Engine-Driven Compressor DPF Regeneration via Fixed-Load Control
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Solution Overview
Problem
Existing engine-driven compressors with diesel engines face challenges in efficiently regenerating diesel particulate filters (DPFs) due to variable engine loads, leading to unstable temperatures and incomplete PM regeneration, which can cause damage to the filter elements and increased emissions.
Innovation Solution
Implementing a 'fixed-load type forced regeneration method where the engine is maintained at a predetermined rotational speed and fuel injection is adjusted to stabilize the temperature within the DPF, ensuring PM is burned at a temperature below its self-ignition point, thereby preventing damage and ensuring complete regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the engine runs under low load for a long time, then fuel consumption is reduced, but NO2 is not generated and PM cannot be burned in the DPF
Solution Approach 1:
The system performs preliminary heating of the DPF using exhaust gas heat before PM accumulation reaches critical levels. By maintaining the DPF temperature above the oxidation catalyst activation temperature during low-load operation, the system creates conditions that enable continuous PM oxidation without requiring high-load operation or additional fuel injection.
Solution Approach 2:
The system changes the temperature parameter of the DPF by controlling engine operating conditions and fuel injection timing. By adjusting the exhaust gas temperature to maintain optimal conditions for NO2 generation and PM oxidation, the system enables effective regeneration during low-load operation rather than requiring high-load conditions.
2Temperature
If the engine transits to high-load operation after PM deposition exceeds a certain amount, then exhaust gas temperature increases, but a large amount of PM starts to burn by themselves causing cracks or melts in the DPF body and filter element
Solution Approach 1:
The system continuously monitors DPF temperature and PM deposition levels, adjusting engine operating parameters and fuel injection timing based on real-time feedback. When the DPF approaches temperatures that could cause PM self-ignition, the system modulates fuel injection to control exhaust gas temperature, preventing the thermal runaway condition that would cause cracks or melts.
Solution Approach 2:
The system extracts the PM oxidation function from the high-load operation phase and separates it into a controlled process that can occur during low-load operation. By using exhaust gas heat and controlled fuel injection to generate NO2, the system performs PM oxidation without requiring the high temperatures that would cause uncontrolled self-ignition and structural damage.
3Reliability
If additional fuel is injected to increase oxidation catalyst temperature for forced regeneration, then PM is burned, but the process becomes complex and fuel consumption increases
Solution Approach 1:
The system uses the engine's own exhaust gas heat and operating conditions to perform PM oxidation in the DPF. By controlling fuel injection timing and engine load, the system enables the exhaust gas itself to provide the necessary temperature and NO2 for PM regeneration, eliminating the need for separate heating systems or complex control mechanisms.
Solution Approach 2:
The system merges the PM oxidation function with the normal engine operation process. By integrating fuel injection control with the existing engine management system, the system performs regeneration as part of normal operation rather than requiring a separate, complex regeneration mode with additional hardware.
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 reliable and stable PM regeneration, reducing the risk of filter element damage and maintaining efficient engine operation while minimizing fuel consumption and emissions.
Implementation Method 1
NO2 is generated by the action of an oxidation catalyst when heated to its activation temperature or more by the exhaust gas during operation of the engine
Implementation Method 2
the filter element is accommodated at a downstream of the oxidation catalyst... continuously burning and removing PM by means of the heat of the exhaust gas
Implementation Method 3
the NO2 can be used as an oxidizer in burning of PM so as to regenerate the filter element
Implementation Method 4
PM deposited on the filter element is forcibly burned with NO2 as an oxidizer
Data Source
AI summary
Provided is a forced-regeneration treatment method for an exhaust-gas aftertreatment device (DPF) and an associated engine-driven compressor. When the amount of particulate matter (PM) deposited in a filter element of a DPF reaches a predetermined amount and a forced-regeneration start command is input, a capacity controlling means of the engine-driven compressor is disabled to close an intake valve and to open the discharge side of a compressor main unit to atmosphere, thereby causing the compressor main unit to achieve a low-load state. The operation mode of the engine is switched to a predetermined forced-regeneration mode to operate the engine at a predetermined speed and to increase the temperature of the gas. The temperature inside the DPF is increased to reach a temperature at which an oxidative catalyst is activated and to a temperature lower than the self-combustion temperature of the PM, thereby forcibly burning the PM.