In the present study, an innovative design of the urea-selective catalytic reduction (SCR) system without conventional mixing elements was developed. The aim was to obtain a high degree of urea decomposition, and uniform ammonia distribution at the inlet to the catalyst, while minimising the liquid film deposition and keeping the compact design. The concept of the design was based on creating high turbulences and elongating the flow paths of the droplets. The design was verified through a series of numerical simulations based on the Reynolds-averaged Navier–Stokes (RANS) approach and a discrete droplet model (DDM) spray representation. The analysis included various operating conditions as well as subcooled and superheated sprays. A uniform ammonia distribution was achieved regardless of the operating points and spray properties. Additionally, in the case of the flash-boiling injection, a further reduction of the wall film was observed.

In the present study, a flow rig with optical access intended for spray investigations in exhaust system-relevant conditions was analysed in terms of flow and temperature in the spray area using numerical simulations. The operation of the rig was examined for a wide range of exhaust mass flow rates, temperatures and various forms of UWS (urea-water solution) spray plumes. The locations of the injector and thermocouple were verified. Both conventional and flash-boiling injections were considered to assess the effect of the interaction of sprays with a gas flow. The results showed a highly uniform flow in the visualisation area, with only minor fluctuations near the walls. A similar observation was carried out for the temperature distribution. It was found that the extreme operating conditions caused substantial deformations of the spray plumes. However, the selected injector location allowed us to properly observe the spray formation regardless of the flow conditions. The study showed that the examined test rig enabled reliable spray investigations for a wide range of operating points.