Multi-Function Exhaust System for Diesel and Natural Gas Engines

Abstract

A multi-functional exhaust system for diesel and natural gas engines includes a rectangular box housing, a selective catalytic reduction (SCR) unit, at least one reductant injector, a plurality of sensors, and a mixing duct to mix the injected reductant and the exhaust gas. A portion of the mixing duct runs in parallel beside the SCR unit reducing the overall length of the housing. Another portion of the mixing duct routes the exhaust gas through a 180 degree bend to redirect the exhaust gas to the SCR unit. The SCR unit and mixing duct are positioned within the housing and in fluid communication with an inlet and an outlet of the housing. The inlet is in fluid communication with an engine, and the outlet is in fluid communication with an exhaust outlet so that the housing can be secured as the exhaust system.

What is claimed is: 
     
         1 . A multi-functional exhaust system for diesel and natural gas engines comprises:
 a rectangular box housing;   a passageway;   a mixing duct;   a selective catalytic reduction (SCR) unit;   at least one nitrogen oxide (NO x ) sensor;   at least one temperature sensor;   at least one pressure sensor;   at least one reductant injector;   the rectangular box housing comprises an inlet and an outlet;   the inlet being in fluid communication with the mixing duct through the passageway;   the mixing duct being in fluid communication with the SCR unit, wherein the mixing duct mixes the exhaust gas and the reductant agent from the at least one reductant injector;   the SCR unit being in fluid communication with the outlet; and   the at least one NO x  sensor, the at least one temperature sensor, the at least one pressure sensor, and the at least one reductant injector traversing into the rectangular box housing.   
     
     
         2 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the inlet traversing into the rectangular box housing; 
 the inlet being adjacently positioned with the mixing duct; 
 the outlet traversing into the rectangular box housing; and 
 the outlet being adjacently positioned with the SCR unit. 
 
     
     
         3 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the rectangular box housing further comprises at least one muffler unit; 
 the at least one muffler unit being positioned within the rectangular box housing adjacent to the inlet; and 
 the at least one muffler unit being in fluid communication with the inlet. 
 
     
     
         4 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the rectangular box housing further comprises at least one muffler unit; 
 the at least one muffler unit being positioned within the rectangular box housing adjacent to the outlet; and 
 the at least one muffler unit being in fluid communication with the outlet. 
 
     
     
         5 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the mixing duct comprises at least one mixing vane, an elongated portion and a shortened portion; 
 the elongated portion being adjacently positioned with the passageway, wherein the generated exhaust gas flows through the elongated portion; 
 the shortened portion being perpendicularly positioned with the elongated portion opposite of the passageway, wherein the shortened portion causes the generated exhaust gas to bend 180 degrees to bring the generated exhaust gas to the SCR unit; 
 the shortened portion being adjacently positioned with the SCR unit; and 
 the at least one mixing vane being internally connected to the mixing duct. 
 
     
     
         6 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the rectangular box housing further comprises an oxidation catalyst unit; 
 the oxidation catalyst unit being positioned within the rectangular box housing; and 
 the oxidation catalyst unit being in fluid communication with the SCR unit. 
 
     
     
         7 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the rectangular box housing further comprises an oxidation catalyst unit and a particulate filter unit; 
 the oxidation catalyst unit being positioned within the rectangular box housing; 
 the oxidation catalyst unit being in fluid communication with the SCR unit; 
 the particulate filter unit being positioned within the rectangular box housing adjacent to the oxidation catalyst unit; and 
 the particulate filter unit being in fluid communication with the oxidation catalyst unit. 
 
     
     
         8 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the at least one NO x  sensor being traversed into the mixing duct; 
 the at least one NO x  sensor being positioned in between the passageway and the SCR unit; and 
 the at least one NO x  sensor being electrically connected with an emissions control unit. 
 
     
     
         9 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the at least one temperature sensor being positioned in between the SCR unit and the outlet; and 
 the at least one temperature sensor being electrically connected with an emissions control unit. 
 
     
     
         10 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the at least one pressure sensor being positioned in between the SCR unit and the outlet; and 
 the at least one pressure sensor being electrically connected with an emissions control unit. 
 
     
     
         11 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 1  comprises;
 the at least one reductant injector being in fluid communication with the mixing duct, wherein the reductant injector provides the reducing agent from a secondary tank; and 
 the at least one reductant injector being electrically connected with an emissions control unit. 
 
     
     
         12 . A multi-functional exhaust system for diesel and natural gas engines comprises:
 a rectangular box housing;   a passageway;   a mixing duct;   a selective catalytic reduction (SCR) unit;   at least one nitrogen oxide (NO x ) sensor;   at least one temperature sensor;   at least one pressure sensor;   at least one reductant injector;   the rectangular box housing comprises an inlet and an outlet;   the inlet being in fluid communication with the mixing duct through the passageway;   the mixing duct being in fluid communication with the SCR unit, wherein the mixing duct mixes the exhaust gas and the reductant agent from the at least one reductant injector;   the SCR unit being in fluid communication with the outlet;   the at least one NO x  sensor, the at least one temperature sensor, the at least one pressure sensor, and the at least one reductant injector traversing into the rectangular box housing;   the at least one reductant injector being in fluid communication with the mixing duct, wherein the reductant injector provides the reducing agent from a secondary tank; and   the at least one reductant injector being electrically connected with an emissions control unit.   
     
     
         13 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the inlet traversing into the rectangular box housing; 
 the inlet being adjacently positioned with the mixing duct; 
 the outlet traversing into the rectangular box housing; and 
 the outlet being adjacently positioned with the SCR unit. 
 
     
     
         14 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the rectangular box housing further comprises at least one muffler unit; 
 the at least one muffler unit being positioned within the rectangular box housing adjacent to the inlet; and 
 the at least one muffler unit being in fluid communication with the inlet. 
 
     
     
         15 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the rectangular box housing further comprises at least one muffler unit; 
 the at least one muffler unit being positioned within the rectangular box housing adjacent to the outlet; and 
 the at least one muffler unit being in fluid communication with the outlet. 
 
     
     
         16 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the mixing duct comprises at least one mixing vane, an elongated portion and a shortened portion; 
 the elongated portion being adjacently positioned with the passageway, wherein the generated exhaust gas flows through the elongated portion; 
 the shortened portion being perpendicularly positioned with the elongated portion opposite of the passageway, wherein the shortened portion causes the generated exhaust gas to bend 180 degrees to bring the generated exhaust gas to the SCR unit; 
 the shortened portion being adjacently positioned with the SCR unit; and 
 the at least one mixing vane being internally connected to the mixing duct. 
 
     
     
         17 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the rectangular box housing further comprises an oxidation catalyst unit; 
 the oxidation catalyst unit being positioned within the rectangular box housing; and 
 the oxidation catalyst unit being in fluid communication with the SCR unit. 
 
     
     
         18 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the rectangular box housing further comprises an oxidation catalyst unit and a particulate filter unit; 
 the oxidation catalyst unit being positioned within the rectangular box housing; 
 the oxidation catalyst unit being in fluid communication with the SCR unit; 
 the particulate filter unit being positioned within the rectangular box housing adjacent to the oxidation catalyst unit; and 
 the particulate filter unit being in fluid communication with the oxidation catalyst unit. 
 
     
     
         19 . The multi-functional exhaust system for diesel and natural gas engines as claimed in  claim 12  comprises;
 the at least one NO x  sensor being traversed into the mixing duct; 
 the at least one NO x  sensor being positioned in between the passageway and the SCR unit; 
 the at least one NO x  sensor being electrically connected with the emissions control unit; 
 the at least one temperature sensor being positioned in between the SCR unit and the outlet; 
 the at least one temperature sensor being electrically connected with the emissions control unit; 
 the at least one pressure sensor being positioned in between the SCR unit and the outlet; and 
 the at least one pressure sensor being electrically connected with the emissions control unit.