Particulate separator

A particulate separator for a gaseous fluid is provided. The particulate separator includes a sealable collection container defining a collection volume therein. The particulate separator also includes a gaseous fluid conduit provided through the sealable collection container. The gaseous fluid conduit defines an inner channel therein. The gaseous fluid conduit includes an inlet and an outlet. The gaseous fluid conduit also includes an arcuate segment provided between the inlet and the outlet. The arcuate segment includes a plurality of slits formed therein. The plurality of slits is configured to provide fluid communication between the collection volume and the inner channel of the gaseous fluid conduit.

TECHNICAL FIELD

The present disclosure relates to a particulate separator, and more particularly to a particulate separator for use with a gaseous fluid source.

BACKGROUND

Use of gaseous fuels, such as, natural gas, may be more in demand over the use of other hydrocarbon fuels in internal combustion (IC) engines. Gaseous fuels may be comparatively less expensive than the hydrocarbon fuels, and may burn relatively cleaner during operation. Cleaner burning of the gaseous fuels result in a reduced amount of combustion byproducts, such as, carbon monoxide, oxides of nitrogen (NOx), and unburned hydrocarbons.

However, sometimes, the gaseous fuel flowing through various parts of the engine system may include particulate contaminants therein. The gaseous fuel containing the particulate contaminants may flow towards and sometimes even enter into various components of the engine system positioned downstream of a gaseous fuel tank. This may damage or lead to failure of the respective components of the engine system.

U.S. Pat. No. 5,120,335 describes a separator to separate products finely ground in a mill from a gas current consists of a housing which can be attached to the mill discharge site, having a tubular cylindrical insert which extends into the housing. The gas current is led into this tube and returned along its outer side. By sharply deflecting the gas current at the outlet of the tube, the product is separated and collected. In order to improve the efficiency of separation, the insert is designed so as to be formed by an inner tube and an outer tube, which form an annular space which serves to return the gas. A plate shapes the annular space as a spiral flow channel. There are slits in the outer tube located at the height of the bottom of the flow channel formed by the plate.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a particulate separator for a gaseous fluid is disclosed. The particulate separator includes a sealable collection container defining a collection volume therein. The particulate separator also includes a gaseous fluid conduit provided through the sealable collection container. The gaseous fluid conduit defines an inner channel therein. The gaseous fluid conduit includes an inlet and an outlet. The gaseous fluid conduit also includes an arcuate segment provided between the inlet and the outlet. The arcuate segment includes a plurality of slits formed therein. The plurality of slits is configured to provide fluid communication between the collection volume and the inner channel of the gaseous fluid conduit.

In another aspect of the present disclosure, a gaseous fuel system is disclosed. The gaseous fuel system includes a gaseous fuel source. The gaseous fuel system also includes a gaseous fuel rail. The gaseous fuel system further includes a particulate separator provided in fluid communication with the gaseous fuel source and the gaseous fuel rail. The particulate separator includes a sealable collection container defining a collection volume therein. The particulate separator also includes a gaseous fuel conduit provided through the sealable collection container. The gaseous fuel conduit defines an inner channel therein. The gaseous fuel conduit includes an inlet and an outlet. The gaseous fuel conduit also includes an arcuate segment provided between the inlet and the outlet. The arcuate segment includes a plurality of slits formed therein. The plurality of slits is configured to provide fluid communication between the collection volume and the inner channel of the gaseous fuel conduit.

In yet another aspect of the present disclosure, an engine system is disclosed. The engine system includes a fuel injector. The engine system also includes a gaseous fuel source. The engine system further includes a gaseous fuel rail. The engine system includes a particulate separator provided in fluid communication with the gaseous fuel source and the gaseous fuel rail. The particulate separator includes a sealable collection container defining a collection volume therein. The particulate separator also includes a gaseous fuel conduit provided through the sealable collection container. The gaseous fuel conduit defines an inner channel therein. The gaseous fuel conduit includes an inlet and an outlet. The gaseous fuel conduit also includes an arcuate segment provided between the inlet and the outlet. The arcuate segment includes a plurality of slits formed therein. The plurality of slits is configured to provide fluid communication between the collection volume and the inner channel of the gaseous fuel conduit.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.FIG. 1is a schematic view of a portion of an engine system100. The engine system100includes an engine102. As shown in the accompanying figures, the engine102includes an engine block (not shown) that defines a plurality of cylinders (not shown).

In the illustrated embodiment, the engine102is a multi cylinder IC engine. The engine102may be powered by any one or a combination of known liquid or gaseous fuels including, but not limited to, gasoline, diesel, natural gas, petroleum gas, and bio-fuels. In the illustrated embodiment, the engine102is powered by the combination of liquid and gaseous fuels. The amount of gaseous fuel being supplied to the cylinders may be over 90%, and less than 10% of the fuel may be liquid fuel. Although individual gases, such as, methane, propane, and so on are within the scope of the present disclosure, natural gas containing a mixture of gas species is particularly applicable to the present disclosure. In addition, the liquid fuel is chosen for the ability of compression ignition at the compression ratio of the engine102. For instance, the liquid fuel may be distillate diesel fuel or some other liquid fuel that is suitable for compression ignition to in turn ignite a charge of gaseous fuel in one of the cylinders.

Further, the engine system100may include a plurality of fuel injectors108. For clarity purposes, only one injector108is shown herein. The injector108is positioned for direct injection of gaseous fuel and/or liquid fuel into one of the cylinders. The engine system100also includes a manifold110. The manifold110includes a plurality tubes extending between an inlet port112and the injector108. The engine system100may further include a controller (not shown). The controller may be communicably coupled with the injector108, in order to selectively control the timing and quantity of both gaseous and liquid fuel injection events.

The engine system100includes a gaseous fuel delivery module114. In the illustrated embodiment, the gaseous fuel is maintained in a liquid state in a cryogenic liquefied natural gas tank116of the gaseous fuel delivery module114. The gaseous fuel delivery module114also includes a pump118. The pump118may be a variable displacement cryogenic pump. The pump118may be communicably coupled to the controller, and may be controlled in order to pump the gaseous fuel from the tank116. A pressure regulator117may be associated with the tank116, in order to maintain a pressure build-up in the tank116. The gaseous fuel delivery module114may also include an in-line filter120positioned downstream of the pump118, with respect to a gaseous fuel flow direction. The gaseous fuel pumped by the pump118flows through the in-line filter120and a heat exchanger122of the gaseous fuel delivery module114. While flowing through the heat exchanger122, the gaseous fuel expands into a gas, and is maintained within an accumulator124of the gaseous fuel delivery module114.

The gaseous fuel delivery module114also includes a gaseous fuel common rail126. An upstream side of the gaseous fuel common rail126fluidly communicates with the accumulator124, via a gas pressure control valve128.

The gas pressure control valve128may be communicably coupled to the controller. In an exemplary embodiment, the gas pressure control valve128may be embodied as an electronically controlled valve that supplies a controlled quantity of gaseous fuel from the accumulator124to the gaseous fuel common rail126. Further, a downstream side of the gaseous fuel common rail126is fluidly connected to the injector108through one of the inlet ports112of the manifold110.

The gaseous fuel within the tank116may sometimes include particulate contaminants therein. These particulate contaminants may be small flecks of metallic or non-metallic debris that become entrained in the gaseous fuel during a gas filling process or may be present within the tank116itself A particulate separator130is provided in the gaseous fuel delivery module114. The particulate separator130is configured to separate out the particulate contaminants which may be present in the gaseous fuel. In the illustrated embodiment, the particulate separator130is provided between the gas pressure control valve128and the gaseous fuel common rail126. In another embodiment, the particulate separator130may be provided between the gaseous fuel common rail126and the manifold110. The particulate separator130will be described in detail with reference toFIGS. 2-4, later in this section.

As shown in the accompanying figures, the engine system100also includes a liquid fuel delivery module132. Further, the liquid fuel delivery module132includes a liquid fuel tank134. The tank134is configured to hold the source of liquid fuel therein. The liquid fuel delivery module132further includes a pump136provided in fluid communication with the tank134. The pump136is configured to receive the liquid fuel from the tank134, via a fuel filter138, and further deliver the liquid fuel to a liquid fuel common rail140. The pump136may be communicably coupled to the controller, such that an output of the pump136may be controlled to maintain a desired pressure within the liquid fuel common rail140. In another example, the liquid fuel delivery module132may include a fixed displacement pump and a pressure control valve in order to return a quantity of the liquid fuel from the liquid fuel common rail140back to the tank134for controlling a pressure in the liquid fuel common rail140. A downstream side of the liquid fuel common rail140is fluidly connected to the manifold110via one of the inlet ports112, and to the injector108by the plurality of tubes.

The particulate separator130will now be explained in detail. Referring toFIGS. 2, 3, and 4, the particulate separator130includes a high pressure, sealable collection container200defining a collection volume202(seeFIG. 3) therein. The sealable collection container200of the illustrated embodiment has a cylindrical design. Alternatively, the shape of the sealable collection container200may be rectangular, or square, without limiting the scope of the present disclosure. The sealable collection container200may be made of any suitable metal or polymer known in the art.

The particulate separator130includes a two piece design, having a cap member206and a base chamber208. The base chamber208is embodied as an open top, closed bottom container within which the collection volume202of the particulate separator130is defined. Further, the cap member206may be threadably coupled to the base chamber208. For this purpose, the cap member206and the base chamber208may include corresponding threads provided thereon. Alternatively, any other known releasable mechanical fastening means, for example, bolts, latches, etc. (not shown) may also be used to couple the cap member206with the base chamber208, in order to form the sealable collection container200. The cap member206of the particulate separator130includes a pair of apertures, namely a first aperture210and a second aperture212. The first and second apertures210,212are provided within a wall214of the cap member206. In one example, the first and second apertures210,212may be located diametrically opposite to each other.

As shown in the accompanying figures, the particulate separator130includes a gaseous fluid conduit or a gaseous fuel conduit, hereinafter referred to as conduit216. In the illustrated embodiment, the conduit216defines an inner channel218for a passage of the gaseous fuel therethrough. The conduit216may embody a tube or a pipe having a hollow configuration. The conduit216may be made of a metal, for example, steel or a stainless steel. In the illustrated embodiment, the conduit216is coupled with the cap member206of the particulate separator130. During assembly, the conduit216is passed through the first and second apertures210,212of the cap member206respectively, so that the conduit216creates a seal with the wall214. The conduit216is positioned along an inner periphery of the cap member206. In an alternate embodiment, the conduit216may be provided in the base chamber208of the sealable collection container200.

The conduit216includes an inlet segment220and an outlet segment222. The inlet segment220of the conduit216may be connected to the gas pressure control valve128and the outlet segment222of the conduit216may be connected to the gaseous fuel common rail126(seeFIG. 1). The conduit216also includes an arcuate segment224defined between the inlet segment220and the outlet segment222. The arcuate segment224has an inner periphery226and an outer periphery228. The arcuate segment224is provided, such that, the arcuate segment224defines a bend230. The bend230makes an angle α of approximately90degrees between the inlet segment220and the outlet segment222(seeFIG. 4). It should be noted that the angle α made by the bend230of the arcuate segment224may include in a range approximately between 85 to 100 degrees. The angle α of the bend230of the arcuate segment224may vary for different applications.

The arcuate segment224of the conduit216includes a plurality of slits232formed therein. A wall segment234in a portion of the arcuate segment224of the conduit216defining the slits232may have a thickness, such that the thickness of the wall segment234decreases in a direction of a flow of the gaseous fuel thereover. The direction of flow of the gaseous fuel is shown using arrows inFIG. 4.

Further, each of the plurality of slits232define an opening236(seeFIGS. 2 and 3). The slits232are configured to provide fluid communication between the inner channel218of the conduit216and the collection volume202of the sealable collection container200. In the illustrated embodiment, the slits232are provided at a bottom portion of the arcuate segment224. Further, the slits232may be provided along the outer periphery228of the arcuate segment224.

As shown in the accompanying figures, the slits232may have a triangular shape. More particularly, the slits232may be provided such that the openings236of the slits232has a larger dimension at the outer periphery228of the arcuate segment224and has a smaller dimension at the inner periphery226of the arcuate segment224. It should be noted that the shape and dimensions of the slits232does not limit the scope of the present disclosure, and may vary according to a particular application. Accordingly, the slits232may have any of a circular, elliptical, trapezoidal, or rectangular shape.

INDUSTRIAL APPLICABILITY

As described above, the gaseous fuel present in the gaseous fuel tank of the gaseous fuel delivery module may contain debris or particulate contaminants therein. Unless otherwise prevented from contacting various components positioned downstream of the gaseous fuel tank, this debris may damage the components of the gaseous fuel delivery module and prevent or degrade an operation thereof The damage of the components may also affect the quantity of the gaseous fuel supply to the injector of the engine system. This may affect an overall performance of the engine system. Further, the components of the engine system may need to be replaced in a situation wherein irreparable damage is caused by the debris.

The present disclosure describes the use of the particulate separator130for filtering the gaseous fuel received from the tank116of the gaseous fuel delivery module114. The working of the system will now be explained with reference toFIGS. 1-4.

The gaseous fuel is introduced within the conduit216of the particulate separator130through the inlet segment220. On exiting the inlet segment220, the gaseous fuel flowing through the conduit216is deflected from its path, and enters the arcuate segment224of the conduit216. The bend230of the arcuate segment224is configured to provide a rotational motion to the gaseous fuel flowing through the conduit216. This rotational motion may cause a centrifugal force to act on the gaseous fuel and also the particulate contaminants which may be present in the gaseous fuel flow entering into the particulate separator130via the inlet segment220. The particulate contaminants may collide with the wall segment234forming the bend230in the arcuate segment224. The particulate contaminants, which are generally heavier compared to the gaseous fuel, may be separated out from the gaseous fuel due to the centrifugal force. These separated particulate contaminants may further fall into the collection volume202of the sealable collection container200through the openings236of the plurality of slits232formed in the arcuate segment224.

The gaseous fuel from which the particulate contaminants are separated out exits the conduit216of the particulate separator130through the outlet segment222. The gaseous fuel may then flow into the gaseous fuel common rail126and further be introduced within the injector108, via the manifold110. The injector108may atomize the received liquid and gaseous fuels into a fine spray, and introduce the fuels within the cylinders of the engine102for combustion purposes. Further, the sealable collection container200of the particulate separator130may be disassembled from the engine system100as required in order to remove the accumulated particulate contaminants therewithin

Accordingly, the particulate separator130may contain or collect the particulate contaminants and/or debris therewithin, and thereby minimize or prevent damage to the components of the engine system100present downstream of the tank116. This may lead to a reduction in an overall cost and downtime associated with the operation of the engine system100. Further, the particulate separator130of the present disclosure may be easily installed and removed from the engine system100. During a non-operational state of the engine system100, the particulate separator130may be removed, in order to remove the particulate contaminants accumulated within the collection volume202and/or to clean the particulate separator130, and may be reassembled later.