Patent Grant
8839622
This document relates to the operation of a fluid expansion system, including some systems that comprise a turbine apparatus to generate energy from gaseous fluid expansion.
A number of industrial processes create heat as a byproduct. In some circumstances, this heat energy is considered “waste” heat that is dissipated to the environment in an effort to maintain the operating temperatures of the industrial process equipment. Exhausting or otherwise dissipating this “waste” heat generally hinders the recovery of this heat energy for conversion into other useful forms of energy, such as electrical energy.
Some turbine generator systems have been used to generate electrical energy from the rotational kinetic energy a turbine wheel. For example, the rotation of the turbine wheel can be used to rotate a permanent magnet within a stator, which then generates electrical energy. Such turbine generator systems use a compressed gas that is expanded during the flow over the turbine wheel, thereby causing the turbine wheel to rotate. In some circumstances, the fluid flowing toward the turbine wheel can include “slugs” of liquid state fluid intermixed with the gaseous state fluid. The presence of liquid slugs in the working fluid can reduce the efficiency of the turbine system.
Some embodiments of a generator system can be used in a Rankine cycle to recover heat from one of a number of commercial applications and to convert that heat energy into useable electrical energy. For example, the Rankine cycle may employ a working fluid that recovers heat from a commercial compressor interstage cooler or a commercial exhaust oxidizer. The heated and pressurized working fluid can then be directed to the generator system for generation of usable electrical energy. In particular embodiments, the generator system may include a turbine generator apparatus to generate electrical energy and a liquid separator arranged upstream of the turbine generator apparatus. In such circumstances, the liquid separator can receive the heated and pressurized working fluid so as to separate a substantial portion of the liquid state droplets or slugs of working fluid from the gaseous state working fluid. The gaseous state working fluid can be passed to the turbine generator apparatus with the substantial portion of liquid state droplets or slugs removed, thereby protecting the turbine generator apparatus from damage caused by such liquid state working fluid.
In some embodiments, a generator system for use in a Rankine cycle may include a turbine generator apparatus and a liquid separator. The turbine generator apparatus may include an inlet conduit to direct a working fluid toward a turbine wheel that is rotatable in response to expansion of the working fluid. The liquid separator may separate a liquid state portion of the working fluid from a gaseous state portion of the working fluid. The liquid separator may be connected in the Rankine cycle upstream of the turbine generator apparatus so that the gaseous state portion of the working fluid is directed to the inlet conduit after separation of the liquid state portion.
In particular embodiments, a method may include directing heated and pressurized working fluid in a Rankine cycle toward a liquid separator arranged in the Rankine cycle upstream of a turbine generator apparatus. The method may also include separating a liquid state portion of the heated and pressurized working fluid from a gaseous state portion of the heated and pressurized working fluid. The method may further include directing the gaseous state portion of the working fluid to an inlet conduit of the turbine generator apparatus and toward a turbine wheel that is rotatable in response to expansion of the working fluid.
In some embodiments, a generator system for use in a Rankine cycle may include a low pressure reservoir for a working fluid of a Rankine cycle and a pump device to pressurize the working fluid delivered from the low pressure reservoir. The system may also include a liquid separator to separate a liquid state portion of the working fluid from a gaseous state portion of the working fluid. The liquid separator may be arranged in the Rankine cycle downstream of the pump device so as to receive the pressurized working fluid from the pump device. The system may further include a turbine generator apparatus that generates electrical energy in response expansion of the working fluid. The turbine generator apparatus may be arranged in the Rankine cycle downstream of liquid separator so that the gaseous state portion of the working fluid is directed to the turbine generator apparatus after separation of the liquid state portion. The system may also include a flow valve arranged in the Rankine cycle upstream of the turbine generator apparatus so as to selectively close the flow of the working fluid to the turbine generator apparatus. The system may further include a bypass valve arranged in the Rankine cycle to selectively open a bypass conduit that directs the working fluid toward the low pressure reservoir without passing into the turbine generator apparatus. The flow valve and the bypass valve may be mechanically coupled to one another to operate in unison. The system may also include a transportable system package that houses the low pressure reservoir, the pump device, the liquid separator, the turbine generator apparatus, the flow valve, and the bypass valve.
These and other embodiments described herein may provide one or more of the following advantages. First, some embodiments of a fluid expansion system may include a liquid separator arranged upstream of a turbine generator apparatus. The liquid separator may be configured to separate and remove a substantial portion of any liquid state droplets (or slugs) of working fluid that might otherwise pass into the turbine generator apparatus 100. Because a substantial portion of any liquid-state droplets or slugs are removed by the liquid separator, the turbine generator apparatus may be protected from erosion or damage caused by such liquid state working fluid.
Second, the fluid expansion system may be equipped with a dual control valve system that provides flow control during transient flow conditions, protection for the turbine generator apparatus, and efficient power output from the turbine generator apparatus. In some cases, first and second control valves may be mechanically coupled to one another so as to operate in unison, for example, by activation of a single actuator device.
Third, the fluid expansion system can be used to recover waste heat from industrial applications and then to convert the recovered waste heat into electrical energy. The heat energy can be recovered from an industrial application in which heat is a byproduct, such as commercial exhaust oxidizers (e.g., a fan-induced draft heat source bypass system, a boiler system, or the like), refinery systems that produce heat, foundry systems, smelter systems, landfill flare gas and generator exhaust, commercial compressor systems, food bakeries, and food or beverage production systems. Furthermore, the heat energy can be recovered from geo-thermal heat sources and solar heat sources.
Fourth, some embodiments of the turbine generator apparatus may be arranged so that the fluid outflow to the outlet side of the turbine wheel is directed generally toward the rotor, the stator, or both (e.g., toward a permanent magnet, toward generator components disposed around the permanent magnet, or both). Such a configuration permits the fluid to provide heat dissipation to some components of an electrical generator device.
Fifth, some embodiments of the turbine generator apparatus may include a turbine wheel that is coupled to bearing supports on both the input side and the outlet side of the turbine wheel, which provides a configuration favorable to rotordynamics operation and lubrication. For example, one bearing support may be located adjacent to the input face of the turbine wheel, and a second bearing support may be located on the outlet side but axially spaced apart from the wheel outlet (e.g., not immediately adjacent to the turbine wheel outlet). Accordingly, the turbine wheel can be supported in a non-cantilevered manner with bearing supports on both the input side and the outlet side of the turbine wheel. Also, the turbine generator apparatus may be configured to provide service access to the bearing supports without necessarily removing the turbine wheel or the rotor from the turbine generator casing.
Sixth, some embodiments of the turbine apparatus may include at least two seals on opposing sides of the turbine wheel (e.g., at least one seal on the input side and at least one seal on the outlet side). These seals may be part of subsystem that provides a thrust balance effect to the turbine wheel during operation. In such circumstances, the thrust balance provided by the subsystem can permit significant pressure ratio implementations across the turbine wheel.
Seventh, some embodiments of the turbine generator apparatus can reduce the likelihood of leakage to or from the external environment. For example, if a portion of the working fluid diverges from the flow path and seeps past the seal around the turbine wheel, the leaked fluid may merely reenter the fluid flow path (rather than leaking outside of the fluid flow path and into the environment).
Eighth, some embodiments of the turbine generator apparatus can be used in a Rankine Cycle, such as an organic Rankine Cycle, to generate kinetic energy from fluid expansion. Such kinetic energy can be used, for example, to generate electrical power. Other embodiments of the turbine generator apparatus may be configured for use in other fluid expansion operations, for example, a Carnot cycle, a gas letdown system, a cryogenic expander system, or a process expansion system.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
Referring to
Some embodiments of the fluid expansion system 10 include a reservoir 20 that contains at least a portion of the working fluid in an expanded and cooled condition. For example, the working fluid disposed in the reservoir 20 may be in a liquid state after passing through a cooling stage of a Rankine cycle or the like. The reservoir 20 has an internal volume that is accessed by a number of ports for the flow of working fluid into and out of the reservoir 20. In this embodiment, the reservoir 20 is mounted to the package housing 12 of the system 10 so that the reservoir 20 can be transported contemporaneously with the turbine generator apparatus 100. As shown in
It should be understood that the package housing 12 depicted in
Still referring to
Some embodiments of the fluid expansion system 10 also include a liquid separator 40 arranged upstream of the turbine generator apparatus 100. As previously described, the turbine generator apparatus 100 receives the heated and pressurized working fluid so as to generate kinetic energy from the expansion of the working fluid therein. The turbine generator apparatus 100 may be configured to operate when the heated and pressurized working fluid is in a gaseous state. In such circumstances, the likelihood of erosion or other damage to the turbine generator apparatus 100 may be increased when a portion of the working fluid includes droplets or “slugs” of fluid in a liquid state. Also, the efficiency of the turbine generator apparatus 100 may be decreased when a portion of the working fluid includes droplets or slugs in a liquid state. Accordingly, the liquid separator 40 may be arranged upstream of the turbine generator apparatus so as to separate and remove a substantial portion of liquid state droplets or slugs of working fluid that might otherwise pass into the turbine generator apparatus 100.
The liquid separator 40 may be in the form of a cyclone separator device, a coalescing membrane device, or the like. In the embodiment depicted in
The liquid separator may include a secondary reservoir 42 to which the separated liquid-state droplets or slugs or working fluid are directed. The secondary reservoir 42 may be arranged below main body of the liquid separator so that the separated liquid-state fluid can be gravity fed toward the secondary reservoir 42. The secondary reservoir 42 may be in fluid communication with the previously described reservoir 20, thereby permitting the separated liquid-state droplets to return to the working fluid contained in the reservoir 20. Accordingly, the liquid separator 40 can be arranged upstream of the turbine generator apparatus 100 in a manner such that the gaseous state working fluid can be passed to the turbine generator apparatus 100 while a substantial portion of any liquid-state droplets or slugs are removed and returned to the reservoir 20.
Still referring to
Furthermore, in these embodiments, the liquid separator 40 can serve as a reservoir volume to improve the system stability during transient conditions. For example, if the flow of the working fluid is initiated toward the turbine generator apparatus 100 before the working fluid has been sufficiently heated and pressurized, a random burst of liquid-state fluid flow may pass towards the turbine generator apparatus 100. The liquid separator 40 can serve as an accumulator device that protects the turbine generator apparatus 100 from such a burst of liquid-state fluid flow. Thus, in addition to reducing the likelihood of erosion damage to the turbine generator apparatus 100, the liquid separator 40 may improve the system stability during transient conditions.
Still referring to
Referring now to
Furthermore, the fluid expansion system 10 can be constructed in a manner that provides simplified transportation to the desired installation location. For example, the package housing 12 for the fluid expansion system may have overall dimensions that permit transport through a standard double-door passage. In some embodiments, the package housing 12 of the fluid expansion system 10 may have a width W (refer, for example, to
Referring now to
As shown in
After the working fluid has received heat recovered from the heat source 60, the heated and pressurized working fluid returns to the fluid expansion system 10 and is directed toward the turbine generator apparatus 100. The liquid separator 40 is arranged upstream of the turbine generator apparatus 100, so the heat and pressurized working fluid passes through the liquid separator 40 before passing to the turbine generator apparatus 100. As previously described, the liquid separator 40 may be arranged upstream of the turbine generator apparatus so as to separate and remove a substantial portion of any liquid state droplets or slugs of working fluid that might otherwise pass into the turbine generator apparatus 100. In this embodiment, the liquid separator 40 includes a secondary reservoir 42 to which the separated liquid-state droplets or slugs or working fluid are directed. The secondary reservoir 42 may be in fluid communication with the previously described reservoir 20, thereby permitting the separated liquid-state droplets to return to the working fluid contained in the reservoir 20. Because a substantial portion of any liquid-state droplets or slugs are removed by the liquid separator 40, the turbine generator apparatus 100 may be protected from damage caused by such liquid state working fluid. In addition, the liquid separator 40 may improve the system stability during transient conditions (as previously described in connection with
Still referring to
Referring to
Still referring to
In some embodiments, the first and second valves 72a-b of the dual control valve system 70 may operate in unison so as to provide protection for the turbine generator apparatus during transient flow conditions and to provide efficient power output from the turbine generator apparatus 100. In this embodiment, the first valve 72a is linked to the second valve 72b so that actuation of one valve results in actuation of the other. For example, the first valve 72a and second valve 72b may be coupled to the same actuator device (e.g., a servo actuator, a hydraulic actuator, a pneumatic actuator, a hand-operated lever, or the like) so that a user can signal the actuator device to adjust the two valves 72a-b in unison. In another example, the first valve 72a may have a first actuator and the second valve 72b may have a second actuator, both of which operate in response to control signals from the same controller device. In some embodiments, one or both of the first and second valves 72a-b may comprise actuator-controlled butterfly valves that control the flow path of the working fluid (as depicted, for example, in
Referring now to some embodiments of the turbine generator apparatus 100, the turbine generator apparatus 100 can generate kinetic energy from expansion of the working fluid. As previously described, the fluid expansion system can be part of a closed system, such as a Rankine Cycle or the like, in which a pressurized and heated working fluid is permitted to expand and release energy in the turbine generator apparatus 100.
Referring to
In some embodiments, the turbine wheel 120 is shaft mounted and coupled to a rotor 140. The rotor 140 may include a magnet 150. As such, the turbine wheel 120 is driven to rotate by the expansion of the working fluid in the turbine generator apparatus 100, and the rotor 140 (including the magnet 150) rotate in response to the rotation of the turbine wheel 120. In certain embodiments, the turbine wheel 120 is directly coupled to the rotor 140, for example, by fasteners, rigid drive shaft, welding, or other manner. In certain embodiments, the turbine wheel 120 can be indirectly coupled to the rotor 140, for example, by a gear train, cutch mechanism, or other manner.
As shown in
In the embodiments in which the first and second bearing supports 115 and 145 comprise magnetic bearings, the turbine generator apparatus 100 may include one or more backup bearing supports. For example, the first and second bearing supports 115 and 145 may comprise magnetic bearings that operate with electrical power. In the event of a power outage that affects the operation of the magnetic bearing supports 115 and 145, first and second backup bearings 119 and 149 may be employed to rotatably support the turbine wheel 120 during that period of time. The first and second backup bearing supports 119 and 149 may comprise ball bearings, needle bearings, journal bearings, or the like. In this embodiment, the first backup bearing support 119 includes ball bearings that are arranged near the first magnetic bearing support 115. Also, the second backup bearing support 149 includes ball bearings that are arranged near the second magnetic bearing support 145. Thus, in this embodiment, even if the first and second bearing supports 115 and 149 temporarily fail (e.g., due to an electric power outage or other reason), the first and second backup bearing supports 119 and 149 would continue to support both the turbine wheel 120 and the rotor 140 in a non-cantilevered manner.
Still referring to
The turbine generator apparatus 100 may include a number of longitudinally extending fins 170. The fins 170 may support the stator 162 in relation to the rotor 140 and direct the working fluid axially through the body casing 107. For example, the working fluid can exit to the outlet side 125 of the turbine wheel 120 and be directed by a contoured surface 142 of the rotor 140 toward the longitudinal fins 170. In some circumstances, the longitudinal fins 170 may serve as cooling fins that shunt at least a portion of the heat byproduct from the stator 162 to the longitudinal fins 170 for subsequent heat dissipation by the fluid flow. As the working fluid flows along the longitudinal fins 170, the working fluid passes along components of the electrical generator device 160 so as to dissipate heat therefrom. In this embodiment, the working fluid is directed to flow over the stator 162, as well as, between the stator 162 and rotor 140. The electrical generator device 160 may include a number of electronic components (including the stator 162) that produce significant heat during operation, so dissipation of such heat can reduce the likelihood of component failure. As shown in
Referring now to the turbine generator apparatus 100 in more detail as shown in
The flow diverter cone 110 is arranged to extend into a portion of the inlet conduit 105 so as to direct the working fluid toward the turbine wheel inlet 124 disposed near the input side 126 of the turbine wheel 120. The flow diverter cone 110 may include a number of pre-swirl vanes 112 that impose a circumferential flow component to the inlet fluid flow. As such, when the working fluid flows into the turbine wheel inlet 124, the flow may have a circumferential swirl component that is at least partially similar to the rotational direction of the turbine wheel 120. In some embodiments, the pre-swirl vanes 112 may be fixedly mounted to the flow diverter cone 110 at a predetermined angle so as to provide the desired tangential flow component. Alternatively, the pre-swirl vanes 112 can be adjustably mounted to the flow diverter cone 110 so that the angle of the vanes 112 can be adjusted (e.g., by movement of an actuator 163, such as a hydraulic or electrical actuator coupled to the vanes 112) to vary the pre-swirl angle of all vanes 112 in unison according to varying fluid flow conditions. In certain embodiments, the flow diverter cone 110 can house elements of the system, for example, one or more actuators 163 and other components. Although the pre-swirl vanes 112 are depicted as being mounted to the diverter cone 110 in this embodiment, the pre-swirl vanes 112 can be fixedly mounted or adjustably mounted to the inlet conduit 105 near an inducer channel 117 to provide the desired tangential flow of the working fluid.
Still referring to
When the working fluid flows into the turbine wheel inlet 124, the working fluid acts upon the turbine blades 122 so as to impose a rotational force upon the turbine wheel 120. In particular, the turbine wheel 120 that rotates about the wheel axis as the working fluid expands and flows toward the outlet side 125 of the turbine wheel 120. For example, in some embodiments that employ an engineered fluid for use in an organic Rankine cycle, the working fluid may be pressurized and heated (in this example, to a temperature of about 230° F.) as it enters the inlet conduit 105 and thereafter may expand as it flows over the turbine wheel 120 and exits to the outlet side 125 (in this example, at a temperature of about 120° F.). In alternative embodiments, the temperatures of the working fluid in the pressurized and heated state and the expanded state may be different from the previous example. In particular, the working fluid temperatures in the pressurized and heated state and in the expanded state may be selected based on a number of factors, such as the specific application in which the turbine generator apparatus 100 is used, the properties of the working fluid, and the like. At least a portion of the energy released from the expansion of the working fluid can be converted into kinetic energy in the form of rotation of the turbine wheel 120. As previously described, in this embodiment, the turbine wheel 120 is a shrouded turbine wheel that includes a number of turbine blades 122 that translate the force from the working fluid acting against the blades 122 into the rotational motion of the turbine wheel 120. The turbine blades 122 can extended from the contoured hub of the turbine wheel 120 to the wheel shroud 123 and may be angled or contoured so as to impose a rotational force on the turbine wheel 120 as the working fluid acts against the blades 122.
Still referring to
For example, in some embodiments, the arrangement of the turbine wheel 120 permits the turbine wheel 120 to be supported by bearing supports both the input side 126 and the outlet side 125 (e.g., including the region extending toward the outlet conduit 109). As previously described, the turbine wheel 120 can be rotationally supported by the first bearing support 115 (
Such a configuration of the bearing supports 115 and 145 on both the input side 126 and the outlet side 125 of the turbine wheel can provide an environment that is favorable to rotordynamic operation and lubrication. For example, employing bearing supports on opposing sides of the turbine wheel 120 may provide more uniform lubrication and load distribution along the rotational interfaces of the bearing supports (as compared to an overhung turbine wheel that is cantilevered from a bearing support). In addition, such a configuration can improve temperature control of the rotational interfaces. Further, the arrangement of the turbine wheel 120 in the turbine generator apparatus 100 can reduce the time and disassembly operations normally required for inspection and service of the bearing supports. For example, the bearing supports 115 and 145 can be accessed for inspection and servicing without necessarily removing the turbine wheel 120 from the turbine apparatus 100. As shown in
Still referring to
As shown in
Such an arrangement of the driven member 150 on the outlet side 125 of the turbine wheel 120 facilitates the use of the expanded working fluid as a heat dissipation medium. In some circumstances, the heat dissipation flow provided by the expanded working fluid may reduce or eliminate the need for an external cooling system for the rotor 140 and/or stator 162 (and other components of the electrical generator device 160). For example, the expanded working fluid may flow along the longitudinal fins 170 at a rate so as to cool the stator 162 without employing an external cooling system to remove heat from the stator 162.
Still referring to
In certain embodiments, the turbine wheel 120 can be pressure balanced. For example, when the working fluid exits to the outlet side 125 of the turbine wheel 120, a low pressure region may be created near the turbine wheel outlet, which creates a thrust force is in the axial direction toward the outlet side 125. To counter this low pressure region and the resulting thrust force, the reaction pressure reservoir 137 is arranged on the input side 126 of the turbine wheel 120. The reaction pressure reservoir 137 may be in fluid communication with the exhaust conduit 130 so as to substantially equalize the pressure regions on both sides of the turbine wheel 120, thereby providing a thrust balance arrangement for the turbine wheel 120.
For example, as the turbine wheel 120 operates, a small amount of working fluid may seep into the reaction pressure reservoir 137 (e.g., some fluid may seep along the dynamic seal surface of the first seal 113). As shown in
It should be understood that, in other embodiments, the reaction pressure reservoir 137 may be in fluid communication with the exhaust conduit 130 via internal channels through the first frame member 116 and the exhaust conduit (rather than using the external piping of the second conduit 111). For example, the first channel 135 may be in fluid communication with a second channel bored partially through the first frame structure 116 and partially through the wall of the exhaust conduit 130. In such circumstances, the reaction pressure reservoir 137 can be in fluid communication with the exhaust conduit 130 so as to substantially equalize the pressure regions on both sides of the turbine wheel 120.
Still referring to
Thus, such an arrangement of the turbine wheel 120 can provide a hermetically sealed turbine generator apparatus 100. Some embodiments of the hermetically sealed turbine generator apparatus 100 may be useful, for example, when the working fluid is a regulated or hazardous fluid that should not be released into the external environment. In some circumstances, the regulated or hazardous fluids may include engineered fluids that are used in a number of organic Rankine cycles. For example, certain embodiments may use GENETRON 245fa, a product of Honeywell International, Inc., as a working fluid. In alternative embodiments, the working fluid may comprise other engineered materials. Accordingly, the turbine generator apparatus 100 can be employed in an organic Rankine cycle so as to reduce the likelihood of leaking the working fluid into the surrounding environment.
Referring now to
As previously described, in particular embodiments, the turbine generator apparatus 100 can be used to convert heat energy from a heat source into kinetic energy (e.g., rotation of the rotor 140), which is then converted into electrical energy. For example, the turbine generator apparatus 100 may output electrical power that is configured by an electronics package to be in form of 3-phase 60 Hz power at a voltage of about 400 VAC to about 480 VAC. As previously described, alternative embodiments may out electrical power having other selected settings. In some embodiments, the turbine generator apparatus 100 may be configured to provide an electrical power output of about 2 MW or less, about 50 kW to about 1 MW, and about 100 kW to about 300 kW, depending upon the heat source in the cycle and other such factors. Again, alternative embodiments may provide electrical power at other Wattage outputs. Such electrical power can be transferred to a power electronics system and, in some embodiments, to an electrical power grid system. Alternatively, the electrical power output by the turbine generator apparatus 100 can be supplied directly to an electrically powered facility or machine.
Similar to previously described embodiments, the Rankine cycle 200 may include a pump device 210 that pressurizes the working fluid. The pump device 210 may be coupled to a reservoir 212 that contains the working fluid, and a pump motor 214 can be used to pressurize the working fluid. The pump device 210 may be used to convey the working fluid to a heat source 220 of the Rankine cycle 200. As shown in
Still referring to
When the first control valve 222a is opened, the heated and pressurized working fluid may be directed to the liquid separator 40 (
After passing through the liquid separator 40, the heated and pressurized working fluid may pass through the inlet conduit 105 and toward the turbine wheel 120 (
Still referring to
In some embodiments of the Rankine cycle 200, the working fluid may flow from the outlet conduit 109 of the turbine generator apparatus 100 to a condenser 250. The condenser 250 may include a motor 252 that is used to remove excess heat from the working fluid so that a substantial portion of the working fluid is converted to a liquid state. For example, the motor 252 may be used to force cooling airflow over the working fluid. In another example, the motor 252 may be used to force a cooling fluid to flow in a heat exchange process with the working fluid. After the working fluid exits the condenser 250, the fluid may return to the reservoir 212 where it is prepared to flow again though the cycle 200.
Referring to
In this embodiment, the commercial compressor may include a plurality of compressor stages 310, 320 and 330. A first heat exchanger 315 may be arranged between the first and second compressor stages 310 and 320 so as to remove heat from the compressor fluid. The working fluid of the Rankine cycle passes through a first section 316 of the heat exchanger 315 to receive a portion of the heat dissipated from the compressor fluid flow. In some circumstances, the compressor fluid may require further cooling, so a coolant fluid may pass through a second section 318 of the heat exchanger 315 to further dissipate any excess heat from the compressor fluid. After removing the excess heat from the compressor fluid, the coolant fluid may be directed to a cooling tower or the like. As shown in
Still referring to
Accordingly, the working fluid of the Rankine cycle can be incrementally heated by a series of heat exchangers 315 and 325 arranged after the compressor stages 310 and 320 of a commercial compressor interstage cooling process. Such a process permits the waste heat from an industrial process to be recovered and converted into electrical energy (e.g., by expansion of the working fluid in the turbine generator apparatus 100). In some circumstances, the electrical energy generated by the turbine generator apparatus 100 can be used to at least partially power the industrial process that generates the heat (e.g., the electrical power can be used to at least partially power the commercial compressor system). Moreover, in alternative embodiments, the kinetic energy from the rotation of the turbine wheel 120 in the turbine generator apparatus 100 can be used to mechanically power the commercial compressor system. For example, the turbine wheel 120 in the turbine generator apparatus 100 can be coupled to at least one of the compressor high-speed shafts to augment the power required to rotate the compressor high-speed shaft (e.g., in a multi-stage turbo compressor application). Although the plurality of compressor stages 310, 320 and 330 can be used to heat the working fluid in the Rankine cycle, it should be understood that (in other embodiments) only one of the compressor stages (e.g., stage 310) may be used as the heat source for the working fluid.
The embodiments described in connection with
Referring to
In this embodiment, the Rankine cycle 400 includes the fluid expansion system 10, the industrial process 420 in which heat is byproduct (e.g., commercial exhaust oxidizer to the like), and a condenser 450 (e.g., an evaporative condenser or the like). The industrial process 430 may include an exhaust stack 425 through which a heated exhaust fluid is expelled. The heated exhaust fluid may be a byproduct of the industrial process 420. For example, in some oxidizer systems, the exhaust fluid may pass into the exhaust stack 425 at a temperature of about 200° F. or more, about 250° F. or more, about 300° F. to about 800° F., about 350° F. to about 600° F., and in some embodiments at about 400° F. Rather than allowing the heated exhaust fluid to be fully dissipated to the environment without recovering the heat energy, the Rankine cycle 400 may incorporate the fluid expansion system 10 to recover at least a portion of the heat energy and generate electrical power therefrom. For example, the working fluid that passes that passes through the turbine generator apparatus 100 may be heated in a heat exchanger 427 arranged proximate to the exhaust stack 425 of the industrial process 420. Thus, the exhaust stack 425 of the industrial process 420 may serve as an evaporator or other heat source that transfers heat energy to the working fluid before the working fluid passes through the turbine generator apparatus 100. In this embodiment, the heat exchanger 427 is disposed in the exhaust stack 427 so as to recover at least a portion of the heat energy from the exhaust fluid and to transfer that heat energy to the working fluid of the Rankine cycle 400.
Still referring to
After the working fluid is expanded in the turbine generator apparatus 100, the working fluid may be directed to a condenser unit 450 of the Rankine cycle 400. The condenser unit 450 may comprise, for example, and evaporative condenser that outputs the working fluid in a cooled state (e.g., in a liquid state). The expanded and cooled working fluid is then directed to the reservoir 20 of the fluid expansion system 10 where it awaits passage through the pump 30 and to the heat exchange process. This fluid cycle can be repeated so as to recover the waste heat from the industrial process 420 and thereafter convert the heat energy into electrical energy (e.g., by expansion of the working fluid in the turbine generator apparatus 100).
The embodiments described in connection with
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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