Staged Fuel Injector Premixer for Multi-Fuel Combustion
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Solution Overview
Problem
Combustion engines face challenges in efficiently operating on a range of fuel types with varying calorific values, often resulting in emissions issues and limited applicability due to engine design and component limitations.
Innovation Solution
A fuel injector system with a premixer and distributor that allows staged fuel delivery, featuring multiple fueling orifices and conduits, enabling seamless operation across fuels with different calorific values by adjusting fuel flow rates and delivery locations, minimizing emissions and preventing flashback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fuel injector design is used, then device complexity is reduced, but adaptability to different fuel types deteriorates
Solution Approach 1:
The fuel injector is divided into multiple independent orifice sets (first, second, and third sets) positioned at different locations within the premixer. Each orifice set can be selectively activated based on the specific fuel type being used, allowing the single injector design to adapt to different fuels without requiring complete redesign.
Solution Approach 2:
The fuel injector is designed with multi-functional capability to operate with various fuel types including natural gas, biogas, hydrogen, and other gaseous fuels. The distributor system enables selective activation of different orifice sets, making the single injector design universally applicable across multiple fuel types while maintaining optimized performance for each.
2Device complexity
If fuel is injected at a single location, then device complexity is reduced, but combustion efficiency and emissions performance deteriorate
Solution Approach 1:
The fuel delivery system is segmented into multiple injection locations within the premixer, with different orifice sets positioned at distinct locations. This segmentation allows staged fuel delivery where fuel is injected at multiple points along the flow path, improving mixing and combustion efficiency while maintaining a relatively simple overall device structure.
3Object-generated harmful factors
If traditional fuel injection systems are used, then emissions control is difficult, but if premixing is implemented, then emissions are reduced while device complexity increases
Solution Approach 1:
The system performs preliminary mixing of fuel and air in the premixer before combustion occurs. By pre-mixing the fuel with air in controlled proportions through the multiple orifice sets, the system achieves lean-burn conditions that reduce harmful emissions such as soot and unburned hydrocarbons, while the structured premixer design keeps the added complexity manageable.
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 operation of combustion engines on a wide range of fuels without significant emissions degradation, allowing for flexible fuel switching without downtime or performance loss, and supports lean-burn strategies.
Implementation Method 1
a premixer coupled with the nozzle... defining a plurality of flow channels each extending between an upstream end that forms an opening in the fuel injector structured to receive inflowing air into the fuel injector, and a downstream end. The premixer further has formed therein a plurality of fueling orifices positioned to deliver fuel into the plurality of flow channels
Data Source
AI summary
A fuel injector for a combustion engine includes an injector head including a nozzle, a premixer, and a distributor structured to distribute a plurality of different fuels to different sets of fueling orifices in the premixer. A pilot assembly of the fuel injector is coupled to the premixer and includes a first fueling passage for a first fuel and a second fueling passage for a second fuel. Multiple sets of fueling orifices are positioned within the fuel injector, the fueling orifice sets being selectively connectable to a plurality of different fuel supplies, and both located and sized so as to accommodate a wide range of flow rates to enable a combustion engine coupled with the fuel injector to operate on fuels having a range of Wobbe indices and compositions.