System and methods for engine air path condensation management

A method for an engine system having an engine air intake system and a light off catalyst coupled to an engine exhaust, comprising:

• compressing air in a compressor driven by a turbo coupled to the engine exhaust upstream of the catalyst;
• forcing said compressed air through a heat exchanger into the engine air intake system;
• collecting condensate formed by the heat exchanger in a reservoir connected to said heat exchanger;
• when the engine is operating at a high load and engine oil is not present in said condensate, routing said condensate into the engine exhaust upstream of the catalyst and downstream of the turbo;
• when the engine is operating at a high load and engine oil is present in said condensate, routing said condensate into a position in the air intake system;
• and
• when the engine is operating at a low or moderate load, routing said condensate to either the intake system or to the engine exhaust downstream of the catalyst.

An engine system having an engine air intake, and a light off catalyst coupled to an engine exhaust, comprising:

• a turbocharger having a compressor driven by a turbo coupled to the engine exhaust upstream of the catalyst;
• a heat exchanger having an input coupled to said compressor and an outlet coupled to the air intake system;
• a reservoir coupled to a bottom of said heat exchanger to collect condensate formed by the heat exchanger;
• at least one sensor to detect a presence of engine oil and a presence of engine coolant in said condensate;
• a first metering valve coupled between said reservoir and the air intake system;
• a second metering valve coupled between said reservoir and the engine exhaust upstream of the catalyst and downstream of said turbo;
• a third metering valve coupled between said reservoir and the engine exhaust downstream of the catalyst;
• and
• a controller to control said first, second and third metering valves based upon said detection of engine oil or absence of said engine oil, to route said condensate as follows:
• activating said first metering valve when the engine is operating at a high load and said contaminate detection indicates engine oil is present;
• and
• activating said second metering valve when the engine is operating at a high load and said contaminate detection indicates engine oil is not present.