SYSTEM”

CROSS-REFERENCE TO RELATED APPLICATIONS

This Patent Application claims priority from Brazilian Patent Application No.

BR102021005846-3 filed on March 25, 2021 , the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

This invention concerns, in general, a new ethanol reforming system for generating hydrogen intended, in particular, for application in a diesel cycle engine, and also concerns a method for generating hydrogen through an ethanol reforming system applied to a diesel cycle engine.

PRIOR ART BACKGROUND

According to the prior art, there are different models of vehicles, machinery, and motorised equipment whose main power source are internal combustion engines and, in many cases, these engines are diesel engines, also known as diesel cycle engines. Usually, this type of engine is applied to vehicles and machinery that, in a certain sense, operate and work at a high frequency, due to their high cost and, at the same time, low consumption of fuel and greater engine duration.

As is generally known in the art, combustion engines emit a high concentration of carbon dioxide - C02, which is one of the main pollutants present in the atmosphere and also one of the main ones responsible for the greenhouse effect. Currently, it is well known that there is constant research into trying to control the emission of this and of other pollutants and, therefore, companies propose numerous technical solutions ranging from proposals to treat gases expelled by internal combustion engines to a potential solution for these engines with technologies that are often very complex and expensive, which impede the widespread application thereof.

In order to obtain alternative solutions for the use of internal combustion engines, and, in particular, diesel cycle ones, numerous proposals are known concerning the improvement of the catalyzers, the calibration of the combustion chambers to obtain optimised fuel combustion, as well as technological attempts that seek the combination and/or replacement of the diesel fuel with an alternative fuel, such as hydrogen. In any case, while proving themselves efficient in ecological terms, in terms of the significant reduction of polluting emissions in the atmosphere, the use of hydrogen has, in a certain sense, some risks due to the fact that vehicles and machinery still require the provision of a hydrogen-stocking tank, making the proposal dangerous if not suitably designed and developed.

According to the prior art, some solutions applied to combustion engines are also known aiming to reduce emissions through the provision of a catalytic device, known as a catalyzer, that transforms the highly polluting gases into less polluting gases. To this end, some of these models use an ethanol application so as to obtain hydrogen and a small portion of other components and thus reduce carbon dioxide - C02 - emissions in the atmosphere.

However, as can be seen, the known vehicles and machinery in the prior art that use internal combustion engines, in particular diesel cycle ones, have systems consisting of very expensive structures, both for the application of internal combustion engines and for providing effective solutions, seeking to reduce the emission of pollutants into the atmosphere. In other words, the known technologies currently available are lacking in efficient solutions that entail a system able to substantially reduce the levels of pollutant emissions in the atmosphere, in particular of carbon dioxide - C02 - and, in parallel, to obtain a configuration with low application costs as far as regards the consumption of fuel and, in addition, with suitable safety levels for use on public roads when alternative fuel sources, such as hydrogen, are used.

Therefore, these are, in general, some of the problems, drawbacks, and solutions intended to, respectively, reduce, eliminate, and provide with the development of this invention.

SUMMARY OF THE INVENTION

Therefore, in consideration of the scenario described above, this invention aims to provide a new ethanol reforming system for generating hydrogen and a method for generating hydrogen in a reforming system, which are designed to be applied, in particular, to diesel cycle engines, consisting of the technical, construction, functional, and operational features aimed at resolving the problems, limitations, and drawbacks generated by the prior art, as indicated earlier, in order to obtain, thus, solutions capable of significantly improving the levels of polluting emissions in the atmosphere, of reducing the consumption of diesel fuels, and, moreover, of providing a safe way to use hydrogen as a complementary fuel to the diesel engine.

The aforementioned aims are reached by a system and a method according to the appended set of claims. CONCISE DESCRIPTION OF THE FIGURES

The features, advantages, and technical effects of this invention, as indicated above, will be more suitably understood beginning from the following detailed description, given merely by way of example, and not limiting possible embodiments, and with reference to the schematic figures attached, wherein:

• Figure 1 shows a schematic diagram of the ethanol reforming system for generating hydrogen, according to one embodiment of this invention;

• Figure 2 shows a flow chart of the method for generating hydrogen with an ethanol reforming system, according to operational aspects of this invention.

DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

In the following description, the terms that may be used such as vehicle, machinery, or equipment should be interpreted interchangeably to indicate any type of machine that functions using an internal combustion engine, particularly a diesel cycle internal combustion engine, such as, for example: vehicles in general, work and transport vehicles, farm and construction machines, power generation and transformation equipment, or any other type of machine comprising a diesel cycle internal combustion engine enabling the application of the ethanol reforming system for generating hydrogen according to this invention.

Making reference, now, to the attached figures, the ethanol reforming system for generating hydrogen according to this invention basically consists of a diesel cycle engine 10 equipped with combustion chambers 12 connected to a diesel fuel tank (not represented in the figures), the gas outlet ducts 14 of said combustion chambers 12 comprising two segments, the first a recirculation segment 14a and the second an exhaust segment 14b. The recirculation segment 14a is connected to the air supply duct 16 of the diesel cycle engine 10 and is equipped with ethanol reforming equipment 18 consisting of a honeycomb catalytic converter 20 arranged downstream of an ethanol injector 22 that is in fluid communication with an ethanol tank 24 via ducts 24.

The ethanol reforming system for generating hydrogen also comprises an engine control unit 28, such as an electronic ignition control unit, which is connected to the lambda sensor 29 and temperature sensors 30 arranged along the exhaust segment 14b, in at least one engine speed and torque sensor 32, and in at least one ethanol level sensor 34 arranged in the ethanol tank 24, said control unit 28 being configured to receive the data from said sensors 30, 32, 34 and, based on predefined parameters, drive the ethanol supply pump 36 to inject ethanol through said ethanol injector 22 into the honeycomb catalytic converter 20, the moment in which the molecules break due to the flow of hot gases in the recirculation segment 14a and, as a result, cause the generation of hydrogen and other sub-products at a lower concentration, such as dimethyl ether.

As indicated in Figure 1 , the generated hydrogen is conducted to the combustion chambers 12 in order to replace, in part, the volume of diesel fuel that must be supplied, given that the hydrogen has a higher energy potential than diesel fuel and its energy balance enables the reduction of diesel fuel injection, obtaining the same energy and, at the same time, performing the same work with a significant reduction in C02 emissions in the atmosphere.

Preferably, the temperature parameters of the exhaust gases identified by the temperature sensors 30 arranged in the exhaust segment 14b are of the order of 450- 540C, more particularly around 500C.

More preferably, the engine speed parameters identified by the sensors 32 arranged in the diesel cycle engine 10 are of the order of 850 to 4000 rpm, more specifically around 2500 rpm, as the torque parameters of the diesel cycle engine 10 are of comprised between 250 to 450 Nm, more specifically around 350 Nm.

Advantageously, the honeycomb catalytic converter 20 arranged downstream of the ethanol injector 22 is a ceramic monolith adapted for applications in diesel cycle engines.

In addition, said ethanol tank 24 may comprise a temperature sensor 38 that is connected to a supply module 40 configured to monitor and transmit the data relating to the ethanol tank 24 to the engine control unit 28 and, in addition, drive the ethanol supply pump 36 to inject ethanol through said ethanol injector 22 into the honeycomb catalytic converter 20.

As mentioned earlier, this invention also concerns a method for generating hydrogen through an ethanol reforming system applied to a diesel cycle engine, said method essentially comprising the following steps: a) starting the diesel combustion engine; b) controlling the conditions for the work flow of the ethanol reforming system; c) controlling the temperature of the exhaust gases in the exhaust segment; d) controlling the diesel engine working conditions; e) controlling the ethanol tank conditions; once all the conditions mentioned above have been checked and confirmed to be within the predetermined parameters, an engine control unit controls the following successive steps: f) injecting ethanol in the honeycomb catalytic converter of an ethanol reformer arranged in the recirculation segment of the exhaust gases of the combustion chambers for generating hydrogen, which is directed to the engine combustion chambers; g) monitoring the working torque of the diesel cycle combustion engine for adjusting the injection of diesel fuel into the engine combustion chambers.

More specifically, according to a particular embodiment of this invention, step

(b) of the hydrogen-generating method basically consists of the following steps: b) checking that all the conditions are within the predefined parameters for the work flow of the ethanol reforming system, b1) if any of the conditions is not within the predefined parameters for the work flow, waiting and repeating step (b); b2) if all the conditions are within the predefined parameters for the work flow of the ethanol reforming system, moving on to step (c).

In addition, according to a particular embodiment of the hydrogen-generating method according to this invention, during step (c), the following steps may also be performed: c) checking that the temperature of the exhaust gases in the exhaust segment are within the predefined parameters; c1 ) if the temperature is not within the predefined parameters, waiting and repeating step (c); c2) if the temperature is within the predefined parameters, moving on to step (d).

During step (d) for checking the working conditions of the diesel cycle engine of the hydrogen-generating method according to this invention, the working speed and torque of the diesel cycle combustion engine are identified, so that: d1 ) if the working speed of the engine is not within the predefined parameters, you wait and repeat step (d); d2) if the working speed of the engine is within the predefined parameters, you proceed with the following step; d3) if the working torque of the engine is not within the predefined parameters, you wait and repeat step (d); d4) if the working torque of the engine is within the predefined parameters, you proceed with step (e).

During step (e) for checking the conditions of the ethanol tank, you check, in particular, whether the ethanol level is within the predefined parameters and, thus: e1) if the ethanol level is not within the predefined parameters, you wait and repeat step (e); e2) if the ethanol level is within the predefined parameters, you move on to step (f).

In addition, during step (g) for monitoring the working torque of the diesel cycle combustion engine, it should be checked whether the working torque has increased and, in this case: g 1 ) if the working torque of the engine has not increased, you wait and repeat step (g); g2) if the working torque of the engine has increased, you adjust the injection of diesel fuel into the combustion chambers of the engine and return to step (b).

In particolare, the exhaust gas temperature parameters identified in step (c) in the exhaust segment are of the order of 450 to 540C, more specifically around 500C.

More preferably, the engine speed parameters identified during step (d) are comprised between 850 to 4000 rpm, more specifically around 2500, as the torque parameters of the diesel cycle engine are of the order of 250 to 450 Nm, more specifically around 350 Nm.

According to the preceding, advantages of the system and method for ethanol reforming are evident.

From the foregoing, the advantages of an ethanol reforming system and method according to the invention are evident.

The ethanol reforming system for the generation of hydrogen and applied to a diesel cycle engine, according to the present invention, allows the use of hydrogen molecules as a fuel source for the engine 10, this generation and supply of hydrogen being controlled according to the demand for work, thus allowing the elimination of complementary tanks and tanks for the storage of a very large volume of hydrogen, which makes the solution much safer. Furthermore, with the system of the present invention, it is possible to significantly reduce the emission of pollutants, such as carbon dioxide - C02 and others, since the recirculation of gas takes place for a second combustion of these pollutants, as well as the reduction of diesel consumption. , which contributes to the reduction of the emission of pollutants usually emitted when using this type of fuel. Furthermore, the method of hydrogen generation through an ethanol reformer applied to a diesel cycle combustion engine, as defined by the present invention, can achieve technical, functional and operational effects on diesel fueled engines so that, by controlling the temperatures of the exhaust gas and by monitoring the conditions of the engine's operating cycle, a control unit can manage the pumping and injection of ethanol into a honeycomb catalyst arranged in the engine gas recirculation segment, so that the molecules of ethanol "break down" generating mainly hydrogen, which enters the combustion chamber of the engine and therefore, since it includes a high amount of energy compared to diesel, it becomes possible to provide an energy balance to reduce the amount of diesel injected, thus obtaining the same energy, doing the same job, but significantly reducing C02 emissions. Furthermore, as mentioned above, the present invention allows the use of hydrogen as a substitute, at least in part, of the total volume usually injected of diesel fuel, without the need for a tank or tank to contain the hydrogen, aspect which eliminates significant accident risks. The particular indicated ranges of temperature, speed and torque also allow, in particular synergy, to increase the above effects as they optimize the production of hydrogen.

Finally, it is clear that modifications and variations may be made to the reforming system and method according to the present invention, which however do not go beyond the scope of protection defined by the claims.