Turbocharged Engine Cooling System Retrofit for NOx Reduction
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Solution Overview
Problem
Existing retrofit solutions for reducing NOX emissions in turbocharged diesel-engine systems, such as those in General Electric's Dash 7 and Dash 8 locomotives, are costly and space-prohibitive, requiring new radiators, coolant tanks, and additional components, which are not suitable for these models and can reduce power at high ambient temperatures.
Innovation Solution
A method and kit for retrofitting the cooling system by reconfiguring coolant flow to direct it from one radiator to another without passing through the lubricant cooler, using a plumbing patch with control valves to manage coolant flow between radiators and the intercooler, allowing for reduced NOX emissions without replacing expensive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If separate radiators and additional cooling components are installed to reduce NOX emissions, then emissions improve, but device complexity and cost increase
Solution Approach 1:
The cooling system is segmented into two independent circuits: a primary circuit for engine cooling and a secondary circuit for charge-air intercooler cooling. This allows separate temperature control for each component, enabling reduced NOX emissions through cooler intercooler air while maintaining proper engine operating temperature, without requiring a complete system redesign
Solution Approach 2:
The existing radiator is made multi-functional by adding a secondary cooling circuit that can operate independently or in conjunction with the primary circuit. The radiator serves both engine cooling and intercooler cooling functions, eliminating the need for entirely separate cooling systems while achieving emission reduction goals
2Object-generated harmful factors
If new radiators and cooling components are installed to reduce NOX emissions, then emissions improve, but manufacturing cost increases
Solution Approach 1:
Instead of discarding the existing radiator and cooling system components, the invention recovers and retains them while adding a secondary cooling circuit. This approach reuses valuable existing components, significantly reducing retrofit costs compared to complete system replacement while still achieving the required emission reductions
Solution Approach 2:
A plate heat exchanger is introduced as an intermediary component that enables the secondary cooling circuit to function independently. This intermediary allows cool coolant to be directed to the intercooler without requiring complete system overhaul, providing a cost-effective path to emission reduction by adding rather than replacing
3Object-generated harmful factors
If additional cooling components are added to reduce NOX emissions, then emissions improve, but available space decreases
Solution Approach 1:
The secondary cooling circuit for the intercooler is merged with the existing radiator infrastructure rather than installing completely separate components. By integrating the secondary circuit into the existing system architecture and using the same radiator space, the solution achieves emission reduction without proportionally increasing space requirements
4Object-generated harmful factors
If coolant flow is redirected to reduce intercooler temperature, then NOX emissions improve, but lubricant cooler performance may deteriorate
Solution Approach 1:
The cooling system is divided into separate circuits that can operate independently. The secondary circuit draws coolant directly from the radiator to cool the intercooler, separate from the primary circuit that serves the engine and lubricant cooler. This segmentation ensures that intercooler cooling demands do not compromise lubricant cooling availability
Solution Approach 2:
The secondary cooling circuit is designed to draw pre-cooled coolant directly from the radiator before it enters the engine cooling circuit. This preliminary cooling action allows the intercooler to receive cool coolant without affecting the temperature of coolant available to the lubricant cooler, maintaining both cooling functions simultaneously
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 a 29°F reduction in manifold air temperature and a 9°F reduction in coolant setpoint for the air impellers, improving NOX emissions while maintaining engine performance and reducing costs by reusing original components and adding only inexpensive hardware and modifying control software.
Implementation Method 1
The heat may be conducted away from the one or more engines via a recirculating coolant, e.g., water, and dissipated into the ambient air via one or more radiators
Implementation Method 2
The coolant may draw heat from various engine components or systems, which include lubricant coolers, cylinder jackets, and/or charge-air intercoolers
Data Source
AI summary
A method for retrofitting a cooling system of a turbocharged engine system. The method comprises reconfiguring the cooling system so that at least some coolant flows from a first radiator to a second radiator, and from the second radiator to an inlet of an intercooler without first passing through a lubricant cooler. The method may be applied to a cooling system originally configured so that at least some of the coolant would flow through the first and second radiators in parallel, and from the first and second radiators to the lubricant cooler, before flowing to the inlet of the intercooler.