The present invention generally relates to an engine fueling system for an internal combustion engine, and more particularly, to a two point fuel system for gas power generation.
Natural gas (NG) may be supplied to engines as fuel and comprises several different gases including methane and others, such as, ethane, propane, butane, carbon dioxide, oxygen, hydrogen, and nitrogen. Natural gas also may include water and hydrogen sulfide, and large or unsaturated hydrocarbons, which are hydrocarbons with double or triple covalent bonds between adjacent carbon atoms.
For internal combustion engines, engine startup time can have strict requirements with respect to critical applications for power generation. Typical NG engine configurations incorporate fuel upstream of the compressor which permits operation with low pressure NG systems. However, this configuration introduces a delay in fuel delivery from the fueling point to the cylinders known as the “fuel transport delay.” This, in turn, extends cranking time and consequently, delays the engine startup by several seconds. Improvements in the foregoing are desired.
The present disclosure provides an engine fueling system that includes multiple fueling valves such that the fuel transport delay can be reduced. The fueling system may also include an electrically driven compressor to improve engine properties during engine startup.
In an illustrative embodiment of the present disclosure, an engine fueling system is disclosed. The engine fueling system comprises: a first compressor; an intake air throttle operably coupled to the first compressor and positioned downstream of the first compressor; a primary fuel path in communication with a fuel supply, wherein a first fuel from the fuel supply is injected into the primary fuel path upstream from the compressor; and a secondary fuel path in communication with the fuel supply, wherein a second fuel from the fuel supply is injected into the secondary fuel path downstream from the compressor.
The engine fueling system may further comprise a charge air cooler positioned downstream of the first compressor and operably coupled to the first compressor and the intake air throttle. Where the engine fueling system comprises a charge air cooler, the second fuel from the secondary fuel path may be injected upstream from the intake air throttle and the charge air cooler; alternately, the second fuel from the secondary fuel path may be injected downstream from the intake air throttle and upstream of the charge air cooler. The engine fueling system may further comprise a mixer operably coupled to the first compressor and the intake air throttle, wherein the first fuel from the primary fuel path and the second fuel from the secondary fuel path may mix to form a mixed fuel.
The engine fueling system may further comprise a second compressor positioned downstream from the intake air throttle. Where the engine fueling system comprises a second compressor, the second compressor may be configured to increase engine speed rate time during engine startup and decrease load ramp rate. Operating settings of the second compressor may be configured to adjust in real time according to the requirements of the engine. The engine fueling system may further comprise an air filter positioned upstream of the first compressor, wherein the first fuel from the primary fuel path is injected downstream from the air filter and upstream of the first compressor. The second fuel from the secondary fuel path may have a pressure of at least 0.5 bar absolute.
In another illustrative embodiment of the present disclosure, a method of fueling an internal combustion engine is disclosed. The method comprises the steps of: providing an engine fueling system, comprising: a plurality of combustion cylinders; a first compressor upstream from the plurality of combustion cylinders, a primary fuel path in communication with a fuel supply and in selective communication with the plurality of combustion cylinders via a first valve; and a secondary fuel path in communication with the fuel supply and in selective communication with the plurality of combustion cylinders via a second valve; injecting a first fuel from the fuel supply into the primary fuel path upstream from the first compressor; injecting a second fuel from the fuel supply into the secondary fuel path downstream from the first compressor; selectively fueling the plurality of combustion cylinders by the primary fuel path, the secondary fuel path, or both the primary fuel path and the secondary fuel path; and delivering at least the first fuel or at least the second fuel into the plurality of combustion cylinders via injection or fumigation.
The method of fueling an internal combustion engine may further comprise the step of mixing the first fuel from the primary path and the second fuel from the secondary path to form a mixed fuel. Where a mixed fuel is formed, the method may further comprise the step of injecting the mixed fuel into an intake manifold operably coupled to the plurality of combustion cylinders. Where a mixed fuel is formed, the method may further comprise the step of injecting the mixed fuel directly into each of the plurality of combustion cylinders via a plurality of individual injector ports, each of the plurality of individual injector ports coupled to one of the plurality of combustion cylinders.
The engine fueling system of the method may further comprise an air intake throttle and a charge air cooler, wherein the charge air cooler is positioned upstream from the plurality of combustion cylinders and downstream of the first compressor. Where the system includes the air intake throttle, the air intake throttle may be positioned upstream from the plurality of combustion cylinders and downstream of the first compressor. The second fuel from the secondary fuel path may be injected upstream from the intake air throttle, the charge air cooler, and the plurality of combustion cylinders; alternately, the second fuel from the secondary fuel path may be injected downstream from the intake air throttle and upstream of the charge air cooler and the plurality of combustion cylinders. The engine fueling system may further comprise a second compressor positioned downstream from the intake air throttle. Where the engine fueling system includes a second compressor, the method may further comprise the step of increasing engine speed rate time during engine startup via the second compressor. Where the engine fueling system includes a second compressor, the method may further comprise the step of decreasing load ramp rate via the second compressor. Where the engine fueling system includes a second compressor, the method may further comprise the step of adjusting operating settings of the second compressor in real time according to the requirements of the engine.
Where the fueling system includes an air intake throttle, the air intake throttle may be positioned upstream from the plurality of combustion cylinders and the first compressor. The first compressor may be an electrically powered turbocharger and may be a hybrid turbocharger. The method may comprise the step of adjusting the operating settings of the first compressor in real time according to requirements of the engine.
The engine fueling system of the method may comprise an air filter positioned upstream of the first compressor. Where the engine fueling system includes an air filter, the first fuel from the primary fuel path may be injected downstream from the air filter and upstream of the first compressor. The first fuel from the first primary fuel path and the second fuel from the secondary fuel path may be injected simultaneously. The second fuel from the secondary fuel path may have a pressure of at least 0.5 bar absolute.
In yet another illustrative embodiment of the present disclosure, an engine fueling system for an internal combustion engine is disclosed. The engine fueling system comprises: a plurality of combustion cylinders; and a mixer, a compressor, a charge air cooler, and an intake air throttle upstream from the plurality of combustion chambers; wherein the mixer, the compressor, the charge air cooler, and the intake air throttle are operably coupled to each other; wherein the compressor is an electrically powered turbocharger positioned upstream from the plurality of combustion cylinders and downstream of the intake air throttle; and wherein the electrically powered turbocharger is configured to increase engine speed ramp up during engine startup. The electrically powered turbocharger may be a hybrid turbocharger. Operating settings of the compressor may be configured to adjust in real time according to the requirements of the engine.
In yet another illustrative embodiment of the present disclosure, an engine fueling system is disclosed. The engine fueling system comprises: a plurality of combustion cylinders; a compressor upstream from the plurality of combustion cylinders; a primary fuel path in communication with a fuel supply and in selective communication with the plurality of combustion cylinders via a first valve, wherein a first fuel from the fuel supply is injected into the primary fuel path upstream from the compressor; and a secondary fuel path in communication with the fuel supply and in selective communication with the plurality of combustion cylinders via a second valve, wherein a second fuel from the fuel supply is injected into the secondary fuel path downstream from the compressor; wherein the plurality of combustion cylinders is selectively fueled by the primary fuel path, the secondary fuel path, or both; and wherein at least the first fuel or the second fuel is driven into the plurality of combustion cylinders via injection or fumigation.
The first fuel from the primary fuel path and the second fuel from the secondary fuel path may mix to form a mixed fuel. In such an embodiment, the mixed fuel may be injected into an intake manifold operably coupled to the plurality of combustion cylinders. In an embodiment with mixed fuel, the mixed fuel may by injected directly into each of the plurality of combustion cylinders via a plurality of individual injector ports, wherein each of the plurality of individual injector ports may be coupled to one of the plurality of combustion cylinders. The engine fueling system may further comprise an air intake throttle and a charge air cooler, wherein the air intake throttle and the charge air cooler are positioned upstream from the plurality of combustion cylinders and downstream of the compressor. Where the engine fueling system includes an air intake throttle and a charge air cooler, the second fuel from the secondary fuel path may be injected upstream from the intake air throttle, the charge air cooler, and the plurality of combustion cylinders; alternately, the second fuel from the secondary fuel path is injected downstream from the intake air throttle and upstream of the charge air cooler and the plurality of combustion cylinders.
The engine fueling system may further comprise an air filter positioned upstream the compressor, wherein the first fuel from the primary fuel path is injected downstream from the air filter and upstream of the compressor. The first valve and the second valve may be operated simultaneously. The second fuel from the secondary fuel path may have a pressure of at least 0.5 bar absolute.
The present disclosure provides an engine fueling system that includes multiple fueling valves such that the fuel transport delay can be reduced. The fueling system may also include an electrically driven compressor to improve engine properties during engine startup.
Referring first to
Engine 132 includes at least one combustion chamber 134 and an intake manifold 136 (as shown in at least
As shown in
Fuel (e.g., gas) flows from fuel supply 102 to engine 132. More particularly, as shown in
Primary fuel path I is configured to inject fuel upstream from compressor 114 at mixer 112 as shown in at least
Secondary fuel path II is configured to inject fuel downstream from compressor 114. As shown in
The configuration of fueling system 100 enables engine startup times of engine 132 to be greatly reduced. That is, engine speed ramp up of engine 132 to a transient state is improved. During startup of engine 132, the ECM (not shown) simultaneously opens fuel injectors or valves 108, 126 to allow fuel from primary fuel path I and secondary fuel path II to flow. Once valves 108, 126 are opened, fuel flowing through secondary fuel path II flows through mixer 128 and intake air throttle 118 and into cylinders 134 to enable engine 132 to start. During this time, when valve 108 is opened during engine startup, fuel flowing through primary fuel path I flows into mixer 112 where the fuel is mixed with air passing through air filter 110. The air fuel mixture then proceeds to compressor 114 or in some cases, through compressor bypass valve line 121 and compressor bypass valve 120. Then, the air fuel mixture flows through charge air cooler 116 and into mixer 128. At mixer 128, the air fuel mixture is mixed with fuel from secondary flow path II.
Mixer 128 is operably coupled to an ECM such that the desired air to fuel ratio can be sent to cylinders 134. When the air fuel mixture mixes with fuel from the secondary fuel path, a mixed fuel is formed and the air fuel ratio of the mixed fuel is measured via sensors (not shown) and compared to a predetermined air fuel ratio threshold stored in the ECM. Based on the comparison with the threshold, the ECM (not shown) can adjust the amount of fuel received from secondary fuel path II to maintain the desired air fuel ratio within engine fueling system 100. In an alternate embodiment, secondary fuel path IIA is employed with mixer 130 to function in the manner described above. In another alternate embodiment, secondary fuel path IIB is employed with mixer 142 to function in the manner described above.
In a further embodiment, as shown in
Advantageously, the configuration of fuel system 100 provides for a reduced engine startup time during cranking. That is, secondary fuel paths II, IIA, IIB, or IIC function to reduce the fuel transport delay, which reduces the engine startup time during cranking. For example, the present configuration provides for engine 132 to transition from 0 revolutions per minute (rpm) to 18000 rpm in 10 seconds. Additionally, a high pressure fuel source or a high pressure fuel system is not required in engine fueling system 100 due to the presence of a secondary fuel path. Pressures of the secondary fuel path II, IIA, IIB, or IIC can be at least 0.5 bar absolute because the intake throttle can be partially closed and create the necessary pressure differential to drive fuel into the intake manifold. Moreover, because the fuel supply used can be low pressure, engine fueling system 100 is of a low cost architecture as compared to port fueling or high pressure architectures, which require additional units such as a high flow injector pump.
Referring now
Downstream from throttle 218 and upstream from engine 232 is an electrically powered compressor 238. Electrically powered compressor 238 functions to assist engine 232 during engine startup and transient operation of a vehicle. During an engine start, compressor 238 boosts engine 232 from the starting speed of the vehicle to an idling state of the vehicle to provide a fast speed ramp up from 0 revolutions per minute (rpm) to an idling speed. Stated another way, compressor 238 assists engine 232 in reducing the engine speed ramp up (i.e., it will take a shorter time for the engine to ramp up from 0 rpm to 1800 rpm, for example) and the load ramp up time (e.g., from 0% to 100% load) by expediting the availability of high density air/fuel mixture (i.e., compressed mixture) in the intake manifold, which translates into high engine torque.
Furthermore, electrical compressor 238 enhances genset performance during load pickup by providing a fast engine boost build as compared to a conventional turbocharger. Moreover, the engine boost provided by electrical compressor 238 enables synchronization with an ECM (not shown) to provide dynamic real time adjustment of electrically powered compressor 238 depending on the requirements of engine 232.
In another embodiment, as shown in
While the invention has been described by reference to various specific embodiments it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described, accordingly, it is intended that the invention not be limited to the described embodiments but will have full scope defined by the language of the following claims.
This application is a national phase filing of International Application No. PCT/US2019/043248, filed Jul. 24, 2019, which claims the benefit of U.S. Provisional Application Ser. No. 62/702,738, filed on Jul. 24, 2018, and titled “TWO POINT FUEL SYSTEM FOR GAS POWER GENERATION,” the complete disclosures of which being expressly incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/US2019/043248 | 7/24/2019 | WO |
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WO2020/023639 | 1/30/2020 | WO | A |
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International Search Report and Written Opinion issued by the ISA/US, Commissioner for Patents, dated Oct. 22, 2019, for International Application No. PCT/US2019/043248; 8 pages. |
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20210215094 A1 | Jul 2021 | US |
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62702738 | Jul 2018 | US |