This invention relates to a hybrid combined cycle power and propulsion system for a vessel, in particular for liquified natural gas (LNG) and hydrogen carriers.
Vessel operators require reductions operational costs, whilst conventional vessels are subject to increased restrictions on operations which may be harmful to the environment. Improved performance to address these is issues is desirable.
In accordance with the present invention a hybrid combined cycle power and propulsion system, the system includes a steam turbine, at least one gas turbine, at least one auxiliary generator; an electric propulsion drive system and an energy storage system, each connected to a section of an AC bus; the system further including a source of steam for the steam turbine, and a control system for controlling operation of the steam turbine, gas turbine, auxiliary generators, electric drive propulsion system and energy storage system; wherein the primary source of steam for the steam turbine is exhaust gas from the gas turbine; the primary source of gas for the gas turbine is boil off gas from the cargo hold; wherein the AC bus includes a plurality of sections of AC bus coupled together by bus ties closed in normal operation forming a closed ring AC bus; and the electric propulsion drive system includes a variable speed drive, driving an electric motor coupled through a drive shaft to a propeller.
The use of a closed ring system is made possible by having fast acting switches, e.g. semiconductor switches. Without these, conventionally, bus ties have been left open in normal operation because they cannot be opened sufficiently quickly in the event of a fault, to prevent the fault propagating into other parts of the system. In the event of a failure of supply in a conventional system, a bus tie can be closed to allow energy from a different bus to be supplied to consumers, but the sharing of supplies is not a standard feature of operation, so all buses need to have their open generators operating in normal use, which reduces efficiency.
The electric propulsion drive system may include a permanent magnet motor.
The use of a permanent magnet motor allows the system to run without a gear box because the permanent magnet motor can run sufficiently slowly to match the propeller speed, so there is no need for a gear box to bring the speed of the motor down to that of the propeller. Conventionally motors run at around 720 rpm and the propeller runs much more slowly, perhaps at closer to 1/10th of the motor speed.
The primary source of energy for the energy storage system may be electricity generated by one of the steam turbine, gas turbine, or auxiliary generators.
The system may further include a shore connection to enable the vessel consumers to be powered from the shore supply.
The system may include a single fuel gas turbine and one or more spark ignited auxiliary generators.
This helps to minimize emissions.
The propulsion system electric motor may include a low speed bi-directional motor coupled to each drive shaft and propeller of the vessel.
The propulsion system may further include bow thrusters electrically coupled to the AC bus. These are optional.
The vessel may include a liquified natural gas carrier, LPG carrier, hydrogen carrier and other large ships
The electric motor may include a bi-directional motor.
This avoids the need for a gearbox to move between forward and reverse. The variable frequency/variable speed drive is used to adjust the speed of forward or reverse propulsion.
The system may further include an onboard gas supply for the gas turbine.
An example of a vessel hybrid combined cycle power and propulsion system in accordance with the present invention will now be described with reference to the accompanying drawings in which:
The present invention addresses the need to reduce operational expenditure on vessels, as well as enabling vessels to operate in a more environmentally friendly manner. Typically ships have three or four, four stroke engines installed for electrical power generation during maneuvering and terminal activity and slow speed two stroke engines for propulsion. LNG carriers have to deal with gas boil off from the cargo tanks during a voyage and traditionally, this gas has been used as fuel for engines and auxiliary steam boilers.
The present invention proposes a combination of energy sources in a hybrid combined cycle power plant with high efficiency permanent magnet propulsion motors.
An energy storage system (ESS) is included to ensure the most efficient operation of the power plant, allowing safe and reliable operation with only one combustion engine running in a closed ring distribution system.
Electrical power distribution is included in the hybrid system and the number of generators needed can be reduced by using energy storage. The total fuel spend on board the vessel includes fuel used for both steam and electricity. Conventionally, a fault in the gas turbine would trip the steam turbine and leave the vessel with no power for a period of time. Thus, vessels operating in this way had to have redundancy in running generators. The use of energy storage in combination with the steam and gas turbines avoids blackouts occurring and the energy storage also contributes to absorbing variable peak loads, enabling the gas turbine and steam turbine to operate with a stable load and at maximum operating efficiency. Thus, a vessel may be operated with only one gas turbine and one steam turbine installed together with other types of auxiliary generator, as the main propulsion generators are fed from the AC bus which has access to the energy storage system, in case of need, in the event of a fault in the main electrical energy supply. The high power required during sea going in heavy weather (the sea-margin) is covered by the auxiliary generators being operational, in addition to the gas turbine and the steam turbine. This means that a relatively small gas turbine and steam turbine with support from the energy storage, both normally operating at 90-100% load, i.e. at optimal efficiency produces a significant reduction in emissions and fuel consumption.
The steam turbine is driven by the gas turbine exhaust, which reduces the total emissions from the vessel and there are also capital cost reductions in only needing to have one gas turbine. The auxiliary generators are used as redundancy generators, as well as being operated during high load demand, maneuvering, waiting, and terminal operations. The energy storage acts as a short term back up to transfer from the steam turbine or gas turbine to one or more auxiliary spark-ignited four stroke gas engines. In normal operation, the main propulsion comes from the electricity generated by the gas turbine, once the vessel has reached a certain minimum cruising speed. The four stoke gas engines are sufficient to act as “get me home” engines. Further reductions in operating cost can be achieved with this hybrid combined cycle arrangement, as only one of the auxiliary engines is generally needed for loading and unloading of cargo, particularly with the assistance provided by the energy storage. As more power is needed to unload a vessel, typically both four stroke engines are in use for that, with the gas turbine on standby. As it takes about 6 to 10 minutes for the gas turbine to start up, then if a fault occurs with one of the four stroke engines, the other gas four stroke and the energy storage cover for this and there should be little effect on the loading or unloading operations. The gas turbine and the four stroke gas engines can both be fueled by the boil off gas from the cargo holds, which would otherwise be liquified and returned to the cargo tanks, or burnt off and wasted. In addition, provision of separate tanks for bunkering, for example zero carbon fuels, such as bioLNG and eLNG, allows the ship to still operate, even with empty cargo tanks.
The energy storage system 10 include a suitable store of energy, such as chemical or electrical energy storage, for example batteries, kinetic energy storage, such as flywheels, or other types of energy storage, such as capacitors, or super capacitors. The low pressure steam heating distribution 2 is coupled through the low pressure to high pressure steam heat exchanger 14 to the high pressure steam line and connected to the steam turbine and to an economiser 15 of the auxiliary engine exhaust waste heat recovery. Each of the auxiliary boiler 1, auxiliary generators 3 and gas turbine 8 are coupled to fuel metering devices 13, which provide data to control systems (not shown), so that the combination of operational energy sources may be optimised. The steam turbine 6 typically produces a half to a third of the power output of the gas turbine 8. An example of a gas turbine 7 that is suitable for this application is an SGT400 gas turbine, producing 12.9 MW of power, whereas the power output of the steam turbine 6 is typically lower, of the order of 5.6 MW. The new power system integrates the combined cycle power plant with the steam heating system. The heat recovery steam generator economizer may supply hot water to two steam flash vessels that provide more steam to the steam turbine, as well as hot water to a heat exchanger that pre-heats feedwater to the auxiliary boiler, reducing fuel consumption of the auxiliary boiler. In addition, pre-heating may be applied to the fuel gas using heat exchange to cool combustion air, so reducing the energy needed. This enables a significant improvement in the total fuel consumption to be achieved. For all of the examples given herein, the specific power outputs, operating voltages and gas turbine type and energy storage type used will depend on the customer requirement and the examples should not be treated as limiting.
Combustion air cooling is achieved by circulating the combustion air from combustion air source 91 through pipes 92 using a combustion air cooling pump 89. The combustion air flows through heat exchangers 87, 88 in contact with the boil off gas pipeline 84, or pumped fuel pipeline 82, respectively and is cooled down, then pumped back to supply cooled air 98 to the turbine. The effect of this combination of elements in the system is to reduce the amount of energy needed to heat up the fuel gas 99 for the turbine 8, as well as reducing the energy needed to cool down the combustion air 98 for the turbine. For example, typical steam consumption during ballast at 6 to 7 Bar (g), 170° C., the fuel gas heater 85 has steam capacity of 100 to 400 kg/h, requiring 80 to 300 kW at a typical rating of 650 kW and the forcing vaporiser has a steam capacity of 300 to 1400 kg/h, requiring 220 to 1050 kW at a typical rating of 1650 kW. To provide redundancy on the vessel, the example of
Electrical power is also supplied from the main switchboard 20, 21 to subsidiary switchboards, such as a directly connected cargo switchboard 32, 33 also operating at 6.6 kV AC, through connection 75, 72 with switches normally closed. The cargo switchboards 32, 33 are coupled together by a connection 71 with switches normally closed. The cargo switchboard 32, 33 connects to lower voltage consumer switchboards 34, 35 via a transformer 38, 40, operating in this example at 440V AC, or connects via other transformers 39, 41 to other consumer switchboards 36, 37 operating in this example at 220V AC. A connection 73 between lower voltage switchboards 34, 35 has switches normally open. Similarly, a connection 74 between the other consumer switchboards 34, 35 has switches normally open. The main switchboards also have connections 43, 45 via transformers 42, 44 to utility switchboards 46, 47 operating at 440V AC, with switches normally closed. In this example, the port utility switchboard 47 is shown connected, with switches normally closed, to an emergency switchboard 48, also at 440V AC, supplied by an emergency generator 49 and from this, via transformers to first and second emergency switchboards 51, 52 in this example at 220 VAC, may be coupled together through a coupling 53, set with switches normally open. The emergency switchboard supplies in this example a 220V AC general service UPS 56, 57 on both the port and starboard sides. (Although not shown, input 58a is also connected to emergency switchboard 48 through a connection from output 58b). The utility switchboards may also be connected to uninterruptable power supplies (UPS) at 110V DC, through an AC/DC rectifier (not shown), as well as being connected through transformers to 220V AC switchboards 59, 60. As with the main switchboard, the port and starboard sides of utility switchboards 46, 47 and 220V switchboards 59, 60 may also be coupled together by connection 61, 62 with normally open switches. The low voltage part of the design, 440V, 220V and 110V, is also customer specific and the arrangement of low voltage switchboards illustrated is just one option and not limited to only this arrangement.
Optional bow tunnel thrusters 63, 64 may be supplied from respective sides of the main switchboard 20, 21. A transformer 65, 67 and AC/AC converter 66, 68 bring the supply to the correct voltage for the thruster motors 69, 70. The example shown is based on a typical arrangement of a vessel with accommodation and the main switchboard mounted at the aft end of the vessel.
The energy storage 10 may include battery packs, in this example, battery packs producing 6 MW of power. As well as the energy storage 10, one of the auxiliary generators 3b, 4b, for example a spark ignited gas engine which may produce about 5.3MW of power; and a steam turbine 6, which may produce 5.7 MW of power, may all be connected to one AC bus, or switchboard 20, in this case, the port aft switchboard. These sources of power may produce fairly similar amounts of power. The gas turbine 8, the other auxiliary generator 3a, 4a and an optional shore supply connection 22 may be provided on a second AC bus 21. The two AC buses 20, 21, typically port and starboard aft on a twin engine vessel, may be coupled together via a coupling 23, with switches 101 normally closed. These switchboards are typically operated at 6.6 kV AC. Main propulsion is provided by electrical variable speed motors 24, 25, each producing about 10.5 MW of power, one coupled to each switchboard 20, 21. The generated power from the AC buses 20, 21 is fed through transformers 28a, 28b, 29a, 29b independently along cables 102, 104 to AC/DC, DC/AC converter circuits 26a, 26b, 27a, 27b to the motor. By contrast with the example of
The aft main switchboards also have connections 43, 45 via transformers 42, 44 to aft utility switchboards 46, 47 operating at 440V AC, with switches 106 normally open. In this example, each of the port and starboard aft switchboards 47, 46 are shown connected, with switches normally closed, to a general service 230V UPS fed from an emergency switchboard 48, also at 440V AC, supplied by an emergency generator 49, located forward. The after switchboards 46, 47 also supply lower voltage switchboards 59, 60 via transformers, in this example at a lower voltage of 230V. The switchboards 59, 60 are also able to be coupled together, via switches 106, normally open.
Electrical power is also supplied from the main switchboard 20, 21 to subsidiary switchboards, such as a directly connected port and starboard forward switchboards 32, 33 also operating at 6.6 kV AC. The supply is to a closed ring formed by connections 75, 72, 71 with all switches 105 normally closed. The two forward switchboards 32, 33 are coupled together by the connection 71 with the switches 105 normally closed. Each of the forward switchboards 32, 33 may support an optional bow tunnel thruster 63, 64 including a three-phase transformer 65, 67, an AC/AC converter 66, 68 and thruster motor 69, 70. The forward switchboards 32, 33 may connect to lower voltage consumer switchboards 34, 35 via a transformer 38, 40 on each switchboard. A connection 73 between the lower voltage switchboards 34, 35 has switches 106 normally open in operation. In this example, the consumer switchboards operate at 440V AC. Each of these switchboards 34, 35 may supply a general service UPS, located forward and operating, in this example at 230V. A further set of connections via other transformers 107 to other consumer switchboards 108, 109 operating, in this example, at 230V AC may be provided. A connection 110 between these consumer switchboards 34, 35 has switches 106 normally open.
Unlike the example of
A minimum speed is set to meet a desired arrival time at the next port. Propulsion power is increased to the point where the gas turbine generator and steam turbine generator are operating above 90% rated power and as in all other modes efficiency is continuously measured, in this case of the combined gas turbine generator and the steam turbine generator. Suitable remedial action is taken if the efficiency drops below a rated value. The control system controls the air lubrication and propulsion power, whilst minimising the power to the re-liquification plant by careful use of the natural boil off gas. The most fuel efficient speed of operation is preferred and measurements of fuel consumption and distance travelled are made to keep this under review and make suitable adaptations.
The present invention has a number of benefits. In particular, it allows the operational cost of the vessel to be reduced, as the vessel can be operated with minimal maintenance crew onboard and with unmanned machinery space. Fuel spending is reduced, as compared with a dual fuel diesel electric (DFDE) as well as slow speed two-stroke direct drive with auxiliary engines, by using energy storage and fuel optimization. The carbon emissions and methane slip are reduced compared to a conventionally powered LNG carrier by using gas turbines in a hybrid combined cycle system. Lubrication oil consumption is also reduced compared to conventional LNG carriers and other ships. Operation in accordance with the present invention, reduces noise and vibration for the crew and the marine echo system. As the machinery is physically smaller and lighter, the vessel can take more cargo, giving a reduced unit freight cost. Replacing LNG with Hydrogen as fuel may be achieved, making the design attractive over the longer term too, as operators may have to move away from using fossil fuels to meet government requirements.
Use of electrical propulsion improves the maneuvering capabilities of the vessel, as well as the operational flexibility, whilst minimising noise and vibration for the crew and the marine ecosystem. In combination with condition-based monitoring, there is less need for maintenance and operational support may be provided remotely, onshore. The present invention enables the vessel to operate with greater efficiency at higher speed, reducing the number of days at sea for the same distance covered. The unit freight cost may be significantly reduced with the increased speed and additional cargo that can be carried in the available time. Using the hybrid combined cycle system of the present invention, the fuel consumption for the steam boiler may be reduced significantly. Minimal heat is required for the machinery compared to a 2-stroke solution. A propulsion management system (PMS) is provided with a fuel optimization function (ECO mode). Only a single fuel is used for all of the energy generation systems, which simplifies logistics and reduces the overall capital expenditure. There are fewer fuel tanks and fuel systems that need to be heated and overall, there is more space available for cargo. 4-stroke auxiliary generators, for example, spark plug ignited gas engines are inherently more efficient that 2 stroke engines.
Number | Date | Country | Kind |
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2113071.1 | Sep 2021 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/075310 | 9/12/2022 | WO |