Segmented EGR Cooling System with Upstream Catalyst
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Diesel engines with high EGR cooling demands face inadequate cooling using engine coolant alone, leading to potential fouling in EGR coolers due to hydrocarbon deposition when cooled to lower temperatures, and require excessively large coolers that exceed available package space.
Innovation Solution
An EGR cooling system comprising multiple finned EGR coolers configured to cool EGR to successively lower temperatures, with a catalyst positioned upstream to remove particulate matters and hydrocarbons, and an auxiliary cooling loop using a lower temperature coolant to reduce fouling and increase heat transfer surface area without clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a standard-sized EGR cooler is used, then the EGR cooling system occupies less package space, but it cannot provide adequate cooling for high EGR cooling demands
Solution Approach 1:
The EGR cooling system is divided into multiple EGR coolers (first EGR cooler and second EGR cooler) connected in series. Each cooler handles a portion of the cooling demand, allowing the system to achieve high cooling capacity while keeping individual cooler sizes compact and suitable for engine compartment packaging.
2Temperature
If EGR is cooled to lower temperatures to meet cooling demands, then adequate cooling is achieved, but hydrocarbon deposition causes fouling in the EGR cooler
Solution Approach 1:
A catalyst is positioned upstream of the EGR coolers to pre-treat the EGR stream by oxidizing and removing hydrocarbons and particulate matters before the EGR enters the cooling sections. This preliminary action prevents hydrocarbon deposition and fouling in the EGR coolers while allowing the system to operate at lower temperatures for adequate cooling.
3Device complexity
If engine coolant alone is used for EGR cooling, then the system is simpler, but it is inadequate for high EGR cooling demands
Solution Approach 1:
The system utilizes the existing engine coolant system for the first EGR cooler, maintaining simplicity. For the second EGR cooler, an auxiliary coolant loop is introduced that can serve multiple cooling purposes in the engine compartment, making the additional cooling capacity more integrated and less complex than a completely separate system.
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 meets high EGR cooling demands without significantly increasing the EGR cooling system size, reduces fouling by removing hydrocarbons, and enhances heat dissipation while avoiding clogging, thus optimizing engine performance and packaging.
Implementation Method 1
a catalyst configured to remove particle matters and/or hydrocarbons from the EGR
Implementation Method 2
a finned EGR cooler that comprises a plurality of channels for dissipating heat in the EGR, the plurality of channels increasing heat transfer surface area
Implementation Method 3
channels for dissipating heat in the EGR
Implementation Method 4
heat transfer surface area
Implementation Method 5
EGR coolers configured to cool the EGR using a coolant
Data Source
AI summary
An EGR cooling system is provided. The EGR cooling system comprising a plurality of EGR coolers configured to cool the EGR to a plurality of successively lower temperatures, where at least one of the plurality of EGR coolers includes a finned EGR cooler that comprises a plurality of channels for dissipating heat in the EGR, the plurality of channels increasing heat transfer surface area while having sufficient fin spacing to avoid clogging. The EGR cooling system may further comprise a catalyst configured to remove particle matters and/or hydrocarbons from the EGR, the catalyst positioned upstream of at least one of the plurality of EGR coolers.