CFD Simulation of SCR Systems Using a Mass-Fraction-Based Impingement Model

Computational fluid dynamics (CFD) are an essential tool for the development of diesel engine aftertreatment systems using selective catalytic reduction (SCR) to reduce nitrous oxides (NOx). In urea-based SCR, liquid urea–water solution (UWS) is injected into the hot exhaust gas, where it transforms into gaseous ammonia. This ammonia serves as a reducing agent for NOx. CFD simulations are used to predict the ammonia distribution in the exhaust gas at the catalyst inlet. The goal is to achieve the highest possible uniformity to realize homogeneous NOx reduction across the catalyst cross section. The current work focuses on the interaction of UWS droplets with the hot walls of the exhaust system. This is a crucial part of the preparation of gaseous ammonia from the injected liquid UWS. Following experimental investigations, a new impingement model is described based on the superposition of four basic impingement behaviors, each featuring individual secondary droplet characteristics. The droplet–wall heat transfer, depending on surface temperature and impingement behavior, is also calculated using a newly parameterized model. Applying the presented approach, the cooling of a steel plate from intermittent spray impingement is simulated and compared to measurements. The second validation case is the distribution of ammonia at the catalyst inlet of an automotive SCR system. Both applications show good agreement and demonstrate the quality of the new model.