This invention relates to a combustion apparatus with fuel pre-heating. The invention was originally conceived in connection with diesel-engines for motor vehicles, but it also has other applications, such as in connection with stationery engines, marine engines and engines for other purposes, engines that burn other fuel oils, and boilers.
Nearly every conventional diesel engine has an air inlet system through which air is drawn from the atmosphere into the engine, a fuel supply system for supplying fuel from a fuel tank to the engine and an exhaust system for exhausting combustion gas from the engine to the atmosphere.
In the art of diesel engine combustion efficiency, it is known that the combustion efficiency, and therefore fuel economy, of a diesel engine can be improved if the fuel is warmed before it is injected into the engine. In order to achieve this, it is known to provide a heat exchanger between the fuel supply system and the engine's coolant system. However, the engine compartments of most designs of motor vehicle are already overcrowded, and the addition of such a heat exchanger, between the fuel supply system and the cooling system, adds to the overcrowding in the engine compartment and consequent difficulty in servicing the vehicle.
A primary aim of the present invention, or at least of specific embodiments of it, to provide a combustion apparatus with improved efficiency that alleviates the problem discussed above.
In accordance with a first aspect of the present invention, there is provided a combustion apparatus comprising a combustor having an air inlet system through which air can be drawn air from the atmosphere to the combustor, a fuel supply system for supplying fuel to the combustor, and an exhaust system for exhausting combustion gas from the combustor to the atmosphere, wherein a heat exchanger is provided between the exhaust system and the fuel supply system so that, in use, heat is transferred from the exhaust gas to the fuel so as to warm the fuel and thus improve the combustion efficiency of the engine. When applied to a conventional layout of motor vehicle with a fuel tank disposed towards the rear of the vehicle, with the engine disposed in an engine compartment towards the front of the vehicle, and with the exhaust system leading from the engine towards the rear of the vehicle, the heat exchanger can therefore conveniently be disposed beneath the vehicle away from the engine compartment so as not to cause overcrowding of the engine compartment.
In one arrangement of the first aspect of the invention, the exhaust system includes a loop portion for feeding a proportion of the exhaust gas from a first point in the exhaust system to a second point in the exhaust system upstream of the first point relative to the main flow of exhaust gas in the exhaust system, and the heat exchanger is provided between the loop portion and the fuel supply system so that, in use, heat is transferred from the exhaust gas in the loop portion to the fuel so as to warm the fuel.
Turning to a previously unrelated topic, in the art of diesel engine emissions, it is known that the emissions (particularly of nitrogen oxide and nitrogen dioxide) of a diesel engine can be reduced if some of the exhaust gas is cooled and recirculated through the engine. It is therefore known to provide an exhaust gas recirculation system for feeding a proportion of the exhaust gas from the exhaust system to the air inlet system.
In one relatively simple example of exhaust gas recirculation, gas to be recirculated is branched from the exhaust system near its open end, passed through a cooling pipe and then fed into the intake system immediately before the engine's inlet manifold. Air is drawn along the cooling pipe on the outside of the pipe by a venturi fitted near the open end of the exhaust system, and so heat is transferred to the air from the exhaust gas that is drawn through the pipe to cool the recirculating exhaust gas. The heat that is extracted from the recirculating exhaust gas is therefore completely wasted.
In another more complex example of exhaust gas recirculation, gas to be recirculated is branched from the exhaust system immediately after the engine's exhaust manifold and passed through an intercooler and control valve before being fed into the intake system immediately before the engine's inlet manifold. The valve is controlled by an electronic box of tricks that receives signals from various sensors around the engine. In the intercooler, heat is transferred from the recirculating exhaust gas to the coolant of the engine's cooling system which, although well above ambient temperature, is well below the temperature of the recirculating exhaust gas. Again, the heat that is extracted from the recirculating exhaust gas is completely wasted. Furthermore, the addition of an intercooler between the exhaust gas recirculation system and the cooling system adds to the overcrowding of the engine compartment and consequent difficulty in servicing the vehicle. Moreover, the size and/or efficiency of the cooling system may need to be increased to cope with the additional demand placed on it by the intercooler.
A subsidiary aim at least of specific embodiments of the present invention is to provide a combustion apparatus not only with improved efficiency but also with improved emissions and that alleviates at least some of the problems discussed above.
In another arrangement of the first aspect of the invention, the exhaust system includes an exhaust gas recirculation system for feeding a proportion of the exhaust gas to the air inlet system, and the heat exchanger is provided between the exhaust gas recirculation system and the fuel supply system so that, in use, heat is transferred from the recirculating exhaust gas to the fuel so as to cool the recirculating exhaust gas and warm the fuel. A single heat exchanger can therefore be used for the purposes of both improving emissions and improving fuel efficiency.
In one embodiment in which the exhaust system includes an exhaust return pipe and the fuel supply system includes a fuel feed pipe, a portion of the fuel feed pipe may simply be coiled around a portion of the exhaust return pipe so as to form the heat exchanger.
In another embodiment in which the exhaust system includes an exhaust return pipe, the fuel supply system may simply include a sleeve disposed around a portion of the exhaust return pipe so that, in use, fuel passes between the sleeve and the portion of the exhaust return pipe and heat is exchanged.
In the case where the exhaust system includes a catalytic converter, the exhaust return pipe preferably branches from the exhaust system downstream of the catalytic converter. In the case where the exhaust system includes a silencer, the exhaust return pipe preferably branches from the exhaust system downstream of the silencer. The exhaust gas is therefore subjected to cooling in the catalytic converter and/or the silencer before a proportion of the exhaust gas is recirculated. In the case where the exhaust system has a loop portion as discussed above, the exhaust return pipe preferably rejoins the exhaust system upstream of the silencer.
The heat exchanger may employ a heat exchange fluid that, in use, flows between a portion of the exhaust system and a portion of the fuel supply system. In this case, means may be provided for controlling the flow of the heat exchange fluid in dependence upon the temperature of the fuel and/or the temperature of the exhaust gas.
A gas bypass system may be provided for controlling the proportion of the exhaust gas that passes through the heat exchanger. The bypass system may be arranged to control the proportion in dependence upon the temperature of the fuel and/or the temperature of the exhaust gas.
The control of the heat exchange fluid flow and/or of the proportion of exhaust gas and/or fuel that passes through the heat exchanger can be used to ensure that appropriate cooling of the recirculating exhaust gas and warming of the fuel is achieved but without overheating of the fuel.
The combustion apparatus may further include means for conditioning liquid fuel in the fuel supply system between the heat exchanger and the combustor. Ultrasonic conditioning is known per se from patent documents U.S. Pat. No. 3,865,350 and DE10250483A1 so as to break down long chain molecules in and homogenise the liquid fuel and thus improve the fuel efficiency and/or reduce the emissions of the combustion apparatus. However, by ultrasonically conditioning the liquid fuel after it has been heated, it is believed that a synergistic effect is achieved. As an alternative to, or addition to, ultrasonically conditioning the fuel, it may also be conditioned by microwave energy, by other electromagnetic radiation, or by electromagnets.
This combination of heating and conditioning of the fuel may be used in combustion apparatus where the fuel is heated other than by the exhaust system. Therefore, in accordance with a second aspect of the invention, there is provided a combustion apparatus having a system for supplying liquid fuel to the combustor, the fuel supply system including means for heating the liquid fuel, and means for conditioning the liquid fuel after it has been heated by the heating means.
Means may be provided for varying the ultrasonic, microwave, electromagnetic radiation or magnetic field that is applied to the liquid fuel. The field varying means may be manually adjustable, for example to take account of different fuels that may be used in the combustion apparatus, and/or automatically in response to sensors of the state of operation of the combustion apparatus, for example to take account of varying fuel flow rates.
The combustion apparatus may take the form of a diesel engine.
A third aspect of the invention relates to a motor vehicle having a diesel engine system and a fuel tank, the fuel tank being disposed towards the rear of the vehicle, the engine being disposed in an engine compartment towards the front of the vehicle, and the exhaust system leading from the engine towards the rear of the vehicle. This is a conventional layout for a motor vehicle.
In accordance with the third aspect of the invention, the engine is in accordance with the first aspect of the invention, and the heat exchanger is disposed beneath the vehicle away from the engine compartment. This therefore makes use of the conventional vehicle layout, and the heat exchanger does not cause any overcrowding of the engine compartment.
In accordance with a fourth aspect of the present invention, there is provided an exhaust and fuel supply component or assembly for a combustion apparatus of the first aspect of the invention or for a motor vehicle of the third aspect of the invention, the component or assembly comprising a heat exchanger that is adapted to provide, or to form part of, the exhaust system and that is adapted to provide, or to form part of, the fuel supply system.
Specific embodiments of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which:
Referring to
The car 10 has an exhaust gas recirculation (EGR) system provided by a pipe 44,46 which is branched from the tailpipe 42 at the rear 26 of the car 10, extends forwardly beneath the car and is branched into the inlet manifold 20 of the engine 16. In use, the pressure differential of the exhaust gas in the tailpipe 42 above the air in the inlet manifold 20 causes some of the exhaust gas to flow from the tailpipe 42 along the EGR pipe 44,46 to the inlet manifold 20 and re-enter the engine 16.
The EGR system causes the NO and NO2 emissions of the engine 16 to be reduced, and the reduction is enhanced if recirculating exhaust gas is cooled between the tailpipe 42 and the inlet manifold 20. Also, the combustion efficiency of the engine 16 is increased if fuel is warmed before it is injected into the engine 16. In order to provide cooling of the recirculating exhaust gas and warming of the fuel, a heat exchanger 48 is fitted beneath the car away from the engine compartment. Fuel passes from the fuel pipe 28 through the heat exchanger 48 to the fuel pipe 30, and recirculating exhaust gas passes from the EGR pipe 44 through the heat exchanger 48 to the EGR pipe 46. During normal operating conditions of the engine 16, the recirculating exhaust gas entering the heat exchanger 48 via the EGR pipe 44 is hotter than the fuel entering the heat exchanger 48 via the fuel pipe 28. Heat is transferred in the heat exchanger 48 from the exhaust gas to the fuel. Accordingly, the fuel leaving the heat exchanger 48 in the fuel pipe 30 is warmer than the fuel entering the heat exchanger 48 in the fuel pipe 30, and the exhaust gas leaving the heat exchanger 48 in the EGR pipe 46 is cooler than the exhaust gas entering the heat exchanger 48 in the fuel pipe 44. The heat exchanger 48 therefore has the double effect of enhancing the reduction of NO and NO2 emissions of the engine 16 and increasing the combustion efficiency of the engine 16.
Any suitable form of heat exchanger 48 may be employed. For example,
A second form of heat exchanger 48 is shown in
A third form of heat exchanger 48 is shown in
The various forms of heat exchanger 48 described with reference to
For example, referring to
It will be appreciated that, in the arrangement shown in
Referring to
The forms of heat exchanger 48 and control described above with reference to
In
In addition to, or instead of conditioning the fuel ultrasonically, the unit 118 may be operable to condition the fuel using microwave or other electromagnetic radiation and/or a magnetic field produced by an electromagnet, again with the electromagnetic or magnetic field varied in dependence upon the various parameters.
It should be noted that the embodiments of the invention have been described above purely by way of example and that many modifications and developments may be made thereto within the scope of the present invention.
Number | Date | Country | Kind |
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0606813.4 | Apr 2006 | GB | national |
0704149.4 | Mar 2007 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB2007/001255 | 4/4/2007 | WO | 00 | 10/3/2008 |