Fuel Injector Premixer Distributor for Variable Wobbe Index Fuels
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Solution Overview
Problem
Combustion engines face challenges in efficiently operating on a range of fuel types with varying calorific values, often resulting in emissions issues and limited applicability due to engine design and component limitations.
Innovation Solution
A fuel injector system with a premixer and distributor that allows staged fuel delivery, featuring multiple fueling orifices and conduits, enabling seamless operation across fuels with different calorific values by adjusting fuel flow rates and delivery locations, thereby accommodating a wide range of Wobbe index fuels without significant emissions degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional fuel injection system is used, then the engine can operate on traditional fuels, but it has limited applicability and cannot efficiently operate on a range of fuel types with varying calorific values
Solution Approach 1:
The fuel injection system is segmented into multiple independent orifice sets (first, second, and third orifice sets) with different flow characteristics. Each orifice set can be selectively activated based on the fuel type being used, allowing the system to adapt to different fuel calorific values without requiring complete system redesign. This segmentation enables flexible fuel type adaptation while maintaining manageable system complexity through modular design.
Solution Approach 2:
The system incorporates variable geometry diffusers that can change their flow characteristics dynamically. The diffusers include adjustable vanes that can alter the flow angle and mixing patterns depending on operating conditions and fuel type. This dynamic adjustment capability allows the same physical structure to optimize performance across multiple fuel types, enhancing adaptability without proportionally increasing complexity.
2Productivity
If single-stage fuel delivery is used, then the injection system is simpler, but it cannot achieve optimal mixing and combustion for fuels with different calorific values
Solution Approach 1:
The system performs preliminary fuel-air mixing in the diffuser section before the fuel reaches the combustion chamber. The variable geometry diffusers pre-mix the fuel with air in controlled patterns, creating optimized mixture compositions before combustion. This preliminary action ensures that regardless of the fuel type's calorific value, the mixing process is already optimized, improving combustion efficiency without requiring complex real-time adjustments during combustion.
Solution Approach 2:
The fuel delivery system is divided into multiple staged injection paths through different orifice sets positioned at different locations and angles. This segmentation allows different proportions of fuel to be delivered through different paths, enabling precise control over fuel-air mixing ratios. The staged delivery approach optimizes combustion efficiency for various fuel types by selecting appropriate orifice combinations, while the modular segmented design keeps system complexity manageable.
3Object-generated harmful factors
If fuel injection parameters are not optimized for different fuels, then the system operation is simpler, but emissions increase and performance degrades
Solution Approach 1:
Different orifice sets are designed with locally optimized geometries and flow characteristics suited for specific fuel types. The first orifice set may be optimized for high-calorific fuels while the second and third sets are optimized for lower calorific value fuels. This local quality optimization ensures that emissions are minimized for each fuel type by using the appropriately designed orifices, while the modular local optimizations can be selectively activated based on fuel type without requiring complete system redesign.
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
Enables flexible operation on various fuels with reduced emissions and improved efficiency, allowing for smooth transitions between fuel types without compromising performance or increasing emissions, suitable for lean-burn strategies and hydrogen-rich fuels.
Implementation Method 1
The premixer has formed therein a plurality of fueling orifices positioned to deliver fuel into the plurality of flow channels
Implementation Method 2
The distributor forms a first fuel gallery fluidly connecting a first one of the plurality of fuel delivery conduits with the first and the third sets of fueling orifices
Implementation Method 3
directing the mixed air and gaseous fuel injected at the upstream, downstream and third locations through a nozzle of the fuel injector and into a combustor
Data Source
AI summary
A fuel injector for a combustion engine includes an injector head including a nozzle, a premixer, and a distributor structured to distribute a plurality of different fuels to different sets of fueling orifices in the premixer. A pilot assembly of the fuel injector is coupled to the premixer and includes a first fueling passage for a first fuel and a second fueling passage for a second fuel. Multiple sets of fueling orifices are positioned within the fuel injector, the fueling orifice sets being selectively connectable to a plurality of different fuel supplies, and both located and sized so as to accommodate a wide range of flow rates to enable a combustion engine coupled with the fuel injector to operate on fuels having a range of Wobbe numbers and compositions.