There is an increasing interest in the expanded use of natural gas for car and trucks because of its lower cost as compared to gasoline or diesel fuel, its lower green house gas emissions, lower hydrocarbon emissions and the increased supply available by using gas from shale. Natural gas can be used in either dedicated natural gas only engines or in bi-fuel engines that can operate on either natural gas or gasoline and are presently in use in light duty vehicles. These engines provide the driver with the option of using gasoline when natural gas in not available or more expensive. Bi-fuel engines can also provide the driver with extended range since the range with a given stored volume of natural gas is substantially less than that of gasoline. Bi-fuel engines are particularly important for expanding natural gas use beyond fleet vehicles, which use their own natural gas refueling system and can meet their operation goals without the option of gasoline operation. The use of bi-fuel natural gas/gasoline engines can significantly expand natural gas utilization through its use in non fleet light duty vehicles. Another important application is in long haul heavy duty trucks.
A drawback of present bi-fuel engines, relative to natural gas only engines, is the limitation on performance and efficiency resulting from the constraint of compression ratio and turbocharging imposed by the requirement to prevent knock when the engine is operated with gasoline. With an octane number of around 90, gasoline has a substantially lower knock resistance than natural gas, which can have an octane number of 130. As a result, present bi-fuel engines operate with less performance and efficiency than is possible when the engine is designed for operation with only natural gas. The knock constraint is particularly important for bi-fuel engines that must compete with diesel engines in heavy duty vehicle applications. It is highly desirable for these engines to provide the same efficiency and torque as diesel engines.
Moreover, even when bi-fuel engines are operated with natural gas, constraints on high compression ratio and turbocharging that are imposed by engine knock can prevent these engines from having the same torque and efficiency as a diesel engine. Operation at high pressure, such as with the use of high compression ratio and/or turbocharged operation, can be significantly constrained, albeit to a lesser degree than the case with gasoline, when the knock resistance quality of the available natural gas is low. Knock under these circumstances limits the exploitation of the higher knock resistance of natural gas that is provided by the higher octane number of natural gas, which is made mostly from methane. Pure, or neat, methane has an octane number of about 130.
For natural gas engines, the knock properties of the fuel is measured by the methane number, which measures the amount of reactive hydrogen in the fuel divided by the amount of reactive carbon in the fuel. The distribution of the Methane Number (MN) in natural gas in the US is shown in Table 1. In the US, the mean Methane Number of natural gas is about 90, with a minimum of about 73 and a maximum of about 96. The variation in methane number results in changes in the octane rating.
Because of the knock limitation, the energy efficiency of a conventional naturally aspirated, port fuel injected gasoline engine is typically 25-30% lower than that of a diesel engine. It would be desirable to remove this drawback, and operate a spark ignited bi-fuel engine at an efficiency that is comparable to a diesel engine. Gasoline engines are less expensive than diesel engines, partially because exhaust aftertreatment is considerably simpler and less expensive, through the use of three-way catalysts. In addition, the three-way catalyst is more robust for meeting stringent emission requirements and a spark ignition engine can provide higher RPM operation, resulting in higher power at a given level of torque.
A bi-fuel spark ignition engine is disclosed. The engine can operate on gasoline, natural gas or a combination of the two. The amount of each fuel that is used by the engine is based on the engine's operating parameters, such as RPM and torque. In some embodiments, the operator can provide input, such as the availability of natural gas, which affects the operation of the engine. In some embodiments, an anti-knock agent is used to prevent knock at higher values of torque.
The lower efficiency drawback of bi-fuel engines can be alleviated by on-demand use of natural gas as an anti-knock fuel at higher values of torque, when the engine is mainly operated on gasoline. In addition, a greater amount of knock suppression can be obtained by on-demand use of a directly injected alcohol or alcohol-water mixture as an anti-knock additive, which is provided by a small additional tank.
The low cruising range (i.e. distance that can be travelled on one tankful of fuel) of natural gas fueled vehicles can be alleviated by operation which maximizes the use of gasoline when the torque is sufficiently low for the engine to operate with gasoline, thereby minimizing the consumption of natural gas. This concept also allows for the optional increased use of natural gas when it is available and when frequent refueling intervals do not represent a hardship to the operator.
At low torque, or when natural gas is expensive (instructed by the operator 150), and/or when extended range is desired (instructed by the operator 150), the engine 130 may operate mostly on gasoline, maximizing the gasoline consumption and minimizing the natural gas consumption. At conditions of higher torque, the engine 130 may use gasoline/natural gas mixtures, in order to use the larger octane of natural gas. In some embodiments, to minimize natural gas consumption, only as much natural gas as needed to prevent knock is used. As the load increases, an increased fraction of natural gas/gasoline ratio is used, as the knock requirements of the fuel typically increase with load (at a given RPM). Thus, the controller 140 may receive input, such as from the engine 130, providing information about the torque being exerted. Based on this information, the controller 140 may adjust the ratio of gasoline to natural gas that is introduced to the engine 130 by adjusting the inputs to valves 160, 170. In some embodiments, input from the operator 150 may also be used to vary the ratio of the two fuels as described above. Alternatively a knock sensor in the engine could be used to provide close-loop feedback on the amount of natural gas required.
If the amount of natural gas is limited or not available, or is insufficient to provide the required knock resistance at the highest loads, knock suppression can be provided by on-demand direct injection of an anti-knock agent, such as alcohol or an alcohol water mixture, provided by a small additional tank. As discussed in U.S. Pat. Nos. 7,225,787 and 7,314,033, which are incorporated herein by reference in their entireties, directly injected anti-knock agents, such as alcohol or alcohol-water mixtures, can provide very strong knock suppression in a spark ignition engine due to the evaporative cooling when the liquid is transformed into a gas.
Because engine knock is less limiting at higher engine speed since the time allowed for autoignition (knock) is reduced, the relative amounts of natural gas and gasoline may be adjusted. At lower speeds, for a given torque level, the fraction of natural gas is higher than at higher speeds. Also, the need for the antiknock additive can be adjusted with speed.
The above calculations do not include the cooling effect when depressurizing the natural gas. The expansion cooling of the natural gas will have a positive impact on the anti-knock properties of the fuel. It is possible to inject the natural gas either in the manifold, or in the cylinder. In either case, the expansion cooling will reduce the temperature of the air/natural gas mixture and reduce the tendency of the engine to knock.
The knock suppression that is provided by the directly injected anti-knock agent, such as alcohol or alcohol-water mixture, allows increased engine efficiency through the use of high compression ratio, highly turbocharged/downsized engine, as well as engine downspeeding. This makes it possible to increase spark ignition engine efficiency to a level that is comparable to a diesel engine.
The natural gas, gasoline and directly injected anti-knock additive can thus be used in a variety of combinations. When the engine 230 is operating with gasoline supplied by a first tank 210 as the primary fuel, natural gas and/or the directly injected alcohol or alcohol-water mixture can be used to prevent knock at higher values of torque. When there is natural gas available in the second tank 220, it can be used for knock suppression throughout most of the torque range, thereby reducing the use of the directly injected anti-knock additive from a small third tank 280 to a very small amount, e.g. less than 0.5 gallons for every 100 gallons of gasoline, for port fuel injected gasoline and typical driving. If there is no natural gas available in the second tank 220 or if the operator 250 wishes to conserve the use of natural gas, all of the knock suppression can be provided by the directly injected anti-knock agent (i.e. alcohol or alcohol-water mixture fluid) from a small third tank 280. The use of natural gas as a knock suppressant which is added at higher values of torque can either be controlled by the operator 250 or automatically controlled by the controller 240.
Operation of the vehicle with simultaneous use of natural gas and gasoline and where the natural gas is used at higher values of torque to prevent knock can provide the benefits of:
When natural gas from the second tank 220 is employed as the primary fuel rather than gasoline, the directly injected anti-knock additive is used to suppress knock at high values of torque and/or to compensate for the use of lower octane natural gas (when using natural gas with lower methane numbers). The consumption of the directly injected anti-knock additive can be very small (e.g. less than 1 gallon for every 100 gallons of natural gas equivalent gasoline energy) because of the high octane of the natural gas.
Options for the fueling system include port fuel injection of the gasoline, direct injection of the gasoline and port fuel injection of the natural gas.
The presence of the two fuels and the antiknock agent allows for flexibility of operation during transients. Thus, during startup, it may be best to use primarily natural gas to prevent the generation of non-methane hydrocarbon emissions during the cold start process (which constitutes a large fraction of the total hydrocarbon emission). Because the natural gas response is fast, it can minimize enrichment required during fast transients. Similarly, the directly injected antiknock fluid can also provide very fast response. Directly injected antiknock fluid can be adjusted for each cylinder, in order to minimize its consumption. In a multicylinder engine, knock constrains vary from cylinder to cylinder, mostly due to the variation of residuals among the cylinders.
There are a number of options for further reducing the amount of the knock suppression fluid. They include direct injection of gasoline, non-uniform injection of the knock suppression fluid so that it is concentrated in the peripheral region of the cylinder where knock is most likely to occur, increased use of EGR, increased use of spark retard, and engine up-speeding. Direct injection of gasoline is much more effective for a typical light duty vehicle driving cycle in contrast to a driving cycle with prolonged high torque operation as would be the case for heavy duty long haul trucks or vehicles during heavy towing.
Thus, as long as natural gas is available for use, the requirement for the directly injected alcohol or alcohol-water mixture could be limited to significantly less than 1 gallon for every 100 gallons of either gasoline or gasoline-energy-equivalent natural gas. With an appropriately sized tank, knock suppression fluid tank need only to be refilled once every 500 gallons for a light duty vehicle. The refill interval could be more frequent for a heavy-duty vehicle because of prolonged high torque operation. This could be mitigated by use of non-uniform alcohol injection to increase knock resistance.
In another embodiment of this invention, there is no capability for direct injection of knock suppression fluid. Only natural gas is introduced into the gasoline engine to prevent knock at levels of torque where it would otherwise occur. The gasoline could be either port fuel or directly injected. When natural gas is not available, premium gasoline (having higher octane than regular gasoline) could be used to compensate for reduced knock resistance. The natural gas/gasoline ratio in the engine could be limited to the amounts needed to prevent knock and can be determined by closed loop control using a knock detector. A closed loop control system would allow use of natural gas of varying octane levels. However, the maximum torque that the engine can deliver is lower than in the case with the antiknock fluid, as it is limited by knock.
The octane level of natural gas can vary significantly due to variations in small concentrations of hydrocarbons, other than methane. When a natural gas fuel with a lower Methane Number (and, consequently, octane) is used, the natural gas/gasoline ratio would be higher at each value of torque. Maximum knock resistance would be obtained by operation with 100% or close to 100% natural gas at the highest level of torque.
In one embodiment, an automatic or operator controlled system can be employed to use more natural gas than is needed for knock prevention and to control gasoline and natural gas consumption rates so as to maximize refueling convenience of the operator. For example, the operator may want to refill the gasoline tank at the same time as the natural gas refill or at some multiple of the natural gas refill time. When natural gas is available and convenient and the prices of natural gas are lower than those of gasoline, the operator may wish to maximize the consumption of the natural gas. The controller uses information provided by the operator to modify the consumption rate of natural gas. Some of these options are illustrated in
For example,
In the case where a high compression ratio engine has the capability for high turbocharging, such as with a compression ratio of 12 or more, and the vehicle does not have the capability for direct injection of alcohol, a control system which reduces the maximum level of turbocharging and/or increases spark retard can be used to allow drivability, albeit at lower maximum torque when there is no natural gas available and the engine is operated on gasoline alone.
The natural gas can be in the form of Compressed Natural Gas (CNG) or Liquefied Natural Gas (LNG).
In addition, it would be possible to fill the primary gasoline tank with an alcohol, for flex-fueled cars. In this case, the requirement of natural gas to prevent knock is decreased. Care needs to be taken that water is not accidentally introduced into the gasoline tank for conditions where there would be phase separation between the gasoline in the tank and the water-alcohol mixtures.
In addition to natural gas, the above considerations apply to the other gaseous fuels that contain methane, or that contain propane or propane blends. These fuels may be liquids or gasses.
In another embodiment, the directly injected anti-knock agent from the third tank does not contain alcohol and is instead water or a mixture of water and some liquid that is not alcohol.
The embodiments described above could be used in stationary engines as well as engines in vehicles. These engines could be used for decentralized electricity production for industry, commercial buildings and homes.
The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.
This application claims priority of U.S. Provisional Patent Application No. 61/176,553, filed May 8, 2009, the contents of which are incorporated by reference in its entirety.
Number | Date | Country | |
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61176553 | May 2009 | US |