The disclosure generally relates to systems and methods for using toroidal vortex induction diffusers in internal combustion engines, and more particularly to methods and systems for using toroidal vortex induction diffusers to achieve high levels of fuel mixture homogeneity in combustion engines using hard-to-mix fuels like Hydrogen (H2), Methanol (CH3OH), Ethanol (C2H5OH) and other gaseous and liquid fuels.
The following references describe problems with the state of the art that are more fully described below. These references are incorporated by reference herein to the extent consistent with this disclosure:
Decarbonization and sustainability mandates pose serious uncertainties to the future of Internal Combustion Engines (ICEs).
Due to the challenges associated with combustion instabilities, the power density and efficiency of H2 engines, also known as H2 Internal Combustion Engines or H2-ICEs, are much lower compared to that of Diesel engines.
Typical combustion issues with H2 engines, defined as engines burning any fuel mixture combination that includes Natural Gas (NG), Ammonia (NH3) and Hydrogen (H2), or with carbon neutral fuels such as Methanol (CH3OH), Ethanol (C2H5OH), synthetic gasoline, etc., are large variations in the Coefficient of Variation of Indicated Mean Effective Pressure (COV-IMEP), high propensity to Lubrication Oil Preignition (LOP), Knock and Preignition. Because of these limitations, only low levels of engine Indicated Mean Effective Pressure (IMEP) and Indicated Thermal Efficiency (ITE), and high levels of Nitrous Oxide (NOx) emissions can be obtained.
Current H2-ICEs have performance parameters limited to the following ranges:
However, the performance level needed for H2-ICEs to compete with Hydrogen Fuel Cells would require performance parameters in the following ranges:
There is a need to address the foregoing deficiencies in the art.
In certain embodiments, achieving levels of competitive efficiency and power density with zero-emissions, may necessitate holistic system solutions including the key components of the engine system like ignition, injection, and combustion chamber which may be properly integrated to meet or exceed performance targets. Certain embodiments may be able to burn green fuels like Hydrogen (H2) while having engine power densities and efficiencies approaching those of Diesel engines (i.e., “Diesel-like performance”) but with net-zero emissions.
In certain embodiments, validated CFD simulation tools may be used to design highly effective mixing devices to assure proper mixing during steady state, as well as during transient operations. In certain embodiments, the proper mixing of injected Hydrogen (H2) and/or Methanol (CH3OH) may be achieved.
In certain embodiments, performance levels may be achieved to enable H2-ICEs to compete against Hydrogen Fuel Cells. In certain embodiments, the following performance parameters may be achieved:
In certain embodiments, highly homogeneous mixtures defined as mixtures having a Uniformity Index (UI) greater than 0.9 may be used to achieve the foregoing performance levels. Where the UI=1−(Standard Deviation of Lambda/Mean Lambda).
In certain embodiments, a toroidal induction diffuser for enhancing mixing of engine intake air and fuel in an engine cylinder is disclosed comprising: an engine intake port having a first longitudinal axis; an engine intake runner upstream of the engine intake port having a second longitudinal axis; a toroidal structure located around one of the first longitudinal axis and the second longitudinal axis; wherein the toroidal structure includes a first one or more holes for introducing a first fuel flow into the engine intake port or the engine intake runner. The first fuel flow may be in one of a direction aligned with, counter to, or transverse to a direction of flow of intake air to the engine intake runner or engine intake port.
The toroidal induction diffuser may further comprise one or more cross branch structures extending radially from the toroidal structure to one of the engine intake port or the engine intake runner, wherein the one or more cross branch structures may comprise a second one or more holes for introducing a second fuel flow into the engine intake port or the engine intake runner. The second fuel flow may be in one of a direction aligned with, counter to, or transverse to an intake air flow direction into the engine intake runner or engine intake port. The first fuel flow may be counter to the intake air flow direction and the second fuel flow may be transverse to the intake air flow direction. The first fuel flow may be aligned with the intake air flow direction and the second fuel flow may be transverse to the intake air flow direction. The first fuel flow may be counter to the intake air flow direction and the second fuel flow may be counter to the intake air flow direction. The first fuel flow may be aligned with the intake air flow direction and the second fuel flow may be aligned with the intake air flow direction. The first fuel flow may be counter to the intake air flow direction and the second fuel flow may be aligned with the intake air flow direction. The first fuel flow may be aligned with the intake air flow direction and the second fuel flow may be counter to the intake air flow direction.
The toroidal structure may be symmetric about at least one of the first longitudinal axis, the second longitudinal axis, or the intake air flow direction. The size of and geometry of the toroidal structure may be functions of one or more of engine intake runner and port geometries, intake air flow direction, velocity and Reynolds number. The size of and the geometry of the one or more cross branch structures may be functions one or more of engine intake runner and port geometries, intake air flow direction, velocity and Reynolds number. A size of, a geometry of, a number of and an orientation of the first one or holes may be functions of one or more of engine intake runner and port geometries, intake air flow direction, velocity and Reynolds number. A size of, a geometry of, a number of and an orientation of the second one or more holes may be functions of one or more of engine intake runner and port geometries, intake air flow direction, velocity and Reynolds number.
The fuel may comprise at least one of H2, CH3OH, and C2H5OH. A fuel-air mixture in the engine cylinder may have a Uniformity Index (UI) greater than about 0.9 according to the following equation:
The fuel-air mixture in the engine cylinder may have a Uniformity Index (UI) of about 0.98.
In certain embodiments,
In certain embodiments, the power density of an H2 engine may be less than 60% of its Diesel counterpart due to these combustion instabilities. For example, if the base Diesel engine operates at 25 bar BMEP (brake mean effective pressure), the H2 engine version may operate at less than 15 bar BMEP before the combustion becomes unstable. Accordingly, if for the Diesel version the engine efficiency is in the range of 48%, in the H2 version the engine efficiency may be in the range of 40%.
As discussed in references [1]-[8] above, homogenous H2 mixtures may prevent the occurrence of LOP at BMEP levels above 16 bar. Combustion CFD studies, as well as engine testing, have indicated that it is very difficult to thoroughly mix H2 with air. This may be due to the incredibly small molecular mass of H2 which limits the diffusion of H2 in air, resulting in highly stratified mixing with conventional H2 port fuel injection (PFI) systems, as shown in
In contrast, certain embodiments shown in
In certain embodiments, a PFI diffuser induction device may use the principle of toroidal vortex flow to thoroughly mix H2 and air in the intake runner and port of a H2-ICE. Toroidal vortices in liquids and gases may enable thorough mixing in a two-component system, which in certain embodiments may include air and hydrogen. When H2 enters a stream of air flow in the form of a toroidal vortex, it may tend to swallow the air into the vortex where a low-pressure region may be formed due to the swirling velocity of the vortex. This method of mixing may be more effective that the typical mixing via conventional injection.
In certain embodiments shown in
In certain embodiments,
In certain embodiments as shown in
The arrangement shown in the embodiments of
In certain embodiments with reference to
In certain embodiments with reference to
In certain embodiments,
In certain embodiments as shown in Step 910, Engine Design and Operating Conditions may be input. In certain embodiments, a CFD turbulence model such as RNG Zeta-F or Reynolds Stress Model or Detached Eddies Simulation (DES) or Large Eddies Simulation (LES) may be adapted and the transport parameters for mass and heat such as Prandtl and Schmidt numbers may be adapted to the specific engine characteristics such as a) cylinder bore & stroke, b) engine rpm, c) intake runner geometry, d) Lambda, e) fuel type, and f) fuel injector geometry, to match the empirical data from bench flow visualization testing simulating engine operations as step 930 for each application segment such as industrial, marine and heavy duty on-off highway.
In certain embodiments, the adapted CFD turbulence model may be used to simulate the intake and compression processes in terms of flow and Lambda distribution. In certain embodiments as shown in Step 920, a first simulation of the current engine configuration may be conducted to establish a baseline. In certain embodiments, the target improvements in terms of mixture homogeneity and required mixing levels may be formulated based on results of the simulation. In certain embodiments, a strategy may be defined to achieve the targeted improvements in terms of type and geometry of the injector, injection pressure and duration, and Toroidal Vortex Induction Diffuser design and location in the intake runner or port. In certain embodiments as shown in Step 940, iterative simulations of the configuration resulting from the initial strategy may be conducted and the results may be analyzed in terms of mixture homogeneity to arrive at validated adapted CFD 950. In certain embodiments as shown in step 960, a baseline simulation of the toroidal vortex inducer configuration may be conducted using validated adapted CFD 950. Certain embodiments as shown in step 970 may further improve the system in terms of Toroidal Vortex Induction Diffuser design and location in the intake runner or port and injector design and location in the intake runner or port as needed based on fundamental fluid mechanics principles based on results of the iterative simulations to arrive at final toroidal vortex inducer configuration 980.
In certain embodiments,
In certain embodiments,
In certain embodiments with the Toroidal Vortex Induction Diffuser, the in-cylinder mixture Lambda distribution may be nearly homogeneous with a uniformity index UI=0.98, which is a substantial improvement compared to the peripheral induction diffuser portrayed in
In certain embodiments,
In certain embodiments,
In certain embodiments, a conventional Induction Diffuser may admit fuel laminarly at the periphery of the intake channel resulting in poor mixing, whereas a Toroidal Vortex Induction Diffuser may admit fuel in the center of the intake runner with a toroidal vortex flow which enables thorough mixing of the injected fuel with the intake air. In certain embodiments, the toroidal vortex flow may result in a highly homogeneous mixture being created inside the cylinder which may enable improvement in engine combustion stability, power output, engine efficiency and transient response. In certain embodiments, improvements in engine efficiency (BTE) and transient response to load changes are expected to follow the trend of the improvements measured in power output.
While the invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the true spirit and scope of the invention as defined by the appended claims. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, method, operation or operations, to the objective, spirit, and scope of the invention. All such modifications are intended to be within the scope of the claims appended hereto. In particular, while the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the invention. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not a limitation of the invention.
This application claims priority of U.S. Patent Application No. 63/706,490, entitled “Toroidal Vortex Induction Diffuser,” and filed Oct. 11, 2024 and U.S. Patent Application No. 63/708,588, entitled “Toroidal Vortex Induction Diffuser,” and filed Oct. 17, 2024. The entirety of the foregoing patent applications is incorporated by reference herein to the extent consistent with the present disclosure.
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Number | Date | Country | |
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63708588 | Oct 2024 | US | |
63706490 | Oct 2024 | US |