IMPROVED FUEL SYSTEM FOR DIESEL TYPE ENGINES USING CARBONACEOUS AQUEOUS SLURRY FUELS
20190032551 ยท 2019-01-31
Inventors
Cpc classification
Y02T10/30
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02M43/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M57/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M61/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M63/0012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M59/466
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M67/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M59/46
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M57/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M63/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B45/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02B45/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M55/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M61/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M57/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M43/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M67/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present invention provides an improved fuel injection system and related method for controlling fuel heating and circulation in diesel type engines configured to use carbonaceous aqueous slurry fuels. The fuel injection system comprises: at least one fuel injector including an injector nozzle through which fuel is atomised and a fuel injector pump for pressurising fuel for supply to the injector nozzle; and a controlled bleed valve fluidly connected to each fuel injector and positioned to allow a controlled amount of carbonaceous aqueous slurry fuel to flow from the fuel injector.
Claims
1. A fuel injection system of a diesel type engine configured to use carbonaceous aqueous slurry fuels, the fuel injection system comprising: at least one fuel injector including an injector nozzle through which fuel is atomised and a fuel injector pump for pressurising fuel for supply to the injector nozzle; and a controlled bleed valve fluidly connected to each fuel injector and positioned to allow a controlled amount of carbonaceous aqueous slurry fuel to flow from the fuel injector; wherein the controlled bleed valve comprises at least one of an electronically controlled bleed valve or a hydraulically controlled bleed valve.
2. (canceled)
3. A fuel injection system according to claim 1, wherein the controlled bleed valve is operated to allow flow from the fuel injector after the fuel injection pump draws fuel into the injector and before the fuel injector injects fuel through the injector nozzle.
4. A fuel injection system according to claim 1, wherein the controlled bleed valve is fluidly connected by the injector around or between the fuel injector pump and the injector nozzle.
5. A fuel injection system according claim 1, wherein the injector nozzle includes a flow valve for controlling flow through the injector nozzle and the controlled bleed valve is fluidly connected to the injector at or around said flow valve.
6. A fuel injection system according to claim 1, wherein the flow valve includes a valve seat, and the controlled bleed valve is fluidly connected to the injector at or around the valve seat of the flow valve.
7. A fuel injection system according to claim 1, wherein the flow valve comprises a needle valve.
8. A fuel injection system according to claim 1, wherein the controlled bleed valve is fluidly connected to the fuel injector pump.
9. A fuel injection system according to claim 8, wherein the fuel injector pump comprises a plunger pump including a cylinder and driven plunger for pumping fuel to the injector nozzle and the controlled bleed valve is fluidly connected to a pump volume in the cylinder between the plunger and a fuel inlet of the plunger pump.
10. A fuel injection system according to claim 1, wherein each controlled bleed valve is fluidly connected to a fuel recycle system.
11. A fuel injection system according to claim 10, further including a fuel delivery pump for pumping fuel to the fuel injector, and wherein the fuel recycle stream is fluidly connected between the outlet of the controlled bleed valve and an inlet of the fuel delivery pump.
12. A fuel injection system according to claim 10, further including a fuel circulation main, wherein the return from the fuel circulation main is fluidly connected to the inlet of the fuel delivery pump.
13. A fuel injection system according to claim 10, wherein the fuel recycle stream includes a connection to a waste stream into which flow can be selectively diverted to remove fluid from the fuel recycle stream.
14. (canceled)
15. A fuel injection system according to claim 1, further comprising a service tank into which fresh carbonaceous aqueous slurry fuel is feed, the service tank being fluidly connected to an inlet of the fuel delivery pump.
16-17. (canceled)
18. A fuel injection system according to claim 1, further including a fuel preconditioning system fluidly connected to the inlet of the injector system, the fuel preconditioning system including a fuel preheater for heating the fuel to a service temperature.
19-20. (canceled)
21. A fuel injection system according to claim 1, wherein the flow through the bleed valve is controlled by the flow duty of the bleed valve for a given fuel delivery pressure.
22-23. (canceled)
24. A diesel type engine configured to use carbonaceous aqueous slurry fuels comprising a fuel injection system comprising at least one fuel injector, each injector including: an injector nozzle through which fuel is atomised and a fuel injector pump for pressurising fuel for supply to the injector nozzle; and a controlled bleed valve fluidly connected to each fuel injector and positioned to allow a controlled amount of carbonaceous aqueous slurry fuel to flow from the respective injector, wherein the controlled bleed valve comprises at least one of an electronically controlled bleed valve or a hydraulically controlled bleed valve.
25. (canceled)
26. A method for controlling fuel heating and circulation in a diesel type engine using of carbonaceous aqueous slurry fuels, the diesel type engine including a fuel injection system according to claim 1, the fuel injector operating to inject fuel into a combustion chamber of the engine, the method including the steps of: operating the bleed valve to allow flow from the fuel injector between fuel injection events into the combustion chamber.
27. A method according to claim 26, wherein the controlled bleed valve is operated to allow flow from the fuel injector after the fuel injection pump draws fuel into the injector and before the fuel injector injects fuel through the injector nozzle.
28. (canceled)
29. A method according to claim 26, wherein the flow through the bleed valve is controlled by the flow duty of the bleed valve for a given fuel delivery pressure.
30. A method according to claim 26, wherein each controlled bleed valve is fluidly connected to a fuel recycle system, and during normal engine operation, the fuel recycle stream directs fuel from the bleed valves to the inlet of the fuel delivery pump.
31-36. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] The present invention will now be described with reference to the figures of the accompanying drawings, which illustrate particular preferred embodiments of the present invention, wherein:
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
DETAILED DESCRIPTION
[0062] The present invention comprises a fuel injection system and related method for controlling fuel heating and circulation in diesel type engines using carbonaceous aqueous slurry fuels.
[0063] The fuel injection system (
[0064] Without wishing to be limited to any one theory, the inventors have discovered that carbonaceous aqueous slurry fuels generally behave adversely to high shear or cavitation conditions such as experienced through pressure relief valves and throttling valves. Problems include a particle decrepitation and particle agglomeration. These effects are increase significantly with increased temperature. Agglomeration is further increased by contamination of the circulating slurry from the use of seal oil to protect fuel injector pump plungers and valve spindles. The Inventors have found that this contaminated fuel need to be used as soon as possible to reduce the tendency for agglomeration (oil causes coal in coal-water slurries and bitumen in bitumen-water slurries to agglomerate). The current art of returning the circulating flow to the service tank will therefore lead to a build-up of destabilised slurry fuel which is likely to lead to blocking of fuel strainers and solid dropout in fuel lines (particularly at fittings and sudden increase in flow area).
[0065] It should be appreciated carbonaceous aqueous slurry fuels comprise an aqueous slurry or suspension type fuel that includes carbonaceous particles suspended in an aqueous medium. The carbonaceous particles may be sourced from any suitable carbonaceous source including, but not limited to a variety of coal, chars, bitumen, charcoal, wood, various hydrocarbons, and organic matter whether biological in nature or organic compounds etc. Preferably, the carbonaceous material is coal. Any type of coal may be used, for example anthracite, bituminous coal, or a brown or lignitic coal may be used. This is particularly advantageous as coal is readily available as a carbonaceous source. It is preferred that the carbonaceous source has low ash content, preferably less than 2 wt %, more preferably less than 1 wt %, most preferably less than 0.5 wt %. An example of one suitable type of carbonaceous aqueous slurry fuels is taught in International Patent Publication No. WO2015048843A1, the contents of which again should be understood to be incorporated into this specification by this reference.
[0066] In the case where the carbonaceous particles are coal, it is preferred that the coal has undergone some form of pre-treatment. Pre-treatment may include removal of the bulk of the mineral ash contamination and in the case of the lower rank coals some form of densification and alteration of the surface properties to render the coal more hydrophobic to enable a fuel with a higher coal loading to be achieved. For example bituminous coal demineralisation can be achieved by selective agglomeration, flotation and cyclones. An example of one suitable injector nozzle, forming part of a blast atomiser type injector is taught in International Patent Publications WO2013142921A1 and WO2015048843A1 by the same applicant, the contents of which again should be understood to be incorporated into this specification by this reference.
[0067] Carbonaceous aqueous slurry fuels can be used to replace heavy fuel oil for diesel type engines, particularly for stationary electricity generation at greater than the 5 MW scale, and for large shipping. The fluid properties of coal water slurry fuels are significantly different to diesel and fuel oils, in particular the coal slurry have a much higher shear-thinning non-Newtonian viscosity, and both the coal particles and contaminant mineral particles are abrasive to low hardness steel, preventing the fuel from lubricating the fuel system. Coal water slurry fuels have been successfully demonstrated in adapted diesel type engines in a number of demonstration programsprovided hardened fuel system components were used, and the fuel had a sufficiently low viscosity.
[0068] Embodiments of the present invention can be configured to use a carbonaceous aqueous slurry fuel characterised as a type of micronized refined carbon fuel (MRC). Micronising involves fine milling a solid carbonaceous (carbon-containing) material to about 10 to 60 microns. Refining involves physically cleaning the carbonaceous material, so as to remove most of the mineral matter to produce a fuel with approximately 1 percent mineral content. The fine carbonaceous material and water are combined to produce an aqueous slurry/suspension containing 40 to 50% water.
[0069] It should be appreciated that the present invention is suitable for use in a directly injected combustion chamber of a compression ignition or diesel type engine. The particular engine may therefore comprise a conventional compression ignition or diesel type engine, or an engine improved, modified or otherwise derived from conventional compression ignition or diesel engines to operate using a fuel including carbonaceous particles suspended in an aqueous medium.
[0070] One example is a direct injection carbon engine (DICE)which is one type of a diesel type engine 112, which has been modified to enable combustion of water-based slurry of micronised refined carbon fuel (MRC) as shown in
[0071]
[0072] As previously noted, the controlled bleed valve V1 is preferably be selected to provide fast opening and closing to enable full opening and closing cycles during the period between the end of one injection event and the beginning of another, and more preferably during the period between refilling of the fuel pump and the beginning of the next injection event. It should be appreciated that controlled bleed valve V1 can comprise any suitable bleed valve. A number of valve configurations would be suitable, including both inwards and outwards opening valves, which are either directly operated using a solenoid acting to pull open a spring loaded valve spindle, or indirectly using a small high speed servo hydraulic valve which controls hydraulic oil flow to either open or close the valve via a hydraulic piston attached to the slurry valve. A number of commercial actuation equipment are available, for example Moog brand actuation equipment, but in all cases the valve switching the slurry flow should be provided with hard valve surfaces such as tungsten carbide or ceramic inserts to resist abrasion and galling by the particles in the slurry, and have provision to protect any sliding valve spindles from slurry ingress. In embodiments, this can be advantageously provided by applying a high pressure sealing fluid to the valves spindle, in a similar manner to that provided to protect the other injector components in particular the pump plunger and cut off needle, and which would therefore be advantageously facilitated by incorporating the high speed slurry valve into the same unit injector assembly. In some embodiments, the controlled bleed valve V1 comprises a Moog brand electronically controlled valve/actuator, for example 72 series servo valves, which is preferably adapted for use with a carbonaceous aqueous slurry fuel as noted above.
[0073] Referring to
[0074] The service tank 110 feeds fuel to the fuel delivery pump 120 of the fuel preconditioning circuit 114. The fuel delivery pump 120 can comprise any suitable pump including those known in the art for diesel engines, such as mechanical, hydraulic, inline, unit injectors or the like. The fuel preconditioning circuit 114 is used to condition the fuel to suitable properties (temperature, pressure, viscosity and the like) prior to being fed into the fuel injector system of the engine 112. As illustrated, the main fuel preheater 122 is located before fuel strainer 127 thereby allowing the strainer 127 to take advantage of the reduced viscosity of the preheated slurry. The fuel preheater 122 can comprise any suitable fuel preheating unit, including those known in the art for diesel engines which thermally heat the fuel to a selected temperature. Similarly, the fuel strainer 127 can comprise any suitable fuel filter or straining unit, including those known in the art for diesel engines. Fuel preheat should be varied according to the properties of the fuel and the return bleed flow to maximise the temperature of the injected fuel whilst minimising the average time that fuel is at elevated temperature. The preheater typically heats the fuel flowing therethrough to a temperature of between 50 to 150 C., preferably between 70 to 130 C. The acceptable time-temperature profile will be different for different fuels. The present invention differs considerably from current art by allowing close control of fuel delivery conditions to the engine to achieve best combustion and thermal efficiency (maximum fuel preheat) whilst substantially reducing the time-temperature at conditions that cause fuel destabilisation.
[0075] It should be appreciated that the components of the fuel preconditioning circuit 114 are well known in the art and can be selected from known components, for example as discussed in K. Nicol The direct injection carbon engine, IEA Clean Coal Centre report CCC/243, December 2014https://www.usea.org/sites/default/files/122014_The %20direct %20injection %20 carbon %20engine_ccc243.pdf, the contents of which should be understood to be incorporated into this specification by this reference.
[0076] The preconditioning circuit 114 is connected to feed stream 139 via valve V3 (
[0077] The illustrated engine 112 (
[0078]
[0079]
[0080] In each of the illustrated embodiments in
[0081] In each of the illustrated embodiments in
[0082] The controlled bleed valve can be fluidly connected to the injector at any suitable location. As shown in
[0083] In other embodiments, the controlled bleed valve V1 is fluidly connected to the fuel injector pump 154 and therefore take the bleed flow for the recycle stream 130 from the pump volume of the fuel injector pump 154.
[0084] The pressure drop of the bleed flow from the injector 150 is advantageously controlled by the pressure drop in in the conducting channels in the injector 150 both before and after the electronically controlled bleed valve V1 to reduce the shear intensity experienced by the bleed flow as compared to a similar flow passing over throttling valves.
[0085] A bleed flow of fuel from the injectors 120 in the engine 112 (see
[0086] During fuel system flushing the electronically controlled bleed valves V1 can be advantageously operated with an extended duty cycle, including continuously open, to provide rapid system flushing. To ensure complete flushing the injector can be advantageously operated for several cycles preferably at the end of the fuel system flushing period. This method will flush the injector passages below the cut of valve (i.e. needle valve) including the cut off valve seat and injector atomiser nozzles 152. During the flushing cycle, valves V2 is operated to feed flushing fluid 173 and valve V3 and/or V4 are operated to remove waste fluid from the fuel injection system 100 and the overall circuit. This allows the engine 112 and in particular the fuel injection system 100 to be regularly flushed and cleaned to remove any sludge or deposits in that system. Additionally, this provides the ability to flush the fuel system and comprising fuel injection system 100 for shut-down.
[0087] Whilst not illustrated, if a circulation main is desirable and used in the fuel injection system, the return from this main should be to the inlet of the low pressure fuel delivery pump(s) 120 and not the service tank 110. This eliminates mixing hot fuel with the cooler fuel in the service tank 110 and reduces the tendency for fuel destabilisation.
[0088] It is to be appreciated that the fuel injection system 100 and engine 112 can be used in a variety of applications, including as a stationary power generation engine, and a transportation engine, such as an engine in an ocean going vessel.
[0089] For ocean going vessels, the use of carbonaceous slurry fuels can advantageously address sulfur emissions limits for ocean vessels which in many jurisdictions have been restricted to use fuel oil on board with a sulphur content of no more than 0.5%, and in some cases of now more than 0.10%. The sulfur content of carbonaceous slurry fuels, particularly micronized refined carbon fuel (MRC) can be tailored to meet this specific sulfur content restriction. An engine such as disclosed in relation to the present invention, that uses such fuel can therefore assist in meeting these requirements.
[0090] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.
[0091] Where the terms comprise, comprises, comprised or comprising are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.