Catalytic Combustion Startup Control Using Heater-Based Fuel Injection

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Solution Overview

Problem

The existing catalytic combustion apparatus requires a longer time to activate due to fuel injection after the catalyst temperature is fully raised, leading to elongated startup times and potential catalyst deterioration from excessive raw fuel concentration.

Innovation Solution

A control method that supplies oxidant gas and injects fuel into the catalytic combustion apparatus, with the controller adjusting the fuel injection amount based on the heater's output to prevent temperature drops and optimize combustion initiation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fuel injection is delayed until the catalyst temperature is fully raised, then catalyst deterioration from excessive raw fuel concentration is prevented, but the activation time of the apparatus is elongated

Engineering Contradiction:
Improvecatalyst durabilityVSAvoidactivation time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary heating of the catalyst using an electric heater before fuel injection begins. This preliminary action raises the catalyst temperature to a safe level where fuel can be injected without causing excessive raw fuel concentration that would deteriorate the catalyst, while still allowing relatively quick activation.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The fuel injection amount is dynamically adjusted based on the real-time temperature of the catalyst. As the catalyst temperature rises during the heating phase, the system progressively increases the fuel injection amount from a low initial level, optimizing both the activation speed and catalyst protection throughout the startup process.

Inventive Principle:
Principle #15Dynamics

2Loss of time

If fuel injection starts early to reduce activation time, then the apparatus activates faster, but the catalyst may deteriorate due to excessive raw fuel concentration

Engineering Contradiction:
Improveactivation timeVSAvoidcatalyst durability
Core Design Contradiction:
Loss of timeVSReliability

Solution Approach 1:

The system continuously monitors the catalyst temperature and uses this feedback information to control the fuel injection amount. The controller adjusts the injection rate based on the measured temperature, ensuring that fuel is injected at an amount that the current catalyst temperature can handle, thus preventing catalyst deterioration while enabling early activation.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system changes the injection amount parameter dynamically during the startup process. Initially, a small injection amount is used when the catalyst temperature is low, and as the temperature increases, the injection amount parameter is increased. This parameter adaptation allows the system to achieve fast activation without exceeding the catalyst's处理能力 for raw fuel.

Inventive Principle:
Principle #35Parameter changes

3Productivity

If the injection amount is increased to speed up combustion initiation, then activation is faster, but the temperature may drop due to excessive raw fuel

Engineering Contradiction:
Improvecombustion initiation speedVSAvoidcatalyst temperature
Core Design Contradiction:
ProductivityVSTemperature

Solution Approach 1:

The injection amount is made dynamic rather than fixed. The system continuously adapts the injection rate to match the catalyst's thermal state and combustion progress. This dynamic adjustment ensures that the injection amount is increased sufficiently to maintain combustion initiation speed while never exceeding the level that would cause temperature drop from excessive raw fuel.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach allows for early activation of the catalytic combustion apparatus, reducing startup time and preventing catalyst deterioration by limiting raw fuel injection to match the heater's output, thus maintaining optimal temperature and efficiency.

Implementation Method 1

a heater (452) for heating the raw fuel supplied to the catalyst (451)

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a catalyst (451) for combusting the raw fuel

Methodology Applied
Scientific EffectCatalytic combustion: Catalysis

Data Source

PatentUS11898750B2Control method for a catalytic combustion apparatus and a catalytic combustion system
Publication Date: 2024.02.13 NISSAN MOTOR CO LTD
  • US11898750B2 patent drawing
  • US11898750B2 patent drawing
  • US11898750B2 patent drawing

AI summary

A method for controlling a catalytic combustion apparatus having a heater capable of heating fuel to be supplied to a catalyst includes a step of supplying oxidant gas to the catalytic combustion apparatus, and an injection step of injecting the fuel into the catalytic combustion apparatus. The injection step also includes an electric power feeding step of supplying electric power to the heater, and a setting step of setting an injection amount of the fuel to be injected into the catalytic combustion apparatus in response to output of the heater.