EGR cooling and condensate regulation system for natural gas fired co-generation unit

A method for super cooling and removing condensate in recycled exhaust gas in a natural gas fueled, internal combustion engine driven co-generation unit comprising the steps of:

• (a) passing exhaust gas from the exhaust ports of the internal combustion engine through a first air-to-gas cooling unit to initially cool the exhaust gas;
• and,
• (b) subsequently passing said exhaust gas exiting from said first air-to-gas cooling unit through a second air-to-gas cooling unit to super cool said exhaust gas and condense entrained water vapor;
• (c) passing said super cooled exhaust gas into the intake manifold of said engine wherein said first air-to-gas cooling unit and said second air-to-gas cooling unit operate, in cooperation, to achieve controlled exhaust gas cooling and water vapor regulation by selective condensation.

An exhaust gas cooling and condensate regulation system for a natural gas fueled, internal combustion engine driven co-generation unit having a supercharger and utilizing recycled exhaust gas comprising:

• (a) a fluid cooling system for cooling said internal combustion engine which fluidly communicates with a fluid cooled manifold to initially cool the exhaust gas exiting the engine,
• (b) a turbo intercooler unit for cooling the compressed air/recycle exhaust gas/fuel intake admixture prior to said admixture entering the engine intake manifold comprising a fluid cooled compressed air/recycle exhaust gas/fuel intake admixture radiator in liquid communication with an intercooler radiator for exhausting heat from said coolant and a circulation pump for circulating said coolant;
• (c) a first air-to-gas cooling unit for cooling the exhaust gas to be recycled, having an inlet in communication with the exhaust ports of the internal combustion engine and an outlet;
• and,
• (d) at least one second air-to-gas cooling unit for further cooling said exhaust gas and condensing entrained water vapor in said exhaust gas, having an inlet in communication with the outlet of the first air-to-gas cooling unit and an outlet in communication with the fuel inlet port of the internal combustion engine wherein said first air-to-gas cooling unit and said second air-to-gas cooling unit operate, in cooperation, to achieve controlled exhaust gas cooling and water vapor regulation by selective condensation.