The following relates to heat transfer systems and methods.
Various aspects of the present disclosure are now summarized to facilitate a basic understanding of the disclosure, wherein this summary is not an extensive overview of the disclosure, and is intended neither to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present various concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. The present disclosure provides heat transfer systems and methods.
Disclosed examples include a heat transfer system including a plurality of power supplies, each power supply of the plurality of power supplies configured to power a heat exchanger of a plurality of heat exchangers. The system further includes transfer pipes connecting the plurality of heat exchangers. Each heat exchanger of the plurality of heat exchangers includes an enclosure defining an interior; an induction coil within the interior; and a plurality of electrically conductive tubes within the induction coil for heating a molten salt material in the plurality of conductive tubes using a current induced by the induction coil.
Referring now in more detail to the figures, several embodiments or implementations are hereinafter described in conjunction with the drawings, wherein like reference numerals are used to refer to like elements throughout, and wherein the various features are not necessarily drawn to scale. The present disclosure provides systems and methods for heat transfer and heat storage. These aspects of the disclosure find utility in association with using electricity to heat salt. In addition, although illustrated in particular contexts, the disclosed concepts can be employed in any setting where heat transfer and heat storage systems are used.
The system 100, 130 stores energy in one example during off-peak demand time periods for subsequent recovery during peak demand time periods (e.g. as “on peak” electricity 114). In one possible application, this can be used in an overall system with further components to receive power from an electric power grid (not shown) via the power source 120 in
Such systems may be quite large (e.g. 100 megawatts). Such systems may also comprise multiple smaller systems such as 5, 10, 20, 30 megawatt systems as required for the application. As a result, the required number of induction power supplies may vary from several down to one.
The use of the induction molten salt heat transfer system 200 presents a significant advance over different forms of salt heat transfer systems. In particular, other systems employ immersion resistance heaters for heating molten salt, but these suffer from severe corrosion. By using induction heating in the system 200, non-contacting heat exchange is achieved to avoid these problems.
As shown in
The water pump and control station 250 controls circulation of water from the water tower 240 to the induction coils of the individual heat exchangers 300, and provides for cooling water circulation in a double wall water-cooled chamber, where used.
The system 200 includes a 6 inch inlet 260 and a 6 inch outlet 270 for transfer of molten salt for the heat exchange process. The salt is transferred through a system of insulated and heated transfer pipes 210 from the inlet 260 to the outlet 270. Electrical power is provided to operate the power supplies 310 via indoor vacuum breakers 280 from the secondaries of the outdoor transformers in one example, and various bus wires and leads 292 interconnect the power supplies 310 with the heat exchangers 300.
With reference to
The heat exchanger 300 may include an outer double walled stainless steel vessel to contain the induction coil 340.
The induction coil 340 is preferably a hollowed structure with coolant fluid such as water being circulated through the induction coil, e.g., from the dual water pump and control station of
The heat exchanger 300 may also include appropriate non-conductive spacers to assure straightness and linearity of the individual tube bundle members.
The bell ends are designed to affect proper flow (e.g. designed with the correct number of passes). Thus, these ends are extended slightly beyond the power coil ends.
In certain implementations, the tubes form a bundle designed in a series/parallel combination to maximize heat transfer to a specified flow rate while keeping pressure drop within reasonable limits for system design and other elements of the energy storage system pump design and safety reasons. The Example of
In one example, four such heat exchangers 300 are connected in series as shown in
Embodiments described herein allow for heating multiple tubes at the same time each having the same heating effect because the field is uniform throughout the coil ID, thus enabling all the tubes to heat the salt uniformly at the same time.
The heat exchangers 300 can also individually include one or more sensors for humidity/moisture, temperature, etc., with the vessel including a port 335 for wiring to such internal sensors. In one example, the vessel itself is a dual-wall structure with coolant fluid flowing between the walls. In addition, in order to mitigate heating of the vessel structure itself by operation of the internal induction coil, the vessel may be fashion from carbon steel or other suitable material, with one or more iron laminations or other magnetic shunt structures along the inner diameter of the chamber wall to provide a low reluctance between the induction coil and the vessel wall to combat induced current flow and thus inductive heating in the vessel itself.
As shown by
In operation, the induction coil 340 is energized by the associated power supply 310 for the individual heat exchangers 300, which convert the input (e.g., line) frequency power to a higher frequency (e.g., 300-500 Hz in one example). The high frequency current flows through the induction coils 340 of the individual heat exchangers 300 to produce an induction field within the interior of the individual induction coils. The presence of the conductive material of the array tubes within this field induces current flow within the tube material, thereby heating the transported salt material through conduction and/or convection. The molten salt flowing through the tubes absorbs the heat multiple times during transport back and forth within each of the individual heat exchangers 300, and the salt picks up and overall additional thermal energy level to transportation through two or more series-connected heat exchangers to reach a final temperature before flowing to the storage apparatus (e.g., storage tank 110 in
The illustrated system 200 and heat exchangers 300 advantageously provide efficient transfer of thermal energy to a transported salt material, in which the induction heating system is not in contact with, or otherwise immersed in the heated salt material. Thus, compared with conventional salt heating systems, the apparatus and techniques of the present disclosure advantageously avoid contact wear and/or erosion. Moreover, the induction heat transfer system can be operated using a programmable logic controller or other configurable control system (such to monitor and control the molten salt flow rate, power supply power level and resulting salt temperature).
Advantageously, the conductive tubes may be placed close together to increase efficiency. For example, placing the conductive tubes at a distance from each other of approximately 25% or less of conductive tube diameter may bring efficiency into the range of 90% or better. The conductive tubes may be made of a nonmagnetic material, which results in a more efficient heat transfer.
In this embodiment, none of the conductive tubes touch each other either directly or indirectly (e.g. through a metallic spacer) while under the presence of the induction field produced by the induction coil. The conductive tubes are separated by air, inert gas or dielectric. The conductive tubes may be identical. There may be end shortened Faraday copper rings provided at each end of the power coil. A Faraday ring is a shorted turn of copper or stainless steel. The induction field from the power coil produces a current in the Faraday ring but opposite in direction, and thus an electric field opposing that of the power coil. As a result, the field from the power coil cannot reach the outer bell ends of the heat exchanger and thus will not inductively heat them. As a result, energy is not wasted and electrical efficiency remains high.
The depth to which the current is produced in each tube is a function of the resistivity of the tube, its wall thickness, its permeability, and the frequency of the applied current. For example, the depth may be given by:
Resistivity is in micro-ohm in.
The objective in this case is choosing a tube material that is compatible with the caustic nature of the salt or salts. This objective could be met by choosing an Inconel base alloy or a 316 stainless. When a 316 stainless steel shell is selected, this eliminates the need for internal iron laminations. Thus, an embodiment comprises a 316 stainless steel shell with no internal iron laminations.
In addition, the tube wall thickness needs to be equal to or slightly less than the depth of current penetration. Doing this allows for as even as possible current distribution across the tube wall. If selected correctly, the entire wall of the tube will be heated by induction, and not just a thin outer layer. The purpose is to assure that benefits of inductive coupling directly coupling to tube is realized so that heat transfer is maximized to the flowing fluid. As a result, the time of heat transfer is minimized, making the entire system essentially directly responsive to a change to the power supply setting. Also, the gradient across the wall of the tube will be minimized so as to allow less thermal stress on the tube allowing the system to apply higher salt temperatures.
The efficiency of this induction tube induction is proportional to the ratio of the total area within all the tubes to the area within the induction coil. Thus, the greater the number of tubes within the coil the higher the electrical coupling efficiency.
Electrical coupling efficiency is proportional to:
This efficiency can range between 85% to 95%.
Electrical coupling efficiency would be maximized if the cross sectional area within the coil ID is equal to the area of the load, which would mean that the areas are equal. However, this is not possible because there is insulation and gaps between the tubes and the tubes cannot touch.
Generally, the induction coil ID is as close to the tube bundle OD while allowing some insulation on the coil ID to increase the thermal efficiencies while minimizing the ratio of the area inside the coil to the sum of all the areas within the tube ODs to as close to one as possible.
The thermal efficiencies depends on the insulation package used and is expected to be 90% to 95% or better.
The transmission line losses from the power supply to the induction coil range from 2 to 3.5%.
The power supply efficiencies range from 92% to 96%.
The above-discussed efficiencies will be application specific, but represent a reasonable range that can be expected.
A PLC (programmable logic controller) is included that integrates all diagnostics, menu driven operating screens for closed loop temperature control by varying kW to each reactor vessel. The system is also integrated into operations for safety interlocks and flow control.
In a preferred embodiment, low power is applied to the tubes to pre-heat the tubes to set point temperature. Valves open, and power level increases to high power to heat tubes to approximately 1150° F. Power level adjusts to maintain set point temperature through T/C set point closed loop control.
Elements that comprise the systems and methods described herein include the following.
Power leads/bus to convey current to the induction coil.
Power port for each vessel to allow the passage of power and water to the induction coil terminals while maintaining a air tight seal.
Controls that allow either the manual or automatic adjustment of signals (voltage, current, frequency and power) so as to control and provide the proper heating effect from the tubes to the flowing molten salt to raise the salt temperature to the desired process or set point temperature.
Thermocouples or optical pyrometers to measure the inlet molten salt temperature and the temperature of the salt as its temperature is being raised, thus providing the ability to monitor and provide manual or closed loop temperature control via a set point controller.
As a result, the flow rate of the incoming salt or its temperature may vary but the system will be able to adjust and still maintain the set point target temperature of the exiting molten salt.
Faraday rings to suppress the field produced by the induction power coil and thus inhibit the field from coupling to the bell ends and thus over heating them; thus the Farady increase the system efficiency.
All other coil insulation supports.
One of the main advantages of this system is that that at no time is any of the induction heating system submersed into or touching the molten salt. Thus, contact wear or erosion are not an issue. In other words, at no time are the heating elements in this the induction in contact with the salt so there is no corrosion or degradation to the induction coil and life is not affected.
Advantageously, the embodiments described herein provide the ability to accurately control the rate of rise of the salt (fluid) temperature within the tube bundle. Also advantageously, the embodiments described herein provide the ability to control the temperature of the tubes. Also advantageously, closed loop temperature control is possible by using thermocouples to sense the outlet temperature of the salt or tubes. Also advantageously, a customer can change the flow rate of the salt and the system will respond to accurately maintain the set point salt rise in temperature. Also advantageously, due to using solid state power supplies to provide kw/current/voltage control of power to the induction coil, the response time is much faster that other conventional means of heating liquid salt. Also advantageously, the various aspects of the design permit embodiments of the invention to be used in applications for heating other liquids as well.
The above examples are merely illustrative of several possible embodiments of various aspects of the present disclosure, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, circuits, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component, such as hardware, processor-executed software, or combinations thereof, which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the disclosure. In addition, although a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”
In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. In addition, the reference numerals in the drawings do not necessarily imply any specific order.
This application claims priority to, and the benefit of, U.S. Provisional Patent Application Ser. No. 62/201,302, filed on Aug. 5, 2015, entitled INDUCTION MOLTEN SALT HEAT TRANSFER SYSTEM, the entirety of which application is hereby incorporated by reference.
Number | Date | Country | |
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62201302 | Aug 2015 | US |