Method for operating an engine with a fuel reformer

• US 8,539,914 B2
• Filed: 04/08/2010
• Issued: 09/24/2013
• Est. Priority Date: 04/08/2010
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kerns, James Michael, Leone, Thomas G., Shelby, Michael Howard
• Primary Examiner(s): Truong, Thanh K
• Assistant Examiner(s): HOLBROOK, TEUTA BAJRAMOVIC
• Application Number:
  US12/756,858
• Publication Number:
  US 20110132306A1
• Time in Patent Office: 1,265 Days
• Field of Search: 123/549, 123/1.A, 123/3, 123/568.15, 123/682, 123/478, 123/445, 123/306, 123/575, 477/100, 701/104, 701/105, 250/343, 250/344, 250/334.12
• US Class Current: 123/3
• CPC Class Codes: F02B 43/10 Engines or plants characterised by use of other specific gases, e.g. acetylene, oxyhydrogen
• CPC Class Codes: F02B 43/12 Methods of operating
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

Methods for operating a flexible fuel engine with a fuel reformer which reforms a fuel into a gaseous fuel reformate are provided. Operating parameters of the fuel reformer and delivery of reformate to the engine are adjusted based on an alcohol content of the fuel.

Claims

1. A method for operating an engine with an alcohol reformer, comprising:

delivering a fuel comprising alcohol to the alcohol reformer;

reforming the fuel into a reformate gas including a H₂ via a catalyst in the alcohol reformer coupled to an engine exhaust passage;

delivering the reformate gas from the alcohol reformer to an engine cylinder; and

adjusting an amount of engine exhaust gas in thermal contact with the alcohol reformer based on an alcohol content of the fuel.

2. The method of claim 1, wherein adjusting the amount of engine exhaust gas in thermal contact with the alcohol reformer based on the alcohol content of the fuel includes increasing the amount of engine exhaust gas in thermal contact with the alcohol reformer with decreasing alcohol content of the fuel.

3. The method of claim 1, wherein the alcohol content of the fuel is determined based on readings from a sensor in a fuel supply line.

4. The method of claim 1, wherein the alcohol content of the fuel is determined based on readings from a sensor in an exhaust of the engine.

5. The method of claim 1, wherein the alcohol content of the fuel is estimated based on an amount of reformate output by the reformer, wherein the amount of reformate output by the reformer is determined by pressure and/or temperature changes in a reformate storage tank or reformate fuel line.

6. The method of claim 1, further comprising monitoring the reformer by comparing a first estimate of the alcohol content of the fuel with a second estimate of the alcohol content of the fuel, identifying reformer degradation based on the comparison, and reporting reformer degradation to an engine diagnostic system.

7. A method for operating an engine with an alcohol Reformer which reforms a fuel comprising alcohol into a reformate including H₂, comprising:

delivering a fuel comprising alcohol to the alcohol reformer;

activating the alcohol reformer to produce reformate gas, including H₂, from the fuel, via endothermic dehydrogenation of alcohol as it passes through a catalyst in the reformer, based on an alcohol content of the fuel;

delivering the reformate gas to a cylinder of the engine;

adjusting an operating condition of the alcohol reformer based on an alcohol content of the fuel; and

deactivating the alcohol reformer if a refueling event occurs while the engine is running.

8. The method of claim 7, wherein activating the reformer to produce reformate gas based on an alcohol content of the fuel follows a refueling event, where the refueling event includes refilling the engine with fuel, and wherein an alcohol content of the fuel varies with refilling.

9. The method of claim 7, further comprising during an engine start immediately following a refueling event, operating the engine using reformate, if available, produced during a previous engine operation.

10. The method of claim 7 wherein deactivating the alcohol reformer if a refueling event occurs while the engine is running includes diverting exhaust gas away from the alcohol reformer via a bypass conduit, and adjusting delivery of reformate gas to the engine based on the alcohol content of the fuel, including increasing a relative amount of reformate delivered to the engine when the alcohol content of the fuel is greater, and decreasing the relative amount of reformate delivered to the engine when the alcohol content of the fuel is lower.

11. The method of claim 7, wherein activating the reformer includes supplying the fuel to the reformer, and wherein adjusting the flow rate of fuel supplied to the alcohol reformer based on an alcohol content of the fuel includes increasing the flow rate of fuel supplied to the reformer with decreasing alcohol content.

12. The method of claim 7, further comprising increasing a temperature of the reformer with decreasing alcohol content of the fuel, wherein increasing the temperature of the reformer includes increasing an amount of engine exhaust gas in thermal contact with the reformer.

13. The method of claim 7, further comprising, if the reformer outputs non-reformed fuel, sending the non-reformed fuel to a fuel injection system of the engine.

14. The method of claim 7, further comprising, if the reformer outputs non-reformed fuel, sending the non-reformed fuel to a fuel tank.

15. The method of claim 7, wherein adjusting an operating condition of the alcohol reformer based on an alcohol content of the fuel includes increasing a flow rate of fuel supplied to the reformer with decreasing alcohol content of the fuel, the method further comprising adjusting delivery of reformate to the engine based on the alcohol content of the fuel, and delivering the fuel from a fuel tank to a fuel injector coupled to the cylinder of the engine.

16. A method for operating an engine, comprising;

delivering a fuel comprising alcohol to the alcohol reformer;

reforming the fuel into a reformate gas, including a H₂, when an alcohol content of the fuel is above a threshold, the reforming comprising driving an endothermic dehydrogenation of alcohol via exhaust heat as it passes through a reformer catalyst;

not reforming a fuel into a reformate gas, including H₂, when an alcohol content of the fuel is below the threshold; and

not reforming the fuel into a reformate gas, including H₂, if a refueling event occurs while the engine is running.

17. The method of claim 16, further comprising storing a portion of reformate gas in a reformate storage tank when the alcohol content of the fuel is above the threshold, and operating the engine with fuel from a fuel tank when the alcohol content is below the threshold, wherein the threshold depends on one or more properties of the reformer catalyst, the properties of the reformer catalyst including surface area and age.

18. The method of claim 17, further comprising operating the engine with reformate gas from the reformate storage tank, if available, and delivering ethanol via a fuel line to the reformer, and via a fuel injector to the engine, where the fuel injector is separate from the fuel line.

19. The method of claim 16, where not reforming the fuel into a reformate gas includes diverting exhaust gas away from the alcohol reformer via a bypass conduit.

20. The method of claim 16 further comprising, when the alcohol content of the fuel is above the threshold, adjusting the temperature of the alcohol reformer based on the alcohol content of the fuel by adjusting a temperature of fuel supplied to the reformer, where the temperature of fuel supplied to the reformer is increased by increasing power to a heater coupled to the reformer.