Systems and methods for actively managing pilot fuel storage tanks

Patent metadata

Field	Value
Publication number	US-12421908-B1
Application number	US-202418653783-A
Country	US
Kind code	B1
Filing date	May 2, 2024
Priority date	May 2, 2024
Publication date	Sep 23, 2025
Grant date	Sep 23, 2025

Abstract

An internal combustion engine system is described herein. The system uses a pilot fuel to assist in the ignition of the primary fuel or uses a pilot fuel rather than a primary fuel in some instances. The pilot fuel is stored in one or more pilot fuel storage tanks that are actively managed to maintain a desired physical state of the pilot fuel stored in the one or more storage tanks. A controller detects conditions within the one or more pilot fuel storage tanks and issues control commands depending on the detected conditions. The conditions can include a temperature, a pressure, or a level of the pilot fuel stored in the pilot fuel storage tanks.

First claim

What is claimed is:

1. A system comprising:
an internal combustion engine that consumes a primary fuel and a pilot fuel;
a primary fuel tank providing the primary fuel to a primary fuel rail for use by the internal combustion engine;
a pilot fuel system configured to generate the pilot fuel from the primary fuel, the pilot fuel system including:
a reactor that receives the primary fuel, the reactor configured to convert the primary fuel from an alcohol to an ether, wherein a product of the reactor comprises the pilot fuel, unreacted primary fuel, and water; and
a product pump that receives the pilot fuel from the reactor and pumps the pilot fuel into the internal combustion engine or one or more pilot fuel storage tanks for use by the internal combustion engine;
a gaseous pilot fuel feed line comprising a first feed input located within the one or more pilot fuel storage tanks at a location that preferably receives a gaseous portion of the pilot fuel stored in the one or more pilot fuel storage tanks;
a liquid pilot fuel feed line comprising a second feed input located within the one or more pilot fuel storage tanks at a location that preferably receives a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks;
a pilot feed valve configured to receive the gaseous portion of the pilot fuel, the liquid portion of the pilot fuel, or a combination of the gaseous portion of the pilot fuel and the liquid portion of the pilot fuel; and
a controller configured to actively manage a physical state of the pilot fuel stored in the one or more pilot fuel storage tanks, the controller comprising:
a memory storing computer-executable instructions; and
a processor in communication with the memory, the computer-executable instructions causing the processor to perform acts comprising:
receiving a storage condition of the one or more pilot fuel storage tanks;
determining if the storage condition of the one or more pilot fuel storage tanks is within a range; and
upon determining that the storage condition is not within the range, issuing a control output to bring the storage condition to within the range.

2. The system of claim 1 , wherein the primary fuel comprises methanol and the pilot fuel comprises dimethyl ether.

3. The system of claim 1 , wherein the storage condition comprises a level of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a pilot fuel pump to increase a flowrate of the pilot fuel pump to increase a production of the pilot fuel by the reactor of the pilot fuel system.

4. The system of claim 1 , wherein the storage condition comprises a level of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a storage tank pressure regulator to change a pressure of the one or more pilot fuel storage tanks to change an amount of the pilot fuel condensed into a liquid in the one or more pilot fuel storage tanks.

5. The system of claim 1 , wherein the storage condition comprises a temperature of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a heater to change the temperature of the liquid portion of the pilot fuel stored in the one more pilot fuel storage tanks.

6. The system of claim 1 , wherein the storage condition comprises a pressure in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a heater to change a temperature of a liquid portion of the pilot fuel stored in the one more pilot fuel storage tanks to cause a change in a vapor pressure of the liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks.

7. The system of claim 1 , wherein the one or more pilot fuel storage tanks comprises a purified tank configured to store a purified pilot fuel and a blended product tank configured to store a blend comprising the pilot fuel, water, and unreacted primary fuel.

8. The system of claim 7 , further comprising a blend valve configured to receive the purified pilot fuel from the purified tank, the blend of the pilot fuel, water, and the blend from the blended product tank, or a combination of the purified pilot fuel and the blend.

9. A system for actively managing a physical state of a pilot fuel for an internal combustion engine, the pilot fuel produced in a reactor from a primary fuel used for the internal combustion engine, the system comprising:
a gaseous pilot fuel feed line comprising a first feed input located within one or more pilot fuel storage tanks at a location that preferably receives a gaseous portion of the pilot fuel stored in the one or more pilot fuel storage tanks;
a liquid pilot fuel feed line comprising a second feed input located within the one or more pilot fuel storage tanks at a location that preferably receives a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks; and
a pilot feed valve configured to receive the gaseous portion of the pilot fuel, the liquid portion of the pilot fuel, or a combination of the gaseous portion of the pilot fuel and the liquid portion of the pilot fuel; and
a controller, the controller comprising:
a memory storing computer-executable instructions; and
a processor in communication with the memory, the computer-executable instructions causing the processor to perform acts comprising:
receiving a storage condition of the one or more pilot fuel storage tanks used to store the pilot fuel, wherein the storage condition comprises a pressure in the one or more pilot fuel storage tanks, and wherein a control output comprises an instruction to instruct a heater to change a temperature of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks;
determining if the storage condition of the one or more pilot fuel storage tanks is within a range; and
upon determining that the storage condition is not within the range, providing the control output to the heater to bring the storage condition to within the range.

10. The system of claim 9 , wherein the primary fuel comprises methanol and the pilot fuel comprises dimethyl ether.

11. The system of claim 9 , wherein the storage condition further comprises a level of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a pilot fuel pump to increase a flowrate of the pilot fuel pump to increase a production of the pilot fuel by the reactor of a pilot fuel system.

12. The system of claim 9 , wherein the storage condition further comprises a level of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a storage tank pressure regulator to change a pressure of the one or more pilot fuel storage tanks to change an amount of the pilot fuel condensed into a liquid in the one or more pilot fuel storage tanks.

13. The system of claim 9 , wherein the storage condition further comprises a temperature of a liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks, and wherein the control output comprises an instruction to instruct a heater to change the temperature of the liquid portion of the pilot fuel stored in the one or more pilot fuel storage tanks.

14. The system of claim 9 , wherein the one or more pilot fuel storage tanks comprises a purified

Assignees

• Caterpillar Inc

Inventors

• Anders Jonathan W
• Ginter David Mark
• Svensson Kenth I

Classifications

• F02D19/0671

  Means to generate or modify a fuel, e.g. reformers, electrolytic cells or membranes · CPC title

• F02D19/0647

  the gaseous fuel being liquefied petroleum gas [LPG], liquefied natural gas [LNG], compressed natural gas [CNG] or dimethyl ether [DME] · CPC title

• F02D19/0668

  Treating or cleaning means; Fuel filters · CPC title

• F02D19/0665

  Tanks, e.g. multiple tanks · CPC title

• F02D19/0655

  at least one fuel being an alcohol, e.g. ethanol (F02D19/084 takes precedence) · CPC title