Integrated Injector Emulsification for Dynamic Diesel Emission Control
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Solution Overview
Problem
Current diesel engine technologies face challenges in achieving low NOx and soot emissions due to the nitrogen oxide-soot trade-off, requiring complex and costly exhaust gas aftertreatment systems, and existing water-diesel emulsion systems are not dynamically adaptable to varying engine operating conditions.
Innovation Solution
An integrated emulsification system within the injector that produces a homogeneous water-fuel emulsion with a variable composition, using a multi-stage emulsification process to minimize emulsion volume and adaptation time, allowing for rapid adjustment to dynamic operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-diesel emulsion is used to reduce NOx and soot emissions, then emission reduction is achieved, but the system lacks dynamic adaptability to varying engine operating conditions
Solution Approach 1:
The patent implements dynamic adaptability by enabling continuous adjustment of the water-to-fuel ratio in the emulsion based on real-time engine operating conditions. The system uses sensors to monitor parameters such as load, speed, and temperature, and dynamically modifies emulsion composition through controllable injection valves or variable geometry mixers, allowing the system to optimize emissions reduction across different operating points rather than using a fixed emulsion formulation.
Solution Approach 2:
The system changes physical and chemical parameters of the emulsion dynamically - specifically the water content percentage, droplet size distribution, and emulsion stability characteristics - by adjusting mixing ratios, injection pressures, and residence times in the mixing chamber. These parameter changes enable the emulsion to adapt its combustion properties to match varying engine demands while maintaining emissions reduction benefits.
2Object-affected harmful factors
If multi-stage emulsification process is used to produce homogeneous emulsion, then emission reduction efficiency is improved, but device complexity increases
Solution Approach 1:
The emulsification process is divided into multiple stages: pre-mixing of water and fuel at controlled ratios, high-shear mixing to create initial emulsion droplets, and a second mixing stage for homogenization and stabilization. Each stage performs a specific function - the first stage creates the basic emulsion structure, while the second stage refines droplet size distribution and ensures uniform composition. This segmentation allows complex emulsification to be achieved through a series of simpler, more manageable process steps.
Solution Approach 2:
The patent employs nested mixing chambers where smaller mixing elements are positioned within larger chambers, creating concentric zones of different shear rates and flow patterns. The inner chamber performs high-intensity mixing while the outer chamber provides gentler homogenization. This nested configuration allows multiple mixing functions to be integrated in a compact space, reducing overall device complexity while maintaining multi-stage emulsification effectiveness.
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 significantly reduces NOx and soot emissions by ensuring a homogeneous fuel distribution and efficient combustion, while minimizing the volume of emulsion in the injection system and reducing the need for complex aftertreatment systems.
Implementation Method 1
Water and fuel are emulsified to form a water-fuel emulsion by means of an emulsifying device integrated into an injector
Implementation Method 2
multi-stage emulsification process to minimize emulsion volume and adaptation time
Implementation Method 3
an injector or injection nozzle for injecting the water-fuel emulsion into an associated combustion chamber
Implementation Method 4
The resulting improved fragmentation of the injection jet into smaller fuel droplets leads to better mixing
Implementation Method 5
Diesel engine combustion is characterized by the injection of a self-igniting fuel, or diesel, under very high pressure through an injector into a combustion chamber
Implementation Method 6
This combustion phase, also known as the combustion of a 'premixed' mixture, is characterized by higher combustion temperatures due to the relatively rapid combustion reactions
Data Source
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AI summary
An emulsifying system for an internal combustion engine is proposed, wherein the emulsifying system has an emulsifying device for producing a water-fuel emulsion and an injector for injecting the water-fuel emulsion into a combustion chamber, wherein the emulsifying device is arranged within the injector. Furthermore, an emulsifying method for producing a water-fuel emulsion for an internal combustion engine is proposed, wherein fuel in a fuel accumulator and water in a water accumulator are pressurized and are supplied separately to an injector for injecting the fuel and the water into an associated combustion chamber, and/or fuel and water are emulsified by means of an emulsifying device integrated in an injector.