The present disclosure relates generally to apparatus and methods for thermally managing emission abatement devices.
There are a variety of ways to heat emission abatement devices. For example, fuel-fired burners and electric heaters have been used in connection with some types of emission abatement devices.
According to an aspect of the present disclosure, there is provided an apparatus comprising a fuel-fired burner that is positioned in an exhaust gas passageway and comprises a swirler configured to swirl exhaust gas of a reciprocating or Wankel engine so as to stabilize in the exhaust gas passageway a flame generated by the burner without use of supplemental combustion air when the engine is operating at idle and above idle. The swirl-stabilized flame is useful for thermally managing an emission abatement device. An associated method is disclosed.
Such flame stabilization has a number of benefits. For example, it promotes use of the burner during occurrences of relatively high exhaust gas flow rates which might otherwise blow out the flame. In addition, the diameter of the burner can be reduced since the burner can handle such relatively high flow rates. Further, flame stabilization promotes reduction of the flame length, thereby allowing the burner length to be reduced accordingly. A relatively compact burner package can thus be provided for applications where space economy may be a factor (e.g., onboard a vehicle).
The burner may have a plurality of swirlers for swirling exhaust gas to promote flame stabilization. In an exemplary implementation, the burner has three swirlers, two in a pilot section of the burner and one in a main section of the burner. One of the swirlers of the pilot section is positioned about a pilot fuel nozzle for stabilizing a pilot flame generated by the pilot section. The other pilot section swirler is positioned about a perforated pilot tube to promote passage of oxygen present in exhaust gas through apertures defined in the pilot tube into the pilot flame. The swirler in the main section is used to stabilize a main flame initiated by the pilot flame.
Swirl stabilization of the pilot flame and/or the main flame is useful for thermally managing a variety of emission abatement devices. Such emission abatement devices include, but are not limited to, oxidation catalysts (e.g., diesel oxidation catalysts), particulate filters (e.g., catalyzed or uncatalyzed diesel particulate filters), selective catalytic reduction devices (“SCR devices”), and/or NOx traps.
The above and other features of the present disclosure will become apparent from the following description and the attached drawings.
a is a sectional view of a portion of a pilot tube showing a wall-cooling layer of exhaust gas formed on an inner surface of the pilot tube;
While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives following within the spirit and scope of the invention as defined by the appended claims.
Referring to
Illustratively, the swirler 22 swirls exhaust gas to generate an outer swirl zone 24 of swirling exhaust gas which induces generation of an inner recirculation zone 26 of recirculating exhaust gas within the swirl zone 24. In the swirl zone 24, exhaust gas swirls around an axis 28 of the burner 12 (e.g., in a clockwise direction or counter-clockwise direction) as the exhaust gas advances downstream along the axis 28. In the recirculation zone 26, exhaust gas recirculates back toward the swirler 22. The swirl zone 24 may have a relatively high velocity depending, for example, on the output of the engine 16. However, the recirculation zone 26 has a relatively low velocity conducive to flame stabilization. In other words, the velocities in the recirculation zone 26 are sufficiently low to allow the flame 14 to reside therein without being blown out by the potentially higher velocities in the outer swirling zone 24. The flame 14 is thus stabilized in and near the recirculation zone 26 by use of the swirler 22.
The swirler 22 may be configured to generate one or more secondary recirculation zones 29 as well. Illustratively, the swirler 22 provides a sudden change in the flow area (i.e., a “dump plane”) at its periphery. Such a feature generates secondary recirculation zones 29 just downstream therefrom. The zones 29 may thus be used to promote flame stabilization in the zones 29 in addition to or in place of the recirculation zone 26.
It is within the scope of this disclosure to configure the swirler 22 so as to swirl the exhaust gas to achieve any swirl number, the swirl number being indicative of the amount of swirl induced in the flow per unit length. For example, swirl numbers between about 0.5 and about 2.0 may be particularly useful to promote stabilization of the flame 14. Swirl numbers between about 0.76 and 1.1 may be most useful to promote stabilization of flame 14.
Swirl stabilization of the flame 14 has a number of benefits. For example, it promotes use of the burner 12 during occurrences of relatively high exhaust gas flow rates which might otherwise blow out the flame 14. This may be particularly useful with vehicles such as relatively large commercial vehicles (e.g., truck tractors, buses) that have a relatively large engine (e.g., 12.7 liter engine) capable of producing a relatively large amount of exhaust gas. In addition, flame stabilization promotes provision of a relatively compact burner package for applications where space economy may be a factor. In particular, the diameter of the burner 12 can be reduced since the burner 12 can handle relatively high exhaust gas flow rates. Further, the burner length can be reduced since flame stabilization results in a shorter flame length. The burner 12 with its swirler 22 is thus particularly useful in an exhaust system.
The emission abatement device 18 is thermally managed by use of the swirl-stabilized flame 14. In particular, exhaust gas passing through the burner 12 is heated thereby and advances to the emission abatement device 18 to heat the emission abatement device 18.
The device 18 may take a variety of forms. Exemplarily, the device 18 may include an oxidation catalyst (e.g., diesel oxidation catalyst), a particulate filter (e.g., catalyzed or uncatalyzed diesel particulate filter), an SCR device, and/or a NOx trap.
According to one example, the device 18 includes an oxidation catalyst and a particulate filter. In such a case, the oxidation catalyst is positioned fluidly between the burner 12 and the particulate filter. The exhaust gas heated by the swirl-stabilized flame 14 heats the oxidation catalyst to its operational temperature (e.g., between about 250° C. and about 300° C.). The oxidation catalyst then oxidizes fuel that has been introduced into the exhaust gas at the burner 12 or at a location separate and from the burner 12. Heat generated by the exothermic reaction at the oxidation catalyst heats the particulate filter to burn off particulate matter trapped thereby so as to regenerate the particulate filter for further use. It is within the scope of this disclosure to use the swirl-stabilized flame to regenerate the particulate filter without the assistance of an oxidation catalyst.
In the case where the device 18 is an SCR device, the swirl-stabilized flame 14 is used to facilitate establishment of the SCR device within its operational temperature range. In the case of a NOx trap, the swirl-stabilized flame 14 may be used to elevate the temperature of the NOx trap to facilitate de-sulfurization of the NOx trap. Further, the burner 12 may be used with the exhaust systems of U.S. Pat. No. 6,871,489, the disclosure of which is hereby incorporated by reference herein.
Referring to
The burner 112 comprises a pilot section 130 and a main section 132. The pilot section 130 generates a swirl-stabilized pilot flame 134 used to initiate a swirl-stabilized main flame 136 of the main section 132. Once the main flame 136 is initiated, the pilot section 130 can be shut down to extinguish the pilot flame 134 or can be continued to be operated.
The pilot section 130 comprises a swirl-stabilized pilot fuel dispenser 138 (see also
The dispenser 138 dispenses fuel supplied by a pilot fuel line 148 into the recirculation zone 26 for ignition of the fuel by an igniter 146 that extends into the recirculation zone 26. In this way, the pilot flame 134 is initiated in the pilot tube 142. Moreover, the pilot flame 134 is stabilized in the pilot tube recirculation zone 26 due to the relatively low exhaust gas velocities in that zone 26. A flow-obstructing device 150 which may be used to hold the pilot flame 134 is mounted in the pilot tube 142 to further facilitate stabilization of the pilot flame 134.
A second swirler 122b of the pilot section 130 mates against the housing 118 and is secured thereto so as to be mounted in the passageway 120. The pilot tube 142 extends through an aperture defined in the swirler 122b such that the swirler 122b surrounds the pilot tube 142 and the pilot tube 142 is secured to the swirler 122b. The pilot tube 142, the swirler 122a, and the dispenser 138 secured to the pilot tube 142 are thus mounted in the passageway 120.
The swirler 122b is configured, for example, as a plate comprising inclined radially extending vanes 153 that swirl exhaust gas outside the pilot tube 142 in either a clockwise or counter-clockwise direction (depending on the orientation of the vanes 153) about the burner axis 145. In this way, the swirler 122b causes exhaust gas to pass through apertures 154 defined in the pilot tube 142 so as to “feed” oxygen present in the exhaust gas to the pilot flame 134 for combustion with the pilot fuel. In addition, exhaust gas which passes through the apertures 154 into the pilot tube 142 due to the swirler 122b forms a generally annular wall-cooling layer 155 of exhaust on the inner surface of the pilot tube 142. This wall-cooling layer 155 serves as a layer of thermal insulation between the pilot tube 142 and the pilot flame 134, thereby enhancing the durability of the pilot tube 142 and permitting use of less costly materials for the pilot tube 142. The thickness of the wall-cooling layer 155 may be about ⅛ inch.
The main section 132 is positioned just downstream from the pilot section 130. A main fuel dispenser 156 secured to the housing 118 receives fuel from a main fuel line 122c and dispenses that fuel into the main section 132 for generation of the main flame 136.
The main section 132 comprises a third swirler 122c for swirl-stabilization of the main flame 136. The swirler 122c is configured, for example, as a plate comprising inclined radially extending vanes 159 that swirl exhaust gas in either a clockwise or counter-clockwise direction (depending on the orientation of the vanes 159) about the burner axis 145 upon passage of the exhaust gas through the swirler 122c. This generates immediately downstream from the swirler 122c an outer swirl zone 24 of swirling exhaust gas in the housing 118 of the main section 132. This outer swirl zone 24 of the main section 132 induces an inner recirculation zone 26 of recirculating exhaust gas within the main section outer swirl zone 24. The main flame 136 is stabilized in this main section recirculation zone 26 due to the relatively low exhaust gas velocities present in this zone 26. A transition member 160 secured to an upstream side of the swirler 122c facilitates passage of exhaust gas through the swirler 122c.
The swirler 122c comprises a dump plane 162 along an outer periphery of the swirler 122c. The dump plane 162 is an imperforate annular wall that blocks flow of exhaust gas therethrough so as to generate a radially outer recirculation zone immediately downstream from the dump plane 162 for flame stabilization in that zone also. It is within the scope of this disclosure to omit the dump plane 162 and extend the vanes 159 to the outer periphery of the swirler 122c.
The burner 112 may include a fuel-dosing section 164 for dispensing fuel into the heated exhaust gas for use with a downstream oxidation catalyst or other component of the emission abatement device 18. In such a case, the fuel-dosing section 164 has a fuel-dosing dispenser 166 secured to the housing 118. The dispenser 166 dispenses dosing fuel supplied by a dosing fuel line 168 into the passageway 120 at a location between the swirler 122c and a fourth swirler 122d. The swirler 122d is configured, for example, as a plate comprising inclined vanes 172 that swirl the dosing fuel and exhaust gas in either a clockwise or counter-clockwise direction (depending on the orientation of the vanes 172) about the burner axis 145 upon passage through the swirler 122d. In this way, the dosing fuel is thoroughly mixed with the exhaust gas upon arrival at the emission abatement device 18. It is within the scope of this disclosure to omit the fuel-dosing section 164 altogether from the apparatus 10 or to include the fuel-dosing section 164 as a component separate from the burner 112 such that the fuel-dosing section is positioned downstream from the burner 112 at some location between the burner 112 and the emission abatement device 18.
It is within the scope of this disclosure to configure the swirlers 122a, 122b, 122c, 122d so as to swirl the exhaust gas to achieve any swirl number. For example, swirl numbers between about 0.5 and about 2.0 may be particularly useful to promote flame stabilization of flames 134 and 136. Swirl numbers between about 0.76 and 1.1 may be most useful to promote such flame stabilization.
Referring to
The direction of inclination of the vanes 144, 153, 159, 172 of the swirlers 122a, 122b, 122c, 122d may take a variety of forms. For example, all the vanes of the swirlers 122a, 122b, 122c, 122d may be inclined to swirl exhaust gas in the same direction about the axis 145. In other examples, the vanes 144, 153, 159, 172 of one or more swirlers 122a, 122b, 122c, 122d may be inclined to swirl exhaust gas in clockwise direction whereas the vanes 144, 153, 159, 172 of the other swirler(s) 122a, 122b, 122c, 122d may be inclined to swirl exhaust gas in a counter-clockwise direction.
The vanes 144, 153, 159, 172 of any swirler 122a, 122b, 122c, 122d may have different pitches (the “pitch” is the angle of inclination of a vane). For example, some of vanes of a given swirler may have one or more pitches to swirl exhaust gas in a clockwise direction and some of the vanes of that same swirler may have one or more pitch angles to swirl exhaust gas in a counter-clockwise direction. Use of such pitch angles promotes mixing of exhaust gas. An example of such a swirler is shown in
The vanes 144, 153, 159, 172 of any swirler 122a, 122b, 122c, 122d may be fixed against movement relative to the housing 118 or may be movable relative to the housing 118. As such, the pitch of the vanes may be invariable or variable.
Referring to
The vanes 230 are mounted within a stationary frame for pivotable movement relative thereto. Exemplarily, the vanes 230 are secured to a stationary outer mounting ring 234 surrounding the vanes 230 and a stationary inner mounting hub 236. The hub 236 is mounted within the mounting ring 234 by a plurality of stationary mounting rods 238 (e.g., five). A transition member 260 is secured to the upstream side of the hub 236 to facilitate passage of flow through the swirler 222.
The pitch adjuster 232 comprises a drive unit 240 and a connector 242 operable by the drive unit 240 to pivot the vanes 230 to adjust their pitch. The drive unit 240 may have a motor (e.g., electric motor) and associated reduction gearing for rotating a rotatable drive shaft 244. The connector 242 comprises a lever 246 secured to the shaft 244 to be pivoted thereby upon rotation of the shaft 244. Such pivoting movement of the lever 246 moves a link 248 back and forth to cause a rotatable ring 250 to rotate about a swirler axis 252 of the swirler 222. Rotation of the ring 250 causes a pivot 254 associated with each vane 230 and extending through the mounting ring 234 thereto to pivot about a vane axis 256 of the vane 230. Such pivotable movement of the pivots 254 causes each vane 230 to rotate about its vane axis 256 to adjust the pitch thereof. In this way, a desired swirl number associated with the exhaust gas can be achieved in order to promote flame stabilization of either or both of the pilot flame 134 and the main flame 136 in the case of a non-zero swirl number and to promote reduction of engine back pressure in the case of a zero or near-zero swirl number.
Further, in the case of a burner having multiple swirlers as with the burner 112, such pitch adjustment can be used to swirl the flow in opposite directions. In particular, the vanes of one or more swirlers may be configured by the adjuster 232 to swirl exhaust gas in one direction whereas the vanes of one or more other swirlers may be configured by the adjuster 232 to swirl exhaust gas in an opposite direction.
It is within the scope of this disclosure to achieve any swirl number by use of the swirler 220 and pitch adjuster 232. For example, swirl numbers between about 0.5 and about 2.0 may be particularly useful to promote flame stabilization. Swirl numbers between about 0.76 and 1.1 may be most useful to promote flame stabilization.
Referring to
Referring to
Referring to
Guide vanes 425 of the swirler 422b are used to direct exhaust gas that passes the guide vanes 425 toward the fuel dispensers 156. There are two pairs of guide vanes 425, each pair being associated with one of the fuel dispensers 156. The guide vanes 425 of each pair are inclined toward one another at a pitch 427 of, for example, about 60° in order to direct exhaust gas axially toward the associated fuel dispenser 156.
Referring to
A flow-obstructing device 450 is secured to and extends from a distal end of the tube 451. Exemplarily, the device 450 is shaped generally as half of a spoon. The device 450 serves, for example, as a flame holder for the pilot flame 134 and/or the main flame 136 to further assist in flame stabilization.
Each of the swirlers 22, 122a, 122b, 122c, 222, 422b or combinations thereof provides means for swirling exhaust gas so as to stabilize in the exhaust gas passageway 20 or 120 a flame 14, 134, and/or 136 generated by the burner 12 or 112 for thermal management of the emission abatement device 18.
While the concepts of the present disclosure have been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.
There are a plurality of advantages of the concepts of the present disclosure arising from the various features of the systems described herein. It will be noted that alternative embodiments of each of the systems of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of a system that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the invention as defined by the appended claims.
This application is a continuation of U.S. application Ser. No. 11/152,869, filed Jun. 15, 2005, and is a continuation in part of U.S. application Ser. No. 10/931,009, filed Aug. 31, 2004, which claimed the benefit of U.S. Provisional Patent Application Ser. No. 60/546,139 filed on Feb. 20, 2004 and U.S. Provisional Patent Application Ser. No. 60/536,327 filed on Jan. 13, 2004, the entirety of all above applications is hereby incorporated by reference.
Number | Date | Country | |
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60546139 | Feb 2004 | US | |
60536327 | Jan 2004 | US |
Number | Date | Country | |
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Parent | 11152869 | Jun 2005 | US |
Child | 11871701 | Oct 2007 | US |
Number | Date | Country | |
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Parent | 10931009 | Aug 2004 | US |
Child | 11871701 | Oct 2007 | US |