When gas is compressed in a compressor, mechanical energy is converted to heat energy. The compressed and heated gas leaves the compressor and requires the gas to be cooled before the next process. Current compression systems, specifically natural gas compressors, release all of the heat energy into the ambient air, either directly through fin fan coolers or by means of cooling water in cooling towers.
In embodiments, methods and systems are provided to recover lost energy during a compressed gas cool down process. A two-phase cooling system is used to cool the gas and convert at least some of that energy into electricity. More specifically, gas cooling is used to recover the heat by driving a turbo expander or a screw expander to convert the recovered heat to mechanical energy. The power recovery expander is coupled directly to a power generation-conversion system having a high speed induction machine and a medium voltage drive (MVD) system. In particular embodiments this MVD system may have semiconductor switching devices formed of silicon such as IGBTs or SiC devices such as MOSFETs. The MVD system interacts with the heat of compression energy recovery system to condition the generated energy and restore it back to an electrical distribution system.
In one aspect, a system includes an evaporator to receive a flow of natural gas at a first temperature and to output the flow of natural gas at a second temperature lower than the first temperature. The evaporator may receive a flow of cooling media to cool the natural gas and output a flow of heated cooling media. The system may further include: a heat-to-mechanical energy converter coupled to the evaporator to receive the flow of heated cooling media and to output first cooled cooling media; an induction generator coupled to be driven by the heat-to-mechanical energy converter; a medium voltage drive coupled to receive power from the induction generator and to condition the power for output to an electrical distribution system; and a condenser to condense the first cooled cooling media to provide the flow of cooling media to the evaporator.
In an embodiment, the heat-to-mechanical energy converter comprises an expander to reduce a pressure of the flow of heated cooling media. For high speed constructions, the expander may be a turbo or screw expander directly coupled to the induction generator. The system may further include a pump coupled to the condenser to pump the cooling media to the evaporator. The system may recover energy from the natural gas at the first temperature and provide the recovered energy to the distribution system.
In an embodiment, the system may further include a controller to control operation of the heat-to-mechanical energy converter, where the system is a heat of compression energy recovery system.
In an embodiment, the system may further include a second condenser coupled to the condenser to further condense the first cooled cooling media. This second condenser may provide a flow of second cooling media to the medium voltage drive and receive a flow of heated second cooling media from the medium voltage drive. The second condenser may further provide a flow of third cooling media to the induction generator and receive a flow of heated third cooling media from the induction generator. The system also may include at least one bypass valve which, when enabled, is to cause at least a portion of the flow of heated cooling media from the evaporator to be directed to the condenser.
In another aspect, a method includes: receiving, in an evaporator of an energy recovery system, a flow of heated material at a first temperature, cooling the heated material in the evaporator using a flow of cooling media, and outputting the flow of heated material at a second temperature lower than the first temperature; providing a flow of heated cooling media from the evaporator to an expander of the energy recovery system; driving, via the expander, an induction generator coupled to the expander using the flow of heated cooling media; and receiving, in a drive system coupled to the induction generator, power from the induction generator, conditioning the power for delivery to a distribution system, and delivering the conditioned power to the distribution system.
In an embodiment, the method may further include: outputting first cooled cooling media from the expander to a condenser coupled to the expander; and condensing the first cooled cooling media to provide the flow of cooling media to the evaporator. The method may also include reducing, in the expander, a pressure of the heated cooling media. In one embodiment, the heated material may be compressed natural gas, and the method further comprises outputting the flow of compressed natural gas at the second temperature to a distribution system. The method also may include controlling at least one of a flow rate and a pressure drop in the expander to cause a shaft of the induction generator to operate at a substantially steady rate. The method also may include: providing, from a second condenser coupled to the condenser, a flow of second cooling media to the drive system; receiving a flow of heated second cooling media from the drive system; and cooling the heated second cooling media. And, the method also may include: providing, from the second condenser, a flow of third cooling media to the induction generator; receiving a flow of heated third cooling media from the induction generator; and cooling the heated third cooling media. The method also may include controlling at least a portion of the flow of heated cooling media to bypass the expander on a path from the evaporator to the condenser.
In yet another aspect, a system includes: a compressor to compress natural gas to output compressed natural gas; an evaporator to receive the compressed natural gas at a first temperature and to output the compressed natural gas at a second temperature lower than the first temperature, the evaporator to receive a flow of cooling media to cool the compressed natural gas and to output a flow of heated cooling media; an expander coupled to the evaporator to receive the flow of heated cooling media and to output first cooled cooling media; an induction generator coupled to be driven by the expander; a medium voltage drive coupled to receive power from the induction generator and to condition the power for output to an electrical distribution system; a condenser to condense the first cooled cooling media to provide the flow of cooling media to the evaporator; and a controller to control a flow rate of the flow of heated cooling media to the expander. In an example, the controller may control a bypass system coupled between the evaporator, the expander and the condenser, where the controller is to cause at least a portion of the flow of heated cooling media to bypass the expander.
A heat-to-mechanical energy converter is much like a steam turbine, in that a liquid is heated until it changes from a liquid to a hot gas (like steam). This hot gas then is used to drive a turbo expander (steam turbine), resulting in cooled gas ready to be condensed. The turbo expander drives a generator that produces electricity. At a high level, a heat of compression energy recovery system includes: a gas cooling system; a heat-to-mechanical energy converter; a generator and IGBT-based MVD; and a control system.
Referring now to
With reference to
As further illustrated, converter and generator system 110 also includes an induction generator 112, which may be a high speed medium voltage (MV) induction generator that, in an embodiment, may operate at speeds up to 15,000 RPM. Understand that higher speed applications are possible.
Still with reference to
With reference to
The hot natural gas heats the refrigerant past its boiling point, causing the refrigerant to evaporate, which also provides additional cooling, such that the refrigerant is now a hot gas. In an embodiment that uses R600a, evaporator 125 can operate at 288 PSIG and, as described below a condenser 140 can operate at 94 PSIG. At 288 PSIG the R600a is heated to about 220° F. to evaporate, and at 94 PSIG it can be cooled to 120° F. to condense.
Evaporator 125 may be incorporated as a shell and tube heat exchanger that cools the natural gas and heats the refrigerant. In evaporator 125, this cooling media is thus heated and exits via a conduit 128 as a heated cooling media which may be a two-phase media, namely a hot gas, e.g., at 288 PSIG 220° F. Evaporator 125 may cool the incoming natural gas to an exit temperature of between approximately 100° and 130° F.
Evaporator 125 thus absorbs heat from the hot natural gas and evaporates the cooling media. The cooling medium gas output from evaporator 125 is used to power an expander 130/generator 112, which operates to cool the heated cooling media. By moving the heat from a higher temperature to a lower temperature, energy can be removed. Turbo expander 130 is a heat-to-mechanical energy converter, which reduces the pressure and removes heat from the gas, resulting in cooled gas ready to be condensed. The cooling medium is in a gas form at this point at an output of turbo expander 130 and at low pressure, e.g., 94 PSIG. While embodiments herein use this turbo expander to cool the heated cooling media and drive generator 112, other systems such as a screw expander or so forth instead may be used. For example for a system with power recovery less than approximately 1 MW, a screw expander may be used to reduce system cost and size. In embodiments with energy recovery exceeding, e.g., 1 MW, a turbo expander may be used.
Turbo expander 130 drives generator 112, which produces electricity. By way of the direct coupling of turbo expander 130 to induction generator 112, there is no need for any speed reduction gear. As such, turbo expander 130 drives induction generator 112, thus recovering mechanical energy from turbo expander 130, which cools the heated cooling media to a lower temperature, e.g., between approximately 90° and 120° F.
In another embodiment, the cooling media may be R134a. With this refrigerant, R134a may be available, for example, at 500 PSIG and 210° F. when entering turbo expander 130. At the outlet of turbo expander 130, the pressure of this cooling media may be approximately 170 PSIG, and may circulate at a flow range of 152,000 to 215,000 lb/hr.
And in an embodiment that uses R600a as the cooling media, turbo expander 130 may be configured so that the speed range may start as low as 5000 RPM. And induction generator 112 may be implemented with a lower speed machine, allowing the utilization of standard commercial machine designs.
As shown, turbo expander 130 thus outputs cooled gas or liquid media, still potentially in a two-phase condition, to condenser 140, via a conduit 135. Condenser 140, by way of forced air provided via one or more cooling fans 142, further cools and condenses the incoming cooling media into a cooled liquid. As illustrated, condenser 140 provides this cooled cooling media to a pump 150, which completes the closed loop. Pump 150 operates to pump the liquid refrigerant from 94 PSIG to 298 PSIG, which feeds it into evaporator 125 via conduit 155.
Since the cooling load from the gas compressor is not constant, cooling may be controlled. On some compressor applications, the gas cooling can be controlled. In such applications controller 160, namely a heat of compression energy (HCE) controller, would be configured to control the cooling liquid flow, and further vary the generator load to control the load on turbo expander 130 to maximize the energy recovery. On other applications where controlled cooling is not required, controller 160 will maximize the energy required without regard to gas outlet temperature. The high pressure refrigerant gas is letdown in turbo expander 130 to a lower pressure based on a predetermined flow rate and pressure drop, allowing shaft operation of induction generator 112 at 15,000 RPM.
As an example control technique, in general terms, for an amount of power (e.g., based on a step of 1000 kW) to be delivered at utility grid 105, a grid controller of MVD 114 sends a mechanical power control signal to controller 160 to produce the requested amount of active power. Controller 160 operates turbo expander 130 by regulating the flow amount of cooling medium, observing predetermined pressure and temperature at its output. Subsequently, the required output mechanical torque is developed by turbo expander 130 at a constant speed of 15000 RPM. In turn, induction generator 112 transforms mechanical power at the shaft into high frequency electrical energy, which is conditioned by MVD 114 and delivered to utility grid 105 at rated voltage, current, and frequency. As discussed above, MVD system 114 can be based on Si-based devices such as IGBT switches for low cost applications where system de-rating is permitted, i.e., for high speed and high power system applications where the output switching frequency of the silicon power devices is larger than 2 kHz. For high efficiency power conversion and reduced footprint applications, MVD system 114 may be based on SiC power devices such as SiC MOSFETs or on hybrid power converter stages combining both SiC and Si-based power devices. In another preferred embodiment, several slices can be connected in series/parallel combinations to meet a desired electrical power system rating. An MVD control system is designed to interact with utility grid 105 and energy recovery system 120 to achieve the desired performance and electrical power generation rating.
In an embodiment, a medium power building block (MPBB) is a regenerative converter system having a transformer to be operated at a 1 MW<Power<2.2 MW range. For a 1000 kW recovery system rating, the transformer can be operated at a light load point and the efficiency will be the highest. For a recovery system operating at 2.2 MW, the transformer efficiency will be at the minimum acceptable efficiency. The preferred transformer rating can be within 750 kVA-1000 kVA for a slice system. In order to balance impedances at the transformer secondary windings, windings are wound in side by side arrangement. There are three parallel primary windings for each secondary winding. Side by side arrangement of windings reduces coupling between secondary windings and also increases equivalent impedance seen by the AFE (active front end) converter stage. Extra series inductance per phase may be inserted at the transformer primary or secondary when the AFE is switched at less than 3 kHz to ensure converter control stability. The required inductance may be in the range of 5%. When the AFE is operated above 3 kHz, additional filtering may not be required but system de-rating may be mandatory to handle switching loss content and keep each IGBT cold plate within its boundaries (e.g., <1400 W).
Still with reference to
While energy recovery system 120 of
Referring now to
In the embodiment of
To recover at least portions of this heat generated, pumps and various conduits may be provided to enable cooling media that flows through MVD system 214 and induction generator 212 to be communicated to and from recovery system 220 such that electrical energy may be recovered from this heat. More specifically as illustrated in
A similar arrangement of an additional pump 280 is provided in association with MVD system 214. As illustrated, pump 280 couples to a set of conduits extending from MVD system 214, and receives a flow of cooled cooling media, e.g., R134a, from condenser 246 of recovery system 220. Thus as shown, pump 280 receives, via a conduit 282, a flow of cooled cooling media, namely cool R134a, that is provided by condenser 246, which it in turn provides to MVD system 214. In embodiments, this R134a may be at a temperature of between approximately 90° and 122° F. Condenser 246 also operates to cool incoming heated R134a flow of cooling media received from MVD system 214 via another conduit 284. In an embodiment, this hot R134a may flow from MVD system 214 at a temperature of between approximately 90° and 122° F.
Note that in the embodiment of
With an arrangement as in
To this end, it is possible to provide for various bypass paths within a converter system to enable dynamic control, e.g., based on operating conditions such as temperature, pressure or so forth. Referring now to
At system start up some systems will require a bypass of all or a portion of the feedback loop within recovery system 320, note the presence of valves 390, 392 and 394. Note that these valves may be controlled by controller 360. For example, based on temperature and/or pressure conditions at point 335, controller 360 may cause at least a portion of the hot gas exiting evaporator 325 to bypass input into turbo expander 330, by appropriate control of one or more of valves 390, 392, 394. Note that valves 392 and 394 act as both bypass and pressure control valves.
Note further that in the embodiment of
Referring now to
In the particular embodiment illustrated in
As further illustrated in
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
This application claims priority to U.S. Provisional Patent Application No. 62/782,533, filed on Dec. 20, 2018, in the names of Tony King and Dean Sarandria, entitled “Heat Of Compression Energy Recovery System Using A High Speed Generator Converter System,” the disclosure of which is hereby incorporated by reference.
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