Patent Application
20210388764
The present disclosure provides systems and methods for power production with combustion of a carbonaceous fuel as well as input of heat from a low-grade heat source, such as a solar heat source.
Carbon dioxide (CO2) is a known product of the combustion of carbonaceous fuels, and power production systems utilizing combustion of carbonaceous fuels are required to capture produced CO2. U.S. Pat. No. 8,596,075 to Allam et al., describes a power production system using a CO2 working stream whereby CO2 produced from combustion can be withdrawn for various end uses. U.S. Patent Pub. No. 2013/0118145 to Palmer et al. describes a power production system using a CO2 working stream whereby a stream of heated, high pressure recycled CO2 can be further heated with a solar heater. This appears to require that solar heating occurs within a supercritical CO2 stream at pressures in excess of 150 bar (or even higher than 300 bar) and at temperatures above 500° C. Such temperature and pressure conditions, however, lead to significant challenges with respect to the design of a concentrated solar power (CSP) receiver if the supercritical CO2 is to be heated directly. If the supercritical CO2 is to be heated by an intermediate heat transfer loop, the challenge then becomes finding heat exchanger materials that can not only handle the high temperature and pressure of the supercritical CO2, but also possibly undesirable effects from heater transfer fluids that may be used with CSP applications at high temperatures, such as temperatures in excess of abut 400° C. Accordingly, there remains a need in the art for additional systems and methods for power production with the ability to incorporate solar heating.
The present disclosure relates to systems and methods whereby a variety of low-grade heat sources, such as solar energy, may be effectively integrated with a supercritical CO2 power cycle such as, for example, by interfacing the low-grade heating directly with a recuperative heat exchanger train instead of utilizing terminal heat transfer (e.g., heating to the highest desired temperature in the cycle). As such, the present disclosure encompasses power production systems and methods whereby low-grade heating is integrated with a CO2 power cycle, such as by directly interacting with a recuperator heat exchanger.
In some embodiments of the present disclosure, a turbine exhaust gas can be preheated before it enters the recuperative heat exchanger train and/or after it enters the recuperative heat exchanger train (i.e., part way through the recuperator heat exchanger). The low-pressure fluid in the CO2 power cycle is directly heated while still providing high temperature heat recovery in the recycle CO2 but without direct communication with the low-grade heat source, such as a concentrated solar power (CSP) system. This configuration can be advantageous since it reduces or eliminates any undesirable effects that may arise from the contact of an intermediate heat transfer fluid with a high-pressure CO2 stream in a heat exchanger. As such, technology and commercial risks can be minimized.
The low-pressure CO2 may also be heated through direct contact with a benign heat transfer fluid that can be managed in a manner such that the recycle CO2 is not permanently contaminated. For example, a CSP system or other form of heat (e.g., flue gas from a gas turbine) may be used to generate steam (other working fluids could include CO2, as well as compounds that form a vapor phase above approximately 100° C. and are a liquid at a temperature no cooler than ambient). This steam may then be merged with the turbine exhaust gas from the CO2 power cycle before it enters the recuperative heat exchanger train and/or after it enters the recuperative heat exchanger train (i.e., part way through the recuperator heat exchanger). The steam may then be separated as liquid water in a dedicated water separation step at the exit of the recuperative heat exchanger train. It can then be pumped back to the heat source and converted into steam to start the process over again.
The advantages of the presently disclosed systems and methods focus on further optimizing the heat transfer performance of the main recuperative heat exchanger train in order to lift the recycle CO2 temperature entering the combustor/heater. This is fundamentally different from known systems and methods utilizing solar heating by directly heating the recycle CO2 stream itself.
In one or more embodiments, the present disclosure provides methods for power generation. In an example embodiment, the method can comprise: combusting a fuel in a combustor with an oxidant in the presence of a compressed stream of carbon dioxide to form a compressed combustion product stream; expanding the compressed combustion product stream across a turbine to generate power and provide an expanded combustion product stream; passing the expanded combustion product stream through a primary heat exchanger to recuperate an available quantity of heat therefrom and form a cooled turbine exhaust stream; removing water from the cooled turbine exhaust stream to provide a stream of carbon dioxide; compressing the stream of carbon dioxide to form the compressed stream of carbon dioxide; recycling the compressed stream of carbon dioxide back to the combustor; heating a circulating fluid stream in a low-grade heat source to form a heated circulating fluid stream; and using the heated circulating fluid stream to increase the available quantity of heat in the expanded combustion product stream. In further embodiments, the method may be characterized in relation to one or more of the following statements, which can be combined in any order or number.
The circulating fluid stream can be recycled back to the low-grade heat source to be reheated after using the heated circulating fluid stream to increase the available quantity of heat in the expanded combustion product stream.
The heat can be transferred from the heated circulating fluid stream downstream from the turbine and upstream from the primary heat exchanger.
The expanded turbine exhaust stream and the heated circulating fluid stream can be passed through a secondary heat exchanger.
The heated circulating fluid stream can be passed through the primary heat exchanger.
The heated circulating fluid stream can be mixed with the expanded turbine exhaust stream downstream from the turbine and upstream from the primary heat exchanger.
The heated circulating fluid stream can be mixed with the expanded turbine exhaust stream while the expanded turbine exhaust stream is passing through the primary heat exchanger.
At least a portion of the circulating fluid stream that is mixed with the expanded turbine exhaust stream can be separated from the expanded turbine exhaust stream after passage through the primary heat exchanger.
The expanded turbine exhaust stream mixed with the circulating fluid can be passed through a separation unit downstream from the primary heat exchanger.
The at least a portion of the circulating fluid stream that is separated from the expanded turbine exhaust stream after passage through the primary heat exchanger can be recycled back to the low-grade heat source to be reheated.
The circulating fluid stream can comprise water.
The circulating fluid stream can comprise carbon dioxide.
The circulating fluid stream can comprise a refrigerant.
The primary heat exchanger can comprise a plurality of heat exchange units.
A side heater can be positioned between a first heat exchange unit and a second heat exchange unit, the expanded turbine exhaust stream can pass through the side heater, and the heated circulating fluid stream can pass through the side heater to provide heat to the expanded turbine exhaust stream.
The heated circulating fluid stream can be mixed with the expanded turbine exhaust stream between two heat exchange units of the plurality of heat exchange units.
The low-grade heat source can be a solar heater.
In one or more embodiments, the present disclosure can provide systems for power generation. In an example embodiment, the system can comprise: a combustor configured to receive a fuel, an oxidant, and compressed stream of carbon dioxide; a turbine configured to expand a combustor exhaust stream received from the combustor; a primary heat exchanger configured to recuperate an available quantity of heat from an expanded turbine exhaust stream received from the turbine; a separator configured to remove water from the expanded turbine exhaust stream received from the primary heat exchanger; a compressor configured to compress a stream of carbon dioxide received form the separator; a line configured to pass compressed carbon dioxide from the compressor to the combustor via the primary heat exchanger; a low-grade heat source configured to provide a heated circulating fluid stream; and at least one combiner configured for combining heat from the heated circulating fluid stream with the expanded turbine exhaust stream. In further embodiments, the system can be characterized by one or more of the following statements, which can be combined in any order or number.
The at least one combiner can include a secondary heat exchanger positioned downstream from the turbine and upstream from the primary heat exchanger, the secondary heat exchanger being configured for exchanging heat between the heated circulating fluid stream and the expanded turbine exhaust stream.
The primary heat exchanger can comprise a plurality of heat exchange units.
The combiner can be positioned between two heat exchange units of the plurality of heat exchange units.
The low-grade heat source can be a solar heater.
The present subject matter will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art. Indeed, the subject matter can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.
The present disclosure relates to systems and methods for power production. The systems and methods can be exemplified in relation to various embodiments whereby solar heating is integrated with a power cycle wherein a high pressure, high temperature recycle CO2 stream is further heated (e.g., in a combustor), expanded in a turbine for power production, cooled in a recuperator heat exchanger, re-pressurized, and re-heated in the recuperator heat exchanger. Non-limiting examples of systems and methods for power production, and elements thereof, that may be suitable for use according to the present disclosure are described in U.S. Pat. Nos. 8,596,075, 8,776,532, 8,959,887, 8,986,002, 9,068,743, 9,416,728, 9,546,814, 10,018,115, and U.S. Pub. No. 2012/0067054, the disclosures of which are incorporated herein by reference. Unlike previous systems and methods utilizing low-grade heating, the presently disclosed systems and methods do not require that a recycle CO2 stream is superheated after already being heated in a recuperator heat exchanger train.
In one or more example embodiments, low-grade heat is provided directly to the recuperative heat exchanger train. As used herein, low-grade heat can mean heat in a range of about 100° C. to about 550° C., about 150° C. to about 500° C., or about 200° C. to about 450° C. This can essentially eliminate any need for heat integration from a further outside source, such as the heat of compression from an air separation unit (ASU), a hot gas compressor, and/or other sources. The low-grade heat, for example, can heat up the turbine exhaust mid recuperative heat exchanger train either directly or indirectly. The addition of heat permits the CP imbalance between the turbine exhaust and recycle CO2 to be mitigated thereby increasing the recycle CO2 temperature into the combustor.
In one or more embodiments, various types of additive heating can be combined. In such instances, the combined heating sources can particularly be added to different streams at different points in the cycle. For example, added heating can be provided from an ASU and/or a hot gas compressor to a recycle stream that is already compressed and ready for recycle back into a combustor (e.g., added to the recycle stream while the recycle stream is being heated in the heat exchanger or added at some point between the hot end of the heat exchanger and the combustor). In such cases, low-grade heat may also be added to the turbine exhaust stream so that it can be superheated before entering the recuperative heat exchanger train. A portion of the heat transfer fluid may also be cooled below the turbine exhaust temperature to provide even further low-grade heating, and this supplement the heating that is provided by the ASU and/or hot gas compressor or even reduce the amount of heating that must be provided from such sources. This supplemental heat provides the same CP benefit as noted above. It may also permit the flow through uncooled compressors (hot gas compressor to intercooled compressor ratio varied) used for low-grade heat generation to be reduced thereby minimizing internal parasitic load consumption and increasing net power generation. The low grade heat addition not only increases efficiency but also power export since it can reduce the need for internal heat generation that leads to higher net efficiency but reduced power output. Alternatively, the flow through uncooled low-grade heat generating compressors may not be reduced and the excess available heat in the recuperative heat exchanger train may be used to thermally supplement a third party industrial process such as in a combined heat and power system or to reduce the effective size of the main heat exchanger train. The addition of low-grade heating according to the present disclosure is particularly beneficial in that can increase the internal temperature approaches within the heat exchanger and reduce the relative size of the heat exchanger.
An exemplary power production system 10 for carrying out a power production method according to the present disclosure is illustrated in
A low-grade heat source 170 is utilized to provide heating to a circulating stream. Any heat source capable of providing heating in the necessary temperature range may be utilized. In some embodiments a CSP heating unit may be utilized. In further examples, a gas turbine or other known heat source typically used in a power generation method may be used. Preferably, the low-grade heat source 170 is configured to provide a heated circulating fluid stream at a temperature in a range of about 100° C. to about 550° C., about 150° C. to about 500° C., or about 200° C. to about 450° C. The circulating fluid may be any material this is flowable under the required temperature conditions and that provides efficient heat transfer. In the exemplified embodiments, the circulating fluid stream for transfer of the low-grade heat need not necessarily be compatible with the turbine exhaust stream since the two streams are not intermixed.
As shown in
The heated circulating fluid stream from the low-grade heat source 170 can be used to increase the available quantity of heat in the expanded combustion product stream. The available quantity of heat in the expanded combustion product stream is utilized to heat the compressed carbon dioxide stream that is passed back to the combustor, and it is desirable to recuperate heat from the expanded turbine exhaust stream to provide such heating. There are definite limits, however, on the amount of heat that can be recuperated in this manner. By adding heat from the heated circulating fluid stream to the expanded turbine exhaust stream, it is possible to increase the available quantity of heat that can be withdrawn in the primary heat exchanger 130 to heat the compressed carbon dioxide stream. Preferably, the addition of the heat from the heated circulating fluid stream leaving the low-grade heat source is sufficient to increase the available quantity of heat from the expanded turbine exhaust stream by at least 5%, at least 10%, or at least 20%. For example, the addition of the heat from the heated circulating fluid stream can be sufficient to increase the available quantity of heat from the expanded turbine exhaust stream by at least 3° C., at least 5° C., at least 10° C., at least 20° C., at least 50° C., or at least 100° C. (up to a maximum or 300° C.). More particularly, the addition of the heat from the heated circulating fluid stream can be sufficient to increase the available quantity of heat from the expanded turbine exhaust stream by about 10° C. to about 300° C., about 20° C. to about 200° C., or about 25° C. to about 100° C. The increase in the available quantity of heat can be calculated by measuring the temperature of the compressed carbon dioxide stream exiting the hot end of the primary heat exchanger 130 with addition of the heat from the heated circulating fluid stream to the expanded turbine exhaust stream and without addition of the heat from the heated circulating fluid stream to the expanded turbine exhaust stream while keeping the temperature of the expanded turbine exhaust stream exiting the turbine substantially constant. In some embodiments, such as when the heated circulating fluid is intermixed with the turbine exhaust stream, there is provided a beneficial increase in the total heating mass flow that is at the original turbine exhaust temperature. Thus, in example embodiments, the mass flow of heated fluid passing through the primary heat exchanger toward the cold end thereof can be increased by at least 5%, at least 10%, at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or at least 90% relative to the mass of the exhaust stream immediately exiting the turbine (e.g., with a maximum mass increase of 200%). In certain embodiments, the mass flow of heated fluid passing through the primary heat exchanger toward the cold end thereof can be increased by about 5% to about 200%, about 10% to about 150%, about 20% to about 100%, or about 25% to about 90%.
After transfer of heat to the turbine exhaust stream, the circulating fluid passes for re-heating in line 177. An optional cooler 175 may be provided in line 177 to reduce the temperature thereof and optionally to withdraw further available heat for use in the power production system 10. The circulating fluid then passes through line 177 back through the low-grade heat source to be re-heated to the desired temperature.
In one or more embodiments, the circulating fluid may be a material that is configured to form a vapor phase above a temperature of approximately 100° C. and is configured for converting to a liquid at a lower temperature (e.g., liquid at approximately ambient temperature, such as in a range of about 15° C. to about 90° C., about 18° C. to about 80° C., or about 20° C. to about 70° C.). In some embodiments, water may be used as the circulating fluid. In other embodiments, carbon dioxide may be used as the circulating fluid. In further embodiments, a mixture of water and carbon dioxide may be utilized as the circulating fluid. In still other embodiments, known refrigerants may be utilized as the circulating fluid.
In addition to the low-grade heating, even further heating can be provided in the present systems and methods. While the low-grade heating is particularly beneficial in providing added heating to the turbine exhaust stream prior to compression, it can still be useful to provide added heating to the compressed, recycle CO2 stream. Referring to
In one or more embodiments, the primary heat exchanger 130 may be formed of a plurality of heat exchange units. The heat from the low-grade heat source 170 then can be added to the turbine exhaust in line 123 at a variety of points and in a variety of manners. In the example embodiment of
In a further example embodiment, as illustrated in
Similar to the foregoing, a plurality of heat exchange units may be utilized in embodiments wherein the circulating fluid is mixed with the turbine exhaust stream. As illustrated in
A further example embodiment is shown in
The foregoing systems and methods are particularly beneficial for integration of low-grade heat sources (such as solar heating systems) with systems and methods utilizing a CO2 working stream. It is understood, however, that such systems and methods may be used for any working fluid with disparities in CP values between high and low pressure.
Many modifications and other embodiments of the presently disclosed subject matter will come to mind to one skilled in the art to which this subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the present disclosure is not to be limited to the specific embodiments described herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The present application claims priority to U.S. Provisional Patent Application No. 62/551,025, filed Aug. 28, 2017, the disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16113076 | Aug 2018 | US |
| Child | 17412934 | US |
