Condensate Injection in Reciprocating Engines for Exhaust Temperature Control
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Solution Overview
Problem
Existing reciprocating engines produce condensate as a byproduct from exhaust gas recirculation systems, which is expelled via drainage systems, necessitating a reduction in condensate output to minimize waste and protect downstream equipment from excessive temperatures.
Innovation Solution
A condensate injection system is introduced to fluidly couple with the combustion chamber and EGR system, injecting condensate during specific engine cycles to regulate temperature and reduce condensate output, utilizing a controller to manage condensate injection based on temperature thresholds and tank levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If condensate is expelled via drainage system, then condensate waste is reduced, but downstream equipment is exposed to excessive temperatures
Solution Approach 1:
The patent converts the harmful condensate byproduct into a beneficial cooling agent by injecting it into the combustion chamber, where it absorbs heat during evaporation and reduces exhaust gas temperature, thereby protecting downstream equipment while eliminating waste
Solution Approach 2:
The patent changes the physical state and temperature parameters of the condensate by injecting it into the high-temperature combustion chamber, where it undergoes phase change from liquid to vapor, absorbing heat and reducing the temperature of exhaust gases before they reach downstream components
2Temperature
If condensate is injected into combustion chamber, then exhaust gas temperature is controlled, but system complexity increases
Solution Approach 1:
The patent makes the condensate injection system multi-functional by using the same injection infrastructure for both condensate management and temperature control, allowing the system to serve multiple purposes (waste reduction, temperature regulation, emission control) without proportionally increasing complexity
Solution Approach 2:
The system uses the engine's own condensate production to fuel the injection system, eliminating the need for external water sources or additional fluid storage systems, thereby reducing overall system complexity while achieving temperature control
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
The system effectively controls exhaust gas temperature, reduces condensate waste, and protects downstream components by injecting condensate into the combustion chamber, enhancing engine efficiency and emission control.
Implementation Method 1
The injector is configured to inject condensate into the combustion chamber during a first portion of an engine cycle
Implementation Method 2
injecting condensate into the combustion chamber during a first portion of an engine cycle... effectively controls exhaust gas temperature
Implementation Method 3
The first portion of the engine cycle includes at least part of a power stroke and/or an exhaust stroke... effectively controls exhaust gas temperature
Data Source
AI summary
A system includes a condensate injection system configured to fluidly couple to a combustion chamber of a reciprocating engine and an exhaust gas recirculation (EGR) system of the reciprocating engine. The condensate injection system includes a condensate tank configured to store condensate collected from the EGR system. The condensate injection system also includes a pump fluidly coupled to the condensate tank. The condensate injection system also includes an injector fluidly coupled to the pump. The injector is configured to inject condensate into the combustion chamber during a first portion of an engine cycle of the reciprocating engine. The first portion of the engine cycle includes at least part of a power stroke and/or an exhaust stroke of the engine cycle.