Challenge:

Design of a dual stream Diesel Oxidation Catalyst concept that processes higher gas volumes without extensive pressure drop - still using conventional 5 2/3 inch monoliths.

    Diesel Oxidation Catalyst

    Available design space

    Original design with pathlines

Solution:    Topology optimization driven design with SIMULIA Tosca Fluid

To create a space-saving design for flow guiding components (like flow splitters, diverters, and collectors) a topology optimization driven design based on an initial design space was executed. After the optimization, the individually optimized components were assembled to create a new dual stream DOC design with significantly reduced pressure drop, enhanced flow split ratio and high flow uniformity across the catalytic sections. The resulting design has optimal performance for improved eco-efficiency.

    Optimized design with pathlines

Benefit:  

Using topology optimization, a new and promising DOC design was generated. The pressure drop has been reduced by 65 % while the flow distribution ratio of the new design concept improved from 47/53 to almost equal. The entire design process took only two weeks.

    Final optimized design concept

(Courtesy of Albonair)