Fuel Vaporizing System with Catalyst and Water Injection
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Solution Overview
Problem
Existing fuel heating and vaporizing systems do not effectively reclaim water and reduce emissions from engines or generators, despite improvements in fuel efficiency and combustion completeness.
Innovation Solution
A fuel heater and vaporizing system incorporating a saddle-shaped heat exchanger thermally coupled with engine exhaust or hot components, combined with a catalyst system using dissimilar metals to create a galvanic reaction for fuel cracking, and a sustainable water injection sub-system to enhance combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fuel is preheated using engine coolant and exhaust, then fuel efficiency is improved, but emissions are not sufficiently reduced
Solution Approach 1:
The patent applies parameter changes by heating fuel to specific temperature ranges (200-400°F for diesel, 100-200°F for gasoline) and introducing water at controlled rates (5-15% of fuel flow rate). These parameter adjustments optimize combustion efficiency while reducing emissions of CO, HC, and NOx through controlled fuel vaporization and combustion temperature modulation.
Solution Approach 2:
The system uses composite approach by combining heated fuel with water injection (5-15% water-to-fuel ratio) to create a mixed combustion chamber environment. This composite fuel-water mixture enables more complete combustion and reduces harmful emissions while maintaining improved fuel efficiency.
2Reliability
If fuel heating system is added, then combustion completeness is improved, but device complexity increases
Solution Approach 1:
The system achieves multi-functionality by using the existing engine coolant and exhaust as heat sources, eliminating the need for separate heating elements. The same thermal energy that would otherwise be wasted is utilized to heat fuel and generate water vapor, reducing overall system complexity while improving combustion completeness.
Solution Approach 2:
The system employs self-service by using the engine's own operational byproducts (hot coolant and exhaust gases) to heat the fuel. This eliminates dependency on external power sources or additional complex heating mechanisms, achieving combustion improvement through the engine's self-generated thermal energy.
3Object-generated harmful factors
If water injection is increased, then emissions are reduced, but fuel consumption increases
Solution Approach 1:
The patent optimizes the water-to-fuel ratio parameter within 5-15% range to achieve emissions reduction without excessive fuel consumption increase. This controlled parameter change ensures that water vapor injection enhances combustion efficiency and reduces harmful emissions while maintaining acceptable fuel economy.
Solution Approach 2:
Water vapor acts as an oxygen carrier and oxidizing agent in the combustion chamber, promoting more complete fuel oxidation. This accelerates the combustion process, reducing emissions of incomplete combustion products (CO and HC) while the heated fuel ensures efficient energy extraction, balancing emissions reduction with fuel consumption.
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 achieves improved fuel efficiency, reduced emissions, and lower fuel consumption by preheating fuel, cracking it with metallic ions, and introducing water vapor into the engine, resulting in cleaner combustion and decreased exhaust emissions.
Implementation Method 1
a heat exchanger configured to thermally couple to the thermal source
Implementation Method 2
a heat exchanger for thermally contacting the source of heated fluid and/or engine exhaust, and/or hot engine component(s)
Implementation Method 3
a catalyst system using dissimilar metals to create a galvanic reaction for fuel cracking
Implementation Method 4
a catalyst system for receiving fuel from the heat exchanger and for cracking the heated fuel
Implementation Method 5
introducing water vapor into the engine
Data Source
AI summary
A fuel heater and vaporizing system comprising an engine; a source of fuel coupled to the engine through a fuel supply line; multiple stages of thermal sources thermally coupled to the fuel supply line between the source of fuel and the engine, wherein the multiple stages of thermal sources are configured to heat the fuel; at least one catalyst system configured to supply a source of ions and H2 coupled to the fuel supply, and a sustainable water injection sub-system coupled to the engine, the sustainable water injection sub-system configured to inject water vapor into the engine.