The present invention refers to an apparatus for recovering thermal energy from the exhaust fumes and gases of heat engines and from the cooling and ventilation air and/or any of the components or auxiliary circuits of the same plants, or of other plants.
In particular, the invention refers to heat generators adapted to serve as heat recovery apparatuses.
More particularly, said heat generators are fire-tube apparatuses.
The invention is especially useful to realize electrical and thermal energy cogeneration plants, particularly in the micro cogeneration sector.
Cogeneration (or “combined production”) is essentially based on using the heat generated by the electricity production phase of thermoelectric generators; such “residual” energy can be used as a heat source for heating buildings or for production and industrial purposes.
A major advantage of micro cogeneration is that it enables widespread, small-scale distributed production of electrical energy for households, the tertiary sector and small-sized industries, whose power requirements are relatively modest.
The spread of micro cogeneration has been hampered by the difficulty of meeting minimum cost per unit of power, yield, reliability and efficiency requirements in small-sized devices. As a consequence, current cogeneration systems range from 100-300 kW to several MW.
The micro cogeneration market offers substantially two options that are based on the same energy generation concept, but on two different types of prime mover. In particular, micro gas turbines can be employed in the 50 to 100 kW range, whereas alternative internal combustion engines with a Diesel or, preferably, an Otto cycle can be used for smaller plants.
The thermal energy produced by the functioning of a prime mover (be it an internal combustion engine or a micro gas turbine) is partly dissipated in the external environment by radiation; while this fraction can effectively be reduced, most of the thermal energy is transferred to the combustion gases (whose temperature in fact ranges from 350 to 600° C.) discharged to the flue and to the cooling air of various engine components and auxiliary circuits.
Heat is not usually recovered from cooling air, essentially due to its low enthalpy and convective heat transfer coefficient, which would require exchangers endowed with large exchange surfaces, adversely affecting the cost/benefit ratio of the cogenerator. Only rarely is cooling air harnessed to heat water, generally in alternative internal combustion engines.
In contrast, devices have already been developed to recover heat from prime mover exhaust fumes, despite their not very high enthalpy and, especially, the risk of acid condensation during cooling.
Such devices are usually fitted downstream of the prime mover; they may be exchangers (also known as recuperators), which use the heat of the combustion fumes, for example to preheat the combustion air, or recovery furnaces, where the fumes are further burned or merely cooled via heat exchangers, preferably dedicated to production of steam, hot water or superheated water.
As an example, according to document GB 2 271 171 exhaust hot gases, discharged by one or multiple heat sources, are cooled on the whole thermal exchange surface of the heat exchanger of a heat generator (in this case, a fire-tube boiler) while in the document U.S. Pat. No. 4,313,399 exhaust hot gases are used as comburent in the combustion chamber of the heat generator, if sufficiently rich in oxygen.
However, apparatuses for the recovery of the enthalpy of prime mover combustion gases and fumes have a major drawback: their close integration with the engine itself.
As a consequence, malfunction of the prime mover or the heat recovery apparatus can compromise the overall efficiency of the cogeneration system. In addition, separate maintenance of the engine and the heat recovery apparatus is difficult, since it generally requires also the shutdown of the component functioning correctly.
Moreover regulation devices are needed, to provide the thermal energy recovered at the temperature required by the user.
Altogether, current heat recovery apparatuses are relatively expensive in terms of the gains they provide (recovery of prime mover thermal loss).
Finally, it is not always simple to transport the heat energy thus recovered to possible users.
If, as noted above, the enthalpy of the cooling air of a prime mover and its auxiliary circuits is difficult to reuse, its recovery from the various heat sources of an industrial plant, e.g. the cooling system of a plastic stamping plant; hot air from industrial painting plants; or exhaust fumes from elderly, poorly efficient industrial furnaces and boilers, is even harder.
Clearly, also in these cases the main issue is the cost/benefit ratio, since ad hoc exchangers and heat energy transport plants are needed for each heat source.
A first object of the disclosed invention is to devise a simple and economical heat recovery method in relation to the amount of thermal and electrical power involved.
A second object of the invention is to devise a heat recovery method characterized by low pollutant emissions and environmental impact.
An additional object of the invention is to devise a heat recovery method characterized by high flexibility in terms of the amount of heat to be recovered.
A further object of the disclosed invention is to devise a heat recovery method characterized by high flexibility in terms of the number and type of plants from which heat can be recovered.
A still further object of the present invention is to devise a method to integrate the heat recovery and production systems with electricity and/or mechanical power production plants.
Another object of the invention is to devise high flexibility means to integrate a prime mover and a fire-tube boiler in terms of the amount of electrical power to be integrated.
Additional objects and advantages of the disclosed invention are better demonstrated by the following detailed description of a preferred embodiment, made in line with the patent claims and with reference to attached diagrams reported purely by way of example and not intended to limit the invention, where:
a, 4b, and 4c report three side and front cross-sections of the apparatus illustrated in
a and 5b are two side and front cross-sections of the apparatus shown in
c reports a detail of the variant shown in
In
As noted above, said generic heat sources 2 can be electrical and/or mechanical power generators, such as internal combustion engines, micro gas turbines, steam turbines, fuel cells; simpler heat sources such as low-efficiency heat generators, whose fumes can still be used to extract thermal energy; and even simpler devices such as heat exchanger batteries of cooling systems of plants such as plastic stamping or extrusion machines.
During operation, said heat sources 2 emit heat substantially as hot gases, i.e. combustion gases F1 and/or cooling and ventilation air F2 heated by the cooling of various types of equipment.
Said heat sources 2 can be for instance:
Hot gases F1 and F2, generated by said heat sources 2, are often insufficient in amount and/or temperature for heat recovery to be feasible and/or economical through individual recovery apparatuses.
According to the disclosed invention the enthalpy of the hot gases F1 and F2 issuing from the heat source 2 is recovered by said generator 3.
More precisely, the combustion gases F1, whose temperature is sufficiently high, are sent to the exchanger 32 to transfer heat, whereas the cooling air F2 is used in the same generator 3 as combustion air for the furnace 31.
Other operating conditions are not excluded, such as those where the cooling air F2 is sufficiently hot to be treated like the combustion gases F1 and is accordingly sent to the exchangers 32, or vice versa, conditions where combustion gases F1, similar to cooling air F2 due to low temperature or high oxygen content, need to be sent to the furnace 31 together with the combustion air, provided they do not adversely affect oxygen combustion.
The heat generator 3 is preferably a type for production of steam and/or hot water and/or diathermic oil; in particular, it is a fire-tube boiler (see
The features of the fire-tube boiler 3 shown in the schematic view of
More in particular (see for instance
A hatch 37 for inspection and maintenance, commonly found on the front of the boiler 3, is schematically drawn in
Upstream of the furnace 31 the boiler 3 also includes at least a burner and the respective fan (or blower), to supply combustion air (not shown in the figures).
All known components of the boiler 3 have now been described.
In the disclosed invention a conveyor 4 carries said combustion gases F1 to at least one part of the exchanger 32, to recover their thermal energy.
The inspection hatch 37 is modified compared with the prior art, to accommodate the conveyor 4 passing through it.
Said conveyor 4 is characterized by an outer part 41 connected directly, or indirectly through ducts, to said one or multiple heat sources 2, to collect their combustion gases F1, and by an inner part 42, which is designed to couple to one or more pipes 33 of the heat exchanger 32 of the fire-tube boiler 3, in particular one or more pipes 33 of at least the third fume circuit 3303, and whose opening 4201 presses against the front pipe plate 3801.
The internal part 42 is designed to rotate and translate axially with respect to the outer part 41, where it is partially inserted, to allow coupling of the conveyor 4 to one or multiple pipes 33, as required by the flow rate and temperature of the combustion gases F1, or to prevent the conveyor 4 from interfering with said pipes 33 if no combustion gases F1 from which energy can be recovered are present.
Therefore, as shown in
As an example, which in no way limits the scope of the invention, the opening 4201 of the mobile internal part 42 is preferably elliptical and/or circular.
Axial translation of the inner part 42 with respect to the fixed external part 41 enables the opening 4201 to approach the pipe plate 3801 within the inversion chamber 35, to intercept said one or more pipes 33, whereas its rotation selects the pipes 33 of said plate 3801 that will carry the combustion gases F1 of the heat source 2, and consequently the number of passes of the combustion gases F1 through the heat generator 3.
As depicted in
For instance, as shown in
In fact, as shown in
Similar considerations also apply to the variant shown in
In the latter case, for the rotation of the inner part 42 of the conduit 4 to serve the purposes described above, the centre of, the opening 4201 must be offset with respect to the centre of the fixed external part 41.
In
The conduit 4 is completed by an interception organ 43, e.g. a butterfly valve 43, positioned in the fixed part 41, designed to exclude the heat source 2 from the boiler 3 in case of malfunction or maintenance, or in the event that the heat recovery apparatus 1 of the disclosed invention is operated as a traditional fire-tube boiler 3.
In the latter case the valve 43 must therefore be closed, while the mobile inner part 42 of the conduit 4 is retracted inside the fixed part 41, so that all the pipes 33 of the boiler 3 carry exclusively the products of its internal combustion. One or more magnets (not shown) can also be fitted in close proximity to the opening 4201 of the conduit 4, for an enhanced coupling of the conduit 4 and the pipe plate 3801, and thus a perfect seal. Alternatively, any means known in the prior art can be used to press the opening 4201 against the pipe plate 3801. According to possible variants of the invention, an additional fan (not shown) can be applied to the flue 36, to enhance circulation of the combustion gases F1 through the fire-tube boiler 3, by forcing them through said pipes 33 of its exchanger 32.
The above description clearly demonstrates that the appropriate number of pipes 33 intercepted by the conduit 4 and the number of passes of the combustion gases F1 through the boiler 3 depend on multiple factors such as the temperature of the combustion gases F1 at the exit from the one or multiple heat sources 2, their amount and, more generally, their thermal energy.
The configurations shown in
If the physical parameters (i.e. temperature and flow rate) of the combustion gases F1 are expected to be substantially stable over time, the configuration (particularly the rotation angle of the mobile internal part 42 of the conduit 4) can be selected manually.
However, it is preferable to have an electronic control unit selecting the most appropriate configuration of the conduit 4 in response to the changes in said physical parameters, which are detected through special sensors.
Clearly, the larger the portion 3201 of the heat exchanger 32 dedicated to the combustion gases F1, the smaller the thermal power that can be supplied to the furnace 31, but modulation of such power is automatically provided by control means with which the heat generator 3 is usually endowed. In fact the power supplied to the furnace is modulated by the user's demand for heat energy, which is met with lower furnace 31 loads if combustion gases F1 are present.
As noted above, the one or multiple heat sources 2 may entail the possibility of recovering in the boiler 3, besides the combustion gases F1, the thermal energy of the cooling and/or ventilation air F2, for instance of engine components and auxiliary circuits of the heat source 2 itself, which would otherwise be dispersed in the environment.
According to a preferred and advantageous embodiment, cooling and/or ventilation air F2, warmer than the ambient temperature (from 60° C. to 90° C.), is sent by known means directly to the furnace 31 of the boiler 3 and used as combustion air. From this viewpoint the heat source 2 therefore serves as a preheater unit of the combustion air for the internal combustion of the boiler 3. Recovery of such additional heat energy in the boiler 3, coupled to the heat recovered from the combustion gases F1, therefore increases the overall efficiency of the heat recovery apparatus 1, which is subject of the invention.
In fact it is well known that the efficiency of a boiler 3 for production of hot water and/or steam is a function of the temperature of inlet air in the burner of the furnace 31 and of the exhaust fumes: the closer the inlet air temperature to the gas temperature at the flue 36, the better the thermal yield of the boiler 3 and therefore of the heat recovery apparatus 1 overall.
Clearly, numerous additional variants of the disclosed heat recovery apparatus 1 are possible, to the person skilled in the art, without exceeding the scope of the appended claims; moreover the various components described above can be replaced with technically equivalent elements upon practical realization of the invention.
The heat source 2 is preferably a prime mover for electrical energy production. Even more preferably such prime mover 2 is, as noted above, an internal combustion engine or a micro gas turbine, two well-established and reliable technologies that require no further description. The heat recovery apparatus 1 according to this preferred embodiment is therefore a cogeneration plant for combined electrical and thermal power production, to which all the above considerations apply.
Compared with the prior art, in the present case the prime mover 2 can lack the traditional integrated recuperator, since it is connected (through said conveyor 4) to the boiler 3, where the heat that would otherwise be dissipated as combustion gases F1 and cooling and/or ventilation air F2 is efficiently recovered.
According to another embodiment the prime mover 2 (or in general the heat source 2) can be joined, through the telescopic conduit 4, to the back of the fire-tube boiler 3, rather than at the level of the inspection hatch (suitably modified to house said conduit 4) as described above.
According to a highly simplified variant of the cogeneration apparatus 1 (or in general the heat recovery apparatus 1), and particularly of the conveyor 4, the mobile inner part 42 is capable only of axial translation with respect to the fixed part 41, not also of rotation. Such configuration is especially practical, as noted above, when the physical parameters of the combustion gases F1 are substantially constant over time and the part 3201 of the heat exchanger 32 dedicated to said combustion gases F1 can be selected manually.
In a further simplified variant the conveyor 4 includes only the external part 41 (henceforth, for the sake of simplicity, the conduit 41), hermetically coupled to the inspection hatch 37 but capable of axial translation to connect to the pipes 33 of the exchanger 32 of the boiler 3 dedicated to said combustion gases F1.
It is therefore clear that the apparatus for heat recovery 1 described above in its preferred embodiment and variants can achieve the intended goals, particularly heat recovery from diverse types of machines in a simple and economical way. For instance, in the case where the heat source 2 is a prime mover (even though the reasoning also applies to the more general case of any alternative heat source 2), the possibility to dedicate part of the heat exchanger 32 of the boiler 3 to cooling the sole combustion gases F1 of said prime mover 2 and to recover cooling and/or ventilation air F2 significantly enhances the overall efficiency of the cogeneration apparatus 1 and allows nearly total recovery of its thermal loss. It is also clear that integration of an existing boiler 3 with an engine 2 suitable for electricity generation can be achieved with a modest investment by any user, who can select the most appropriate size for their level of consumption. Said cogeneration apparatuses 1 are therefore capable of meeting also a user demand characterized by high thermal and low electrical power production. This is easily achieved by replacing the standard hatch 37 of the fire-tube boiler 3 with an additional hatch capable of housing and supporting the conveyor 4.
Integration of a micro gas turbine or an internal combustion engine with an existing or a commercial boiler 3 also significantly reduces their specific cost, since it obviates the need for closely integrated internal devices to recover exhaust fumes (and/or cooling air), as in the known art.
The disclosed cogeneration apparatus 1 is also characterized by a longer service life than traditional systems, to the extent that it enables separate maintenance or replacement of the prime mover 2 and the fire-tube boiler 3, where needed; in addition, repair or replacement of either component does not involve the interruption, even temporary, of electrical and/or thermal power generation.
Finally, the heat generator 3 can also be a water-tube boiler.
Number | Date | Country | Kind |
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AN2009A000023 | May 2009 | IT | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IB2010/001174 | 5/18/2010 | WO | 00 | 12/7/2011 |