Ion Sensor Decoking Heater for Exhaust Burners
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing exhaust aftertreatment systems for diesel engines face challenges in achieving sufficient exhaust gas temperatures for DPF regeneration and NOX reduction, particularly at low engine operating conditions, leading to inefficient operation of aftertreatment devices.
Innovation Solution
An exhaust treatment system incorporating a burner with a flame sensor assembly and control module, which includes an insulator and electric heating element, to detect contamination and maintain optimal operating conditions by heating the burner components, ensuring efficient ignition and heat transfer at low temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a burner is provided to heat the exhaust stream at low engine operating conditions, then the exhaust gas temperature is increased to facilitate DOC light-off and DPF regeneration, but the burner components are subject to contamination and fouling that reduces reliability
Solution Approach 1:
The heating element is activated before the flame sensor is exposed to combustion products, pre-heating the insulator to a temperature sufficient to burn off contamination. This preliminary action prevents fouling from accumulating on the insulator surface, maintaining sensor reliability throughout burner operation.
Solution Approach 2:
The insulator uses its own heating capability to clean itself of contamination. By heating the insulator to a sufficient temperature, combustion products and contaminants are burned off the surface, allowing the flame sensor to continue operating reliably without external cleaning mechanisms.
2Reliability
If the heating element temperature is increased to burn off contamination, then the insulator is cleaned and sensor reliability is improved, but energy consumption increases
Solution Approach 1:
The heating element operates periodically rather than continuously. It is activated at specific intervals to clean the insulator surface, then deactivated to reduce energy consumption. This periodic cleaning maintains sensor reliability while minimizing overall energy usage throughout burner operation.
Solution Approach 2:
The heating element temperature is dynamically adjusted based on the contamination level detected by the flame sensor. When contamination is detected, the heating element temperature is increased to burn off the contamination. Once cleaned, the temperature is reduced to lower energy consumption, optimizing the balance between reliability and energy use.
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 effectively increases exhaust gas temperatures, enhances the efficiency of DPF regeneration and NOX reduction, and extends the longevity of the burner by maintaining clean operation and preventing fouling.
Implementation Method 1
an electric heating element in heat transfer relation with the insulator
Implementation Method 2
raise a temperature of the heating element to a level that is sufficient to burn contamination off of the insulator
Implementation Method 3
The control module may determine whether a flame is present in a combustion chamber based on feedback from the flame sensor assembly
Data Source
AI summary
An exhaust treatment system may include a burner, a flame sensor assembly and a control module. The flame sensor assembly may be at least partially disposed within the burner and may include an insulator and an electric heating element in heat transfer relation with the insulator. The control module may be in communication with the flame sensor assembly. The control module may determine whether a flame is present in a combustion chamber based on feedback from the flame sensor assembly. The control module may detect contamination on the insulator based on feedback from the flame sensor assembly. The control module may operate the heating element in a first mode in response to detection of a contamination in which the control module causes electrical power to be applied to the heating element to raise a temperature of the heating element to burn contamination off of the insulator.