Fuel Processor Reactant Control via Feed-Forward Feedback
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Solution Overview
Problem
Existing control methods for syngas generators face challenges in rapidly responding to varying load conditions and maintaining the desired oxygen-to-carbon (O/C) ratio, leading to issues like carbon formation, excessive fuel consumption, and temperature fluctuations due to slow response times and inaccuracies in reactant supply control.
Innovation Solution
A control method that determines the mass flow rate of a fuel reactant stream based on first, second, and third mass flow factors, incorporating steady-state and dynamic parameters, and process conditions, using a combined feed-forward and feedback control regime with active control of the fuel reactant and passive control of the oxidant reactant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If closed-loop feedback control is used to control fuel reactant supply, then control accuracy is improved, but response time deteriorates due to thermal mass and sensor delays
Solution Approach 1:
The patent applies feed-forward control by using modeled or pre-determined information to anticipate future reactant requirements. The controller predicts needed fuel reactant supply based on modeled syngas generator requirements or pre-determined reactant needs, allowing the system to prepare for future demands rather than merely reacting to past measurements, thus reducing response time while maintaining accuracy.
Solution Approach 2:
The patent combines feed-forward control with feedback control in a hybrid approach. The feedback component uses actual sensor measurements of syngas generator operation and reactant supply to continuously correct and refine the control actions, ensuring accuracy while the feed-forward component handles the speed requirement by anticipating needs before they occur.
2Speed
If open-loop feed-forward control is used to control fuel reactant supply, then response speed is improved, but control accuracy deteriorates due to modeling errors and unusual operating situations
Solution Approach 1:
The patent uses feedback control to correct inaccuracies in open-loop control. Sensors monitor actual syngas generator operation and reactant supply, providing real-time information to the controller to adjust fuel reactant supply, ensuring accuracy even when modeling predictions deviate from actual conditions or during unusual operating situations.
Solution Approach 2:
The patent dynamically adjusts control parameters based on actual operating conditions. The controller modifies fuel reactant supply rates in response to changing syngas generator requirements, thermal mass effects, and sensor readings, allowing the system to adapt to unusual operating situations while maintaining accuracy.
3Device complexity
If passive flow control is used for oxidant reactant supply, then system complexity is reduced, but control precision deteriorates as flow rate varies uncontrolled
Solution Approach 1:
The patent makes the previously static passive flow control dynamic by having the controller actively adjust the fuel reactant supply rate in response to changing oxidant supply conditions. This allows the system to compensate for variations in oxidant flow rate while maintaining the desired O/C ratio, effectively turning passive control into an adaptive system without adding complex active control mechanisms for the oxidant itself.
Solution Approach 2:
The controller uses feedback from sensors monitoring oxidant supply and syngas generator operation to dynamically adjust fuel reactant supply. This feedback mechanism allows the system to compensate for uncontrolled variations in oxidant flow rate, maintaining precise control of the O/C ratio while keeping the oxidant delivery system relatively simple.
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 rapid and precise control of reactant supply, maintaining the desired O/C ratio and reducing variance during steady-state and transient conditions, thereby preventing undesirable effects like carbon formation and excessive temperatures.
Implementation Method 1
A syngas generator is a device that can convert a fuel reactant and an oxidant reactant into a gas stream containing hydrogen (H2) and carbon monoxide (CO), commonly referred to as syngas.
Implementation Method 2
The reactant mass flow rates are controlled to vary the composition, for example the equivalence ratio or oxygen-to-carbon (O/C) ratio, of the reactant mixture supplied to the syngas generator.
Implementation Method 3
The O/C ratio affects various factors during the operation of the syngas generator, for example, operating temperature, carbon (soot and coke) formation and the composition of the product syngas stream.
Data Source
AI summary
The mass flow rate of a first reactant stream supplied to a fuel processor is controlled based on a combined feed-forward and feedback control regime. The method is particularly applicable for actively controlling the fuel supply to a fuel processor in a system comprising a combustion engine, in which the fuel processor is fluidly connected to receive at least a portion of an engine exhaust stream from the engine. In embodiments of the system and method, the supply of fuel is controlled based on three mass flow factors.