Catalyst placement in combustion cylinder for reduction on NOx and particulate soot
AssigneeCatalytica Energy Systems, Inc.
InventorRalph Dalla Betta
Life of this patent
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Abstract
Catalyst structure, engine, and fuel injection system are disclosed, in which a catalyst structure is positioned between a fuel injector and a combustion chamber in which most or all combustion occurs. The catalyst structure typically promotes some combustion of the fuel, reforming of fuel to generate hydrogen and other reduced species of fuel molecules, or both. The catalyst structure may instead or additionally promote evaporation of fuel droplets. Benefits include reduced emissions of pollutants.
Claims24
A fuel injection system for reducing emissions generated by combusting a fuel, said fuel injection system comprising a fuel injector and a catalyst unit for reducing emissions generated by combusting a fuel, said catalyst unit comprising a support having therethrough a plurality of through-holes formed by sidewalls of the support and a catalytically-effective amount of a catalyst on a portion of said sidewalls such that at least one catalyst-coated through-hole is adjacent at least one through-hole having no catalyst coating, said catalyst unit having a size suitable for placement in a reciprocating engine, wherein said catalyst unit
- is positioned downstream of the fuel injector a distance such that the catalyst unit receives a liquid fuel droplet and vaporizes the liquid fuel droplet at operating conditions, and
- is attached to the fuel injector.
A method of combusting a fuel mixture in a reciprocating engine having a fuel injector and a movable piston comprising:
- injecting liquid fuel onto an inlet face of a catalyst unit having channels, said catalyst unit being positioned downstream of the fuel injector between the fuel injector and the piston,
- reacting a first portion of the fuel on the catalyst unit, and
- expelling a remaining fuel portion toward the piston, wherein the act of expelling the remaining fuel portion toward the piston comprises passing said remaining fuel portion through said catalyst unit,
- wherein interior surfaces of a portion of the channels are coated with a catalyst and interior surfaces of the remaining channels are not coated with catalyst such that said interior surfaces of the catalyst-coated channels are in heat exchange relationship with said interior surfaces of the adjacent catalyst-free channels, and wherein the catalyst-coated channels are closed at the outlet face of the catalyst unit and the catalyst-free channels are open at the outlet face of the catalyst unit.
A method of combusting a fuel mixture in a reciprocating engine having a fuel injector and a movable piston comprising:
- injecting liquid fuel onto an inlet face of a catalyst unit having channels, said catalyst unit being positioned downstream of the fuel injector between the fuel injector and the piston,
- reacting a first portion of the fuel on the catalyst unit, and
- expelling a remaining fuel portion toward the piston, wherein the act of expelling the remaining fuel portion toward the piston comprises passing said remaining fuel portion through said catalyst unit,
- wherein interior surfaces of a portion of the channels are coated with a catalyst and interior surfaces of the remaining channels are not coated with catalyst such that said interior surfaces of the catalyst-coated channels are in heat exchange relationship with said interior surfaces of the adjacent catalyst-free channels, and wherein the catalyst-free channels are closed at a face of the catalyst unit and the catalyst-coated channels are open at the outlet face of the catalyst unit.
A fuel injection system for reducing emissions generated by combusting a fuel, said fuel injection system comprising a fuel injector and a catalyst unit for reducing emissions generated by combusting a fuel, said catalyst unit comprising a support having therethrough a plurality of through-holes formed by sidewalls of the support and a catalytically-effective amount of a catalyst on a portion of said sidewalls such that at least one catalyst-coated through-hole is adjacent at least one through-hole having no catalyst coating, said catalyst unit having a size suitable for placement in a reciprocating engine, wherein the catalyst-coated channels are closed at an outlet face of the catalyst unit and the catalyst-free channels are open at an outlet face of the catalyst unit, and
- wherein said catalyst unit is positioned downstream of the fuel injector a distance such that the catalyst unit receives a liquid fuel droplet and vaporizes the liquid fuel droplet at operating conditions.
A fuel injection system for reducing emissions generated by combusting a fuel, said fuel injection system comprising a fuel injector and a catalyst unit for reducing emissions generated by combusting a fuel, said catalyst unit comprising a support having therethrough a plurality of through-holes formed by sidewalls of the support and a catalytically-effective amount of a catalyst on a portion of said sidewalls such that at least one catalyst-coated through-hole is adjacent at least one through-hole having no catalyst coating, said catalyst unit having a size suitable for placement in a reciprocating engine, wherein the catalyst-free channels are closed at a face of the catalyst unit and the catalyst-coated channels are open at an outlet face of the catalyst unit, and
- wherein said catalyst unit is positioned downstream of the fuel injector a distance such that the catalyst unit receives a liquid fuel droplet and vaporizes the liquid fuel droplet at operating conditions.
Dependencies are inferred from the claim text.