WO2015034448A1 - A combustion system with a heat recovery unit - Google Patents

A combustion system with a heat recovery unit Download PDF

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Publication number
WO2015034448A1
WO2015034448A1 PCT/TR2014/000311 TR2014000311W WO2015034448A1 WO 2015034448 A1 WO2015034448 A1 WO 2015034448A1 TR 2014000311 W TR2014000311 W TR 2014000311W WO 2015034448 A1 WO2015034448 A1 WO 2015034448A1
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WO
WIPO (PCT)
Prior art keywords
heat recovery
recovery unit
combustion system
exhaust gas
cylinder block
Prior art date
Application number
PCT/TR2014/000311
Other languages
French (fr)
Inventor
Ergun Guraslan
Kayhan OZDEMIR
Deniz Seker
Original Assignee
Ford Otomotiv Sanayi Anonim Sirketi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ford Otomotiv Sanayi Anonim Sirketi filed Critical Ford Otomotiv Sanayi Anonim Sirketi
Publication of WO2015034448A1 publication Critical patent/WO2015034448A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00—Casings, e.g. crankcases or frames
    • F02F7/0085—Materials for constructing engines or their parts
    • F02F7/0087—Ceramic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/08—Cooling; Heating; Heat-insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
    • F02G5/00—Profiting from waste heat of combustion engines, not otherwise provided for
    • F02G5/02—Profiting from waste heat of exhaust gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F01D9/026—Scrolls for radial machines or engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N5/00—Exhaust or silencing apparatus combined or associated with devices profiting by exhaust energy
    • F01N5/02—Exhaust or silencing apparatus combined or associated with devices profiting by exhaust energy the devices using heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/40—Application in turbochargers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • F05D2300/2112—Aluminium oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • F05D2300/2118—Zirconium oxides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates a combustion system with a heat recovery unit which enables gas entrance at a higher temperature to the heat recovery unit by increasing the combustion temperature in the engine and thus decreases the fuel consumption.
  • Cid Patent Document no CN102777247 an application known in the state of the art, discloses an engine which stores heat and which is formed by remolding the conventional engine.
  • Compressed air compressed by an air compressor enters a compressed air storage tank by a check valve.
  • An electric heater is installed in the compressed air storage tank, and an engine waste gas heater is coated outside the compressed air storage tank.
  • a compressed air pipeline from the compressed air storage tank is connected to a pipeline between an air inlet valve and an air inlet electromagnetic valve by a compressed air outlet electromagnetic valve. The compressed air is heated by the electric heater before the engine is started so that injected fuel oil is relatively easy to ignite.
  • fuel oil in the air cylinder is ignited, the alloy mesh absorbs a small amount of heat and the temperature can rise fast.
  • Combustibles such as hydrocarbon and carbon particles in the air cylinder can be ignited by the red-hot alloy mesh.
  • the said document discloses a system which provides fast heating in order to decrease the disadvantage of cold operation and which stores heat for this.
  • the said patent document does not disclose coating engine block and its components and increasing the ambient temperature and thus increasing the temperature of the gas entering to the thermal recovery system.
  • Cida Patent Document no CN102678235(A) an application known in the state of the art, discloses a power auxiliary system with an internal combustion engine, which comprises the internal combustion engine, a steam turbine, a centrifugal compressor and a waste heat recovery device.
  • the waste heat recovery device converts waste heat generated by the internal combustion engine after fuel is burnt into waste gas energy and converting a liquid working medium into steam by the waste gas energy and heat energy generated by cooling liquid of the internal combustion engine.
  • thermal and mechanical efficiency of the engine is increased and fuel consumption and exhaust emission is decreased with the power auxiliary system with the internal combustion engine.
  • a heat recovery device used for increasing efficiency in an internal combustion engine is disclosed.
  • Chinese Utility Model no CN201696124(U) an application known in the state of the art, discloses an exhaust waste heat recovery device.
  • This device comprises an automobile engine exhaust device, a heat collector, a heat conduction pipe, a hot end of a Stirling heat engine, medium, a piston, a generator, an automobile motor, a hydraulic coupler and an automobile transmission system.
  • the engine exhaust waste heat recovery utilization device is comprised of the heat collector which is connected with the hot end of the Stirling heat engine through the heat conduction pipe, and the heat conduction pipe which is internally filled with heat conduction medium inside the piston.
  • Stirling heat engine is connected with the piston through the medium in the Stirling heat engine.
  • the work done by the piston is respectively transmitted to the generator connected to the automobile engine and the hydraulic coupler connected to the automobile transmission system.
  • the power of an automobile is improved and the consumption of fuel is reduced and it is enabled that the hybrid vehicles can be used more efficiently.
  • a device operating with Stirling cycle is operated as coupled to the internal combustion engine.
  • the efficiency of Stirling type systems are very low relative to the heat recovery devices, and it is quite difficult to benefit from the system since the exhaust gas temperature of the system is also low.
  • the said patent document does not have an explanation about how high exhaust gas temperature can be obtained and no heat recovery device is used.
  • Multi hole ceramic heat storage chamber is connected to the inlet of the first valve and the outlet of the second valve, inlet of the third valve and the outlet of the fourth valve, the inlet of the fifth valve and the outlet of the sixth valve, inlet of the seventh valve and the outlet of the eight valve, the internal hole surface of the first and second multi-hole ceramic heat storage chambers is coated by oxidized reduction catalyst.
  • the waste gas treatment equipment can utilize the waste heat from waste gas for pre-heating the air and remove nitrogen oxides and other harmful gases in waste gas at the same time, thus saving the investment and improving the efficiency.
  • a catalyst system placed in inlets and outlets of the valves is disclosed. The said patent document does not have an explanation about how high exhaust gas temperature can be obtained and no heat recovery device is used.
  • the objective of the present invention is to provide a combustion system with a heat recovery unit which increases the heat recovery by increasing the temperature of the exhaust gas.
  • Another objective of the present invention is to provide a combustion system with a heat recovery unit which decreases fuel consumption.
  • a further objective of the present invention is to provide a combustion system with a heat recovery unit which enables to provide competitive fuel consumption for heavy commercial vehicles working in heavy load conditions.
  • piston and the cylinder head (engine block) is coated with a material in thickness of 0-1 mm and the conductivity coefficient of which is 0.0001-1 W/mk and a thermal barrier is formed.
  • the inner temperature is increased with this thermal barrier formed on the engine block and thus the temperature of the exhaust gas is increased.
  • the temperature of the exhaust gas increases approximately 40-50 °C.
  • heat recovery unit operates efficiently and fuel consumption is reduced with the energy obtained.
  • Zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material in order to form thermal barrier.
  • Figure 1 is the schematic view of the combustion system with a heat recovery unit.
  • the inventive combustion system (1) comprises
  • At least one inlet manifold (4) wherein the air coming from the compressor (3) is transferred to the cylinders, - at least one cylinder block and cylinder head (5) wherein the cylinders are located, which bears the engine components and which is coated in order to increase the temperature of the exhaust gas,
  • At least one piston (6) which is located inside the cylinder block and the cylinder head (5) and which converts combustion energy into mechanical energy
  • At least one exhaust manifold (7) to which the burnt gases coming out of the cylinder block and the cylinder head (5) are transferred
  • At least one waste heat recovery unit (10) which is used to recover thermal energy obtained from the gases the temperatures of which are increased at the outlet of the turbine (9).
  • the air is sucked from the outer environment and taken inside the combustion system (1) through the air suction pipe (2).
  • the air which is sucked comes to the inlet manifold (4) after being compressed.
  • the inlet manifold (4) transfers the air inside the cylinder block and the cylinder head (5).
  • Air- fuel mixture burns inside the cylinder block and the cylinder head (5) upon being compressed by the pistons (6).
  • the gasses generated as a result of combustion in the cylinder block and the cylinder head (5) are transferred to the exhaust manifold (7) and then to the EGR valve (8) from there in order to be used again.
  • the gases which are not transferred to the EGR valve (8) are transferred to the turbine (7) located at the outlet of the exhaust manifold (7), and to the waste heat recovery unit (10) via the turbine (9).
  • the gases that are not used (waste) in the waste heat recovery unit (10) are discharged via the exhaust pipe (1 1).
  • the recovery efficiency of the waste heat recovery unit (10) is in direct proportion with the temperature of the gases entering into the unit (10). As the temperature of the gases entering into the heat recovery unit (10), the ratio of the recovery also increases. The increase in recovery rate reduces the fuel consumption. The fuel consumption is reduced at a certain rate depending on the increase in the temperature of the gases entering into the heat recovery unit (10).
  • the gases generated as a result of the combustion in the engine come to the exhaust manifold (9), they enter into the turbine (9) and to the heat recovery unit (10) from there.
  • the temperature of the gases entering into the heat recovery unit (10) is high as much as the temperature of the gases coming to the exhaust manifold (7).
  • Sending gases at high temperatures to the exhaust manifold (7) enables to directly send gas at high temperatures to the heat recovery unit (10).
  • the parts of the cylinder block and the cylinder head (5) facing the combustion chamber and preferably the pistons (6) are coated in order to form thermal barrier.
  • the cylinder block and the cylinder head (5) is coated with a material preferably in thickness of 0-1 mm, and the conductivity coefficient of which is 0.0001-1 W/mk, and a thermal barrier is formed.
  • the internal temperature is increased with the thermal barrier formed on the cylinder block and the cylinder head (5).
  • the temperatures of the gases going to the exhaust manifold (7) increase between 40- 50 °C.
  • zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material in order to form thermal barrier.
  • the temperatures of the gases entering into the exhaust manifold (7) and the turbine (9) increase by coating the cylinder block and the cylinder head (5) and preferably the pistons (6) such that a thermal barrier is formed.
  • the said high temperature of the gases enables the heat recovery unit (10) to work more efficiently. Therefore, the thermal energy generated by increasing the temperature of the exhaust gas is recovered by being utilized in the heat recovery unit (10) without being discharged from the exhaust pipe (1 1).
  • the exhaust manifold (7) is coated with the thermal barrier.
  • the exhaust manifold (7) is preferably coated with a material in thickness of 0-1 mm and the conductivity coefficient of which is between 0.0001-1 W/mk, and thus the temperature of the gases are increased or maintained. Zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material.
  • thermal barrier is also formed on the exhaust manifold (7) and thus the temperature of the gases are increased and maintained.
  • zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination in order to form thermal barrier in the turbine (9). Therefore a thermal barrier is also formed on the turbine (9) and thus the temperature of the gases are increased and maintained.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Ceramic Engineering (AREA)
  • Supercharger (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Engine Equipment That Uses Special Cycles (AREA)

Abstract

The invention is essentially a combustion system with a heat recovery unit (1) wherein whole exhaust gas temperature is enabled to increase by coating piston (6), cylinder block and the cylinder head (5) with a special coating and potentially discharged energy is utilized by using a waste heat recovery unit (10) instead of discharging this increase.

Description

DESCRIPTION
A COMBUSTION SYSTEM WITH A HEAT RECOVERY UNIT
Field of the Invention
The present invention relates a combustion system with a heat recovery unit which enables gas entrance at a higher temperature to the heat recovery unit by increasing the combustion temperature in the engine and thus decreases the fuel consumption.
Background of the Invention
Many methods are used in order to increase low exhaust temperature and thus fuel efficiency in engines used in heavy commercial vehicles.
Chinese Patent Document no CN102777247 (A), an application known in the state of the art, discloses an engine which stores heat and which is formed by remolding the conventional engine. Compressed air compressed by an air compressor enters a compressed air storage tank by a check valve. An electric heater is installed in the compressed air storage tank, and an engine waste gas heater is coated outside the compressed air storage tank. A compressed air pipeline from the compressed air storage tank is connected to a pipeline between an air inlet valve and an air inlet electromagnetic valve by a compressed air outlet electromagnetic valve. The compressed air is heated by the electric heater before the engine is started so that injected fuel oil is relatively easy to ignite. In a power stroke, fuel oil in the air cylinder is ignited, the alloy mesh absorbs a small amount of heat and the temperature can rise fast. Combustibles such as hydrocarbon and carbon particles in the air cylinder can be ignited by the red-hot alloy mesh. The said document discloses a system which provides fast heating in order to decrease the disadvantage of cold operation and which stores heat for this. The said patent document does not disclose coating engine block and its components and increasing the ambient temperature and thus increasing the temperature of the gas entering to the thermal recovery system.
Chinese Patent Document no CN102678235(A), an application known in the state of the art, discloses a power auxiliary system with an internal combustion engine, which comprises the internal combustion engine, a steam turbine, a centrifugal compressor and a waste heat recovery device. The waste heat recovery device converts waste heat generated by the internal combustion engine after fuel is burnt into waste gas energy and converting a liquid working medium into steam by the waste gas energy and heat energy generated by cooling liquid of the internal combustion engine. By means of the invention, thermal and mechanical efficiency of the engine is increased and fuel consumption and exhaust emission is decreased with the power auxiliary system with the internal combustion engine. In the said system, a heat recovery device used for increasing efficiency in an internal combustion engine is disclosed. However, in these systems, an exhaust gas temperature high enough to be able to use heat recovery device cannot be reached. The said patent document does not have an explanation about how high exhaust gas temperature can be obtained in order that the heat recovery device operates efficiently. It is not disclosed that the exhaust gas temperature can be increased by coating the engine components.
Chinese Utility Model no CN201696124(U), an application known in the state of the art, discloses an exhaust waste heat recovery device. This device comprises an automobile engine exhaust device, a heat collector, a heat conduction pipe, a hot end of a Stirling heat engine, medium, a piston, a generator, an automobile motor, a hydraulic coupler and an automobile transmission system. The engine exhaust waste heat recovery utilization device is comprised of the heat collector which is connected with the hot end of the Stirling heat engine through the heat conduction pipe, and the heat conduction pipe which is internally filled with heat conduction medium inside the piston. Stirling heat engine is connected with the piston through the medium in the Stirling heat engine. The work done by the piston is respectively transmitted to the generator connected to the automobile engine and the hydraulic coupler connected to the automobile transmission system. By means of the engine exhaust waste heat recovery-utilization device, the power of an automobile is improved and the consumption of fuel is reduced and it is enabled that the hybrid vehicles can be used more efficiently. In the said system, a device operating with Stirling cycle is operated as coupled to the internal combustion engine. However, the efficiency of Stirling type systems are very low relative to the heat recovery devices, and it is quite difficult to benefit from the system since the exhaust gas temperature of the system is also low. The said patent document does not have an explanation about how high exhaust gas temperature can be obtained and no heat recovery device is used.
Chinese Utility Model no CN201016573(Y), an application known in the state of the art, discloses waste gas treatment equipment for waste heat recovery and pollutants removal at the same time. Multi hole ceramic heat storage chamber is connected to the inlet of the first valve and the outlet of the second valve, inlet of the third valve and the outlet of the fourth valve, the inlet of the fifth valve and the outlet of the sixth valve, inlet of the seventh valve and the outlet of the eight valve, the internal hole surface of the first and second multi-hole ceramic heat storage chambers is coated by oxidized reduction catalyst. The waste gas treatment equipment can utilize the waste heat from waste gas for pre-heating the air and remove nitrogen oxides and other harmful gases in waste gas at the same time, thus saving the investment and improving the efficiency. In the said system, a catalyst system placed in inlets and outlets of the valves is disclosed. The said patent document does not have an explanation about how high exhaust gas temperature can be obtained and no heat recovery device is used.
It is not disclosed in the present applications that a special coating is made on the piston and the sleeve and the exhaust gas temperature is increased In order that the waste heat recovery unit operates efficiently. Besides, there is no system which utilizes the heat increase occurring in the exhaust gas instead of discharging it. The present applications do not disclose increase in temperature inside the engine and the temperature of the whole gas by making a special coating on the piston and the sleeve, and utilizing potentially discharged energy in the system by using the heat recovery device. High temperature required for the efficient operation of the heat recovery unit is obtained with the inventive system.
The Objective of the Invention The objective of the present invention is to provide a combustion system with a heat recovery unit which increases the heat recovery by increasing the temperature of the exhaust gas.
Another objective of the present invention is to provide a combustion system with a heat recovery unit which decreases fuel consumption.
A further objective of the present invention is to provide a combustion system with a heat recovery unit which enables to provide competitive fuel consumption for heavy commercial vehicles working in heavy load conditions.
Summary of the Invention
In the combustion system with a heat recovery unit which is disclosed in the first claim and the other claims dependant to this claim developed to fulfill the objectives of the present invention, piston and the cylinder head (engine block) is coated with a material in thickness of 0-1 mm and the conductivity coefficient of which is 0.0001-1 W/mk and a thermal barrier is formed. The inner temperature is increased with this thermal barrier formed on the engine block and thus the temperature of the exhaust gas is increased. The temperature of the exhaust gas increases approximately 40-50 °C. Upon the temperature of the exhaust gas increases, the temperatures of the gases entering into the heat recovery unit increase. Therefore, heat recovery unit operates efficiently and fuel consumption is reduced with the energy obtained. Zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material in order to form thermal barrier.
Detailed Description of the Invention
"A combustion system with a heat recovery unit" developed to fulfill the objective of the present invention is illustrated in the accompanying figure, in which:
Figure 1 is the schematic view of the combustion system with a heat recovery unit.
The components given in the figures are assigned reference numbers as follows:
1. Combustion system
2. Air suction pipe
3. Compressor
4. Inlet manifold
5. Cylinder block and cylinder head
6. Piston
7. Exhaust manifold
8. EGR valve
9. Turbine
10. Waste heat recovery unit
1 1. Air outlet
The inventive combustion system (1) comprises
at least one inlet manifold (4) wherein the air coming from the compressor (3) is transferred to the cylinders, - at least one cylinder block and cylinder head (5) wherein the cylinders are located, which bears the engine components and which is coated in order to increase the temperature of the exhaust gas,
at least one piston (6) which is located inside the cylinder block and the cylinder head (5) and which converts combustion energy into mechanical energy,
at least one exhaust manifold (7) to which the burnt gases coming out of the cylinder block and the cylinder head (5) are transferred,
- at least one EGR valve (8) through which the burnt gases coming out of the cylinder block and the cylinder head (5) are passed so that they are used again,
at least one turbine (9) through which the gases that are not transferred to the EGR valve (8) pass,
at least one waste heat recovery unit (10) which is used to recover thermal energy obtained from the gases the temperatures of which are increased at the outlet of the turbine (9).
In the inventive combustion system (1), the air is sucked from the outer environment and taken inside the combustion system (1) through the air suction pipe (2). The air which is sucked comes to the inlet manifold (4) after being compressed. The inlet manifold (4) transfers the air inside the cylinder block and the cylinder head (5). Air- fuel mixture burns inside the cylinder block and the cylinder head (5) upon being compressed by the pistons (6). The gasses generated as a result of combustion in the cylinder block and the cylinder head (5)are transferred to the exhaust manifold (7) and then to the EGR valve (8) from there in order to be used again. The gases which are not transferred to the EGR valve (8) are transferred to the turbine (7) located at the outlet of the exhaust manifold (7), and to the waste heat recovery unit (10) via the turbine (9). The gases that are not used (waste) in the waste heat recovery unit (10) are discharged via the exhaust pipe (1 1). The recovery efficiency of the waste heat recovery unit (10) is in direct proportion with the temperature of the gases entering into the unit (10). As the temperature of the gases entering into the heat recovery unit (10), the ratio of the recovery also increases. The increase in recovery rate reduces the fuel consumption. The fuel consumption is reduced at a certain rate depending on the increase in the temperature of the gases entering into the heat recovery unit (10). After the gases generated as a result of the combustion in the engine come to the exhaust manifold (9), they enter into the turbine (9) and to the heat recovery unit (10) from there. The temperature of the gases entering into the heat recovery unit (10) is high as much as the temperature of the gases coming to the exhaust manifold (7). Sending gases at high temperatures to the exhaust manifold (7) enables to directly send gas at high temperatures to the heat recovery unit (10).
In the inventive combustion system (1), the parts of the cylinder block and the cylinder head (5) facing the combustion chamber and preferably the pistons (6) are coated in order to form thermal barrier. The cylinder block and the cylinder head (5) is coated with a material preferably in thickness of 0-1 mm, and the conductivity coefficient of which is 0.0001-1 W/mk, and a thermal barrier is formed. The internal temperature is increased with the thermal barrier formed on the cylinder block and the cylinder head (5). By means of the thermal barrier, the temperatures of the gases going to the exhaust manifold (7) increase between 40- 50 °C.
In the preferred embodiment of the invention, zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material in order to form thermal barrier. The temperatures of the gases entering into the exhaust manifold (7) and the heat recovery unit (10) by means of the thermal barrier. Therefore, the amount of the energy recovered by the heat recovery unit (10) increases and the fuel consumption is reduced approximately between 0.5-1.5%. The temperatures of the gases entering into the exhaust manifold (7) and the turbine (9) increase by coating the cylinder block and the cylinder head (5) and preferably the pistons (6) such that a thermal barrier is formed. The said high temperature of the gases enables the heat recovery unit (10) to work more efficiently. Therefore, the thermal energy generated by increasing the temperature of the exhaust gas is recovered by being utilized in the heat recovery unit (10) without being discharged from the exhaust pipe (1 1).
By means of the combustion system (1), heat transfer losses are avoided by increasing the exhaust gas temperatures and thus the fuel consumption is reduced. The waste heat recovery units (10) present in the vehicles are used more efficiently by means of the coated cylinder block and the cylinder head (5) and the pistons (6). In an alternative embodiment of the invention, the exhaust manifold (7) is coated with the thermal barrier. The exhaust manifold (7) is preferably coated with a material in thickness of 0-1 mm and the conductivity coefficient of which is between 0.0001-1 W/mk, and thus the temperature of the gases are increased or maintained. Zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination as coating material. Therefore a thermal barrier is also formed on the exhaust manifold (7) and thus the temperature of the gases are increased and maintained. In an alternative embodiment of the invention, zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination in order to form thermal barrier in the turbine (9). Therefore a thermal barrier is also formed on the turbine (9) and thus the temperature of the gases are increased and maintained.

Claims

1. A combustion system with a heat recovery unit (1), which increases the efficiency of the heat recovery obtained from the waste heat by increasing the exhaust gas temperature and thus reduces the fuel consumption, essentially comprising
at least one inlet manifold (4) wherein the air coming from the compressor
(3) is transferred to the cylinders, and characterized by
at least one cylinder block and cylinder head (5) in which the cylinders are present, which bears the engine components and which is coated with a material preferably in thickness of 0-1 mm and the conductivity coefficient of which is 0.0001-1 W/mk in order to increase the exhaust gas temperature,
at least one piston (6) which is located inside the cylinder block (5) and which converts combustion energy into mechanical energy,
at least one exhaust manifold (7) to which the burnt gases coming out of the cylinder block (5) are transferred,
at least one EGR valve (8) through which the burnt gases coming out of the cylinder block (5) are passed so that they are used again,
- at least one turbine (9) through which the gases that are not transferred to the EGR valve (8) pass,
- at least one waste heat recovery unit (10) which is used to recover the thermal energy obtained from the gases the temperature of which is increased at the outlet of the turbine (9).
2. A combustion system with a heat recovery unit (1) according to claim 1, characterized by cylinder block and the cylinder head (5) which is preferably coated with zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination in order to increase the exhaust gas temperatures.
3. A combustion system with a heat recovery unit (1) according to claim 1, characterized by piston (6) which is preferably coated with zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination in order to increase the exhaust gas temperatures.
4. A combustion system with a heat recovery unit (1) according to claim 1, characterized by waste heat recovery unit (10) wherein the thermal energy generated by means of the increase in exhaust gas temperature is utilized and recovered instead of discharging from the exhaust pipe (11).
5. A combustion system with a heat recovery unit (1) according to claim 1, characterized by cylinder block and the cylinder head (5) and piston (6) which increase the temperature of the exhaust gas approximately between 40-50 °C by means of the thermal barrier preferably coated with zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials separately or in combination.
6. A combustion system with a heat recovery unit (3) according to claim 1, characterized by waste heat recovery unit (10) wherein the thermal energy generated by means of the increase in exhaust gas temperature is utilized and recovered instead of discharging from the exhaust pipe (11) and thus which enables the fuel consumption to be reduced approximately between 0.5-1.5%.
7. A combustion system with a heat recovery unit (1) according to claim 1, characterized by exhaust manifold (7) which is preferably coated with zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, ceramic based materials can be used separately or in combination.
8. A combustion system with a heat recovery unit (1) according to claim 1, characterized by turbine (9) which is preferably coated with zirconium, yttrium, titanium, hafnium, aluminum, silisium, lanthanum based, based materials can be used separately or in combination.
PCT/TR2014/000311 2013-09-03 2014-09-03 A combustion system with a heat recovery unit WO2015034448A1 (en)

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