Description:Field of the invention

[0001] The present invention relates to a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators. More specifically, the present invention relates to a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators by mixing hydrogen and natural gas.

Background of the invention

[0002] Hydrogen (H2) represents a viable, renewable fuel for transitioning from fossil fuels to green energy. This transition is expected to occur gradually over time and may be implemented in phases. Initially, the use of hydrogen in blends with other gases, such as natural gas, is likely to be an attractive way to introduce this green fuel into existing facilities. However, there are significant challenges with traditional systems and methods for utilizing hydrogen, either as a stand-alone fuel or as a blended fuel.

[0003] Traditional systems and methods for blending hydrogen with other gases are often costly, inefficient, imprecise, and unreliable. They are typically not fully automated and fail to deliver a precise, consistent, and reliable flow of blended hydrogen gas. Additionally, these systems are expensive to operate and maintain because they are not designed to integrate with existing fossil fuel technology and infrastructure. This incompatibility necessitates extensive modifications, further increasing costs and complexity. Maintaining a precise hydrogen blend is critical due to material compatibility issues and limitations on hydrogen concentration in downstream equipment within existing infrastructure. Traditional technologies are unable to automatically adjust in real-time because they do not monitor the hydrogen percentage continuously, nor do they adjust the blend in response to changing conditions. This lack of real-time adjustment results in inefficiencies and potential safety hazards.

[0004] Moreover, traditional systems and methods are often fixed in place and involve multi-step processes to shut down, change parameters, and restart. This makes them cumbersome and difficult to use with existing technology, leading to operational inefficiencies and decreased usability of hydrogen as a renewable fuel.

[0005] Additionally, traditional systems lack robustness and adaptability to diverse environmental conditions. They often fail under extreme temperatures, high humidity, dust, and physical impacts, limiting their deployment in harsh environments. The inability to withstand these conditions reduces their reliability and increases maintenance costs.

[0006] Another major issue is the lack of remote monitoring and control capabilities in traditional systems. Without real-time data and remote operation, managing and troubleshooting these systems is labour-intensive and time-consuming. This not only adds to the operational costs but also affects the overall efficiency and responsiveness of the system. Furthermore, traditional systems typically involve high emissions of CO2 and other pollutants due to inefficient fuel combustion and lack of proper emission control mechanisms. This contradicts the primary goal of transitioning to green energy, which is to reduce the environmental footprint.

[0007] Therefore, there is a need for a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators by mixing hydrogen and natural gas which overcomes one or more drawbacks of the above-mentioned prior art.

Objects of the invention

[0008] The object of the present invention is to provide a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators.

[0009] Another object of the present invention is to provide a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators that can easily integrate with existing natural gas engine generators minimizing the need for extensive modifications and reducing implementation costs.
[0010] Another one object of the present invention is to provide a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators that maximize fuel efficiency by optimizing the blend of hydrogen and natural gas, ensuring consistent and reliable performance.

[0011] Further object of the present invention is to provide a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators that allows for real-time monitoring and adjustment of fuel blends based on operational conditions, enhancing system responsiveness and reliability.

[0012] One more object of the present invention is to provide a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators that is user-friendly, with straightforward controls and interfaces thereby making the system easy to operate, manage, and maintain.

Summary of the invention

[0013] According to the present invention a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators is provided. The system is integrated with a natural gas engine generator The system comprises a hydrogen gas inlet, a natural gas inlet, a hydrogen gas cascade, a blending unit, a plurality of gas pressure reducing skids, a Programmable Logic Controller (PLC) unit, a plurality of automatic flow control computers and electrically controlled actuators, a plurality of sensors, a safety mechanism, an exhaust gas monitoring unit and a gas outlet. The hydrogen gas inlet is for receiving hydrogen gas into the system and the natural gas inlet is provided for for receiving natural gas into the system. The hydrogen gas cascade is configured to supply hydrogen gas at an initial pressure range of 145-200 bar. The blending unit is connected to both the hydrogen gas inlet and the natural gas inlet.

[0014] The blending unit includes a mixing chamber where hydrogen gas and natural gas are combined to create an optimal fuel blend. The blending unit is equipped with a safety mechanism including slam shut-off valves, solenoid valves, flow meters, pressure gauges, filters, ball valves, and safety relief valves. The plurality of gas pressure reducing skids for hydrogen and natural gas wherein the hydrogen gas from the initial pressure range of 145-200 bar is reduced to an operating pressure of 1-4 bar. The Programmable Logic Controller (PLC) unit is programmed with algorithms to optimize the blend of natural gas and hydrogen based on real-time operational data. The plurality of sensors includes current transformers, engine knock sensors, temperature sensors, and gas leakage detectors, to provide real-time input data to the Programmable Logic Controller (PLC) unit. The plurality of automatic flow control computers and electrically controlled actuators adjusts the hydrogen and natural gas flow rates based on commands from the PLC unit. The exhaust gas monitoring unit for monitoring and reporting emissions of CO2 and other exhaust gases.

[0015] The gas outlet is provided for delivering the blended fuel mixture to the natural gas engine generator, wherein the system reduces CO2 emissions by utilizing the blending unit to mix the hydrogen gas with natural gas and the PLC unit to optimize the blended mixture based on the real-time data from sensors thereby lowering the amount of CO2 produced during operation, and a portion of the natural gas is replaced by hydrogen wherein the resultant mixture combusts without producing CO2.

[0016] In an aspect of the invention, the blending concentration of hydrogen gas is adjusted by a real-time monitoring unit utilizing feed-forward and feedback control algorithms.

[0017] In an aspect of the invention, the desired blend ratio is maintained by performing a daily automatic calibration to account for variations in the natural gas composition.

[0018] In an aspect of the invention, 4-20 mA sensors are used for detecting the gas leakage of hydrogen and natural gas and sending the output to the Programmable Logic Controller (PLC)unit.

[0019] In an aspect of the invention, the Programmable Logic Controller (PLC) provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator in the hydrogen gas cascade for adjusting hydrogen flow based on the load requirements.

[0020] In an aspect of the invention, the pressure gauges continuously monitor the gas pressure within the system and filters are provided for mixing clean gases.
[0021] In an aspect of the invention, the ball valves are provided for manual intervention when needed and safety relief valves is to vent the excess pressure and prevent the overpressure in the system.

[0022] In an aspect of the invention, a method for reducing carbon dioxide (CO2) emissions in natural gas engine generators is provided. Initially the hydrogen gas and natural gas is received into the system through a hydrogen gas inlet and a natural gas inlet. The hydrogen gas is supplied at an initial pressure range of 145-200 bar using a hydrogen gas cascade. The hydrogen gas and natural gas is combined in a blending unit wherein the blending unit comprises a mixing chamber where the gases are mixed to create an optimal fuel blend. A safety mechanism including slam shut-off valves, solenoid valves (12), flow meters, pressure gauges, filters, ball valves, and safety relief valves are utilized to ensure safe and reliable operation. After that a plurality of gas pressure reducing skids are utilized to reduce the hydrogen gas pressure from 145-200 bar to an operating pressure of 1-4 bar. The real-time operational data is then monitored using a plurality of sensors, including current transformers, engine knock sensors, temperature sensors, and gas leakage detectors, to provide input data to a Programmable Logic Controller (PLC) unit. The blend of natural gas and hydrogen gas is performed using the Programmable Logic Controller (PLC) unit programmed with algorithms based on the real-time operational data. The hydrogen and natural gas flow rates are adjusted using a plurality of automatic flow control computers and electrically controlled actuators based on commands from the Programmable Logic Controller (PLC) unit. The Programmable Logic Controller (PLC) unit provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator in the hydrogen gas cascade for adjusting hydrogen flow based on the load requirements. Finally, the blended fuel mixture is delivered to the natural gas engine generator through a gas outlet. The emissions of CO2 and other exhaust gases are monitored and reported using an exhaust gas monitoring unit. The CO2 emissions are reduced using the blending unit to mix hydrogen gas with natural gas and the Programmable Logic Controller (PLC) unit to optimize the blended mixture based on real-time data from the sensors, thereby lowering the amount of CO2 produced during operation.

Brief Description of drawings

[0023] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:

[0024] Figure 1 illustrates the schematic diagram of a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators in accordance with the present invention; and

[0025] Figure 2 illustrates the circuit diagram of a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators in accordance with the present invention.

Detailed description of the invention

[0026] An embodiment of this invention, illustrating its features, will now be described in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

[0027] The present invention relates to a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators by mixing hydrogen and natural gas. The system can easily integrate with the existing natural gas engine generators, minimizing the need for extensive modifications and reduces the implementation costs.

[0028] The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.

[0029] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.

[0030] Referring now to Figure 1, a schematic view of a system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) in accordance with the present invention is illustrated. The system (100) is a modular unit designed to integrate with natural gas engine generators (200).

[0031] The system (100) includes a hydrogen gas inlet (20), a natural gas inlet (30), a hydrogen gas cascade (40), a blending unit (50), a safety mechanism (70), a plurality of gas pressure reducing skids (80), a Programmable Logic Controller (PLC) unit (85), a plurality of automatic flow control computers ( not shown in figure) and electrically controlled actuators ( not shown in figure), a plurality of sensors, an exhaust gas monitoring unit (90), and a gas outlet (95).

[0032] The system (100) can be retrofitted onto a wide variety of generator models and sizes without requiring any modifications or replacements. The system (100) may include attachable and detachable connection points (not shown in figure) for hydrogen gas inlet (20) and natural gas inlets (30) for easy integration with natural gas engine generators (200). The system (100) further includes a plurality of mounting brackets and installation hardware (not shown in figure) compatible with different generator configurations for securely attaching to the natural gas engine generator (200).

[0033] Referring again to Figure 1, the hydrogen gas inlet (20) receives hydrogen gas from the hydrogen gas cascade (40). The hydrogen gas cascade (40) is configured to supply hydrogen gas at an initial pressure range of 145-200 bar. Specifically, the hydrogen gas cascade (40) consists of a series of high-pressure tanks or cylinders (40a) that supply hydrogen at a pressure of 145-200 bar, which is quite high. The hydrogen gas inlet (20) is designed to handle this high pressure safely, directing the gas into the system (100) for further processing.

[0034] The hydrogen gas cascade (40) maintains a constant and stable supply of hydrogen gas available. The plurality of gas pressure reducing skids (referred as PRV in Figure 2) (80) are provided for reducing the pressure of the hydrogen gas. More specifically, the hydrogen gas from the initial pressure range of 145-200 bar is reduced to an operating pressure of 1-4 bar using the gas pressure reducing skids (80). The hydrogen gas cascade uses pressure regulators and safety valves (not shown in figure) to maintain the correct pressure, preventing any fluctuations that could disrupt the system.

[0035] Similarly, the natural gas inlet (30) is configured to receive natural gas from the existing supply lines of the gas engine generator. The natural gas inlet (30) is made compatible with the standard natural gas supply that the generator already uses. The natural gas inlet (30) provides a secure connection for the natural gas to flow smoothly into the system. The natural gas inlet is connected directly to the generator’s supply lines, to integrate with the system (100) without any major modifications. The natural gas inlet (30) allows the natural gas to enter the blending unit (50) where it will be mixed with hydrogen gas. The blending unit (50) combines hydrogen and natural gas in precise amounts to create an optimal fuel mixture.

[0036] Both the gases including the hydrogen gas at its reduced pressure and the natural gas are mixed together in the blending unit (50). Specifically, the blending unit (50) includes a mixing chamber (60) where hydrogen gas and natural gas are combined. The blending unit (50) blend these gases thoroughly and evenly. The optimal blend is then ready to be sent to the natural gas engine generator (200). The blended fuel mixture flows through the gas outlet (95) and into the generator’s (200) engine. The special mixture of hydrogen and natural gas helps reduce CO2 emissions when the generator (200) is running.

[0037] The blending unit (50) works with a Programmable Logic Controller (PLC) unit (85) that constantly monitors data from various sensors to ensure optimal performance. The Programmable Logic Controller (PLC) unit (85) is programmed with algorithms to optimize the blend of natural gas and hydrogen based on real-time operational data. The Programmable Logic Controller (PLC) unit (85) receives real-time information from a variety of sensors, including current transformers, engine knock sensors, temperature sensors, and gas leakage detectors (33). These sensors provide essential data on parameters such as engine load, temperature, and gas leaks. The Programmable Logic Controller (PLC) unit (85) uses this data to adjust the amounts of hydrogen and natural gas, maintaining the optimal blend for efficient engine operation and reduced CO2 emissions. Additionally, the Programmable Logic Controller (PLC) unit (85) provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator (not shown in figure) in the hydrogen gas cascade (40) for adjusting hydrogen flow based on the load requirements. Specifically, when the Programmable Logic Controller (PLC) unit (85) determines how much hydrogen is needed based on the current load or demand on the engine, and sends an appropriate signal within this 0-100 mV range. The actuator receives this signal and adjusts the position of the rotary ball valve accordingly. The rotary valve controls the flow of hydrogen gas entering the system (100). For example, if the engine requires more hydrogen to maintain optimal performance, the Programmable Logic Controller (PLC) unit (85) might send a higher voltage signal, which causes the rotary ball valve actuator to open the valve more, allowing more hydrogen to flow. Conversely, if less hydrogen is needed, the Programmable Logic Controller (PLC) unit (85) sends a lower voltage signal, and the valve closes slightly to reduce the hydrogen flow. By continuously adjusting based on real-time conditions, the Programmable Logic Controller (PLC) unit (85) helps keep the engine running smoothly and efficiently, thereby reducing carbon dioxide (CO2) emissions.

[0038] The current transformers (not shown in figure) measure the electrical load on the natural gas engine generator (200). The measurement helps the Programmable Logic Controller (PLC) unit (85) to understand how much power the engine is using and adjust the gas blend accordingly to maintain optimal performance of the natural gas engine generator (200). The engine knock sensors detect any abnormal vibrations or noises in the natural gas engine generator that indicate inefficient or harmful combustion processes. If knocking is detected, the Programmable Logic Controller (PLC) unit (85) make immediate adjustments to the fuel blend to prevent damage to the natural gas engine generator (200). The temperature sensors (not shown in figure) measure the temperature within various parts of the natural gas engine generator (200) thereby preventing overheating and maintain a safe and efficient temperature. The Programmable Logic Controller (PLC) unit (85) uses the data from the temperature sensors to adjust the gas mix and maintains the optimal temperature range.

[0039] The gas leakage detectors (33) (referred as nitrogen detector and hydrogen detector in Figure 2) are installed to detect any leaks of hydrogen or natural gas. Specifically, 4-20 mA sensors are used for detecting the gas leakage of hydrogen and natural gas and sending the output to the Programmable Logic Controller (PLC) unit (85). The gas leakage detectors (33) provide an immediate alert if there is a leak, allowing the Programmable Logic Controller (PLC) unit (85) to take quick action to shut down the gas flow and prevent any potential hazards. By gathering data from these sensors, the Programmable Logic Controller (PLC) unit (85) make informed decisions and adjustments in real-time.

[0040] The blending concentration of hydrogen gas in the system (100) is adjusted by a real-time monitoring unit utilizing feed-forward and feedback control algorithms in the Programmable Logic Controller (PLC) unit (85). Feed-forward control anticipates changes and adjusts the gas blend in advance, while feedback control makes adjustments based on the actual performance of the system. The combination of the feed forward and feedback control helps in maintaining the optimal gas blend under different operating conditions. For example, if the engine's (200) load is expected to increase, the system (100) predicts this change and adjusts the hydrogen concentration in advance for efficient operation. By anticipating changes, the system (100) can make adjustments to the hydrogen and natural gas mix thereby preventing disruptions in performance and maintaining the steady engine operation. The real-time monitoring unit collects data from sensors by measuring parameters like engine load, temperature, and CO2 emissions etc. If the sensors detect deviations from the desired performance, the feedback control algorithm steps in to correct these deviations. For instance, if CO2 levels are higher than expected, the system (100) increases the hydrogen concentration to reduce emissions. By using both feed-forward and feedback control algorithms, the system (100) achieves a balanced approach by maintaining optimal blending concentration of hydrogen thereby enhancing engine efficiency, reducing harmful emissions, and ensuring a smooth operation under varying conditions.

[0041] After mixing the gases in the blending unit (50), the blended mixture is sent to the engine generator (200) through the gas outlet (95). The system (100) reduces CO2 emissions by utilizing the blending unit (50) to mix the hydrogen gas with natural gas and the Programmable Logic Controller (PLC) unit (85) to optimize the blended mixture based on the real-time data from sensors, thereby lowering the amount of CO2 produced during operation, and a portion of the natural gas is replaced by hydrogen, resulting in a mixture that combusts without producing CO2.

[0042] The blending unit (50) is equipped with a safety mechanism (70) including slam shut-off valves (not shown in figure), solenoid valves (12), flow meters (15), pressure gauges (10), filters (25), ball valves (35), and safety relief valves (22). The slam shut-off valves close and stop the flow of gas if there is a sudden change in pressure thereby preventing any potential accidents or damage that could be caused by unexpected pressure surges. The slam shut-off valves protect both the equipment and the people operating the equipment. The solenoid valves (12) are used to control the flow of gas electronically. The solenoid valves (12) shut down the gas supply instantly if needed particularly in emergency situations where immediate action is required to prevent hazards. The solenoid valves (12) allow the gas flow to be stopped quickly and safely, reducing the risk of leaks or explosions.

[0043] The flow meters (15) measure the amount and pressure of gas flowing through the system (100). The flow meters (15) continuously monitor the gas pressures and flow rates to ensure everything is within safe and optimal levels. The data from the flow meters (15) is used to make real-time adjustments to the mixing of the gas.

[0044] Further the safety mechanism (70) handles any variations in gas pressure in the system and automatically adjust the gas flow to maintain safe operating conditions if the pressure becomes too high or too low by using pressure gauges (10). The pressure gauges (10) are installed throughout the system to continuously monitor the gas pressure at various points. The pressure gauges (10) provide real-time data on the pressure levels of both hydrogen and natural gas, ensuring the gases remain within safe operating ranges. If the pressure gauges (10) detect that the gas pressure is approaching unsafe levels, the system (100) can take corrective actions, such as adjusting the flow rates or shutting down certain components to prevent hazardous overpressure situations.

[0045] Furthermore, the safety mechanism (70) includes filters (25) to remove impurities and contaminants from both the hydrogen and natural gas before they enter the blending unit (50) The filters (25) help to protect the engine from potential damage caused by impurities, contributing to more efficient combustion, reducing wear and tear on engine components, and extending the engine’s (200) lifespan.

[0046] In addition to pressure gauges (10) and filters, (25) the safety mechanism (70) includes ball valves (35) and safety relief valves (22), for maintaining safe operation under various conditions. The ball valves (35) are used to manually control the flow of gases within the system (100) and can be operated by technicians to open or close the gas flow during maintenance, repairs, or emergency situations. The manual control option adds a layer of flexibility and safety, allowing the technicians to quickly and easily manage the gas flow in case of automatic system failures or the need for manual intervention. The safety relief valves (22) are designed to automatically vent excess gas pressure from the system (100). If the pressure within the system (100) exceeds safe levels, these safety relief valves (22) will open to release the excess gas, preventing potential overpressure situations. By venting excess pressure, the safety relief valves (22) protect the system (100) from damage that could be caused by overpressure, ensuring the system's (100) safety and maintaining its integrity and reliability.

[0047] The combination of pressure gauges (10), filters (25), ball valves (35), and safety relief valves (22) work together to continuously monitor, control, and manage the gas pressures and cleanliness within the system (100) thereby providing safe and efficient operation. For instance, if the pressure gauges (10) detect high pressure, the system (100) might first try to adjust the flow rates using the Programmable Logic Controller (PLC) unit (85) and the actuators. If the pressure continues to rise, the safety relief valves (22) will automatically vent the excess gas to bring the pressure back to safe levels. Technicians can also use the ball valves (35) to manually intervene if necessary, ensuring that the system (100) remains under control in all situations.

[0048] The system (100) includes a set of automatic flow control computers and electrically controlled actuators that for managing the flow rates of hydrogen and natural gas. The flow control computers are the devices programmed to precisely regulate the amount of each gas including hydrogen and natural gas entering the blending unit (50). The flow control computers continuously monitor the flow rates and adjust them in real-time to maintain the optimal blend of hydrogen and natural gas for the engine's operation. The electrically controlled actuators are the mechanical devices that respond to the commands from the flow control computers. When the flow control computers determine that an adjustment is needed based on data from the sensors monitoring parameters like gas pressure, engine load, and emission levels flow control computers send signals to the actuators. The actuators then physically adjust the valves that control the flow of hydrogen and natural gas into the blending unit.

[0049] The exhaust gas monitoring unit (90) is placed in the exhaust system (100) of the natural gas engine generator. Specifically, the exhaust gas monitoring unit (90) is installed in the exhaust pipe of the engine generator, close to the point where exhaust gases are expelled from the engine (200). The exhaust gas monitoring unit (90) includes several sensors that are arranged to detect various types of exhaust gases. These sensors are capable of measuring Carbon Dioxide (CO2) to monitor and report the levels of CO2 emissions. The exhaust gas monitoring unit (90) also detect the Carbon Monoxide (CO) to detect harmful CO emissions, and Nitrogen Oxides (NOx) to monitor NOx emissions, which are important for environmental compliance. The sensors within the exhaust gas monitoring unit (90) are connected to the Programmable Logic Controller (PLC) unit (85) via wired or wireless communication channels. The setup allows for real-time transmission of data from the sensors to the Programmable Logic Controller (PLC) unit (85). The exhaust gas monitoring unit (90) is connected to the engine's (200) electrical system data transmission systems to operate without interruption.

[0050] The exhaust gas monitoring unit (90) is integrated into the exhaust pipe using flanges or clamps (not shown in figure) that secure it firmly in place. If the engine has multiple exhaust pipes, each may have its own monitoring unit, or the exhaust streams may be combined into a single pipe where the exhaust gas monitoring unit is placed. The exhaust gas monitoring unit (90)may include heat shields or cooling mechanisms ( not shown in figure) to protect the sensors from the high temperatures of the exhaust gases. The arrangement includes easy access points for maintenance and calibration. This ensures that the sensors can be regularly checked and maintained for accurate readings. The wires from the sensors in the exhaust gas monitoring unit (90) run to the Programmable Logic Controller (PLC) unit (85). The wires are enclosed in protective conduits to shield them from heat and physical damage.

[0051] In an embodiment, the data from the sensors may be transmitted wirelessly to the Programmable Logic Controller (PLC) unit (85), reducing the need for extensive wiring and allowing for more flexible installation. The exhaust gas monitoring unit (90) continuously monitors the exhaust gases as the engine operates. The sensors detect the levels of various gases and send this information in real-time to the Programmable Logic Controller (PLC) unit (85). Based on the data received from the exhaust gas monitoring unit (90), the Programmable Logic Controller (PLC) unit (85) can make real-time adjustments to the fuel blend, optimizing the engine’s performance and reducing harmful emissions.

[0052] In the present embodiment a natural gas generator (200) is configured to operate with the blended fuel mixture. The desired blend ratio is maintained by performing a daily automatic calibration to account for variations in the natural gas composition. The natural gas composition can change due to various factors, such as differences in supply sources or environmental conditions. These variations can affect how the gas burns and, consequently, the natural gas engine's performance and emissions.

[0053] The daily automatic calibration process is done to adjust the system (100) to these changes in gas composition. By doing this every day, the system (100) maintains the blend ratio of hydrogen to natural gas regardless of any variations in the natural gas. The system (100) uses sensors (not shown in figure) to collect data on the current composition of the natural gas. These sensors measure various properties of the gas, such as its chemical makeup and energy content. Based on the data collected, the system adjusts the blend ratio of hydrogen and natural gas. If the natural gas composition has changed, the system (100) will alter the amount of hydrogen mixed with it to run the natural gas engine efficiently and with low emission.

[0054] By the way of non-limiting example, the system (100) automatically checks the natural gas composition before the engine starts its daily operations. The sensors detect any changes from the previous day, and the system recalibrates the hydrogen-to-natural-gas ratio accordingly. Throughout the day, the system (100) continues to monitor the gas composition and make minor adjustments as needed. However, the major calibration happens once daily, setting a stable baseline for the engine's (200) operations.

[0055] In an aspect, a method (not shown in figure) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) in accordance with the present invention is provided for the sake of brevity, the method is described in conjunction with the system (100).

[0056] Firstly, hydrogen gas is received into the system (100) through a hydrogen gas inlet (20), while natural gas is received into the system (100) through a natural gas inlet (30). The hydrogen gas is supplied at an initial pressure range of 145-200 bar using a hydrogen gas cascade (40), which ensures a constant and stable supply of hydrogen gas.

[0057] Next, the hydrogen gas and natural gas are combined in a blending unit (50). The blending unit (50) includes a mixing chamber (60) where the gases are mixed to create an optimal fuel blend. To manage the high pressure of hydrogen gas, the system (100) utilizes a plurality of gas pressure reducing skids (80) that reduce the hydrogen gas pressure from the initial 145-200 bar to an operating pressure of 1-4 bar. The blending unit (50) is equipped with a safety mechanism (700 including slam shut-off valves, solenoid valves (12), flow meters (15), pressure gauges (10), filters (25), ball valves (35), and safety relief valves (22).
[0058] The method also includes monitoring real-time operational data using a plurality of sensors. These sensors include current transformers, engine knock sensors, temperature sensors, and gas leakage detectors, which provide essential input data to a Programmable Logic Controller (PLC) unit (85). The Programmable Logic Controller (PLC) unit (85) is programmed with algorithms that optimize the blend of natural gas and hydrogen based on the real-time operational data.

[0059] To maintain the optimal blend, the system (100) adjusts hydrogen and natural gas flow rates using a plurality of automatic flow control computers and electrically controlled actuators. These adjustments are made based on commands from the Programmable Logic Controller (PLC) unit (85), ensuring control over the gas mixture.

[0060] The blended fuel mixture is then delivered to the natural gas engine generator through a gas outlet (95). An exhaust gas monitoring unit (90) is used to monitor and report emissions of CO2 and other exhaust gases, ensuring compliance with environmental standards.

[0061] The method reduces CO2 emissions by utilizing the blending unit (50) to mix hydrogen gas with natural gas and the Programmable Logic Controller (PLC) unit (85) to optimize the blended mixture based on real-time data from the sensors. This optimization lowers the amount of CO2 produced during operation, as a portion of the natural gas is replaced by hydrogen, resulting in a mixture that combusts without producing CO2.

[0062] Also, the method includes configuring the natural gas engine generator to operate with the blended fuel mixture. The blending concentration of hydrogen gas is adjusted using a real-time monitoring unit that uses feed-forward and feedback control algorithms. These algorithms anticipate changes and make adjustments in advance (feed-forward) while also making corrections based on actual performance (feedback).

[0063] To maintain the desired blend ratio of hydrogen and natural gas, the method performs a daily automatic calibration, accounting for variations in the natural gas composition. This daily calibration ensures consistent performance and optimal emissions reduction.

[0064] Gas leakage of hydrogen and natural gas is detected using 4-20 mA sensors, which act as gas leakage detectors (33). The output from these detectors is sent to the Programmable Logic Controller (PLC) unit (85) for immediate action if any leaks are detected.

[0065] The Programmable Logic Controller (PLC) unit (85) also provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator in the hydrogen gas cascade (40). This actuator adjusts the hydrogen flow based on the load requirements, ensuring that the engine receives the correct amount of hydrogen for optimal performance.

[0066] Finally, the method ensures continuous monitoring of gas pressure within the system (100) using pressure gauges and maintains clean gas mixing using filters (25). For manual intervention, ball valves (35) are used, while safety relief valves (22) vent excess pressure to prevent overpressure situations.

[0067] Thus, the present invention has the advantage of providing a system for reducing carbon dioxide (CO2) emissions in natural gas engine generators. The system can easily integrate with existing natural gas engine generators, minimizing the need for extensive modifications and reducing implementation costs. Additionally, the system maximizes fuel efficiency by optimizing the blend of hydrogen and natural gas, ensuring consistent and reliable performance. Furthermore, the system allows for real-time monitoring and adjustment of fuel blends based on operational conditions, enhancing system responsiveness and reliability. Moreover, the system is user-friendly, with straightforward controls and interfaces, making it easy to operate, manage, and maintain.

[0068] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
, Claims:We Claim:

1. A system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200), the system (100) being integrated with a natural gas engine generator (200), the system (100) includes:
a hydrogen gas inlet (20) for receiving hydrogen gas into the system (100);
a natural gas inlet (30) for receiving natural gas into the system (100);
a hydrogen gas cascade (40) configured to supply hydrogen gas at an initial pressure range of 145-200 bar, characterized in that, the system (100) comprises:
a blending unit (50) connected to both the hydrogen gas inlet (20) and the natural gas inlet (30), the blending unit (50) comprising a mixing chamber (60) where hydrogen gas and natural gas are combined to create an optimal fuel blend;
a safety mechanism (70) equipped with the blending unit (50), the safety mechanism includes slam shut-off valves, solenoid valves (12), flow meters (15), pressure gauges (10), filters (25), ball valves (35), and safety relief valves (22);
a plurality of gas pressure reducing skids (80) for hydrogen and natural gas wherein the hydrogen gas from the initial pressure range of 145-200 bar is reduced to an operating pressure of 1-4 bar;
a Programmable Logic Controller (PLC) unit (85) programmed with algorithms to optimize the blend of natural gas and hydrogen based on real-time operational data;
a plurality of sensors, including current transformers, engine knock sensors, temperature sensors, and gas leakage detectors (33), to provide real-time input data to the Programmable Logic Controller (PLC) unit (85);
a plurality of automatic flow control computers and electrically controlled actuators for adjusting hydrogen and natural gas flow rates based on commands from the Programmable Logic Controller (PLC) unit (85);
an exhaust gas monitoring unit (90) for monitoring and reporting emissions of CO2 and other exhaust gases; and
a gas outlet (95) for delivering the blended fuel mixture to the natural gas engine generator (200), wherein the system (100) reduces CO2 emissions by utilizing the blending unit (50) to mix the hydrogen gas with natural gas and the Programmable Logic Controller (PLC) unit (85) to optimize the blended mixture based on the real-time data from the plurality of sensors thereby lowering the amount of CO2 produced during the operation of the natural gas engine generator (200), wherein a portion of the natural gas is replaced by hydrogen wherein the resultant mixture combusts without producing CO2.
2. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein the blending concentration of hydrogen gas is adjusted by a real-time monitoring unit utilizing feed-forward and feedback control algorithms.
3. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein the desired blend ratio of the hydrogen and natural gas is maintained by performing a daily automatic calibration to account for variations in the natural gas composition.
4. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein 4-20 mA sensors are used as a gas leakage detector (33) for detecting the gas leakage of hydrogen and natural gas and sending the output to the Programmable Logic Controller (PLC) unit (85).
5. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein the Programmable Logic Controller (PLC) unit (85) provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator in the hydrogen gas cascade (40) for adjusting hydrogen flow based on the load requirements.
6. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein the pressure gauges (10) continuously monitor the gas pressure within the system and filters (25) are provided for mixing clean gases.
7. The system (100) for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 1, wherein the ball valves (35) is provided for manual intervention when needed and safety relief valves (22) is to vent the excess pressure and prevent the overpressure in the system.
8. A method for reducing carbon dioxide (CO2) emissions in natural gas engine generators, comprising:
receiving hydrogen gas into the system (100) through a hydrogen gas inlet (20);
receiving natural gas into the system (100) through a natural gas inlet (30);
supplying hydrogen gas at an initial pressure range of 145-200 bar using a hydrogen gas cascade (40);
combining the hydrogen gas and natural gas in a blending unit (50), the blending unit (50) comprising a mixing chamber (60) where the gases are mixed to create an optimal fuel blend;
utilizing a safety mechanism (70) including slam shut-off valves, solenoid valves (12), flow meters (15), pressure gauges (10), filters (25), ball valves (35), and safety relief valves (22) to ensure safe and reliable operation;
utilizing a plurality of gas pressure reducing skids (80) to reduce the hydrogen gas pressure from 145-200 bar to an operating pressure of 1-4 bar;
monitoring real-time operational data using a plurality of sensors, including current transformers, engine knock sensors, temperature sensors, and gas leakage detectors (33), to provide input data to a Programmable Logic Controller (PLC) unit (85);
optimizing the blend of natural gas and hydrogen using the Programmable Logic Controller (PLC) unit (85) programmed with algorithms based on the real-time operational data;
adjusting hydrogen and natural gas flow rates using a plurality of automatic flow control computers and electrically controlled actuators based on commands from the Programmable Logic Controller (PLC) unit (85), the Programmable Logic Controller (PLC) unit (85) provides output commands in the range of 0-100 mV to an electrically controlled rotary ball valve type actuator in the hydrogen gas cascade (40) for adjusting hydrogen flow based on the load requirements;
delivering the blended fuel mixture to the natural gas engine generator through a gas outlet (95);
monitoring and reporting emissions of CO2 and other exhaust gases using an exhaust gas monitoring unit (90);
reducing CO2 emissions by using the blending unit (50) to mix hydrogen gas with natural gas and the Programmable Logic Controller (PLC) unit (85) to optimize the blended mixture based on real-time data from the sensors, thereby lowering the amount of CO2 produced during operation.
9. The method for reducing carbon dioxide (CO2) emissions in natural gas engine generators (200) as claimed in claim 9 wherein a daily automatic calibration to maintain the desired blend ratio of hydrogen and natural gas, accounting for variations in the natural gas composition.