Pilot Fuel Synthesis System for Internal Combustion Engines
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Solution Overview
Problem
Existing systems for generating pilot fuel in internal combustion engines are limited by their inability to store excess dimethyl ether (DME) production, provide DME prior to startup, and meet safety requirements during methanol or DME purge processes, especially when diesel fuel is not available or desirable.
Innovation Solution
A system that converts a primary fuel, such as methanol, into pilot fuel (DME) using a dehydration reaction, with a pilot fuel system comprising a pump, reactor, condenser, separator, and accumulator, allowing for the storage and controlled production of pilot fuel, and a controller to maintain the pilot fuel level within operational ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a dehydration reactor is used to convert methanol to DME, then pilot fuel is generated, but the system cannot store excess DME production or provide DME prior to startup
Solution Approach 1:
The system pre-generates and stores pilot fuel in an accumulator before the engine needs it. The controller activates the pilot fuel system ahead of time to build up sufficient DME inventory in the accumulator, ensuring pilot fuel is available for engine startup and operation without requiring complex on-demand generation systems.
Solution Approach 2:
The primary fuel tank serves dual purposes: storing the main primary fuel (methanol) for engine combustion and serving as the feed source for pilot fuel generation. The pilot fuel pump and reactor system can operate independently to produce and store pilot fuel, making the system versatile in fuel management and eliminating the need for separate dedicated pilot fuel storage.
2Reliability
If the pilot fuel system operates continuously to maintain pilot fuel levels, then pilot fuel supply is consistent, but thermal stresses on the system increase
Solution Approach 1:
Instead of continuous operation, the pilot fuel pump and reactor operate periodically or intermittently. The controller monitors pilot fuel levels in the accumulator and activates the generation system only when levels fall below a threshold, allowing the system to maintain reliable pilot fuel supply while reducing cumulative thermal stress through rest periods.
Solution Approach 2:
The controller continuously monitors the pilot fuel level in the accumulator and uses this feedback to control the operation of the pilot fuel pump and reactor. When the level is sufficient, generation stops; when it drops below a threshold, generation resumes. This closed-loop control ensures consistent pilot fuel availability while minimizing unnecessary operation and thermal stress.
3Ease of manufacture
If methanol is used as primary fuel, then production costs are reduced, but a pilot fuel is required for ignition
Solution Approach 1:
The system generates its own pilot fuel (DME) from the primary fuel (methanol) using an onboard dehydration reactor. This self-service approach eliminates the need for external pilot fuel supplies or complex ignition systems, while maintaining the cost advantages of using methanol as the primary fuel source.
Solution Approach 2:
The system chemically transforms the primary fuel methanol into a different chemical form (dimethyl ether) through dehydration reaction. This parameter change in chemical composition enables the fuel to auto-ignite at compression temperatures, providing the necessary ignition capability without requiring external pilot fuel injection or spark ignition systems.
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 efficient and safe operation by providing a consistent supply of pilot fuel, supporting engine startup and shutdown, and managing power demand fluctuations, while reducing the number of components and thermal stresses on the pilot fuel system.
Implementation Method 1
the reactor configured to convert the primary fuel received from the pump from an alcohol to an ether, wherein a product of the reactor comprises the pilot fuel, unreacted primary fuel, and water
Implementation Method 2
a condenser that receives the product of the reactor, the condenser configured to condense the unreacted primary fuel and the water in the product received from the reactor into liquified unreacted primary fuel and water
Data Source
AI summary
An internal combustion engine system is described herein. The system uses reactor to create pilot fuel from the primary fuel to assist in the ignition of the primary fuel. A controller is used to maintain an operational range of a level of the pilot fuel in an accumulator. The accumulator acts as a buffer to allow the engine to continue to receive the pilot fuel during dynamic and changing conditions of the engine. The controller increases or decreases the rate of production of the pilot fuel by a pilot fuel system to maintain the operational range of the level of the pilot fuel in the accumulator. The controller can receive inputs such as pilot fuel level or power signals from the engine to adjust the rate of production of the pilot fuel to meet engine demand.