Engine controller and methods for controlling emission and power generation system using the same

1. A method for controlling an emission amount in a gas stream emitted from a power generation system comprising a combustion engine operating at stoichiometric conditions and emitting an exhaust gas stream, an exhaust gas recirculation (EGR) system to recirculate a portion of the exhaust was stream to the combustion engine, a three-way catalyst disposed downstream of the combustion engine, one or more processors and a memory which is accessible to the processor, the method comprising:

determining a pre-catalyst emission level in at least one of the one or more processors by measuring at least an EGR set-point value with a pre-catalyst emission sensor disposed upstream of the three-way catalyst, at least one of the one or more processors receiving one or more signals generated by the pre-catalyst emission sensor and using a combustion engine model stored in the memory to correlate at least the EGR set-point value to the pre-catalyst emission level;

determining a post-catalyst emission level in at least one of the one or more processors using a three-way catalyst model stored in the memory to correlate catalyst properties based on the pre-catalyst emission level to the post-catalyst emission level;

determining an adjusted post-catalyst emission level in at least one of the one or more processors based on an error corrected form of the post-catalyst emission level;

determining a difference in at least one of the one or more processors between the post-catalyst emission level and the adjusted post-catalyst emission level and comparing the difference with a threshold value; and

determining, in at least one of the one or more processors, whether the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value and maintaining the emission amount in the gas stream below an emission regulatory limit by sending one or more signals from at least one of the one or more processors to adjust an actual value of an engine operating parameter when the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value.

2. The method of claim 1 , wherein the adjusted post-catalyst emission level is determined based on one or more measured parameters comprising a measured pre-catalyst emission level, a measured post-catalyst emission level, a gas stream humidity, or combinations thereof.

3. The method of claim 1 , wherein the engine operating parameter comprises an exhaust gas recirculation (EGR) set-point, a lambda (λ) set-point, an engine ignition timing, or combinations thereof.

4. The method of claim 1 , comprising determining that adjusting the actual operating parameter is required if the difference is greater than the threshold value, and further comprising sending a signal to adjust the engine operating parameter.

5. The method of claim 4 , further comprising determining an estimated value of the engine operating parameter if the difference is greater than the threshold value and adjusting the actual value of the engine operating parameter based on the estimated value of the engine operating parameter.

6. The method of claim 5 , comprising determining the estimated value of the engine operating parameter based on the adjusted post-catalyst emission level, the emission regulatory limit, and one or both of a λ curve and an EGR curve.

7. The method of claim 6 , wherein the λ curve is indicative of a relationship between the adjusted post-catalyst emission level and a λ set-point, and wherein the EGR curve is indicative of a relationship between at least two of an EGR set-point, an engine load, and the pre-catalyst emission level.

8. The method of claim 6 , wherein the estimated value of the engine operating parameter is determined further based on a combustion engine age, a three-way catalyst age, or a combination thereof.

9. The method of claim 6 , wherein determining the estimated value of the engine operating parameter comprises:

determining a range of estimated values of the engine operating parameter based on the adjusted post-catalyst emission level, the emission regulatory limit, and one or both of the λ curve and the EGR curve; and

selecting the estimated value of the engine operating parameter from the range of estimated values of the engine operating parameter.

10. The method of claim 5 , further comprising adjusting the actual value of the engine operating parameter based on the estimated value of the engine operating parameter such that a number of occurrences of a misfire condition is maintained below a determined number of misfire occurrences.

11. The method of claim 5 , further comprising adjusting the actual value of the engine operating parameter based on the estimated value of the engine operating parameter such that a number of occurrences of a knock condition is maintained below a determined number of knock occurrences.

12. The method of claim 1 , further comprising:

determining a region of operation of the power generation system based at least on location coordinates determined via a global positioning system sensor; and

determining the emission regulatory limit based on the region of operation of the power generation system.

13. The method of claim 1 , wherein an input value to the three-way catalyst model further comprises a gas stream temperature, a gas stream mass flow-rate, or a combination thereof.

14. An engine controller for controlling an emission amount in a gas stream emitted from a power generation system comprising a combustion engine operating at stoichiometric conditions and emitting an exhaust gas stream, an exhaust gas recirculation (EGR) system to recirculate a portion of the exhaust gas stream to the combustion engine, and a three-way catalyst disposed downstream of the combustion engine, the engine controller comprising:

a memory storing one or more processor-executable routines; and

one or more processors to execute the one or more processor-executable routines which, when executed, cause acts to be performed comprising:

determining a pre-catalyst emission level in at least one of the one or more processors by measuring at least an EGR set-point value with a pre-catalyst emission sensor disposed upstream of the three-way catalyst, at least one of the one or more processors receiving one or more signals generated by the pre-catalyst emission sensor and using a combustion engine model stored in the memory to correlate at least the EGR set-point value to the pre-catalyst emission level;

determining a post-catalyst emission level in at least one of the one or more processors using a three-way catalyst model stored in the memory to correlate catalyst properties based on the pre-catalyst emission level to the post-catalyst emission level;

determining an adjusted post-catalyst emission level in at least one of the one or more processors based on an error corrected form of the post-catalyst emission level;

determining a difference in at least one of the one or more processors between the post-catalyst emission level and the adjusted post-catalyst emission level and comparing the difference with a threshold value; and

determining, in at least one of the one or more processors, whether the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value and maintaining the emission amount in the gas stream below an emission regulatory limit by sending one or more signals from at least one of the one or more processors to adjust an actual value of an engine operating parameter when the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value.

15. The engine controller of claim 14 , wherein the engine operating parameter comprises an exhaust gas recirculation (EGR) set-point, a lambda (λ) set-point, an engine ignition timing, or combinations thereof.

16. The engine controller of claim 14 , wherein the acts to be performed further comprise determining an estimated value of the engine operating parameter if the difference is greater than the threshold value and adjusting the actual value of the engine operating parameter based on the estimated value of the engine operating parameter.

17. A power generation system, comprising:

a combustion engine operating at stoichiometric conditions and emitting an exhaust gas stream;

an exhaust gas recirculation (EGR) system to recirculate a portion of the exhaust gas stream to the combustion engine;

a three-way catalyst disposed downstream of the combustion engine; and

an engine controller operably coupled to the combustion engine to control an emission amount in a gas stream emitted from the power generation system, wherein the engine controller comprises:

a memory storing one or more processor-executable routines; and

one or more processors to execute the one or more processor-executable routines which, when executed, cause acts to be performed comprising:

determining a pre-catalyst emission level in at least one of the one or more processors by measuring at least an EGR set-point value with a pre-catalyst emission sensor disposed upstream of the three-way catalyst, at least one of the one or more processors receiving one or more signals generated by the pre-catalyst emission sensor and using a combustion engine model stored in the memory to correlate at least the EGR set-point value to the pre-catalyst emission level;

determining a post-catalyst emission level in at least one of the one or more processors using a three-way catalyst model stored in the memory to correlate catalyst properties based on the pre-catalyst emission level to the post-catalyst emission level;

determining an adjusted post-catalyst emission level in at least one of the one or more processors based on an error corrected form of the post-catalyst emission level;

determining a difference in at least one of the one or more processors between the post-catalyst emission level and the adjusted post-catalyst emission level and comparing the difference with a threshold value; and

determining, in at least one of the one or more processors, whether the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value and maintaining the emission amount in the gas stream below an emission regulatory limit by sending one or more signals from at least one of the one or more processors to adjust an actual value of an engine operating parameter when the difference between the post-catalyst emission level and the adjusted post-catalyst emission level is greater than the threshold value.

18. The power generation system of claim 17 , wherein the engine operating parameter comprises an exhaust gas recirculation (EGR) set-point, a lambda (λ) set-point, an engine ignition timing, or combinations thereof.

19. The power generation system of claim 17 , wherein the acts to be performed further comprise determining an estimated value of the engine operating parameter if the difference is greater than the threshold value and adjusting the actual value of the engine operating parameter based on the estimated value of the engine operating parameter.