EGR cooling and condensate regulation system for natural gas fired co-generation unit
First Claim
1. An exhaust gas cooling and condensate regulation system for a natural gas fueled, internal combustion engine driven co-generation unit utilizing recycled exhaust gas comprising:
- (a) 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
,(b) 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.
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Abstract
A recycled exhaust gas cooling and condensate regulation system for a natural gas fired internal combustion engine driven co-generation plant, which allows efficient exhaust recycled gas combustion while maintaining lower head temperatures to reduce thermal NOx emissions and delivering increased process/utility heat to a proximate co-generation client, is provided. The recycled exhaust gas cooling and condensate regulation system has primary and secondary, air-to-gas, exchanger units, coupled in series, such that the first unit, designed to take exhaust gas exiting the engine, cools the gas to a first exhaust gas temperature effectively super saturating the water vapor in the cooled exhaust gas; and, the second unit, designed to handle lower inlet temperatures, condenses the water vapor and super cools the exhaust gas to <130 F. In one embodiment, the engine intake mixture including the exhaust gas is supercharged. In another embodiment, a separate intercooler circuit is used to cool the compressed intake charge containing the recycled gas prior to entry into the intake engine manifold to further reduce head temperatures and control thermal NOx emissions.
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Citations
18 Claims
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1. An exhaust gas cooling and condensate regulation system for a natural gas fueled, internal combustion engine driven co-generation unit utilizing recycled exhaust gas comprising:
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(a) 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
,(b) 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. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. 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:
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(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. - View Dependent Claims (9, 10, 11, 12, 13, 14)
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15. 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:
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(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. - View Dependent Claims (16, 17, 18)
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Specification