EGR Cooler Catalyst Layout to Prevent Hydrogen Engine Icing
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Solution Overview
Problem
Existing exhaust gas recirculation systems in hydrogen engines face issues with ice formation due to high water content, leading to operational inefficiencies and component blockages, and existing solutions like complete sealing valves or electrical heating are costly, complex, or inefficient.
Innovation Solution
A catalyst containing platinum group metals is positioned downstream of the exhaust gas recirculation cooler, catalyzing the oxidation of hydrogen to generate heat and prevent ice formation, allowing for a conventional exhaust gas recirculation valve with some leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional exhaust gas recirculation valve with leakage is used, then the system allows operation at varying temperatures and conditions, but ice formation occurs in cold ambient conditions due to water condensation
Solution Approach 1:
The invention converts the harmful effect of unburned hydrogen (which causes knocking) into a beneficial heating source. The hydrogen that would normally be wasted is catalytically oxidized in the catalyst arranged downstream of the EGR cooler, generating heat that prevents ice formation in the EGR line during cold operation.
Solution Approach 2:
A catalyst serves as an intermediary component between the EGR cooler and the environment. This catalyst facilitates the oxidation of unburned hydrogen, acting as a mediator that converts chemical energy into thermal energy to prevent ice formation without requiring direct electrical heating or complex thermal management systems.
2Object-affected harmful factors
If a completely sealing EGR valve is used to prevent leakage, then ice formation is avoided, but the valve becomes expensive and fails quickly due to contamination
Solution Approach 1:
Instead of preventing hydrogen from reaching the EGR line (which would require a sealed valve), the invention allows hydrogen to pass through and converts it into a useful heating source. The unburned hydrogen is oxidized in the catalyst, generating heat that prevents ice formation while allowing the use of a conventional, more reliable EGR valve.
3Object-affected harmful factors
If electrical heating or coolant-based heating is used to prevent ice formation, then ice prevention is achieved, but the system becomes complex and energy-intensive
Solution Approach 1:
The system uses its own unburned hydrogen fuel as the heating source. The hydrogen that would normally be wasted is catalytically oxidized to generate heat, making the system self-sufficient for ice prevention without requiring external electrical heating elements or additional coolant routing infrastructure.
Solution Approach 2:
The catalyst acts as a simple intermediary that enables the conversion of chemical energy to thermal energy. This eliminates the need for complex electrical heating systems or additional coolant management components, providing a straightforward solution to ice prevention.
4Object-generated harmful factors
If the catalyst is arranged upstream of the EGR cooler, then nitrogen oxides are reduced, but the EGR cooler and valve become contaminated and the system cannot prevent ice formation effectively
Solution Approach 1:
Instead of placing the catalyst upstream of the EGR cooler as in conventional systems, the invention inverts the arrangement by placing the catalyst downstream. This reversal allows the catalyst to serve a different function: generating heat through hydrogen oxidation to prevent ice formation, rather than focusing solely on nitrogen oxide reduction.
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
Efficiently prevents ice formation in the exhaust gas recirculation line and intake manifold without additional components, using chemical energy from fuel to maintain system functionality at low temperatures.
Implementation Method 1
a catalyst which comprises a platinum group metal (also known as platinum group metals (PGM), Pt, Ir, Os, Pd, Rh, Ru) or a combination of several platinum group metals
Implementation Method 2
catalyzing the oxidation of hydrogen to generate heat
Data Source
Figure 1
AI summary
The invention relates to an exhaust gas recirculation device for an internal combustion engine (1) with an exhaust gas recirculation line (2) comprising an exhaust gas recirculation cooler (11), an exhaust gas recirculation valve (10), and a catalyst (12). The device according to the invention is characterized in that the catalyst (12) is arranged downstream of the exhaust gas recirculation cooler in the direction of flow. A defined fuel concentration in the exhaust gas can be set via specific combustion and/or ignition control, which is then converted in the catalyst with the generation of heat.