Exhaust Condensate Vaporization for EGR Cooling
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Solution Overview
Problem
Existing exhaust gas recirculation systems in internal combustion engines face challenges in cooling and disposing of condensate generated during the cooling process, which can lead to inefficiencies and difficulties in managing exhaust emissions.
Innovation Solution
A method and system that divert exhaust gas for recirculation, cool it, collect condensate, and vaporize it using a heat exchanger's heat exchange surfaces, allowing the vaporized condensate to be reintegrated into the exhaust system, thereby eliminating the need for condensate storage and disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If exhaust gas is cooled for recirculation, then combustion temperature control is improved, but condensate disposal becomes difficult
Solution Approach 1:
The patent converts the harmful condensate byproduct of exhaust cooling into a useful cooling resource. Condensate collected from the exhaust system is sprayed onto the outer peripheral face of the exhaust cooler, where it absorbs heat from the cooler surface and evaporates, providing additional cooling capacity and eliminating the disposal problem.
Solution Approach 2:
The exhaust cooling system serves itself by using its own condensate output as the cooling medium. The condensate generated during exhaust cooling is redirected back to cool the exhaust cooler, creating a self-sustaining cycle where the system's byproduct becomes its own cooling resource, eliminating external disposal requirements.
2Temperature
If a large exhaust cooler with high coolant flow is used, then exhaust cooling capacity is improved, but system complexity and energy consumption increase
Solution Approach 1:
The condensate serves multiple functions: it is first collected as a byproduct of exhaust cooling, then reused as a cooling medium on the exhaust cooler surface. This multi-functional use of condensate enhances cooling capacity without requiring additional cooling systems or increasing overall system complexity.
Solution Approach 2:
The system utilizes the phase transition of condensate from liquid to vapor as it evaporates on the exhaust cooler surface. This phase change absorbs significant latent heat, providing efficient cooling capacity enhancement without requiring proportionally larger cooling equipment or higher coolant flows.
3Use of energy by moving object
If condensate is sprayed onto exhaust cooler, then cooling efficiency is improved, but condensate management complexity increases
Solution Approach 1:
The patent introduces a condensate circulation system that acts as an intermediary between the exhaust cooling process and the condensate disposal problem. Condensate is collected, pumped, and sprayed onto the exhaust cooler, serving as a heat transfer medium that improves cooling efficiency while managing condensate disposal through a controlled circulation pathway.
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 enhances exhaust gas recirculation efficiency by effectively managing condensate, reducing the burden on cooling systems, and improving exhaust treatment by reintegrating vaporized condensate into the exhaust stream, thus optimizing engine performance and emissions control.
Implementation Method 1
vaporizing the collected condensate sprayed onto the heat exchange surface based on an exchange of heat between the collected condensate and diverted exhaust conveyed through the heat exchanger
Implementation Method 2
Cooling exhaust for recirculation can result in condensation of water from exhaust in the exhaust system
Data Source
AI summary
An exhaust system for an internal combustion engine includes an EGR cooler having a heat exchange surface exposed to a flow of exhaust, and a second heat exchange surface. A coolant heat exchanger is fluidly connected to a coolant outlet of the EGR cooler and a coolant pump is fluidly connected to a coolant inlet of the EGR cooler. A condensate collector collects condensate from exhaust, and a condensate pump pumps condensate from the condensate collector to a sprayer to spray condensate onto the second heat exchange surface to vaporize the condensate for discharging out through an outgoing exhaust conduit of the exhaust system.