1, wherein the hydrolysis catalyst coating is applied to the inner surface of the injector mount, the inner surface of the middle tube portion, the inner surface of the outlet tube and the outer edge of the mixer using a plasma spray or a paint spray. 7. An injector mount capable of decomposing urea and urea based deposits and mitigating the formation of urea based deposits for a reductant decomposition reactor, the injector mount comprising: an injector housing;an injector port for injecting urea into the injector mount at a first end of the injector housing;an injector chamber defined by the injector housing that allows passage of urea injected via the injector port to enter into the reductant decomposition reactor;wherein a hydrolysis catalyst coating is applied to a portion of an inner surface of the injector housing, the hydrolysis catalyst coating provided for decomposing urea and urea based deposits that comes in contact with the hydrolysis catalyst coating and for mitigating the formation of urea based deposits;a metallic skirt provided for preventing the injected urea from traveling back into the injector port, the skirt being attached to an inner surface of the injector housing by a post near the injector port, and the skirt having an opening at a back end of the skirt in the injector mount, wherein the hydrolysis catalyst coating is applied to a portion of an inner surface of the skirt for decomposing urea and urea based deposits that comes in contact with the hydrolysis catalyst coating and for mitigating the formation of urea based deposits. 8. The injector mount of claim 7, wherein the skirt extends into the injector chamber of the injector mount and configured to be substantially toward a top portion of a middle tube portion of the reactor. 9. The reactor of claim 1, wherein the skirt extends to a front end of an injector chamber of the injector mount. 10. The reactor of claim 1, wherein the opening at the back end of the skirt is larger than a second opening at a front end of the skirt near the injector port. 11. The injector mount of claim 7, wherein the opening at the back end of the skirt is larger than a second opening at a front end of the skirt near the injector port. 12. The reactor of claim 1, wherein the mixer has a plurality of blades extending in a direction towards the second end of the middle tube portion. 13. The reactor of claim 1, wherein the hydrolysis catalyst coating is applied to a portion of an outer surface of the skirt. 14. The injector mount of claim 7, wherein the hydrolysis catalyst coating is applied to a portion of an outer surface of the skirt. 15. The injector mount of claim 7, wherein the skirt extends to a front end of the injector chamber. 16. The injector mount of claim 7, wherein the skirt extends to a back end of the injector chamber substantially toward a top portion of the middle tube portion.