This invention relates to split-cycle engines and, more particularly, to such engines incorporating water injection for improved power and/or operation.
For purposes of clarity, the following definition is offered for the term split-cycle engine as may be applied to engines disclosed in the prior art and as referred to in the present application.
A split-cycle engine as referred to herein comprises:
a crankshaft rotatable about a crankshaft axis;
a power piston slidably received within a power cylinder and operatively connected to the crankshaft such that the power piston reciprocates through a power (or expansion) stroke and an exhaust stroke during a single rotation of the crankshaft;
a compression piston slidably received within a compression cylinder and operatively connected to the crankshaft such that the compression piston reciprocates through an intake stroke and a compression stroke during a single rotation of the crankshaft; and
a gas passage interconnecting the power and compression cylinders, the gas passage including an inlet valve and an outlet (or crossover) valve defining a pressure chamber therebetween.
United States patents U.S. Pat. No. 6,543,225 B2, U.S. Pat. No. 6,609,371 B2 and U.S. Pat. No. 6,952,923 (Scuderi patents), all assigned to the assignee of the present invention, disclose examples of split-cycle internal combustion engines as herein defined. These patents contain an extensive list of United States and foreign patents and publications cited as background in the allowance of these patents. The term “split-cycle” has been used for these engines because they literally split the four strokes of a conventional pressure/volume Otto cycle (i.e., intake, compression, power and exhaust) over two dedicated cylinders: one cylinder dedicated to the high pressure compression stroke, and the other cylinder dedicated to the high pressure power stroke.
Considerable research has been recently devoted to air hybrid engines. The air hybrid needs only the addition of an air pressure reservoir added to an engine incorporating the functions of a compressor and an air motor, together with the functions of a conventional engine, for providing the hybrid system benefits. These functions include storing pressurized air during braking and using the pressurized air for driving the engine during subsequent starting and acceleration.
Water injection into cylinders of conventional four-stroke internal combustion engines has been applied in the past for knock control in supercharged engines, but is not known to have been used for improving brake thermal efficiency or brake power.
The present invention results from computer modeling studies of the application of water or steam injection to a split cycle engine for increasing brake power output and/or efficiency. Possible results of detonation (knock) control and reduction of NOx emissions were also considered. Summarized conclusions of the study are as follows:
Water injection into the compressor cylinder is predicted to increase brake power and efficiency. Water injection into the crossover passage may have no power or efficiency benefits, but may significantly reduce NOx and detonation effects. It is assumed that any added water is heated externally using a form of waste heat.
Steam injection into the compressor cylinder is predicted to have neutral effects, but steam injection into the crossover passage should increase engine power and efficiency. It is assumed that any added steam is generated externally using waste heat.
Water injection into the expansion cylinder is predicted to significantly improve both brake power and efficiency if the injected water can be made to impinge on the piston or cylinder head in order to generate steam while cooling those parts of the engine.
The predictive methods did not simulate the additional benefits associated with improved detonation resistance and reduced NOx emissions which are well known for SI engines with water and steam injection, and which are very significant. Assumed water/steam injection quantities ranged ˜1-2 times the fuel injection quantity.
Another important assumption with all the predictions is that any injected water is able to evaporate instantly on entering the cylinder or crossover passage. This is practically unlikely, and the benefits of water injection will depend significantly on the speed at which water can be evaporated. The time constants of internal combustion engines are such that it can be difficult to achieve evaporation in the compression cylinder unless the water is present in a very fine droplet form, providing a large surface area, and is hopefully close to its boiling point.
While benefits of water or steam injection appear attractive, there are serious practical issues, notably added hardware complexity, water consumption, freezing protection, oil contamination and possibly corrosion. External steam generation would be a major hardware cost. On the other hand, the split cycle engine stands to gain more from water injection to the compressor than a 4-stroke engine, because the compressor work, and re-expansion losses, are greater than a 4-stroke engine. Although steam injection may be difficult in the expansion cylinder, it may be easier in the crossover passage and could help control crossover wall temperatures.
The summarized conclusions of the report led to the conception of several embodiments of split cycle engines using water injection. These include:
Split cycle engine with direct water injection into the compressor cylinder;
Split cycle engine with direct water injection into the crossover passage prior to the discharge of compressed air into the expansion cylinder;
Split cycle engine with direct steam injection into the crossover passage prior to the discharge of compressed air into the expansion cylinder;
Split cycle engine with direct water injection into the expansion cylinder;
Split cycle engine with direct steam injection into the expansion cylinder;
Split cycle air hybrid engine with direct water/steam injection into one of the compressor cylinder, the crossover passage and the expansion cylinder.
Additional variants and sub-groups are also contemplated.
These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.
The Scuderi Group LLC commissioned the Southwest Research Institute® (SwRI®) of San Antonio, Tex. to perform a Computerized Study. The Study involved constructing computer models used in determining predicted effects on operation of a split-cycle four stroke engine of the direct injection of water and/or steam into the compression cylinder, the crossover passage or the expansion cylinder of the engine. The Computerized Study resulted in the present invention described herein through exemplary embodiments pertaining to a split-cycle engine.
The following glossary of acronyms and definitions of terms used herein is provided for reference.
Referring first to
As shown, the engine includes an engine block 12 having a first cylinder 14 and an adjacent second cylinder 16 extending therethrough. A crankshaft 18 is journaled in the block 12 for rotation about a crankshaft axis 20, extending perpendicular to the plane of the drawing. Upper ends of the cylinders 14, 16 are closed by a cylinder head 22.
The first and second cylinders 14, 16 define internal bearing surfaces in which are received for reciprocation a first power piston 24 and a second compression piston 26, respectively. The cylinder head 22, the power piston 24 and the first cylinder 14 define a variable volume combustion chamber 25 in the power cylinder 14. The cylinder head 22, the compression piston 26 and the second cylinder 16 define a variable volume compression chamber 27 in the compression cylinder 16.
The crankshaft 18 includes axially displaced and angularly offset first and second crank throws 28, 30, having a phase angle 31 therebetween. The first crank throw 28 is pivotally joined by a first connecting rod 32 to the first power piston 24 and the second crank throw 30 is pivotally joined by a second connecting rod 34 to the second compression piston 26 to reciprocate the pistons in their cylinders in timed relation determined by the angular offset of their crank throws and the geometric relationships of the cylinders, crank and pistons.
Alternative mechanisms for relating the motion and timing of the pistons may be utilized if desired. The timing may be similar to, or varied as desired from, the disclosures of the Scuderi patents. The rotational direction of the crankshaft and the relative motions of the pistons near their bottom dead center (BDC) positions are indicated by the arrows associated in the drawings with their corresponding components.
The cylinder head 22 includes any of various passages, ports and valves suitable for accomplishing the desired purposes of the split-cycle engine 10. In the illustrated embodiment, the cylinder head includes a gas crossover passage 36 interconnecting the first and second cylinders 14, 16. The crossover passage includes an inlet port 38 opening into the closed end of the second cylinder 16 and an outlet port 40 opening into the closed end of the first cylinder 14. The second cylinder 16 also connects with a conventional intake port 42 and the first cylinder 14 also connects with a conventional exhaust port 44.
Valves in the cylinder head 22 include an inlet check valve 46 and three cam actuated poppet valves, an outlet valve (or crossover valve) 50, a second cylinder intake valve 52, and a first cylinder exhaust valve 54. The check valve 46 allows only one way compressed air flow into the reservoir inlet port 38 from the second (compression) cylinder 16. The reservoir outlet valve 50 is opened to allow high pressure air flow from the crossover passage 36 into the first (power) cylinder 14. The poppet valves 50, 52, 54 may be actuated by any suitable devices, such as camshafts 60, 62, 64 having cam lobes 66, 68, 70 respectively engaging the valves 50, 52, 54 for actuating the valves.
A spark plug 72 is also mounted in the cylinder head with electrodes extending into the combustion chamber 25 for igniting air-fuel charges at precise times by an ignition control, not shown. It should be understood that the engine may be made as a diesel engine and be operated without a spark plug if desired. Moreover, the engine 10 may be designed to operate on any fuel suitable for reciprocating piston engines in general, such as hydrogen or natural gas.
The manner of operation of the engine of
In
To avoid interference with combustion, water injection after the start of combustion appears desirable. Delay of water injection until after the power piston 24 has reached 30, 50 or 90 degrees crank angle ATDC, or when combustion is at least 30, 50 or 90 percent complete, may provide increasing degrees of power and efficiency improvement.
In accordance with the invention, separate water/steam injectors 100, 102, 104 are mounted in the cylinder head and connected to spray water/steam directly into the compression chamber 27, the crossover passage 92 and the combustion chamber 25, respectively. The injectors may be operated as desired together or separately under varying engine operating conditions to obtain the desired effectiveness for each condition. Modified embodiments of the engine could also be provided using only one of the three water/steam injection locations as development finds to be most beneficial.
1.0 Use of Water or Steam Injection with the Scuderi Split Cycle Engine
GTPower computer models have been used to examine and predict the potential performance and fuel efficiency benefits of water or steam injection into the compressor, crossover passage and expander elements of the Scuderi Split Cycle (SSC) engine at 4000 rpm/full load, with certain assumptions for the water or steam injection conditions, but excluding significant water evaporation time, NOx and detonation aspects. Summarized conclusions are as follows.
Water injection into the compressor cylinder is predicted to increase brake power and efficiency, but water injection into the crossover passage has no benefits, other than potential NOx and detonation effects, that could be significant. It is assumed that any added water is preheated externally using some form of waste heat.
Steam injection into the compressor cylinder is predicted to have neutral effects, but steam injection into the crossover passage should increase engine power and efficiency. It is assumed that any added steam is generated externally using waste heat.
Water injection into the expansion cylinder is predicted to significantly improve both brake power and efficiency if the injected water can be made to impinge on the piston or cylinder head in order to generate steam while cooling those parts of the engine.
The predictive methods did not simulate the additional benefits associated with improved detonation resistance and reduced NOx emissions which are well known for SI engines with water and steam injection, and which are very significant. Assumed water/steam injection quantities ranged ˜1-2 times the fuel injection quantity.
Another important assumption with all the predictions is that the any injected water is able to evaporate instantly on entering the cylinder or crossover passage. This is practically unlikely, and the benefits of water injection will depend significantly on the speed at which water can be evaporated. The time constants of internal combustion engines is such that it can be difficult to achieve evaporation in the compression cylinder unless the water is present in a very fine droplet form, providing a large surface area, and is hopefully close to its boiling point.
While benefits of water or steam injection appear attractive, there are serious practical issues, notably added hardware complexity, water consumption, freezing protection, oil contamination and possibly corrosion. External steam generation would be a major hardware cost. On the other hand, the SSC stands to gain more from water injection to the compressor than a 4-stroke engine, because the compressor work, and re-expansion losses, are greater than a 4-stroke engine. Although steam injection may be difficult in the expansion cylinder, it may be easier in the crossover passage and could help control crossover wall temperatures.
1.2.1 Water & Steam Injection into Compressor Cylinder and Crossover Passage
Water and/or steam injection is modelled with an injector inserted into the relevant part of the engine, i.e. into the compressor (
Either water or steam may be injected at the prevailing pressure conditions associated with the engine component. Variables include water/steam temperature, quantity, injection timing and water/steam composition at the instant of injection; the GTPower model can also track the water and steam species.
Water injection assumes a selectable percentage of the water can be instantaneously evaporated to steam if the downstream temperature and pressure conditions will support steam, the energy for this coming from the working fluid into which the water is injected. The remaining (unevaporated) percentage of the water remains as water in the non-combustion parts of the engine (compressor and crossover), but vaporizes during combustion in the expander. However, any water injected after combustion (in the expander) will remain as water, unless a vapor fraction is specified.
For steam injection, the evaporating energy is externally supplied at the pressure conditions prevailing, so this would depend on a source of waste heat.
Summarized predictions from these models are now described.
The effects/benefits of water/vapor and steam injection are very different for the injection into the compressor versus injection into the crossover passage.
Water injection into the compressor, with vaporization, results in improved power output and brake efficiency with increasing degrees of vaporization. The power and efficiency improvements (
Steam injection into the compressor (single points in
Conversely, steam injection (single points in
Water injection into the crossover passage, on the other hand, has an almost neutral effect on power but significantly reduces the brake thermal efficiency, both of these effects being because the water is not significantly reducing compressor work, but does reduce the expander work by reducing the crossover passage pressure, this effect more than offsetting the benefits of reduced heat losses in the expansion cylinder.
Although this GTPower model has no NOx or autoignition models, it is almost certain that both water and steam injection into the compressor cylinder and crossover passage would have significant benefits on NOx reduction, and performance improvements if the SSC engine is knock limited.
1.2.2 Water & Steam Injection into the Expansion Cylinder
The model (
The model assumes that the heat of vaporization of the water is either provided from the piston, i.e. water is injected, the water is vaporized by the piston, and the heat required to take the vapor from the evaporated steam conditions to a superheat that matches the in-cylinder charge temperature is extracted from the in-cylinder burnt charge. The heat transfer from the piston is adjusted, manually, to reduce its heat loss by an amount equivalent to the heat of vaporization of the water. This might physically be achieved by impinging the water spray onto the piston, without any heat transfer from the cylinder fuel-air mixture; more heat could be extracted by spraying the water onto other internal surfaces of the cylinder, e.g. the exhaust valves and cylinder head.
Steam injection rates, e.g. ˜116% & 232% of fuel flow, have been selected so that the heat of evaporation of the injected water approximately matches the cyclic heat input from combustion into the piston (or multiples, allowing for heat transfer from the cylinder head). Feedpump water injection work is included. Water injection pressures match those of the prevailing cylinder pressures occurring during the injection period.
The change in piston temperature arising from the water impingement/steam latent heat of evaporation is approximately assessed by assuming that the latent heat of evaporation only cools a portion of the piston, the remainder of the piston being at a less critical component temperature. The cooled portion of the piston is arbitrarily assumed to be 10% of the bare piston mass, but can be readily changed.
Predictions are summarized in Table A1 (Steam 1-2 versus baseline) and indicate that the water injection with subsequent evaporation to steam by heat transfer from the piston can improve brake power and brake thermal efficiency by 13-18%.
The 50° ATDC start of injection timing (SOI) is selected to provide a favorable tradeoff between expansion ratio (higher with earlier SOI) and heat transfer from the burning/burned gases.
The cylinder pressure and temperature diagrams (
It may at first sight be puzzling that bulk pressure can increase while bulk temperature reduces. The suggested explanation is that additional (cooler) mass is being added to the initial cylinder contents during the water injection period and this reduces the temperature of the mixture, but this must be set-off against the addition of the evaporative pressure element of the steam enthalpy.
Table A1 indicates estimated maximum 2.5-5.0° C. reduction in 10% of the bare piston weight, assumed to be that area in contact with the water impingement, i.e., probably the piston crown. If heat of evaporation of the steam is drawn from a larger portion of the piston mass, the piston temperature reduction would be proportionally reduced. These temperature reduction estimates are very simplified and only provide a coarse guide of the potential temperature reductions.
The water injection/steam evaporation can be equally applied to the cylinder head to cool the exhaust valve heads.
Bulk cylinder temperatures (
Although the invention has been described by reference to certain specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts disclosed. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.
This application claims the benefit of U.S. Provisional Application No. 60/903,640, filed Feb. 27, 2007.
Number | Date | Country | |
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60903640 | Feb 2007 | US |