The disclosure claims the benefit of priority of co-pending European Patent Application No. 22166554.0, filed on Apr. 4, 2022, and entitled “Internal combustion engine with a fuel reformer and exhaust gas recirculation,” the contents of which are incorporated in full by reference herein.
The disclosure relates to an internal combustion engine assembly including a fuel tank, connected via a fuel supply duct to a first fuel inlet of at least one of a number of cylinders, the cylinders being with an outlet connected to an exhaust system, exhaust gases from the exhaust system being in heat exchanging contact with a reformer unit for steam reforming of alcohol, the reformer unit being with a reformer outlet connected to a second fuel inlet of the cylinders for supplying hydrogen to the second fuel inlet.
Fuel for internal combustion engines (ICE) may contain varying amounts of ethanol. Bio-ethanol may constitute 10% (E10) to 85% (E85) of Bio-fuel mixtures. Fuel of the type E10 is at present used in 14 countries in Europe and increasing use of Bio-ethanol is part of the goal to reduce the dependency of fossil fuels.
As currently available Biofuels can only account for a part of the reduction in CO2 emissions, the increase in efficiency of the ICE is of importance. One method for increasing the thermal efficiency of the ICE includes Waste Heat Recovery in combination with Fuel Reforming technology. Fuel reforming uses the heat available in the exhaust gases to upgrade a low carbon fuel to a higher energy level hydrogen fuel that is combusted, with a higher thermal efficiency of the ICE as a result.
Steam reforming of ethanol requires a relatively large amount of energy, and the temperature that is required for full conversion of ethanol is about 700K. It is known to provide an aqueous ethanol solution to a reformer that is heated by the high-temperature exhaust gases. In the reformer, syngas, consisting of CO and H2 is formed that is fed to a separator that cools the mixed gas, condense water vapor, and separates into gas and liquid. A recovery tank collects recovery solution separated by the separator, and hydrogen is fed to the cylinders of the ICE.
Hydrogen is highly reactive and ignites at surface temperatures of 450° C. at concentration levels between 5% and 95%. This makes safe handling of the hydrogen system a major concern for fuel reform WHR to be an applied in an ICE.
It is an object to provide a combustion engine assembly that is at least partly powered by alcohol, such as bio-ethanol, using steam reforming of the alcohol with improved safety.
A combustion engine assembly is provided, including an alcohol evaporator that is in heat exchanging contact with the exhaust gases and that is with an inlet connected to an alcohol supply unit and with an outlet connected to a first reformer supply duct that is connected to an inlet of the reformer unit via a first control valve, for supplying alcohol steam to the reformer unit, a water evaporator that is in heat exchanging contact with the exhaust gases and that is with an inlet connected to a water tank and that is with an outlet connected to a second reformer supply duct that is connected to the inlet of the reformer unit via a second control valve for supplying water steam to the reformer unit, a reformer purge duct extending from the exhaust system to the inlet of the reformer unit via a purge control valve, adapted for feeding exhaust gases into the reformer unit and via the reformer outlet to the second fuel inlet of the cylinders.
At start of the engine, the exhaust gases are recirculated as an inert purging gas containing N2 and CO2, to remove oxygen entrapped in the fuel reformer unit and other parts of the hydrogen gas system.
The alcohol supply unit may include the fuel tank that is adapted for containing alcohol.
The alcohol supply unit may include a tank for containing alcohol. The outlet of the fuel evaporator can be connected to the tank via a condenser. The alcohol steam that is formed during the exhaust gas recirculation is collected in the tank.
The reformer outlet may be connected to a buffer tank for storing reformed fuel, the buffer tank being with an outlet connected to the second fuel inlet of the cylinders.
The alcohol can include ethanol, such as bio ethanol and/or ethanol included in type E10-E85 fuel.
A cooler may be provided in the exhaust purge duct so that the exhaust gases may be cooled prior to purging to a temperature of between 100° C.-200° C.
The first reformer supply duct may be connected to an alcohol recirculation duct via a pressure control valve that opens at a pressure exceeding a predetermined threshold value, the recirculation duct being connected to the exhaust system, upstream of the reformer unit, or to the tank.
When sufficient pressure of ethanol steam has been built up, the ethanol steam may be removed via the exhaust system via the pressure control valve, until sufficient water steam has been formed for the reforming process to start. The ethanol steam can also be condensed and collected in the tank.
The ethanol outflow duct may be connected to the exhaust system upstream of the reformer to enable combustion using excess air that is injected and use this for pre-heating of the substrate of the reformer unit.
By recondensing the ethanol into liquid and recycling it into the tank until the reforming process starts, the fuel efficiency is increased.
The second reformer supply duct may be connected to a water outflow duct that is connected to the exhaust system, via a pressure control valve that opens at a pressure exceeding a predetermined threshold value, or that is connected to the water tank via a pressure control valve and a condenser.
Until sufficient water steam is present, the water can be recirculated to the exhaust system via the pressure control valve.
The water outflow duct may be connected to the exhaust system downstream of the reformer unit, to enable recirculation of the water until the reformer unit starts and water steam is used in the process.
The water outflow duct may be connected to the exhaust system, via a pressure control valve that opens at a pressure exceeding a predetermined threshold value or may be connected to the water tank via a pressure control valve and a condenser.
The water can also be recirculated via the condenser back into the water tank, so that all water is utilized in the reforming process.
When sufficient water steam pressure has been built up, the purge control valve is closed and the second control valve passing water steam into the reformer is opened so that exhaust gases are flushed out of the reformer, the buffer tank, and the cylinders by the water steam, to avoid coke forming of ethanol in the hot fuel reformer.
An ejector-shaped nozzle may be provided at the second fuel inlet of the cylinders. The recirculated exhaust gases may during the purging step be injected into the inlet ports of the cylinders via an ejector-shaped nozzle, for instance by a Port Fuel Injection (PFI) system. The purging gas ensures that no oxygen is present in the system from start to end before the reforming process starts and H2 is formed.
The system of the present disclosure may:
The internal combustion engine assembly may include a controller that is adapted to carry out a start sequence including:
The start sequence may involve:
Upon stopping the engine, the controller that is adapted to carry out a stop sequence including:
The stop sequence may involve:
A number of embodiments will by way of non-limiting example be described in detail with reference to the accompanying drawings. In the drawings:
A turbocharger 8 compresses the air that is supplied from an air intake 9 and transports the intake air through an air duct 10 to the intake manifold 11, via a cooler 30 for supply to the cylinders 3. The exhaust gases of the fuel that has been burned in the cylinders 3, leave the engine 2 via an exhaust manifold 12 and flow through an exhaust duct 15 to drive the turbocharger 8. After passing the turbocharger 8, the exhaust gases pass via the duct 13 into an integrated catalytic converter/fuel reformer unit 14. Via an exhaust duct 16, the exhaust gases pass to a water evaporator 17 and from there via an exhaust duct 18 to a fuel evaporator/water condenser unit 19 that includes fuel evaporator element and a water condenser element. On leaving the fuel evaporator/water condenser unit 19, the exhaust gases pass to a tail pipe 20 to be expelled into the ambient.
A second fuel pump 23 supplies biofuel from the tank 4 to the fuel evaporator/water condenser unit 19 where the fuel, that is at ambient temperature, is brought in heat exchanging contact with the exhaust gases. The ethanol that is evaporated from the fuel, is supplied via a duct 21 and a control valve 24 to an inlet 34 of a pre-heater/cooler unit 35. The outlet of the fuel evaporator unit 19 is connected to the exhaust duct 13 via a recirculation duct 25 and a regulating pressure release valve 26.
In the fuel evaporator/water condenser unit 19, water is condensed from the exhaust gases and is stored in a water tank 22 that stores the water which is supplied via a condensate drain and water outlet duct 28, a water pump 27 and a duct 29.
The water that has been condensed in the unit 19 and/or that is supplied from the water tank 22 by the pump 27, is evaporated in the water evaporator 17 and is passed as steam to the outlet 32. Through a water steam supply duct 33 and a control valve 36, the water steam enters into a pre-heater/cooler unit 35. The water steam supply duct 33 is connected to the exhaust duct 16 via a recirculating duct 37 and a regulating valve 38.
The inlet 34 of the unit 35 is connected to the exhaust duct 16 via an exhaust gas recirculation (EGR) control valve 39, a duct 40 and a cooler 41. At the inlet 34 of the pre-heater/cooling unit 35, the ethanol and water steam are mixed, the mass ratio being controlled by the mass flows of the pumps 23 and 27. The pre-heated water steam and ethanol steam mixture is fed from the unit 35 to the integrated catalytic converter/fuel reformer unit 14 through duct 46, in which reformer unit 14 the water and steam are transformed into syngas.
The syngas that is formed in the integrated catalytic converter/fuel reformer unit 14 and that includes H2, is transported via a syngas outlet duct 47, through the pre-heater/cooler unit 35 and preheats the water and ethanol by being brought in heat exchanging contact with the water/ethanol steam that is supplied at the inlet 34.
Via an outlet duct 48, the cooled syngas is supplied to a buffer tank 49 in which it is stored in compressed form. From the buffer tank 49, the syngas is transported via a gas supply duct 50 and a reduction valve 51 to a gas inlet manifold 53 that is connected to the cylinders 3.
EGR Purge
At the start of the engine 2, the EGR control valve 39 is opened while the ethanol steam control valve 24 and water steam control valve 36 are closed. First, chilled exhaust gas is supplied to the gas inlet 53 and to the cylinders 3 to evacuate oxygen in the ICE crank case before the start of H2 production, to eliminate the risk of H2 piston blow by. The EGR control valve 39 is opened at the moment the lambda sensor measures a stable value of lambda=1, which ensures that no oxygen is present in the exhaust gases.
The water steam that is generated in the water evaporator 17 increases the pressure in the recirculation duct 37, causing pressure release of the regulating valve 38, which valve opens at a pressure of between 5-10 bar. The water steam is fed into the exhaust duct 16 or can be recirculated into the water tank 22, as shown in the embodiment of
The ethanol steam that is generated in fuel evaporator 19 increases the pressure in the recirculation duct 25, causing pressure release of the regulating valve 26, which valve opens at a pressure of between 5-10 bar. The ethanol steam is fed into the exhaust duct 13 or can be recirculated into a separate tank, as is shown in the embodiment of
Water Steam Priming
The admission of water steam only into the reformer unit 14 can also be carried out under high load conditions of the ICE 2 involving high temperature operating points, for decoking of the reformer unit 14, using water steam to wash out carbon deposits from the reformer unit.
The admission of water steam to the ICE 2 can be carried out to operate the ICE under Humid Air Motor (HAM) conditions with a lambda value of 1 at maximum power output, for reducing NOx formation.
Recirculation of the water steam avoids the risk of coking at start up and ensures that hydrogen that is created in the reforming process and stored in the buffer tank 49, enters a completely oxygen free system.
Reforming Process
The water steam that is formed in evaporator 17 is fed through the evaporator 63, and from there via the control valve 36 to the heat exchanger 35 and the reformer unit 14. During the EGR purging step, the recirculated steam is admitted by the pressure release valve 38 into the duct 70, to a condenser 71 and from there on via a duct 72 back into the water tank 22.
A start sequence of the internal combustion engine assembly 1 in relation to
A stopping sequence may include:
While the disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed, but that the disclosure will include all embodiments falling within the scope of the appended claims.
Number | Date | Country | Kind |
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22166554 | Apr 2022 | EP | regional |
Number | Name | Date | Kind |
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20090035192 | Hwang | Feb 2009 | A1 |
20190323458 | Voice | Oct 2019 | A1 |
Number | Date | Country |
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521165 | Nov 2019 | AT |
522812 | Apr 2021 | AT |
113646515 | Nov 2021 | CN |
2048339 | Apr 2009 | EP |
3618312 | Feb 2005 | JP |
Entry |
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Sep. 23, 2022 European Search Report issued in corresponding EP Application No. 22166554. |
Number | Date | Country | |
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20230313759 A1 | Oct 2023 | US |