Method and system for providing fuel to internal combustion engines

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US 2010/0268443A1 Oct. 21, 2010

METHOD AND SYSTEM FOR PROVIDING Upon injection in the combustion chamber in addition to the FUEL TO INTERNAL COMBUSTION hydrodynamic fuel atomisation a violent degassing takes ENGINES place providing continuous chainbreaking of fuel microdrop let to a fine “nano' sizes. The combination of the gas desorp

FIELD OF INVENTION tion from the fuel solution with the hydrodynamic breaking 0001. The present invention relates to liquid fuel combus up of the injected fuel provides a fundamentally new process tion and, more particularly, to the preparation of liquid fuels of the fuel atomization in the combustion chamber, the fuel to combustion in a combustion chamber of internal combus microdroplets continuously break up to significantly small tion engines. sizes providing an extremely high interfacial curvature and liquid vapour (fuel) pressure increases in as much as 8-10

THE BACKGROUND OF THE INVENTION times. This effect is described by the Kelvin equation and it is 0002. In existing internal combustion engines such as die well known that the quicker liquid fuel evaporates the more sel and gasoline engines, as well as other types of engines a rapid and effective the combustion of the gasoline or diesel is. fuel is injected into a combustion chamber at high pressure. A One more important additional effect of the new injection charge of the fuel is injected by means of Solenoid injectors process: the continuous chain breaking of the fuel droplets controlled by an on-board microcomputer and connected to a caused by the gas desorption prevents coalescence of the common rail. The on-board microcomputer controls injection droplets and formation of the fuel film on the walls of the combustion chamber. As a result more fuel Surface is avail timing and duration as well as an injection pressure by means able for contact with the air. Thus the fuel burns faster and of a two-stage main fuel pump. To provide a better fuel more complete giving less harmful emissions. atomization after injection into combustion chamber the fuel pressure in the common rail upstream the injectors is main 0007 Taking into account this and other objects a method tained at high level, e.g., in diesel engines the fuel pressure is of fuel activation and Supplying into the combustion process maintained at 2000. . . 2400 bars. is presented. The method comprises steps of 0003 Currently different approaches are used to improve 0008 a) Dissolving a gas/mix of gasses in the fuel the fuel atomization and dispersion in the combustion cham thereby transferring the liquid fuel into a state of unsat ber after injection. For example, they use joint injection of urated “fuel/gas' solution without any free gas phase; hydrogen or natural gas with gasoline, in other system a the fuel is dispersed in the absorber to increase the con compressed air stream is directed to the fuel spray injected in tact surface with the gas Supplied to the absorber at high the combustion chamber. There is also an approach where pressure of up to 100 bar; the process is performed, fuel and air are induced with the same charge to reduce a preferably, at lower temperatures, and gas used for dis coalescence of the fuel microdroplets after the injection. Solution can be a mixture of for example, exhaust gases 0004. There are known attempts to disperse fuel by dis and oxygen enriched air having O content of up to 35% Solving some gas, e.g., air or carbon dioxide, in the liquid fuel and fuel/mixture of gases ratio by weight of 1:0.055. The and Subsequently injecting this solution into the combustion purpose of using the mixture with increased oxygen chamber. When injected into the combustion chamber the content is to increase the local concentration of the oxi dissolved gas is released from the Solution providing very fine dant during gas desorption. The presence of locally dispersion of the liquid fuel. In U.S. Pat. No. 6,273,072 available oxidant helps more quicker fuel ignition. (Knapstein et all) and U.S. Pat. No. 701 1,048 (Gurinet all) 0009 b) Activating “fuel/gas' solution by changing the they described methods and devices for implementation and state of the “fuel/gas' solution for a short period of time utilization of the abovementioned effect. The described sys to a boundary state of oversaturated solution in Such way tems require special devices that Supposed to work within a as to minimize or exclude free gas bubbles flashing out certain range of parameters and at the same time certain of the fuel solution flow at the inlet of the main fuel pump conditions should be observed to provide the fuel/gas solution by lowing the pressure of the fuel solution flow or by to the combustion chamber in proper condition. In practice it ultrasound treatment in a hermetic vessel comprising a is difficult to satisfy both of these requirements simulta vibrating element that by ultrafast oscillations forms neously, and the achieved effect is not stable at various loads. partial pressure decrease of the fuel Solution flowing through the vessel.

SUMMARY OF THE INVENTION

0.010 c) Merging the recirculation fuel solution flows 0005. An object of this invention is to provide a method pumped out after the injection from common rail and and apparatus which overcomes the abovementioned disad main fuel pump, cooling down the fuel solution to 50° C. vantages and which provides for further improvement in the and guiding it to the absorber to separate free gas/fuel fuel injection into the combustion chamber that reduces fuel vapor phase.

consumption as well as emissions. 0.011 d) In the fuel system with single stage main fuel 0006. In accordance with invention there are provided pump and distributed injection pumps the return flow is technical solutions for different types of fuel systems. The cooled, separated from free gas/fuel vapor phase and fuel is preparing for injection and combustion in a special guided to the inlet of the main fuel pump. Some fuel after device, an absorber, where the fuel is contacting with the gas the main fuel pump is guided to a nozzle of a jet pump or gasses. The gas pressure inside the absorber is maintained which is used to pump out free gas/fuel vaporphase from higher than the fuel pressure Supplied to the absorber; the gas a gas separator and the mix flow than is fed to the is dissolved in the liquid fuel forming a unsaturated fuel absorber to separated liquid and gas phases. This helps Solution having no free gas phase. The resulted fuel Solution to avoid appearing gas or vapor bubbles that may create is guided to a main fuel pump that further increases the pressure pulses at the outlet of the main fuel pump and pressure of the fuel Solution providing no free gas phase. affect the operation of the fuel injectors.

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0012 e) Preparing the gas mixture to be used for disso jet pump 15. Three-way valves 14 and 16 are used to change lution in the fuel by cooling and compressing the exhaust from standard (base) fuel Supply system to the conditioning gases and mixing it with oxygen enriched airformed by subsystem and vice versa. Check valves 18, 19 prevent fuel to filtering compressed air through a special membrane flow in wrong direction.

filter; prepared gas mixture is guided to the absorber for 0026. The gas preparation Subsystem comprises a reactor dissolving in the liquid fuel. 13 and two air and exhaust gases Supply lines. Air Supply line 0013 With this and other objects in view there is provided, includes a filter 28, a compressor 29, a pressure regulator 30, in accordance with the invention, a system for liquid fuel and an oxygen enrichment membrane filter 31 whereas activation and feeding it to the combustion chamber for com exhaust gases line includes a filter 22, a cooler 23, a compres bustion, comprising:

0014) a) an absorber for fuel conditioning, having a Sor 24 and a pressure regulator 25.

liquid inlet port for providing a fresh liquid fuel from a 0027. The gas mixture is prepared in the reactor 13 by fuel tank, a gas inlet port for providing gas or gas mix mixing the exhaust gases as sources of CO with oxygen ture, an inlet port for providing returned fuel flows from enriched air that is formed after ambient air passes through an engine common rail and main fuel pump, and an the oxygen enrichment membrane filter 31. Mixing of two gas outlet port for Supplying a fuel solution from the streams in equal portions by weight is provided by pressure absorber to an engine; regulators 25 and 30 having common control line. Required 0015 b) a fuel solution activator for momentary trans pressure of the gas mixture is provided by compressors 24 and ferring the fuel solution to a state of oversaturated solu 29 and controlled by the pressure regulators 25 and 30. tion thereby preparing the fuel Solution to a burst gas (0028. The fuel from fuel tank 17 is delivered by feeding desorption at injection into the combustion chamber; pump 11 to the nozzles mounted in the absorber 10. The 0016 c) a fuel supply subsystem for supplying the fresh feeding pump 11 provides the fuel pressure P. The gas mix liquid fuel to the absorber with maintaining fuel level ture from the reactor 13 is guided to the gas inlet port of the inside the absorber between min and max limits: absorber 10 under gas pressure P, which is controlled by 0017 d) a subsystem for collecting returned flows from pressure regulator 17. Pressure regulator 32 maintains the gas the engine and main fuel pump, separating free gas/fuel pressure inside the absorber 10 at set level P. The gas pres vapour, cooling down to 50° C. and guiding the returned sure P is set up lower than the fuel pressure P providing flows to the inlet port of the main fuel pump; satisfactory working condition for the fuel dispersing by the (0018 e) a control system for controlling the fuel supply nozzle in absorber 10. The dispersing of fuel in gas results in and engine operation. achieving significant amount of gas being dissolved in fuel. 0019. The system and method of operation of the inven An outlet port located at the bottom of the absorber 10 is tion with additional objects and advantages thereof will be fluidically connected to the inlet port of the main fuel pump 2. best understood from the following description of specific The differential pressure regulator 12 positioned in the con embodiments when read in connection with the accompany nection line between the absorber 10 and main fuel pump 2 ing drawings. temporary reduces the fuel solution pressure. The reduced

BRIEF DESCRIPTION OF THE DRAWINGS

pressure transfers the fuel solution into the state of oversatu rated solution thus facilitates the gas desorption from the fuel 0020 FIG. 1 shows one of the possible embodiments of by destroying temporary sorption links between liquid and the invention for internal combustion engines having com gas molecules. This step improves effectiveness of the des mon rail injection system. orption process at injection and improves the atomization of 0021 FIG. 2 shows another one possible embodiment of the injected fuel charge. In addition the differential pressure the invention for internal combustion engines having com regulator 12 compensates for pressure pikes arisen during the mon rail injection system. absorber 10 operation. Main fuel pump 2 again increases the 0022 FIG. 3 shows one of the possible embodiments of pressure of the fuel Solution as much as 2 times and returns the the invention for diesel engines having fuel Supply system fuel Solution in the state of unsaturated Solution. In Such state with fuel distribution pump. the main fuel pump 2 delivers the fuel solution to the common rail 1 and unit injectors (not shown) for combustion.

DETAILED DESCRIPTION OF THE DRAWINGS 0029. It is well known that the gas solubility in liquid is proportional to the partial pressure of the gas over the liquid 0023 FIG. 1 of the drawing shows one of the possible Surface and the concentration of the gas dissolved in liquid is embodiments of the system for an internal combustion engine in inverse proportion to the liquid temperature. As fuel solu having common rail injection system. The internal combus tion parameters in Supply line is maintained higher than tion engine can be a standard diesel or gasoline engine. The parameters in the combustion chamberatinjection in addition engine comprises a common rail injection system 1, a two to hydrodynamic breaking of fuel stream by injector the gas stage main fuel pump 2, a fuel tank 3, a primary fuel filter 4, dissolved in the fuel solution violently escapes from the liquid a fine fuel filter 5. The common rail injection subsystem thus providing additional atomization of the fuel to more comprises unit injectors (not shown) for injecting fuel charge finest aerosol as well as even distribution over the volume of into a cylinder combustion chambers and fluidically con the combustion chamber. The faster evaporation on superfine nected with the outlet ports of the common rail. fuel microdroplets at high temperature present in the com 0024. The activation system according to the present bustion chamber provides speedy propagation of the flame invention consists of two Subsystems: a conditioning Sub front. This way faster and more efficiently burnt fuel delivers system and a gas preparation Subsystem. more energy at optimal piston and crankshaft position. As a 0025. The conditioning subsystem comprises an absorber result it takes less fuel to produce the same amount of power, 10, a feeding pump 11, a differential pressure regulator 12, a as well as provides reduction of emissions.

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0030 Since the main fuel pump 2 delivers more fuel than state of the abovementioned “liquid fuel/gas' solution to the internal combustion engine can consume to produce use aboundary state of oversaturated Solution in Such way as ful power recirculation lines are provided for returning excess to minimize free gas bubbles flashing out of the fuel fuel. Recirculation fuel solution flows from first stage of the solution flow at the inlet of the main fuel pump. main fuel pump 2 and from the common rail 1 are merged in 2. A method for providing fuel to internal combustion the jet pump 15: recirculation fuel solution flow from com engines according to claim 1, wherein the step of gas dissolv mon rail having higher pressure is guided to the nozzle of the ing in the liquid fuel flow and transferring liquid fuel to the jet pump 15; the ejected flow creates low pressure in the “fuel/gas' unsaturated Solution is performed at high gas pres mixing chamber and recirculation flow from first stage of the Sure, and highly developed contact Surface between liquid main fuel pump 2 is sucked into the mixing chamber of the jet and gaseous phases, and, preferably, at lower temperatures. pump thus providing lowerpressure at the drainage port of the 3. A method for providing fuel to internal combustion main fuel pump and better conditions for gas separation. engines according to claim 1, wherein the first step of liquid 0031 three-way valve 14 and 16 are used to switch fuel activation transfer to the state of “fuel/gas'unsaturated between conditioned mode and base mode of engine Solution is performed in a special device, an absorber, with operation. In conditioned mode operation the mixed feeding it with liquid fuel and a mixture of gasses Such as recirculation fuel solution flow from jet pump 15 is exhaust gasses and oxygen-enriched air having partial pres guided to the recirculation inlet of the absorber. In base sure of oxygen up to 35%, and “fuel/gasses' ratio by weight mode both valve are set to initial position and recircula of preferably, 1:0.055, based on carbon dioxide and oxygen tion flow from jet pump is guided to the fuel tank 3. enriched air content, and gas mixture pressure up to 100 bar. 0032. In another embodiment (FIG. 2) a gas separator can 4. A method for providing fuel to internal combustion be provided in recirculation line for removing free gas/fuel engines according to claim3, wherein at the second step of the vapour phase from recirculation fuel solution flow. The recir fuel flow activation the state of “fuel/gas’ fuel solution is culation flow is cooled, preferably, to 50° C. in a cooler 6 and changed for a short period of time to the boundary state of then guided to the gas separator 7. The liquid fuel solution oversaturated solution, preferably, before the fuel solution from gas separator is fed to the inlet of main fuel pump 2 and enters an inlet port of the first-stage of the main fuel pump, separated free gas/fuel vapour is guided to the gas port of the e.g., by decreasing liquid fuel flow pressure. absorber 10 using a low pressure compressor 8. 5. A method for providing fuel to internal combustion 0033 FIG.3 shows a preferred embodiment for an internal engines according to claim 4, wherein the step of changing combustion engine having one-stage main fuel pump 2 and the state of “fuel/gas” fuel solution to the boundary state of distributed unit injectors 1. In conditioned mode operation the oversaturated solution before the main fuel pump is per recirculation flow from unit injectors 1 contains high concen formed by a high-frequency ultrasound treatment of the fuel tration of dissolved gasses so it guided back to the inlet of the Solution flow in a hermetical vessel that comprises a special main fuel pump. But passing through a cylinder head it con vibrating element having high-frequency oscillations and tains some free gas/fuel vapor that should be separated from forming local pressure reliefs thus destroying at least partially the recirculation flow as it may damage the unit injectors. The Sorption links between liquid fuel and gas molecules. recirculation flow is cooled preferably to 50° C. in a cooler 18 6. A method for providing fuel to internal combustion and free gas/fuel vapor is separated in a gas separator 19. Ajet engines according to claim 4, wherein return lines are pro pump 15 is used to remove separated free gas/fuel vapor from vided to recycle unused fuel from the main fuel pump and the gas separator 19. To provide operation of the jet pump 15 common rail after injection; both return flows are merged, and Some fuel after the main fuel pump 2 is guided to the nozzle common return flow is guided for separating free gas phase of the jet pump 15 and the low pressure created by the ejected and fuel vapour phase from the liquid fuel flow; the liquid fuel flow sucks the separated free gas/fuel vapor. The mixed flow flow is then cooled down, preferably, below 50° C. and guided from jet pump is guided to the absorber 10. To keep the to the “fuel/gas' oversaturated fuel solution supply line con pressure at the inlet of unit injectors 1 at required level the nected to the inlet port of the main fuel pump. pressure regulator 36 is used. 7. A method for providing fuel to internal combustion lines 0034) To shut the engine out or at idle operation the fuel having fuel distribution pump according to claim 6, wherein Supply should be switched to the base mode using three-way the separated gaseous and vapour flow is guided from the fuel valves 14 and 16 and shutting out the fuel supply to the separator to the absorber using a liquid-jet pump. The return absorber 10.

0035. Before parking the vehicle for a long period of time fuel solution flow from the mail fuel pump is guided to the jet pump nozzle.

the cylinder head and the fuel supply should be flushed from 8. A method for providing fuel to internal combustion conditioned fuel by operating the engine on the base uncon engines according to claim 6, wherein a jet pump is provided ditioned fuel for about 30-90 seconds.

0036. The present invention is not to be construed as lim for merging and guiding the return flows to the absorber, the ited to the forms shown which are to be considered illustrative return flow under high pressure from the common rail is rather than restrictive. guided to a nozzle of the jet pump whereas the return flow with lower pressure after the first stage of the main fuel pump 1. A method for providing liquid fuel to internal combus is Sucked in a mixing chamber of the jet pump thus increasing tion engines including additional steps of a fuel activation the pressure for Supplying the merged fuel solution flow to the prior to injection and combustion in a combustion chamber; absorber and decreasing the backpressure to remove drainage the steps comprising: before the second stage of the main fuel pump. (a) dissolving a gas/gasses in the fuel thus transfer the 9. A method for providing fuel to internal combustion liquid fuel flow into a state of unsaturated fuel solution engines according to claim3, wherein the gaseous mixture is without any free gas phase; providing the “liquid fuel/ formed in a hermetical vessel by compressing and cooling the gas' solution to a main fuel pump, and (b) changing the exhaust gases and simultaneously compressing the air and

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guided it to a membrane filter providing the oxygen enriched prising a Subsystem for collecting and separating free gas/fuel air; the pressure of the gasses inside the vessel is maintained vapour from return flows from the engine and main fuel by a pressure sensor having two set pressure limits: when the pump.

pressure decreases to a lower pressure limit the compressors 14. A system for feeding an internal combustion engine are Switched on, and when the pressure raises to an upper with a conditioned fuel according to claim 10, further com pressure limit the compressors are switched off differential prising a subsystem for controlling the fuel Supply and engine pressure regulators for both gas flows have common control operation, the Subsystem provides three operational modes: base line providing optimal Supply and mixing of gaseous components. (a) a mode of base unconditioned fuel Supply at cold start and 10. A system for feeding an internal combustion engine idling; (b) a mode of conditioned fuel Supply at normal engine with a conditioned fuel, comprising an absorber having a operation under load; (c) a mode of fuel Supply for system liquid inlet port for providing a fresh liquid fuel from a fuel purge with base unconditioned fuel at “hot” shut-down for tank, a gas inlet port for providing gas orgas mixture, an inlet long-term storage, where the conditioned fuel Supply is shut port for providing returned fuel flows from an engine com off and base unconditioned fuel is guided to fuel supply line mon rail and main fuel pump, and an outlet port for Supplying connected to the outlet port of the absorber, the gas pressure a fuel Solution from the absorber to an engine. in the absorber is decreased to the atmospheric pressure by 11. A system for feeding an internal combustion engine connected it to the fuel tank with a vent line, the engine is with a conditioned fuel according to claim 10, further com working in this mode for a short period of time, preferably, prising a fuel Solution activator for momentary transferring less than 1.5 minutes.

the “fuel/gas' solution to a state of oversaturated solution 15. A system for feeding an internal combustion engine thereby preparing the "fuel/gas' solution to a burst gas des with a conditioned fuel according to claim 10, further com orption at injection into the combustion chamber. prising a fuel distribution pump wherein in case of the con 12. A system for feeding an internal combustion engine ditioned fuel the return flows from injectors and the fuel with a conditioned fuel according to claim 10, further com distribution pump are guided to the absorber by an additional prising a fuel Supply Subsystem for Supplying the fuel to the pump to reduce the pressure at drainage of the first stage of the absorber with maintaining fuel level inside the absorber main fuel pump, and in case of the base unconditioned fuel between min and max limits. the return flows are guided to the fuel tank. 13. A system for feeding an internal combustion engine

with a conditioned fuel according to claim 10, further com