WO2019055922A1

WO2019055922A1 - Exhaust aftertreatment apparatus

Info

Publication number: WO2019055922A1
Application number: PCT/US2018/051347
Authority: WO
Inventors: Martin Romzek; Yan SHU; Mark BUGNELL; Dale BOONE
Original assignee: Eberspaecher North America, Inc.
Priority date: 2017-09-15
Filing date: 2018-09-17
Publication date: 2019-03-21

Abstract

An exhaust aftertreatment apparatus having an upstream reactor portion configured to receive an exhaust stream and separate particulate matter; a downstream reactor portion; optionally, one or more intermediate reactor portions; and one or more openings configured for flow of the exhaust therethrough; wherein the apparatus includes one or any combination of features selected from: i) one or more baffles; ii) one or more end wall portions; iii) a mixer; iv) one or more lobed caps; and/or v) one or more outlets configured to direct the exhaust stream exiting the downstream reactor portion into an interior of a housing.

Description

EXHAUST AFTERTREATMENT APPARATUS

FIELD

[001] The present teachings relate to an exhaust system. The exhaust system may find particular use in combination with an internal combustion engine, such as that of a transportation vehicle.

BACKGROUND

[002] Generally, internal combustion engines produce an exhaust stream having toxic gases and pollutants within the exhaust stream. Agencies across the world, such as the United States Environmental Protection Agency, have enacted regulations regarding the exhaust emissions, seeking to reduce the toxic gasses and pollutants. It is now typical that transportation vehicles (e.g., commercial vehicles, such as trucks) are equipped with exhaust aftertreatment systems configured to remove or reduce the toxic gasses and pollutants within the exhaust stream prior to emission of the exhaust stream to the atmosphere.

[003] In efforts to meet stringent emission requirements, it has become common to perform one or a series of chemical reactions within the exhaust system. For example, it is common to employ a direct oxidation catalytic ("DOC") reaction. That reaction is employed to breakdown undesirable hydrocarbons in an exhaust stream into carbon dioxide and water reaction products. It is also common to perform selective catalytic reduction ("SCR"). That reaction typically seeks to convert (by a reduction reaction) one or more nitrogen oxides found in an exhaust stream into benign nitrogen gas and water. There may be employed one or more thermolytic and/or hydrolytic steps by which some or all of the nitrogen oxides present are reacted with reductant (e.g., urea) (provided in micro-droplets) to form an ammonia intermediate product that is thereafter reduced to nitrogen gas and water. Additionally, it is common to perform a separation step for removing particulate combustion products, such as by a filtration process. As a result of the various chemical reactions, a typical exhaust system is required to effectively function as a chemical reaction system, pursuant to which each of the chemical reactions is performed in a portion ("reactor portion") of the after-treatment system. Separation(s) may be performed within a reactor portion or within a separate portion.

[004] One challenge presented by known exhaust after-treatment systems is the overall space required to integrate the exhaust system into a transportation vehicle. For some applications, for instance, "in-line" exhaust after-treatment systems will incorporate each of the reactor portions and a filter serially in a generally straight exhaust stream flow path configuration. To achieve such functionality, along with the straight flow path of the exhaust stream, it may necessarily require that the system extend along almost an entire length of a vehicle from a motor to the rear of the vehicle. This can become complex in integrating the exhaust after-treatment system with other vehicle components (e.g., brake lines, fuel tank, fuel lines, suspension system, electrical wiring, etc) or cargo storage areas (such as the case with heavy duty trucks). One effort to integrate exhaust after-treatment systems while overcoming challenges associated with space constraints has been separating the system into modular reactor portions which are in fluid communication and remotely spaced from one another in the transportation vehicle. These modular systems have been used in vocational transportation vehicles (e.g., dump trucks, cement mixer trucks, garbage trucks, etc). In another effort to overcome the space constraints associated with the in-line exhaust systems, box-style exhaust systems have been recently integrated into transportation vehicles.

[005] Box-style exhaust after-treatment systems occupy a relatively compact volume that has a relatively small length to height and/or width proportion. An exemplary box-style exhaust after- treatment system includes the 1-Box™ configuration used in conjunction with Detroit Diesel engines. A box-style exhaust after-treatment system typically functions by having an exhaust stream flow in multiple different directions along the exhaust system, as opposed to a single direction of flow of an in-line exhaust system. The multiple different directions may be generally counter in direction to each other. By way of example, reactor portions of a box-style system may be located generally parallel and axially off-set with one another to reduce the overall length the exhaust after-treatment system requires within the transportation vehicle. Box-style after-treatment systems to date also have posed some challenges to their efficient operation and implementation.

[006] For example, one challenge which may be present in box-style exhaust after-treatment systems is how to support and fix in place one or more reactor portions with one or more other reactor portions, while also allowing the exhaust stream to flow continuously from one or more reactor portions to other reactor portions. In this regard, challenges are often faced when seeking to route an exhaust stream flowing along a flow axis in a first flow direction to a second flow direction that is significantly different from the first flow direction (e.g., causing the exhaust stream to make a turn of greater than about 60°, greater than about 90°, greater than about 135°), or even generally counter to (e.g., about 180°) the first flow direction. For example, such abrupt changes of flow direction may have the potential to induce irregularities in flow that could detract from the efficiency of reactions in a downstream reactor portion. Thus, there is a need for an exhaust after- treatment system having controlled flow path directional changes that foster efficient chemical reactions in a reaction portion of the system.

[007] As gleaned from the above, reactor portions in exhaust systems typically employ a catalyst which reacts with the exhaust stream passing therethrough. The employment of catalysts tends to be dimensionally dependent (e.g., length, width, height, area and/or volume dependent), as well as possibly being temperature dependent in order that chemical reactants be sufficiently exposed to a catalyst at a desired reaction temperature to achieve the desired reaction. For example, successful reduction of nitrogen oxides often requires that a stream of a reductant (e.g., urea) be injected and mixed with an exhaust stream. Successful mixing within a short exhaust stream flow path length has posed technical challenges. Accordingly, achieving the potentially multiple objectives for a successful mixing and/or chemical reactions within a compact packaging space has produced various competing technical challenges.

[008] Another challenge to box-style after-treatment systems involves temperature management. Some reactor portions may rely on heat of an exhaust stream passing therethrough to activate one or more catalysts within the reactor portion. Initially, at vehicle start-up, under certain ambient and/or engine load conditions, the components of the exhaust system may be at an inefficient reaction (e.g., catalysis, hydrolysis) temperature, thus resulting in less efficient reactions within a reactor portion. Additionally, the ability to secure a box-style system to a transportation vehicle faces challenges as a result of thermal expansion of the system, which may significantly differ from the vehicle structure to which the system is secured.

[009] Still another challenge to successful implementation of the box-style exhaust after- treatment systems is the need to reduce weight, and simplify assembly, while keeping individual components in a stable and fixed position relative to each other.

[010] It would be attractive to have a box-style exhaust after-treatment system that meets one or more of the above needs. SUMMARY

[Oil] The present disclosure relates to improvements for exhaust after-treatment systems. In one aspect, the teachings are direct toward an apparatus including a) an upstream reactor portion which is tubular, has a flow axis extending from a first end region to a second end region, and is configured to receive an exhaust stream and (optionally) to separate particulate matter from the exhaust stream; b) a downstream reactor portion which is tubular and has a flow axis extending from a first end region to a second end region and which is disposed with its flow axis generally parallel with the flow axis of the upstream reactor portion; c) optionally, at least one intermediate reactor portion, which is tubular, with a flow axis extending from a first end region to a second end region, and which its disposed with its flow axis generally axially parallel with the flow axes of the upstream reactor portion and the downstream reactor portion, and wherein the at least one intermediate reactor portion is configured to have a reductant (e.g., a diesel emission fluid, such as urea) introduced therein, hydrolyzed, and mixed with the exhaust stream; d) one or more openings in either or both the upstream reactor portion and downstream reactor portion, any intermediate reactor portion, which is configured for flow of the exhaust stream therethrough; wherein the apparatus includes one or any combination of features selected from: i) one or more baffles configured to support and fix in place relative to each other the upstream reactor portion, the downstream reactor portion, and optionally the at least one intermediate reactor portion, wherein at least one but less than all of the upstream, downstream, and optionally intermediate reactor portions pass through the one or more baffles; ii) one or more end regions having located therein a contoured surface intersecting the flow axis and adapted for redirecting flow of the exhaust stream from an inlet pipe introduced at an angle of about 10□ or greater to a flow axis of the upstream reactor portion to achieve a substantially uniform velocity of the exhaust stream throughout a cross-section of the upstream reactor portion; iii) a mixer within one of the upstream reactor portion, the downstream reactor portion, or the intermediate reactor portion which is configured to be in communication with a reductant stream in order to create turbulence within the reductant stream and being a non-impingement mixer configured to create a plurality of counter- rotating vortex streams; iv) one or more lobed caps configured to redirect a flow of the exhaust stream by at least about 90 degrees (e.g., from about 90 degrees to about 180 degrees) proximate to an inlet end or outlet end of the upstream or downstream reactor portion; iv) one or more outlets configured to direct the exhaust stream exiting the downstream reactor portion into an interior of a housing of the apparatus for heating (at least by convection) of one or more of the upstream reactor portion, the at least one intermediate reactor portion (if present), or downstream reactor portion.

[012] The present disclosure also relates to a method for treating an exhaust stream resulting from internal combustion of a transportation vehicle comprising: a) introducing the exhaust stream with a flow path direction that is at an angle of about 10□ or greater to a flow axis of an upstream reactor portion by way of an inlet opening in the upstream reactor portion (e.g., through a sidewall); b) deflecting the flow path direction of the exhaust stream, upon its entry into the upstream reactor portion, to achieve a generally uniform velocity of fluid across the exhaust stream generally parallel to the flow axis of the upstream reactor portion; c) redirecting the flow path direction of the exhaust stream from the flow direction within the upstream reactor portion to a downstream reactor portion while controlling the velocity of the redirected exhaust stream so it is generally uniform across (in the y direction) the exhaust stream and the flow path direction is generally counter to and generally parallel with the flow axis of the upstream reactor portion; and d) optionally deflecting the exhaust stream in the downstream reactor portion.

[013] The present disclosure also relates to an after-treatment apparatus (or a component or sub-assembly thereof) that includes one or more baffles for fixing in place to one another a plurality of reactor portions. The one or more baffles may be configured to be particularly useful in supporting and fixing one or more reactor portions relative to one or more other reactor portions in a spaced and/or generally parallel position. The one or more baffles may be located near and/or proximate opposing ends or end regions of one or more reactor portions. The one or more baffles may include one or more openings which allow pass through of the exhaust stream. The one or more baffles may include one or more openings for cradling or nesting one or more of the reactor portions. The baffles may be configured to avoid requiring the reactor portions to penetrate through an opening in the baffles.

[014] The one or more end regions provide a solution for redirecting an exhaust system within a very short length of a reactor portion. The one or more end regions may include an end wall portion which may be configured to direct the flow of the exhaust stream along a flow axis of a reactor portion. The one or more end regions may have a contoured surface which may be particularly useful in achieving a substantially uniform velocity of the exhaust stream through a cross-section of a reactor portion. Uniformity of a velocity may be measured generally parallel with the flow axis at a cross-section generally parallel with the y-axis and/or z-axis, generally transverse to a flow axis, or a combination thereof. As the flow of the exhaust stream is directed along a flow axis and quickly achieves uniform velocity, the exhaust stream is able to maximize contact with a catalyst and/or filter within a reactor portion, thereby allowing the reactor portion to have a significantly shorter length.

[015] One or more lobed end caps may be employed at one or more ends of one or more reactor portions. The lobed end caps may receive a flow of the exhaust stream and redirect the flow. A lobed end cap may include a contoured neck which may be particularly advantageous in imparting a uniform velocity on the exhaust stream within a minimal length of the exhaust system.

[016] One or more outlets may be advantageous in redirecting the exhaust stream exiting the apparatus toward a housing, one or more reactor portions, or a combination thereof. The thermal energy remaining within the emitted exhaust stream may warm a housing, one or more reactor portions, and/or one or more catalysts through convective heat. By heating some components of the exhaust system, the reactor portions and catalysts therein are able to more efficiently react with the exhaust stream passing therethrough; particularly in cold-weather and/or start-up conditions.

BRIEF DESCRIPTION OF DRAWINGS

[017] FIG. 1 illustrates an exploded view of an exhaust aftertreatment apparatus.

[018] FIG. 2 illustrates an exploded view of an exhaust aftertreatment apparatus.

[019] FIG. 3 illustrates a plan view of reactor portions of an exhaust aftertreatment apparatus.

[020] FIG. 4 illustrates a perspective view of an exhaust aftertreatment apparatus.

[021] FIG. 5 illustrates a perspective view of an exhaust treatment apparatus.

[022] FIG. 6 illustrates a cross-section of a reactor portion showing an end wall portion.

[023] FIG. 7 illustrates a perspective view of a lobed cap.

[024] FIG. 8 illustrates a path of an exhaust stream flowing through an exhaust aftertreatment apparatus.

[025] FIG. 9 illustrates an incoming surface of a mixer.

[026] FIG. 10 illustrates an outgoing surface of a mixer.

[027] FIG. 11 illustrates a reductant receiving portion of a mixer.

[028] FIG. 12 illustrates a turbulent flow path resulting from the mixer.

[029] FIG. 13 A illustrates an apparatus. [030] FIG. 13B illustrates an apparatus with a transparent housing.

[031] FIG. 13C illustrates an exhaust stream entering an apparatus.

[032] FIG. 13D illustrates an exhaust stream passing through an upstream reactor portion.

[033] FIG. 13E illustrates an exhaust stream passing through an intermediate reactor portion.

[034] FIG. 13F illustrates an exhaust stream passing through a downstream reactor portion and exiting the apparatus.

[035] FIG. 14A illustrates an apparatus.

[036] FIG. 14B illustrates a mixer residing with an apparatus.

[037] FIG. 15A illustrates an exhaust stream entering a mixer.

[038] FIG. 15B illustrates a reductant and exhaust stream within a mixer.

[039] FIG. 15C illustrates a turbulent flow exiting a mixer.

DETAILED DESCRIPTION

[040] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the present teachings, its principles, and its practical application. The specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[041] Unless otherwise stated, or clearly understood from the context of its use, reference herein to "exhaust stream" includes the stream of exhaust fluid initially emitted as a combustion reaction product from an engine, as well as any resulting fluid reaction products occasioned by an after-treatment step as described herein (e.g., a step of a DOC reaction, an SCR reaction, or other reaction, such as a thermolytic and/or hydrolytic reaction).

[042] The teachings herein relate to an apparatus. The apparatus may be particularly useful in treating an exhaust stream. The exhaust stream may be an exhaust resulting from internal combustion. The internal combustion may be from any engine, such as that of a transportation vehicle. Transportation vehicle may include any vehicle suitable for land, water, and/or air transportation. Transportation vehicles suitable for land may include any size truck, bus, car, all- terrain vehicle, rail vehicle, agricultural equipment, construction equipment, etc. Trucks may include light duty, medium duty, heavy duty, vocational trucks, etc. The presented teachings may also be used in non-vehicular applications. For example, the teachings herein may be applied to stationary generators, pump stations, industrial power generating operations, etc. The internal combustion may be in a diesel engine, gasoline engine, or the like. The apparatus may receive an exhaust stream from a motor. An exhaust line may carry the exhaust stream away from an internal combustion engine and to an inlet of the apparatus. The apparatus may function to reduce particulate matter and pollutants occurring with the exhaust stream, ensure an emitted exhaust stream meets environmental standards, or both. The apparatus may function reacting with the exhaust stream to collect, remove, reduce, and/or convert particulate matter and pollutants. The apparatus may include a plurality of components to allow the apparatus to function as recited. The components may include one or more reactor portions, one or more openings, one or more flow pipes, one or more baffles, one or more end wall portions, one or more mixers, one or more fluid delivery devices, one or more lobed caps, one or more insulators, one or more outer caps, one or more attachment brackets, one or more housings.

[043] The apparatus includes one or more reactor portions. The reactor portions may function to react with an exhaust stream, remove particulates from the exhaust stream, house one or more filters, house one or more catalysts, house one or more mixers, receive one or more reductants, or any combination thereof. The one or more reactor portions may have any suitable size and/or shape for reacting with an exhaust stream passing therethrough, remove particulate matter from the exhaust stream, directing the exhaust stream through a reactor portion and/or apparatus, housing one or more other components, or any combination thereof. The one or more reactor portions may be generally cylindrical, cubed, spherical, coned, prismed, the like, or any combination thereof. One or more reactor portions may have generally the same or a differing shape as one or more other reactor portions. One or more reactor portions may have one or more sidewalls extending from one end to an opposing end. One or more filters, catalysts, and/or mixers may be housed and/or enclosed within the one or more sidewalls. One or more reactor portions may have a generally same or differing length and/or width as one or more other reactor portions. Length may be measured along a flow axis of a reactor portion. By have a substantially same length as one or more other reactor portions, one or more baffles, lobed caps, insulators, outer caps, and/or attachment brackets are able to be easily integrated at opposing ends of the apparatus. Width may be measured generally transverse to a flow axis of a reactor portion. One or more reactor portions may have a width which is substantially continuous. One or more reactor portions may have a width which increases, decreases, or both along a length of the reactor portion.

[044] The one or more reactor portions may have a longitudinal axis (e.g., flow axis) extending along their respective length. The longitudinal axis may extend from a first end region of a reactor portion to a second end region of a reactor portion. A first end region may include an end (i.e., first end) of a reactor portion. A second end region may include an opposing end (i.e., second end) of a reactor portion. The longitudinal axis may be generally concentric or off-center with a cross-sectional area of a reactor portion. For example, a longitudinal axis may be concentric with a diameter of a reactor portion. The longitudinal axis of one or more reactor portions may be generally parallel with, perpendicular to, or any angle therebetween relative to the longitudinal axis of one or more other reactor portions. Generally may mean within about 5□ , within about 10□ , or even within about 20□ from the values stated. The longitudinal axis of one or more reactor portions may be concentric with, aligned with, un-centered from, off-set from, or any combination thereof relative to one or more other longitudinal axes of one or more other reactor portions. Longitudinal axes which are generally parallel with and off-set from one another may allow for the reactor portions to be consolidated and placed adjacent to one another (e.g., a box-style exhaust system). Longitudinal axes which are generally parallel with and substantially aligned with one another may allow for reactor portions to form an "in-line" exhaust system. A longitudinal axis may define an axis of a Cartesian coordinate system. The longitudinal axis may define an x-axis of each reactor portion. Generally transverse to the x-axis and/or longitudinal axis may be an y- axis and/or a z-axis. The y-axis, z-axis, or both may located at about a mid-length of a reactor portion. The differing axes may be useful in relating one or more components of the apparatus with one another, an exhaust stream passing through the apparatus, dimensions of one or more components, and the like. A longitudinal axis may be referred to as a flow axis (e.g., with reference to flow through a reactor portion of an exhaust stream).

[045] A flow axis may indicate the direction of flow of an exhaust stream relative to a longitudinal axis and/or along a length of a reactor portion. A flow axis may extend from one end region to an opposing second end region. The flow axis of one or more portions may flow in a same direction and/or opposing direction as the flow axis of one or more other portions. The one or more reactor portions may include an upstream reactor portion, downstream reactor portion, at least one intermediate reactor portion, or any combination thereof. An upstream reactor portion may be the first reactor portion through which an exhaust stream flows through upon entering an apparatus. A downstream portion may be a last reactor portion through which the exhaust stream flows through in an apparatus prior to exiting the apparatus. At least one intermediate reactor portion may be located downstream from an upstream reactor portion, upstream from a downstream reactor portion, or both.

[046] The apparatus may have an aspect ratio. The aspect ratio may be a ratio of the length, height, width, or a combination thereof. A length of the apparatus may be measured parallel to the longitudinal axis, x-axis, or both. A width of the apparatus may be measured perpendicular to the length, parallel with a z-axis, or both. A height of the apparatus may be measured perpendicular to the x-axis and/or z-axis. The aspect ratio may include a length to width aspect ratio, a length to height aspect ratio, and a height to width aspect ratio. A length to width aspect ratio may be about 1 : 1 or greater, about 2: 1 or greater, about 3 : 1 or greater, or even about 4: 1 or greater. A length to width aspect ratio may about 8: 1 or less, about 7: 1 or less, about 6: 1 or less, or even about 5: 1 or less. A length to height aspect ratio may be about 1 : 1 or greater, about 1.5 or greater, or even about 2 or greater. A length to height aspect ratio may be about 4: 1 or less, about 3 : 1 or less, or even about 2.5: 1 or less. A height to width aspect ratio may be about 0.5: 1 or greater, about 1 : 1 or greater, or even about 1.5: 1 or greater. A height to width aspect ratio may be about 3 : 1 or less, about 2.5: 1 or less, or even about 2: 1 or less.

[047] The one or more reactor portions may include one or more filters. The one or more filters may function to collect and/or remove particulate matter from an exhaust stream, break apart larger sizes of particulate matter into smaller particles, carry one or more catalysts, or any combination thereof. Particulate matter may include soot residing within an exhaust stream of an internal combustion engine (e.g., diesel engine). The one or more filters may collect particulate matter on one or more surfaces of the filter (e.g., surfaces created by pores). Accumulated particulate matter may be removed through active, passive, and/or forced regeneration. The one or more filters may burn off accumulated particulate matter. Burning off of particulate matter may occur through a catalyst or a burner. Exemplary filters can be found in US Patent Nos. : 8336301, 8763375, 9074522, 9188039, and 9334785, which are incorporated herein by reference for all purposes. Suitable filters may include cordierite wall flow filters, silicon carbide wall flow filters, ceramic fiber filters, metal fiber flow-through filters, partial filters, the like, or any combination thereof. Suitable filters may include one or more diesel and/or petrol filters. The one or more filters may be located in, adjacent to, proximate with, and/or in fluid communication with one or more reactor portions. For example, a filter may be located in an upstream reactor portion and/or downstream reactor portion. The one or more filters may be located along part of or all of a length of a reactor portion. The one or more filters may carry a catalyst (e.g., coated with a catalyst) or be free of a catalyst. The catalyst may allow a filter to also react with the exhaust stream in addition to removing particulate matter. For example, a particulate filter may also be and/or carry thereon an oxidation catalyst.

[048] The one or more reactor portions may include or be in communication with one or more catalysts. The one or more catalysts may be configured to initiate and/or perform one or more reactions. The one or more reaction portions may function to reduce toxic gasses, toxic pollutants, greenhouse gases, or a combination thereof. Greenhouse gases may include carbon dioxide, methane, nitrous oxide, fluorinated gases, or any combination thereof. The one or more reactions may function to oxidize hydrocarbon, oxidize carbon monoxide, reduce hydrogen compounds, reduce nitrogen oxides, reduce sulfur oxides, oxidize methane, or any combination thereof. Exemplary catalysts may include a diesel oxidation catalyst (DOC), methane oxidation catalyst (MOC), selective catalytic reactor (SCR), ammonia slip catalyst (ACR), the like, or any combination thereof. The one or more catalysts may be located in one or more reactor portions, one or more flow pipes, one or more lobed chambers, or a combination thereof. The one or more catalysts may be located within the same and/or a different reactor portion as one or more other catalysts and filters. For example, an upstream reactor portion may include a diesel oxidation catalyst and a diesel particulate filter. For example, a downstream reactor portion may include both a selective catalyst reactor and an ammonia slip catalyst. One or more catalysts may be combined with a carrier, supported on a support structure, or both. One or more filters may function as a carrier and/or support structure for a catalyst. A plurality of catalysts may be placed in any sequence within the apparatus. As one example, the diesel oxidation catalyst may be located upstream of the selective catalytic reactor and ammonia slip catalyst. As another example, the selective catalytic reactor may be located upstream of the diesel oxidation catalyst.

[049] The one or more catalysts may include an oxidation catalyst (e.g., diesel oxidation catalyst). The oxidation catalyst may function to reduce and/or oxidize carbon monoxide and/or hydrocarbons within the exhaust stream, converting carbon monoxide and/or hydrocarbons into carbon dioxide and/or water, or both. The oxidation catalyst may be located within one or more reactor portions, filters, or both. For example, an oxidation catalyst may be integrated into a particulate filter. The oxidation catalyst may be located within one or more of the upstream, intermediate, and/or downstream reactor portions. The catalyst may react with the high temperature of an exhaust stream as the stream passes through a reactor portion and contacts the catalyst. Upon contact with the hot exhaust stream, the catalyst may convert the carbon monoxide and/or hydrocarbons. The oxidation catalyst may be any catalyst suitable for functioning as recited. Suitable catalysts may include palladium, platinum, rhodium, the like, or any combination thereof.

[050] The one or more catalysts may include a selective catalytic reactor. The selective catalytic reactor may function to reduce nitrogen oxides (NO_x) present within the exhaust stream, convert nitrogen oxides into nitrogen and/or water, or a combination of both. The selective catalytic reactor may be located within one or more reactor portions, filters, or both. The selective catalytic reactor portion may be located downstream of an introduction point of one or more reductants into the apparatus and/or exhaust stream. The selective catalytic reactor may be located within one or more of the upstream, intermediate, and/or downstream reactor portions. The selective catalytic reactor may react with ammonia present within the exhaust stream to reduce and/or convert the nitrogen oxides. The selective catalytic reactor may be located downstream of one or more fluid delivery devices which introduce one or more reductants, one or more mixers, an upstream reactor portion, one or more intermediate reactor portions; upstream and/or within a downstream reactor portion; or any combination thereof. A selective catalytic reactor may be any catalyst suitable for functioning as recited. Exemplary selective catalytic reactors may include one or more ceramic materials, one or more metals, one or more minerals, or a combination thereof. One or more metals may include vanadium, molybdenum, tungsten, precious metals, or any combination thereof. One or more minerals may include zeolites. The selective catalytic reactor may be located in a same or different reactor portion as an ammonia slip catalyst. The selective catalytic reactor may cooperate with an ammonia slip catalyst.

[051] The one or more catalysts may include an ammonia slip catalyst. An ammonia slip catalyst may be useful in eliminate trace amounts of ammonia remaining within an exhaust stream. The ammonia slip catalyst may oxidize some of the ammonia present within an exhaust stream. The ammonia may be oxidized into nitrogen gas and water. The ammonia may be present after the exhaust stream mixes with one or more reductants, reacts within a selective catalytic reactor, or both. The ammonia slip catalyst may be located within one or more reactor portions, filters, or both. The ammonia slip catalyst may be located within one or more the upstream, intermediate, and/or downstream reactor portions. The ammonia slip catalyst may be located downstream of one or more fluid delivery devices which introduce one or more reductants, one or more mixers, an upstream reactor portion, one or more intermediate reactor portions; upstream and/or within a downstream reactor portion; or any combination thereof. The ammonia slip catalyst may be located in a same or different reactor portion as a selective catalytic reactor. The ammonia slip catalyst may be located close to an outgoing end of a reactor portion than an incoming end. For example, the ammonia slip catalyst may be located near an outgoing end of a reactor portion having a selective catalytic reactor therein. An ammonia slip catalyst may be any catalyst able to function as recited. Exemplary ammonia slip catalysts may include one or more metals. The one or more metals may include platinum, palladium, or a mixture thereof. The ammonia slip catalyst may react with remnants of ammonia resulting from one or more reductants.

[052] One or more reductants may be introduced into the exhaust stream. One or more reductants may be particularly useful in aiding one or more subsequent reactions for reducing nitrogen oxides in an exhaust stream. The one or more reductants may be introduced upstream of reducing nitrogen oxides and/or oxidizing ammonia from the exhaust stream. The one or more reductants may include an ammonia-based substance, such as an aqueous urea solution. Heat occurring in the apparatus may result in evaporation of water from the solution, resulting in urea. Heat may decompose the urea into one or more compounds. Upon decomposition, the urea may decompose into isocyanic acid and ammonia. The ammonia may be particularly useful in conjunction with a selective catalytic reactor. The one or more reductants may be introduced within a reactor portion, a mixer, or any other component in fluid communication with the exhaust stream upstream of reducing nitrogen oxides from the exhaust stream. The one or more reductants may be introduced within one or more intermediate reactor portions, downstream of one or more upstream reactor portions, upstream of one or more downstream reactor portions, or any combination thereof.

[053] The one or more reactor portions may include one or more openings. The one or more openings may function to allow flow of an exhaust stream therethrough, into, and/or out of one or more reactor portions, disperse an exhaust stream, change a velocity of an exhaust stream, cooperate with one or more other components of the apparatus (i.e., baffle, lobed cap, flow pipe, end wall portion) to redirect the flow of an exhaust stream, or any combination thereof. One or more openings may have any size and/or shape to allow an appropriate flow of an exhaust stream through one or more of the reactor portions. The one or more openings may be generally circular, oval, egg-shaped, elliptical, square, rectangular, triangular, the like, or any combination thereof. One or more openings may have a length and/or width measured generally transverse to a flow axis of a reactor portion. A length of an opening may be about less than, equal to, or greater than a width of an opening. For example, an inlet opening may have a generally elongated opening shape (e.g., oval shape) with an elongated length (i.e., length greater than width) generally transverse to a flow axis (e.g., of the upstream reactor portion). A length greater than a width may allow for the exhaust stream to be dispersed upon passing through the opening, change velocity upon passing through the opening (e.g., slow down) contact a greater surface area of an end wall portion, or both. One or more openings may have the same or a differing shape as one or more other openings. One or more openings may have a shape reciprocal to a cross-section of an inlet pipe, outlet pipe, one or more baffle openings, or any combination thereof. Reciprocal may mean having a substantially similar shape. One or more openings may include a flared edge about at least part of its periphery. A flared edge may engage and seal with an inlet pipe, outlet pipe, or both. One or more openings may include a flange about its perimeter. A flange may function to abut with and/or seal with one or more other components (e.g., baffle, flow pipe, lobed cap). One or more openings may be located at, inboard, downstream, upstream, or any combination thereof relative to one or more ends of a reactor portion. One or more openings may include one or more inlet openings, outlet openings, or both. One or more openings may include an inlet opening in an upstream reactor portion located inboard (i.e., downstream) from a first end of the upstream reactor portion. One or more openings may include an outlet opening in a downstream reactor portion located inboard (i.e., upstream) from a second end of the downstream reactor portion. One or more openings may interface with one or more inlet pipes, outlet pipes, baffles, lobed caps, or any combination thereof.

[054] The apparatus may include one or more flow pipes. The one or more flow pipes may allow the exhaust stream to enter into and/or exit the apparatus, one or more openings, one or more reactor portions, or any combination thereof. The one or more flow pipes may have any suitable size, shape, and/or configuration to function as described. The one or more pipes may be generally cylindrical, cubed, spherical, coned, prismed, the like, or any combination thereof. The one or more pipes may have a cross-section which is generally circular, elliptical, oval, egg-shaped, square, rectangular, triangular, or a combination thereof. A cross-section of a pipe having one shape may expand into a cross-section having a same and/or differing shape. For example, a pipe may have a generally circular cross-section which expands into a generally elliptical cross-section. The cross-section may be taken through a plane transverse to flow axis of pipe. An expanding cross-section at an inlet pipe may be beneficial in having the flow stream contact a greater surface area of an end wall portion. The one or more pipes may include one or more inlet pipes, outlet pipes, or any combination thereof. An inlet pipe may interface with an inlet opening. An outlet pipe may interface with an outlet opening. The one or more flow pipes may extend from a reactor portion. One or more outlet openings and/or outlet pipes may be configured to direct an exiting exhaust stream toward and/or away from one or more components of the apparatus. For example, one or more outlet pipes may have one or more elbows, may be bifurcated to allow emission of part of the exhaust stream while allowing redirecting of part of the exhaust stream, or any combination thereof. Redirecting an exhaust stream toward one or more components, such as the housing, may allow the exiting exhaust stream to thermally envelope one or more components. The one or more flow pipes may extend at an angle relative to a flow axis of a reactor portion. A flow pipe may be parallel, perpendicular, or any angle therebetween relative to a flow axis. A flow pipe may be about 0D or greater, about 5□ or greater, about 10□ or greater, about 25□ or greater, or even about 45□ or greater relative to a flow axis of a reactor portion. A flow pipe may be about 90□ or less, about 85□ or less, about 75□ or less, or even about 60□ or less relative to a flow axis of a reactor portion.

[055] The apparatus may include one or more end wall portions. The one or more end wall portions may function to stop flow and/or direct flow of an exhaust stream within one or more reactor portions. The one or more end wall portions may have any size, shape, and/or configuration to function as recited. The one or may more end wall portions may have a cross-sectional and/or peripheral shape generally similar to or different from a cross-sectional shape of one or more reactor portions. The one or more end wall portions may have a cross-sectional and/or peripheral shape which is generally circular, oval, elliptical, square, rectangular, triangular, the like, or any combination thereof. The one or more end wall portions may be disposed within one or more reactor portions; adjacent to one or more reactor portions, baffles, lobed caps, or any combination thereof. One or more end wall portions may be disposed at and/or inboard relative to one or more ends of a reactor portion. One or more end wall portions may be located in one or more end regions of a reactor portion. One or more end wall portions may be disposed outboard relative to and/or adjacent to one or more openings (e.g., inlet opening, outlet opening). One or more end wall portions may be located within one or more end wall portions adjacent an incoming exhaust stream path. One or more end wall portions may be located within a reactor portion such that a longitudinal axis of the one or more end wall portions is generally parallel with, perpendicular to, or any angle therebetween relative to a flow axis of a reactor portion. A longitudinal axis may be defined as an axis lengthwise through the end wall portion. The longitudinal axis may be perpendicular to and or off-set from the flow axis to deflect an incoming exhaust stream so it flows generally parallel with the flow axis. The end wall portion may have one or more edges about a perimeter. The one or more edges may include an upper edge and a lower edge. The upper edge may be an edge of the end wall portion located on one side of both the x and z axes (e.g., the x-z plane). The lower edge may be an edge of the end wall portion located on an opposite side of the x and z axes opposite the upper edge. The upper edge may be located adjacent to and/or upstream of an inlet opening. The lower edge may be located in line with and/or downstream of an outlet opening. A line from the upper edge and/or the upstream edge of an inlet opening to the bottom edge may form an angle relative to the flow axis, longitudinal axis, x-axis, and/or x-z plane. Although not limited to, FIG. 6 illustrates an exemplary angle a. The angle may be an acute angle, a right angle, or any angle therebetween. The angle may be about 30 degrees or greater, about 40 degrees or greater, or even about 50 degrees or greater. The angle may be about 90 degrees or less, about 85 degrees or less, or even about 80 degrees or less. The end wall portion may extend across all or part of a width of a reactor portion. The one or more end wall portions may have a contoured surface having one or more contours.

[056] The one or more end wall portions may have one or more contours. The one or more contours may function impart a substantially uniform velocity of the exhaust stream throughout a cross-section of one or more reactor portions. The one or more contours may be about a perimeter, a surface within a perimeter, or both of an end wall portion. The one or more contours may be defined as a contoured surface. A contoured surface may be defined as an exterior surface of the end wall portion which may or may not include the perimeter, be a surface within the perimeter, or a combination thereof. A contoured surface may be adapted for redirecting low of an exhaust stream from one or more flow pipes (e.g., inlet pipe) so that the exhaust stream flows generally parallel with a flow axis of a reactor portion. The contoured surface may be adapted for redirecting flow of an exhaust stream introduced at an angle relative to a flow axis. The angle may be about 10 D or greater, about 30 D or greater, about 50 D or greater, or even about 70□ or greater. The angle may be about 170 D or less, about 150 D or less, about 130 D or less, or even about HO D or less. The contoured surface may have any suitable shape for redirecting or stopping flow of an exhaust stream. The contoured surface may include a single contour or a plurality of contours. The contoured surface may have one or more arcuate surfaces, planar surfaces, or any combination thereof. An arcuate surface may be concave, convex, sinusoidal, the like, or any combination thereof. The contoured surface may have a continuous or discontinuous curvature. The contoured surface may have a continuously curved shape which is resembles a shape similar a C, N, S, U W, the like, or any combination thereof. The contoured surface may be about 10% or greater, about 20%) or greater, or even about 25% or greater of a total surface area of one or more end wall portions. The countered surface may be about 100% or less, about 90% or less, or even about 80% or less of a total surface area of the one or more end wall portions. The contoured surface may or may not have mirror symmetry and/or rotational symmetry about one or more planes and/or axes. The contoured surface may have mirror symmetry about a plane parallel with the flow axis, the x- y plane, or both. The contoured surface may not have mirror symmetry about a plane parallel with the flow axis, the x-z plane, or both. The one or more end wall portions may be located at an end of a reactor portion free of direct contact or in contact with a baffle. The one or more end wall portions may be located at an end of a reactor portion which is or is free of being partially and/or completely circumscribed by a baffle.

[057] The apparatus may include one or more baffles. The baffles may function to join and/or retain one or more reactor portions fixed relative to at least one or more other reactor portions; provide a seal between one or more components of the apparatus (e.g., one or more reactor portions) and one or more other components of the apparatus (e.g., and one or more lobed caps); allow fluid communication between one or more components of the apparatus (e.g., one or more reactor portions) and one or more other components of the apparatus (e.g., one or more lobed caps); or any combination thereof. The baffles may have any size, shape, and/or configuration to function as recited. The baffles may have a general shape similar and/or complementary to a profile of a one or more or a plurality of the reactor portions. For example, the baffle may have a general shape similar to a profile of two or more, or three or more, reactor portions. A profile of the one or more reactor portions may be defined as a profile at first and/or second ends of the one or more reactor portions, generally parallel with a cross-section of the one or more reactor portions, generally perpendicular to one or more flow axes, or any combination thereof. The one or more baffles may have a generally planar structure, non-planar structure or both. The baffles may be mostly planar except for flanges projecting therefrom. The one or more baffles may be formed by any suitable process. The one or more baffles may be stamped, 3D printed, hydroformed, the like or a combination thereof. The one or more baffles may have one or more flanges. The flanges may provide a structure to which other components can mount, provide part of a gas tight seal, or both. The flanges may be about all or part of a periphery, one or more openings, or both. The flanges may face toward and/or be adjacent to one or more other components. The one or more baffles may include a mounting surface. The mounting surface may receive one or more components of the exhaust system or vehicle. The one or more baffles may include one or more portions which extend external of a housing (e.g., heat shield).

[058] One or more baffles may include one or more baffle openings for allow flow through of an exhaust stream, penetrating of one or more reactor portions therethrough, or both. The one or more baffle openings may have a cross-sectional shape similar and/or differing from a cross- sectional shape of one or more reactor portions. The one or more baffle openings may include a single opening or a plurality of openings. One or more baffle openings may be less than or equal to a total number of reactor portions in the apparatus. One or more baffle openings may include 1 or more, 2 or more, or even 3 or more baffle openings. One or more baffle openings may include 8 or less, 7 or less, 6 or less, 5 or less, or even 4 or less baffle openings. A baffle may have so many baffle openings so that all or only some of the reactor portions penetrate therethrough. A baffle may have so many baffle openings so that at least one but less than all of the reactor portions (i.e., upstream, downstream, and one or more intermediate reactor portions) extend therethrough. The one or more baffle openings may partially or completely circumscribe about one or more reactor portions. The one or more baffle openings may have one or more notches, cut-outs, and/or the like such that the opening does not completely circumscribe a reactor portion or other component penetrating therethrough. One or more baffle openings may circumscribe about one or more reactor portions while one or more other baffle openings may only partially circumscribe about one or more reactor portions. The baffle may abut with one or more ends of one or more reactor portions. For example, a surface (e.g., plate portion) of the baffle may abut with a first or second end of a reactor portion through which the exhaust stream does not flow through (e.g., the reactor portion has an end wall portion therein and/or the baffle prevents flow of the exhaust stream). A portion of the baffle which abuts with an end region of a reactor portion having an end wall portion may be solid or have an opening. A flange may abut with the baffle and be located about the perimeter of the opening. The baffle may abut with and/or seal with one or more flanges of one or more reactor portions. A reactor portion may have a flange about an end through which the exhaust stream passes. A flange may abut with the baffle to create a seal. A flange may align with a baffle opening, thus allowing an exhaust stream therethrough. The baffle may be adjacent to, proximate to, engage with, seal with, receive, or be received in one or more lobed caps.

[059] The apparatus may include one or more lobed caps. The one or more lobed caps may function to redirect a flow direction of an exhaust stream, fluidly connect one or more reactor portions to one or more other reactor portions, or both. The one or more lobed caps may have any size, shape, and/or configuration to function as recited. The one or more lobed caps may have a single lobe or a plurality of lobes. A lobe may be defined as generally complementary with one or more cross-sectional shapes of a reactor portion, baffle opening, or both. For example, with a generally cylindrical reactor portion, a lobe may have at least one generally curved cross-section. The cross-section may be taken generally transverse to a flow axis, parallel with a y-z plane, or both. The one or more lobed caps may include an upstream lobed cap, downstream lobed cap, or both. The one or more lobed caps may be configured to redirect flow of an exhaust stream from an upstream reactor portion, to and/or from one or more intermediate reactor portions, to a downstream reactor portion, or any combination thereof. The one or more lobed caps may include a plurality of lobes. Each lobe may have a cross-section shape similar to a cross-section shape of one or more reactor portions. A lobed cap may have a first lobe with cross-section shape similar to one reactor portion and a second lobe with a cross-section shape similar to another reactor portion. A lobe may have the same or a differing depth as another lobe. A depth of one or more lobes may be less than, about equal to, or greater than a height of a lobe cap. Depth of a lobe may be measured generally parallel with a flow axis, x-axis, or both. Height of a lobe cap may be measured generally transverse with af low axis, parallel with a y-axis, or both. A lobe may receive and/or repel an exhaust stream to result in deflecting of the air stream. One or more lobes may be connected to one or more other lobes via one or more contoured necks.

[060] One or more contoured necks may function to redirect the flow of the exhaust stream, impart a generally uniform velocity of the exhaust stream, or both as the exhaust stream transfers from one reactor portion to another reactor portion. The one or more contoured necks may have a contour which is generally parallel with, perpendicular to, or any angle therebetween relative to one or more flow axes of one or more reactor portions. A contour may be defined as a profile line which extends generally parallel with the flow axis and/or x-axis. The one or more contoured necks and plurality of lobes may each have a width. A width may be measured generally parallel with, perpendicular to, or any angle therebetween relative to one or more flow axes. The one or more contoured necks may have a width about less than, equal to, or greater than one or more lobes. For example, the one or more contoured necks may have a width greater than one or more lobes and less than one or more other lobes giving the cap a teardrop shape. Adjacent to one or more lobed caps may be an insulator.

[061] The apparatus may include one or more insulators. The one or more insulators may function to prevent heat and/or vibrations transferring to and/or from the apparatus to a surrounding environment (e.g., surrounding area of transportation vehicle), dampening vibrations (e.g., noise), or a combination thereof. The one or more insulators may function to maintain the thermal energy within the apparatus so that the one or more reactor portions and catalysts remain at a suitable temperature to react with the exhaust stream passing therethrough. The one or more insulators may also function to provide thermal insulation so that heat within the apparatus is prevented from and/or reduced from dissipating into the surrounding environment of a transportation vehicle. The one or more insulators may have a shape differing from, substantially similar to, or complementary with a profile of one or more, or even all of the ends of the reactor portions. The one or more insulators may have a shape differing from or substantially similar to one or more baffles, lobed caps, outer caps, or a combination thereof. The one or more insulators may be located adjacent to and/or external relative to one or more baffles, one or more lobed caps, or both. The one or more insulators may be located adjacent to and/or inward relative to one or more outer caps.

[062] The apparatus may include one or more outer caps. The outer caps may function to seal the ends of the apparatus. The one or more outer caps may have a size and/or shape substantially similar to, differing from, or complementary with a profile of all of the ends of the reactor portions, baffles, lobed caps, insulation, or a combination thereof. The one or more outer caps may fit over one or more baffles, lobed caps, insulation, or a combination thereof. The one or more outer caps may be secured to via mechanical attachments, welding, or the like to the one or more baffles, lobed caps, insulators, or a combination thereof. The one or more outer caps may be located adjacent to, outward from, and/or external of one or more reactor portions, baffles, lobed caps, insulation, a housing, or a combination thereof. The one or more outer caps may be part of or separate from a housing. The one or more outer caps may include one or more attachment brackets.

[063] The apparatus may include one or more fluid delivery devices (e.g., valve, injector). The one or more fluid delivery devices may inject and/or control passage of a reductant into the apparatus, one or more reactor portions, one or more mixers; into contact with the exhaust stream; control flow of a reductant toward a mixer; or any combination thereof. The one or more fluid delivery devices may be any suitable device for releasing and controlling passing of a reductant into the apparatus. The one or more fluid delivery devices may include a single jet and/or nozzle or a plurality of jets and/or nozzles for releasing a reductant. The one or more fluid delivery devices may include 1 or more, 2 or more, or even 3 or more jets and/or spray nozzles. The one or more fluid delivery devices may include 10 or less, 8 or less, or even 6 or less jets and/or spray nozzles. The one or more fluid delivery devices may release a reductant having a droplet size. The droplet size may range be about 5 microns or greater, about 10 microns or greater, or even about 30 microns or greater. The droplet size may be about 180 microns or less, about 150 microns or less, or even about 50 microns or less. For example, droplet size may range from about 5 microns to about 50 microns. A smaller droplet size may allow for more efficient and homogeneous mixing of the reductant with the exhaust stream. The one or more fluid delivery devices may be located in the apparatus, upstream of an ammonia slip catalyst, upstream of a selective catalytic reducer, or both. The one or more fluid delivery devices may be located upstream and/or downstream of a filter, oxidation catalyst, or both. The one or more fluid delivery devices may be connected to and/or in fluid communication with one or more outer caps, insulators, lobed caps, baffles, reactor portions, mixers, or any combination thereof. The one or more fluid delivery devices may inject a reductant into the apparatus such that the reductant flows generally parallel with, perpendicular to, or any angle therebetween relative to a flow axis of a reactor portion, the direction of flow of the exhaust stream within a reactor portion and/or mixer, or a combination thereof.

[064] The apparatus may include one or more mixers. The one or more mixers may function to mix a reactant (e.g., reductant) with an exhaust stream, provide a general uniform mixture of a reactant with the exhaust stream prior to entering one or more reactor portions, or both. The one or more mixers may have any size, shape, and or configuration to allow for mixing and/or optimizing a reaction of a reactant with the exhaust stream. The one or more mixers may be static, dynamic, or a combination of both. The one or more mixers may reside within, adjacent to, or proximate one or more reactor portions. The one or more mixers may reside between an inlet opening and an outlet opening of the apparatus. The one or more mixers may reside within a same and/or different reactor portion as a reactor portion in which a reactant is introduced. A static mixer may rely on one or more blades, openings, and/or flow paths to create turbulence of the exhaust stream and reactant flowing therethrough. The turbulence may provide for a sufficient amount of intensive mixing to allow for a substantially homogeneous mixture of the reactant and exhaust stream.

[065] One benefit of the apparatus disclosed herein is that a mixer may be selected for providing a substantially uniform distribution of one or more reactants. For example, uniformity of distribution of a reductant with the exhaust stream. Uniformity of the reductant may be measured as a percentage, with 100% being perfect uniformity in parts per million values measured at a cross-section transverse to a flow axis. For example, dispersion of the reductant may be measured at cross-section of an inlet of a reactor portion (e.g., SCR inlet) and/or measured at a cross-section of an outlet of a reactor portion (e.g., SCR outlet). The mixer may result in uniformity of the reductant with the exhaust stream of about 90% or greater, 92%> or greater, 95% or greater, or even about 98% or greater. The mixer may result in uniformity of the reductant with the exhaust stream of about 100% or less. The mixer may be an impingement or non-impingement mixer. Impingement may be defined as having one or more surfaces which the reductant contacts resulting in impact of the reductant with a surface of the mixer. Impingement may rely predominately on the impact for mixing. The impact may assist in evaporating water or other liquids from the reductant. Non-impingement may be defined as mixing which relies predominantly on turbulent flow. [066] A static mixer may be a radial blade mixer. A radial blade mixer may have a plurality of blades adjacent to one another in a circumferential direction while leaving free and defining a central core area. For example, a radial blade mixer may have one or more features such as those disclosed in US 20080267780, US 8495866, incorporated herein by reference for all purposes. A radial blade mixer may be defined as an impingement mixer. A mixer may have a shape substantially similar to or differing from a cross-section of one or more reactor portions (e.g., cylindrical). The mixer may have a plurality of blades. The plurality of blades may point radially inward, outward, or both. The plurality of blades may be arranged radially within the mixer, about the mixer, or both. The plurality of blades may have an angle of incidence in relation to a flow axis one the mixer. The flow axis of the mixer may be parallel with, perpendicular to, or any angle therebetween relative to one or more flow axes of one or more reactor portions. One or more blades may or may not partially overlap one or more other blades. One or more blades may or may not extend completely toward a flow axis of the mixer. A central core area may be defined by a plurality of blades which do not extend completely toward the flow axis. The central core area may allow for passage of the exhaust stream and/or reductant therethrough. A plurality of blades may include two or more sets of blades. The two or more sets of blades may be distanced from one another along the flow axis of a mixer. For example, a first set of a plurality of blades may be located at one end of a mixer and a second set of a plurality of blades may be located at an opposing end of the mixer. Each set of blades may have the same or different characteristics as the one or more blades described herein. For example, both a first and second set of blades may be arranged radially within a mixer and define a central core area. One or more blades may be bifurcated. One or more blades may have one or more bends along a length of each blade. The angle of the bend may be acute, right angle, obtuse or any angle therebetween.

[067] A static mixer may include a non-impingement mixer. A non-impingement mixer may function to redirect flow of an exhaust stream and/or reductant, convert laminar flow into turbulent flow and/or vice-versa of an exhaust stream and/or reductant, or both. A non-impingement mixer may include two opposing plate-like portions having a mixing tunnel therebetween, the mixer releasing one or more vortexes of an exhaust stream mixed with a reductant. The mixer may have one or more features such as those disclosed in US Publication No.: 2015/0110681, US Patent Application No. 15/454,215 filed on March 9, 2017, and German Patent Application DE 102016104361.3 filed March 10, 2016, which are incorporated herein in their entirety by reference for all purposes. The static mixer may have any size, shape, and/or configuration to function as recited. The static mixer may have a shape which is generally cylindrical, cubed, sphered, coned, prismed, pyramided, the like, or any combination thereof. A static mixer may have a shape similar to or differing from that of one or more reactor portions. The static mixer may be in fluid communication with one or more reactor portions. The static mixer may be disposed within, adjacent to, or proximate to one or more reactor portions. The static mixer may be disposed between two or more reactor portions. A static mixer may have opposing ends (e.g., opposing plate-like portions). The mixer may include a rim. The rim may partially surround the one both of the opposing ends. The opposing ends may include an incoming end and an outgoing end. The incoming end may be a face of the static mixer which receives an exhaust stream, and/or faces toward an incoming flow of an exhaust stream. The outgoing end may be a face of the static mixer which faces releases an exhaust stream, is opposing the incoming face, and/or faces an outgoing exhaust stream (e.g., an exhaust stream mixed with a reductant). The static mixer may include a plurality of flow openings.

[068] A plurality of flow openings may allow flow of an exhaust stream through the static mixer. The flow openings may be located on the incoming end, outgoing end, or both. The flow openings may include one or more openings at a periphery of the mixer or an opposing end, one or more openings within the periphery, or both. The flow openings may be configured to direct flow into and/or out of the mixer. One or more flow openings may include inlet mixer openings, outlet mixer openings, or both.

[069] One or more inlet mixer openings may function receive the exhaust stream within the mixer. The inlet mixer openings may be located at an incoming end of the mixer. The one or more inlet mixer openings may be configured to receive a substantially laminar flow of an exhaust stream. The one or more inlet mixer openings may be configured to redirect the flow of an incoming exhaust stream. The one or more inlet mixer openings may be centered, off-center, or both relative to the incoming end and/or flow axis of a reactor portion. The one or more inlet mixer openings may be off-center such that the openings are off-set from the flow axis. The one or more inlet mixer openings may be located closer to an upper portion of the mixer. The one or more inlet mixer openings may be in fluid communication with a mixing tunnel. The one or more inlet mixer openings may guide an exhaust stream toward a mixer tunnel, one or more outlet mixer openings, or both. [070] One or more outlet mixer openings may function to release an exhaust stream having a substantially laminar or turbulent flow, cause turbulence in the flow, or both. The one or more outlet mixer openings may result in one or more turbulent streams of an exhaust stream and/or reductant from exiting the mixer. The one or more outlet mixer openings of the outgoing end may be located at a same or opposing side of a flow axis of a reactor portion as one or more inlet mixer opening. The one or more turbulent streams may exhibit characteristics common in a transition from a laminar flow to a turbulent flow and/or a turbulent flow. The one or more turbulent streams may exhibit one or more flowing vortexes of the exhaust stream. The one or more turbulent streams may include a single rotating stream or a plurality of rotating streams. A plurality of rotating streams may be counter-rotating (i.e., rotating in opposing directions). The one or more outlet mixer openings may be configured to direct the flow of an exhaust stream, reductant, or both, toward and/or at an angle relative to one or more flow axes of one or more reactor portions, toward a periphery of the mixer, a rim of the mixer, or any combination thereof. The angle of the flow may parallel, perpendicular, or any angle therebetween relative to a flow axis of a reactor portion. The angle may be about 45□ or greater, about 60□ or greater, or about□ 80 or greater relative to a flow axis. The angle may be about 135□ or less, about 120D or less, or even about 100D or less relative to a flow axis. The one or more turbulent streams may be particularly useful for intensively mixing an exhaust stream with a reductant. The closer the angle the outgoing flow stream is to generally perpendicular relative to a flow axis, the less length along a flow axis may be required to suitably mix the exhaust stream with the reductant, thereby reducing length of one or more reactor portions and/or the apparatus as a whole. The exhaust stream may receive (i.e., come in contact with) a reductant within a mixing tunnel of the mixer.

[071] The plurality of flow openings may guide an exhaust stream to flow through a mixing tunnel. The mixing tunnel may function to receive a reductant, initiate mixing or a reductant with the exhaust stream, redirect and/or guide flow of an exhaust stream from one or more flow openings to one or more other flow openings, or any combination thereof. The mixing tunnel may have any shape, size, and or configuration to allow for introduction and/or initial mixing of a reductant into an exhaust stream. The mixing tunnel may be located within an interior of the mixer. The mixing tunnel may have a generally cylindrical, cubed, sphered, coned, prismed, pyramided, the like, or any combination thereof (e.g., hourglass). The mixing tunnel may be generally parallel with, perpendicular to, or angle therebetween relative to a flow axis of one or more reactor portions. The closer to perpendicular relative to a flow axis, the less length of the apparatus is required for mixing a reductant with an exhaust stream. The mixing tunnel may completely or partially extend across a length (e.g., diameter) of the mixer. The mixing tunnel may be in fluid communication with one or more injectors. The one or more injectors may inject the reductant into the mixing tunnel. The mixing tunnel may be in fluid communication with one or more flow openings. The mixing tunnel pay provide a flow path between one or more flow openings and one or more other flow openings. The flow path may direct an exhaust stream from one or more flow openings (i.e., incoming flow openings) toward one or more other flow openings (i.e., outgoing flow openings).

[072] The apparatus may include a housing. The housing may function to house one or more components of the apparatus, prevent heat transfer from and/or to one or more components of the apparatus, or any combination thereof. The housing may have any size, shape, and/or configuration to function as recited. The housing may be a one-piece component or a multi-piece component. A housing may include one or more housing shells. The housing shells may include a single housing shell or a plurality of housing shells. A plurality of housing shells may allow for easier manipulation and placement of the housing about one or more of the components of the apparatus. The one or more housing shells may include a first housing shell, a second housing shell, or both. A plurality of housing shells may be joined along one or more seams. The seams may be joined by any suitable method, such as welding, adhesives, mechanical fasteners, or any combination thereof. The seams may be generally perpendicular to, parallel with, or any angle therebetween relative to one or more flow axes.

[073] The apparatus may include one or more attachment brackets. The one or more attachment brackets function cooperate with and/or secure the apparatus to a transportation vehicle, such as a vehicle rail or other mounting bracket. The one or more attachment brackets may be responsive to thermal expansion during operation to allow for expansion and contraction of one or more components of the exhaust aftertreatment apparatus without impairing structural integrity of the exhaust aftertreatment apparatus. The one or more attachment brackets may include a sliding feature. A sliding feature may accommodate for thermal expansion and/or contract of the one or more components. An example of one such sliding mount is that in US8713925, incorporated herein by reference for all purposes. The one or more attachment brackets may remain steady and/or fixed while allowing for expansion and contraction of one or more components due to thermal operating conditions. The one or more attachment brackets may have any size, shape, and/or configuration suitable for mounting the apparatus to a transportation vehicle. The one or more attachment brackets may be affixed to and/or integral with one or more of an outer caps, insulators, lobed caps, baffles, reactor portions, housing, housing shell, or any combination thereof. The one or more attachment brackets may be located along any portion of a length of the apparatus or components of the apparatus. The one or more attachment brackets may be located near, proximate to, or at one or more ends of the apparatus. The one or more attachment brackets may include 1 or more, 2 or more, or even 3 or more attachment brackets. The one or more attachment brackets may include 6 or less, 5 or less, or even 4 or less attachment brackets. The one or more attachment brackets may include a pair of attachment brackets (e.g., a first and second attachment bracket). The pair of attachment brackets may be located at opposing ends of the apparatus. The one or more attachment brackets may project from one or more components of the apparatus. The one or more attachment brackets may extend at angle generally parallel with, perpendicular to, or any angle therebetween relative to one or more flow axes of one or more reactor portions. One or more attachment mechanisms may be configured to be welded and/or otherwise mounted to one portions of a transportation vehicle.

[074] The apparatus may be comprised of one or more subassemblies. One or more subassemblies may function to increase efficiency in assembling the apparatus. One or more subassemblies may be comprised of one or more variations and combinations of the components disclosed herein. One or more filters, catalysts, reactor portions, mixers, or any combination thereof may form a reactor subassembly. One or more baffles, lobed caps, insulators, outer caps, attachment brackets, or any combination thereof may form a cap subassembly. One or more outer caps, one or more fluid delivery devices, or both may form a cap subassembly. One or more mixers, one or more fluid delivery devices, or both, may form a mixer subassembly. One or more fluid delivery devices, pumps, reductant reservoirs, or any combination thereof may form a reductant subassembly. The subassemblies may be assembled via one or more mechanical attachments and/or adhesives. One or more mechanical attachments may include a friction fit, snap fit, fasteners, the like or a combination thereof. Adhesives may include welding, gluing (e.g., temporary adhesive as an assembly aid), the like, or any combination thereof. As can be gleaned from these teachings, any number of subassembly combinations may be made with a plurality of the components disclosed herein. Additionally, a subassembly may omit one or more of the components disclosed herein. One or more components may be separate from or integral with one or more other components. For example, a baffle may be integral with a lobed cap.

[075] The disclosure further relates to a kit. The kit may be comprised of one or more of the components disclosed herein. The kit may be comprised of one or more subassemblies of the components. The kit may be used for assembly, service, and/or repair of the apparatus. The kit may include instructions. Instructions may be for assembly, service, repair and/or replacement of one or more components, subassemblies, the apparatus, or a combination thereof.

[076] The disclosure further relates to a method for treating an exhaust stream resulting from internal combustion of a transportation vehicle. The method may include introducing an exhaust stream into an apparatus, deflecting the exhaust stream in the apparatus, reacting with the exhaust stream within the apparatus, redirecting the exhaust stream, and optionally deflect the exhaust stream.

[077] The method may include introducing an exhaust stream into an apparatus. The exhaust stream may be introduced via one or more inlet pipes and/or inlet openings. The exhaust stream may be introduced into one or more reactor portions. The exhaust stream may be introduced into an upstream reactor portion. The exhaust stream may be introduced at an angle of about 10□ or greater relative to a flow axis of a reactor portion. The exhaust stream may be introduced at an angle relative to a flow axis of a reactor portion which is about equal to the angle an inlet pipe is relative to the flow axis. The exhaust stream may be introduced at an angle of about 5□ or greater, about 10□ or greater, about 25□ or greater, or even about 45□ or greater relative to a flow axis of a reactor portion. The exhaust stream may be introduced at an angle of about 90□ or less, about 85□ or less, about 75□ or less, or even about 60□ or less relative to a flow axis of a reactor portion. Upon entering a reactor portion, the exhaust stream may fan and/or spread out across a width of the reactor portion.

[078] The method may include deflecting an exhaust stream within a reactor portion. Deflecting the exhaust stream may allow the exhaust stream to flow along a flow axis of a reactor portion. The exhaust stream may come into contact with one or more end wall portions. After the exhaust stream enters a reactor portion (e.g., upstream reactor portion), the exhaust stream may contact an end wall portion. The end wall portion may deflect the exhaust stream in a direction generally parallel with a flow axis of reactor portion. The exhaust stream may contact a contoured surface of the end wall portion. The contoured portion may impart a generally uniform velocity (e.g., measured generally parallel with a flow axis at a cross-section generally parallel with the y and/or z-axis, transverse to the flow axis, or both) generally parallel to the flow axis of a reactor portion.

[079] The method may include reacting with the exhaust stream. The reactions may include any of the one or more reactions discussed hereinbefore. The method may include incorporating a reductant into the exhaust stream.

[080] The method may include redirecting the exhaust stream. As the exhaust stream passes through the apparatus, the exhaust stream may need to be redirected from one reactor portion to another reactor portion. The exhaust stream may exit one reactor portion and be redirected into another reactor portion. For example, the exhaust stream may exit an upstream reactor portion and be redirected to one or more intermediate reactor portions. For example, the exhaust stream may exit an intermediate reactor portion an be directed to a downstream reactor portion. The exhaust stream may abut with (i.e., run into) one or more lobed caps or lobes thereof. The exhaust stream may be redirected by the one or more lobed caps to a subsequent reactor portion. The exhaust stream may be redirected so that the exhaust stream is flowing generally parallel to a flow axis of one or more intermediate reactor portions, downstream reactor portion, or both.

[081] The method may include deflecting the exhaust stream. As the exhaust stream exits the apparatus, the exhaust stream may be deflected toward one or more outlet openings. The exhaust stream may abut (i.e., run into) one or more end wall portions. The one or more end wall portions may deflect the exhaust stream toward the one or more outlet openings.

[082] The method may include emitting an exhaust stream from the apparatus. The exhaust stream may be emitted from one or more outlet openings. The exhaust stream may be emitted away from the apparatus and/or toward the apparatus. At least a portion of the exhaust stream may be emitted toward a portion of the apparatus. A portion of the exhaust stream may be directed to flow toward the housing, one or more reactor portions, or both. At least part of the exhaust stream may be directed toward the apparatus to allow for the exhaust stream to at least partially envelope and heat one or more components.

[083] The method may include one or more steps of instructing. The instructions may function to guide assembly, service, repair, and/or replacement of one or more components, subassemblies, and/or the apparatus. The instructions may include instructions for assembly, service, repair, and/or replacement. ILLUSTRATIVE EMBODIMENTS

[084] FIGS. 1 and 2 illustrate an exploded view of an exhaust aftertreatment apparatus 10. The apparatus 10 includes an upstream reactor portion 12, an intermediate reactor portion 14, and a downstream reactor portion 16. The upstream reactor portion 12 includes a flow axis 24 extending from a first end 18a to a second end 18b. The intermediate reactor portion 14 includes a flow axis 26 extending from a first end 20a to a second end 20b. The flow axis 26 of the intermediate reactor portion 14 is disposed generally parallel with the flow axis 24 of the upstream reactor portion 12. The downstream reactor portion 16 includes a flow axis 28 extending from a first end 22a to a second end 22b. The flow axis 28 of the downstream reactor portion 16 is disposed generally parallel to the flow axes 24, 26 of the upstream reactor portion 12 and the intermediate reactor portion 14. The upstream reactor portion 12 includes an inlet opening 30. The inlet opening 30 is in fluid communication with an inlet pipe 32. The inlet pipe 32 is generally orthogonal to the flow axis 24 of the upstream reactor portion 12. The inlet pipe 32 includes a flange 33. The flange 33 may be suitable for adapting with a clamp, such as a ring clamp (e.g., Marman clamp, not shown). The inlet opening 30 is located inboard and downstream of an upstream end wall portion 34a. The upstream end wall portion 34a resides within the upstream reactor portion 12. The downstream reactor portion 18 includes an outlet opening 36. The outlet opening 36 is in fluid communication with an outlet pipe 38. Located between the outlet opening 36 and the outlet pipe 38 is a collar 40. The outlet pipe 38 extends at an angle generally perpendicular to the flow axis 28 of the downstream reactor portion 16. The outlet opening 36 is located inboard and upstream of a downstream end wall portion 34b. The downstream end portion 34b resides within the downstream reactor portion 16. Adjacent to the ends of the reactor portions 12, 14, 16 is a pair of baffles 42. The baffles 42 include a plurality of openings 60. Some of the openings 60 may include a notch (as shown in FIG. 1). The baffles 42 may include a plate portion 62 (as shown in FIG. 2). The plate portions 62 abut with ends 18a, 22b of the upstream reactor portion 12 and the downstream reactor portion 16. Adjacent to each baffle 42 is a lobed cap 44. One of the lobed caps 44 is an upstream lobed cap 44a. The upstream lobed cap 44a is in fluid communication with the upstream reactor portion 12 and the intermediate reactor portion 14 via the baffle 42. Another lobed cap 44 includes a downstream lobed cap 44b. The downstream lobed cap 44b is in fluid communication with the downstream reactor portion 16 and the intermediate reactor portion 14 via the baffle 42. Adjacent to both a lobed cap 44 and baffle 42 is an insulator 46. Located at opposing ends of the apparatus 10 are outer caps 48. A urea injector 50 is located at one of the ends of the apparatus 10. The urea injector 50 is in fluid communication with the intermediate reactor portion 14. A housing 52 surrounds the reactor portions 12, 14, 16. The housing 52 includes first housing shell 52a and a second housing shell 52b

[085] FIG. 3 illustrates a plan view of an upstream reactor portion 12, intermediate reactor portion 14, and downstream reactor portion 16. Each reactor portion 12, 14, 16 includes a flow axis 24, 26, 28. Each flow axis 24, 26, 28 extends from a first end 18a, 20a, and 22a to a second end 18b, 20b, 22b of the respective reactor portion 12, 14, 16.

[086] FIG. 4 illustrates a perspective view of an apparatus 10. The apparatus includes two attachment brackets 54.

[087] FIG. 5 illustrates a perspective view of an apparatus 10 assembled. The housing 52 enclosed a plurality of reactor portions 12, 14, 16 (not shown). Opposing outer caps 48 enclose the ends of the apparatus 10. An inlet pipe 32 leads into the apparatus 10. An outlet pipe 38 projects from the apparatus 10.

[088] FIG. 6 illustrates a cross-section view of an upstream reactor portion 12. The cross- section is taken transverse to a flow axis 24 of the upstream reactor portion 12 and the inlet pipe 32. The inlet pipe 32 interfaces with an inlet opening 30. The inlet opening 30 is formed in a sidewall 64 of the upstream reactor portion 12. Residing within the upstream reactor portion 12 is a first end wall portion 34a. The first end wall portion 34a includes an upper edge 66 and a lower edge 68. The upper edge 66 is located adjacent to and upstream of the inlet opening 30. The lower edge 68 is located downstream from the upper edge 66. The first end wall portion 34a extends across an entire width of the upstream reactor portion so that the upper edge is 66 is in direct contact with the sidewall 64 and the lower edge 68 is in direct contact with the sidewall 64. The upstream edge of the incoming opening 30 to the bottom edge 68 form an angle a relative to the flow axis 24. The first end wall portion 34a includes a contoured surface 70. The contoured surface 70 includes a first surface angled 72a toward the inlet pipe 32. The first surface is continuous with a second surface 72b. The second surface 72b is angled toward the flow axis 24.

[089] FIG. 7 illustrates a perspective view of a lobed cap 44. The lobed cap 44 includes a first lobe 74 and a second lobe 76. The first lobe 74 is connected to the second lobe 76 via a contoured neck 78. [090] FIG. 8 is a perspective view of an apparatus 10 showing the flow of an exhaust stream 56 therethrough. The exhaust stream 56 enters the apparatus 10 through the inlet pipe 32. The exhaust stream 56 passes through the inlet opening 30 into the upstream reactor portion 12. The exhaust stream 56 contacts the first end wall portion 34a. The first end wall portion 34a deflects the exhaust stream 56. The exhaust stream 56 fans and/or spreads out within the upstream reactor portion 12. The upstream end wall portion 34a directs the flow of the exhaust stream 56 generally parallel with the flow axis 24 of the upstream reactor portion 12. The exhaust stream 56 may pass through and/or contact a particulate filter and/or an oxidation catalyst (not shown). The exhaust stream 56 exits the upstream reactor portion 12 and passes through a baffle 42. The exhaust stream 56 abuts with the upstream lobed cap 44a (not shown) which redirects the flow of the exhaust stream 56 toward the intermediate reactor portion 14. The upstream lobed cap 44a (not shown) redirects the flow by about 90□ . The exhaust stream 56 passes through the intermediate reactor portion 14 along the flow axis 26. The flow direction of the exhaust stream 56 in the intermediate reactor portion 14 is generally opposite the flow direction of the exhaust stream 56 in the upstream reactor portion 12. An injector 50 may inject a reductant 80 into the intermediate reactor portion 14. Within the intermediate reactor portion 14, the exhaust stream 56 mixes with the reductant 80. The exhaust stream 56 exits the intermediate reactor portion 14 at the second end 20b. The exhaust stream 56 passes through an opening of the baffle 42 and contact a downstream multi-loped cap 44b. The downstream lobed cap 44b redirects the flow of the exhaust stream 56 toward the downstream reactor portion 16. The downstream lobed cap 44b redirects the flow of the exhaust stream 56 by about 90□. The exhaust stream 56 passes through the downstream reactor portion 16 along the flow axis 28. The flow of the exhaust stream 56 in the downstream reactor portion 16 is generally the same direction as the flow direction of the exhaust stream 56 in the upstream reactor portion 12. The flow of the exhaust stream 56 in the downstream reactor portion 16 is generally in the opposite direction as the flow direction of the exhaust stream 56 in the intermediate reactor portion 14. The exhaust stream 56 may pass through and/or contact a filter, a selective catalytic reactor, and/or an ammonia slip catalyst within the downstream reactor portion 16. The exhaust stream 56 passes through an outlet opening 36 and exits the apparatus 10 via an outlet pipe 38. Any remaining portion of the exhaust stream 56 within the downstream reactor portion 16 which contacts a downstream end wall portion 34b (not shown) is deflected toward the outlet opening 36. [091] FIGS. 9-11 illustrate a mixer 82. FIG. 9 illustrates an incoming end 84 of a mixer 82. The incoming end 84 includes a plurality of incoming openings 86. FIG. 10 illustrates an outgoing end 88 of the mixer 82. The outgoing end 88 includes a plurality of outgoing openings 90. FIG. 11 illustrates a mixing tunnel 92 defined between the incoming end 84 and the outgoing end 88. The mixer 82 includes an injector 50 in fluid communication with the mixing tunnel 92.

[092] FIG. 12 illustrates a flow path of an exhaust stream 56 emitted from a mixer 82. The exhaust stream 56 enters the mixer through the incoming openings 86 (not shown). A reductant 80 is injected into a mixing tunnel 92 via an injector 50. The exhaust stream 56, including the reductant 80, is emitted from the outgoing openings 90 on the outgoing end 88. The exhaust stream 56 and reductant 80 are directed upward (i.e., toward the injector 50) and into counter-rotating vortex streams.

[093] FIGS. 13A-13F illustrate a flow path of an exhaust stream 56 through an apparatus 10. FIG. 13 A illustrates an apparatus 10 with a housing 52, opposing outer caps 48, an inlet pipe 32, and an outlet pipe 38. FIG. 13B illustrates an apparatus 10 with a housing 52 which is transparent. The transparent housing 52 exposes an upstream reactor portion 12, an intermediate reactor portion 14, and a downstream reactor portion 16. FIG. 13C illustrates an exhaust stream 56 entering the apparatus 10 through the inlet pipe 32. FIG. 13D illustrates an upstream end wall portion 34a deflecting the exhaust stream 56 about 90 degrees so it is substantially parallel with a flow axis of the upstream reactor portion 12. FIG. 13E illustrates the exhaust stream 56 exiting the upstream reactor portion 12. The exhaust stream 56 is redirected about 180 degrees by an upstream lobed cap 44a. The exhaust stream 56 is redirected to flow substantially parallel with a flow axis of the intermediate reactor portion 14. FIG. 13F illustrates the exhaust stream 56 exiting the intermediate reactor portion 14. The exhaust stream 56 is redirected about 180 degrees by a downstream lobed cap 44b. The exhaust stream 56 is redirected to flow substantially parallel with a flow axis of the downstream reactor portion 16. The exhaust stream 56 exits the apparatus 10 through an outlet pipe 38.

[094] FIGS. 14A-14B illustrate an apparatus 10. The apparatus 10 is formed as an "in-line" exhaust system. The apparatus 10 includes an inlet pipe 32. The inlet pipe 32 is in line with and in fluid communication with an upstream reactor portion 12. The upstream reactor portion 12 includes a direct oxidation catalyst (DOC). The upstream reactor portion 12 is in line with and in fluid communication with an intermediate reactor portion 14. The intermediate reactor portion 14 includes an injector 50 and a mixer 82. The mixer 82 resides within the intermediate reactor portion 14. The intermediate reactor portion 14 is in line and in fluid communication with a downstream reactor portion 16. The downstream reactor portion 16 includes a selective catalytic reductant ("SCR") and may also include a particulate filter, such as a diesel particulate filter (DPF).

[095] FIGS. 15A-15C illustrate a flow of an exhaust stream 56 through a mixer 82. The exhaust stream 56 enters the mixer through the incoming end 84. A reductant 80 is injected into mixing tunnel 92 via an injector 50. The reductant 80 and the exhaust stream 56 exit the mixer 82 via the outgoing end 88. The reductant 80 and the exhaust stream 56 exit the mixer 82 in vortex streams 100. The vortex streams 100 aid to uniformly distribute the reductant 80 with the exhaust stream 56.

[096] As used herein, unless otherwise stated, the teachings envision that any member of a genus (list) may be excluded from the genus; and/or any member of a Markush grouping may be excluded from the grouping.

[097] Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as "parts by weight" herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the of a range in terms of "at least 'x' parts by weight of the resulting composition" also contemplates a teaching of ranges of same recited amount of "x" in percent by weight of the resulting composition." Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[098] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for aid purposes. The term "consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps. Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[099] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the disclosure should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

Claim 1. An exhaust aftertreatment apparatus including:

a) an upstream reactor portion which is tubular, has a flow axis extending from a first end region to a second end region and is configured to receive an exhaust stream, and to optionally, separate particulate matter from the exhaust stream;

b) a downstream reactor portion which is tubular, has a flow axis extending from a first end region to a second end region, and which is disposed with its flow axis generally parallel with the flow axis of the upstream reactor portion;

c) at least one intermediate reactor portions which is tubular, has a flow axis extending from a first end region to a second end region, and which is disposed with its flow axis generally axially parallel with the flow axes of the upstream reactor portion and the downstream reactor portion; wherein the at least one intermediate reactor portion is located downstream from the upstream reactor portion and upstream from the downstream reactor portion, and wherein the at least one intermediate reactor portion is configured to have a reductant introduced therein, hydrolyzed, and mixed with the exhaust stream;

d) one or more openings in either or both the upstream reactor portion and downstream reactor portion, any intermediate reactor portion, which is configured for flow of the exhaust stream therethrough; and

e) one or more baffles configured to support and fix in place relative to each other the upstream reactor portion, the downstream reactor portion, and optionally the at least one intermediate reactor portion, wherein at least one but less than all of the upstream, downstream, and optionally the at least one intermediate reactor portions pass through the one or more baffles.

Claim 2. The exhaust aftertreatment apparatus of Claim 1, wherein the upstream reactor portion, the downstream reactor portion, or both are configured to perform one or any combination of the following reactions: oxidize hydrocarbon, oxidize carbon monoxide, and/or reduction of nitrogen compounds.

Claim 3. The exhaust aftertreatment apparatus of any of the preceding claims, wherein the flow axis of the upstream reactor portion flows in the same direction or an opposing direction as the flow axis of the downstream reactor portion.

Claim 4. The exhaust aftertreatment apparatus of any of the preceding claims, wherein the flow axis of the upstream reactor portion, the flow axis of the downstream reactor portion, or both flow axes flow in a same direction or opposing direction as the flow axis of the intermediate reactor portion.

Claim 5. The exhaust aftertreatment apparatus of any of the preceding claims, wherein the one or more openings include an inlet opening in the upstream reactor portion which is located inboard (i.e., downstream) from the first end.

Claim 6. The exhaust aftertreatment apparatus of Claim 5, wherein the inlet opening has a generally oval shape with an elongated length generally transverse to the flow axis of the upstream reactor portion.

Claim 7. The exhaust aftertreatment apparatus of Claims 5 or 6, wherein the inlet opening interfaces with an inlet pipe which has a generally circular cross-section which expands into a generally elliptical cross-section.

Claim 8. The exhaust aftertreatment apparatus of any of Claims 5 to 7, wherein the inlet opening includes a flared edge for engaging and sealing with an inlet pipe.

Claim 9. The exhaust aftertreatment apparatus of any of Claims 5 to 8, wherein the one or more openings include an outlet opening in the downstream reactor portion which is located inboard (i.e., upstream) from the second end.

Claim 10. The exhaust aftertreatment apparatus of claim 9, wherein the outlet opening interfaces with an outlet pipe which extends generally transverse to the flow axis of the downstream reactor portion.

Claim 11. The exhaust aftertreatment apparatus of any of the preceding claims, wherein at least one of the upstream reactor portion, downstream reactor portion, and optionally the one or more intermediate reactor portions, at least partially penetrate through the one or more baffles.

Claim 12. The exhaust aftertreatment apparatus of any of the preceding claims, wherein less than each of the upstream reactor portion, downstream reactor portion, and the one or more intermediate reactor portions penetrate through the one or more baffles.

Claim 13. The exhaust aftertreatment apparatus of any of the preceding claims, wherein only one of the upstream reactor portion, downstream reactor portion, and the one or more intermediate reactor portions penetrates through the one or more baffles.

Claim 14. The exhaust aftertreatment apparatus of any of the preceding claims, wherein at least one pair of outer end caps substantially cover the first and second ends of the upstream reactor portion, downstream reactor portion, and optionally the one or more intermediate reactor portions; and

wherein the one or more baffles include two or more baffles and the at least one pair of outer end caps is located outboard from the two or more baffles.

Claim 15. The exhaust aftertreatment apparatus of Claim 14, wherein the at least one pair of end caps are symmetrical about an axis or plane transverse to the flow axes of the upstream reactor portion and the downstream reactor portion.

Claim 16. The exhaust aftertreatment apparatus of Claims 14 or 15, wherein the at least one pair of end caps define end enclosures of the exhaust aftertreatment apparatus.

Claim 17. The exhaust aftertreatment apparatus of any of the preceding claims, wherein one or more attachment brackets are directly connected to a housing, the one or more baffles, at least one pair of end caps, one or more end enclosures, or any combination thereof;

wherein the one or more attachment brackets are configured to mount the exhaust aftertreatment apparatus to a vehicle; and wherein one or more attachment brackets are free of direct attachment with the one or more baffles.

Claim 18. The exhaust aftertreatment apparatus of any of the preceding claims comprising: one or more end regions located inboard of one or more of the baffles having located therein a contoured surface intersecting the flow axis and adapted for redirecting flow of the exhaust stream from an inlet pipe introduced at an angle of about 10□ or greater to a flow axis of the upstream reactor portion to achieve a substantially uniform velocity of the exhaust stream throughout a cross-section of the upstream reactor portion.

Claim 19. The exhaust aftertreatment of Claim 18, wherein the contoured surface of the one or more end wall regions is a contour both in the perimeter and interior surface of the one or more end wall portions.

Claim 20. The exhaust aftertreatment apparatus of Claim 18 or 19, wherein the contoured surface is about 25% to about 100% of the surface area of the one or more end wall portions.

Claim 21. The exhaust aftertreatment apparatus of any of the preceding claims comprising: one or more lobed caps adjacent to one or more of the baffles and configured to redirect a flow of the exhaust stream by at least about 90 degrees (e.g., from about 90 degrees to about 180 degrees) proximate to an inlet end or outlet end of the upstream or downstream reactor portion.

Claim 22. The exhaust aftertreatment apparatus of Claim 21 wherein the one or more lobed caps include a first lobe and a second lobe which are generally coplanar with each other.

Claim 23. The exhaust aftertreatment apparatus of claim 22, wherein the first lobe is connected to the second lobe via a contoured neck; and

wherein the contoured neck is configured to impart generally uniform velocity of the exhaust stream as the exhaust stream transfers from the upstream reactor portion to the downstream reactor portion, and optionally the one or more intermediate reactor portions.