Natural Gas Reformer Controller for Lean Burn Engine NOx Reduction
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Solution Overview
Problem
Conventional fuel reformer systems for lean burn gas engines face challenges in reliably maintaining optimum hydrogen levels and air-to-fuel ratios, leading to inconsistent NOx emission reduction, which is costly and inefficient.
Innovation Solution
A reformer system with a controller that adjusts fuel and air flows using valve sets and sensors to maintain a target air-to-fuel ratio, ensuring precise control of hydrogen production and reduction of NOx emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional fuel reformer systems are implemented to reduce NOx emissions, then emissions levels are reduced, but the system complexity and cost increase due to complex networks of valves, heaters, coolers and evaporative systems
Solution Approach 1:
The patent extracts and eliminates unnecessary components from conventional reformer systems by using a simplified valve arrangement that directly controls fuel and air flows to the reformer, removing the need for complex networks of heaters, coolers, and evaporative systems while maintaining effective NOx reduction
Solution Approach 2:
The control valve in the patent performs multiple functions: it simultaneously controls fuel flow to the reformer, regulates air-to-fuel ratio, and maintains hydrogen production levels, replacing what would traditionally require multiple separate control components
2Adaptability or versatility
If conventional fuel reformer systems are implemented to enrich fuel with hydrogen, then lean burn capability is improved, but the reliability of maintaining optimum hydrogen levels deteriorates due to inability to precisely monitor and adjust air, fuel, hydrogen levels
Solution Approach 1:
The patent implements a feedback control system where the controller continuously monitors engine operating parameters and automatically adjusts the control valve to maintain optimal air-to-fuel ratio and hydrogen production levels, ensuring reliable lean burn operation across varying conditions
Solution Approach 2:
The system dynamically adjusts fuel and air flows to the reformer based on real-time engine operating conditions, allowing the reformer to adaptively maintain optimal hydrogen production levels as engine load and speed change
3Productivity
If conventional fuel reformer systems are implemented to facilitate leaner burns, then combustion efficiency is improved, but the precision of controlling air-to-fuel ratio deteriorates due to lack of accurate monitoring and adjustment mechanisms
Solution Approach 1:
The controller receives feedback on actual fuel flow and air flow to the reformer and automatically adjusts the control valve position to maintain the target air-to-fuel ratio, ensuring precise control of hydrogen production and consistent combustion efficiency
Solution Approach 2:
The patent replaces complex mechanical control networks with an electronically controlled valve system that uses sensor feedback and electronic control logic to achieve more precise air-to-fuel ratio management than mechanical systems could provide
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 provides a cost-effective and accurate method for reducing NOx emissions by closely monitoring and controlling fuel and air flows, optimizing combustion and hydrogen output in lean burn gas engines.
Implementation Method 1
a reformer device having a fuel inlet, an air inlet and a gas outlet
Implementation Method 2
a first valve set coupled to the fuel inlet and configured to selectively supply a reformer fuel flow from an engine fuel flow to the fuel inlet, a second valve set coupled to the air inlet and configured to selectively supply a reformer air flow from a compressor outlet air flow to the air inlet
Implementation Method 3
a controller in electrical communication with the first valve set and the second valve set. The controller may be configured to determine a target reformer fuel flow based on a target gas flow, determine a target reformer air flow based on the reformer fuel flow and a target air-to-fuel ratio, adjust the reformer fuel flow according to the target reformer fuel flow, and adjust the reformer air flow according to the target reformer air flow
Data Source
AI summary
A reformer system may include a reformer device having a fuel inlet, an air inlet and a gas outlet, a first valve set coupled to the fuel inlet and configured to selectively supply a reformer fuel flow from an engine fuel flow to the fuel inlet, a second valve set coupled to the air inlet and configured to selectively supply a reformer air flow from a compressor outlet air flow to the air inlet, and a controller in electrical communication with the first valve set and the second valve set. The controller may determine a target reformer fuel flow based on a target gas flow, determine a target reformer air flow based on the reformer fuel flow and a target air-to-fuel ratio, adjust the reformer fuel flow according to the target reformer fuel flow, and adjust the reformer air flow according to the target reformer air flow.