Patent Grant
12312980
This application is the § 371 U.S. National Stage of International Application No. PCT/IB2022/056916, filed Jul. 27, 2022, which claims the priority to Italian Application No. 102021000019994 filed Jul. 27, 2021, the disclosures of which are incorporated by reference herein in their entireties.
The object of the present invention is a plant and a related process in which a working fluid performs a thermodynamic cycle, specifically a closed thermodynamic cycle, e.g., a Rankine cycle, for the generation of electrical and/or mechanical power by the recovery and conversion of heat from a hot source. In particular, the plant and process covered by the invention can achieve a self-sustaining cycle that therefore does not require power supply to the working fluid pumping system (or requires minimal power supply) to operate.
In addition, the process and plant described and claimed here are capable of efficiently extracting energy even from ‘hot’ sources characterized by not excessively high temperatures, e.g., below 130° C., particularly hot sources in which a liquid (typically water) is present at temperatures below 100° C., e.g., between 35 and 80° C.
The present invention can be used in biogas/biomass plants for the recovery of waste heat from the cogeneration process, in geothermal plants for the exploitation of medium/small heat sources, in industrial plants for the recovery of waste heat (conversion of waste heat from industrial processes), and in the household for the production of electricity and the exploitation of heat for sanitary use.
A further use of the expander and its plant may concern systems, both domestic and industrial, in which the heat source is provided by solar energy capture systems.
Uses of the plant in the automotive sector, for example, for heat recovery from the engine, can also be envisaged.
Plants employing piston, screw, scroll volumetric expanders or reactive expanders such as gas turbines are known to recover thermal energy and subsequently produce electricity.
A popular form of implementation of such plants involves the use of one or more turbines as an expansion chamber. However, this solution has some constraints and drawbacks, such as:
It should also be noted that countless currently potentially available heat sources (think of industrial wastewater, or plant cooling water) have a temperature that is not excessively high, often significantly below 100° C., and flow rates that vary over time. The conversion into electricity of the heat provided by such sources, through the employment of turbines, is not cost-effective in relation to the energy produced: turbines are in fact unsuitable for the exploitation of medium/low-temperature heat sources (e.g., between 35 and 90° C.) which, moreover, often have widely variable heat output, a condition that makes the employment of turbines for thermal energy conversion even more inconvenient.
To overcome the drawbacks described above, it is known to use volumetric expanders, either reciprocating or rotary, capable of extracting energy from sources at not excessively high temperatures and also capable of operating at relatively modest fluid flow rates without excessive reduction in efficiency.
Examples of alternative (e.g., single- or multi-piston) volumetric expander plants used for the conversion of thermal energy into mechanical and/or electrical energy-capable of using heat sources at temperatures that may be below 100° C., e.g., on the order of 35-130° C.—are described in patent applications WO2010102874 and WO2014141072. Although these known alternative plants are found to be improved over plants with conventional turbines particularly under the mentioned medium/low-temperature heat source conditions, the Applicant has identified additional aspects that can be improved.
In particular, plants with a working fluid circulating in a closed loop require a pumping system to circulate the same working fluid. The pumps currently used are typically powered by electricity and thus put a burden on the overall efficiency of the system because a fraction of the mechanical and/or electrical energy that can be generated by the system is actually consumed by the pump.
In addition, currently used pumps such as multi-stage centrifugal pumps, vane pumps, gear pumps or orbital screw or spiral pumps (scroll type) have shown poor efficiencies, leakage problems at the high pressure regimes typical of the thermodynamic cycles discussed here, as well as all being subject to major cavitation problems.
The object of the present invention is therefore to substantially solve at least one of the drawbacks and/or limitations of the preceding solutions.
A first objective of the present invention is to make available a high-efficiency plant and process, particularly one that allows high efficiencies to be achieved through conversion of thermal energy into mechanical and/or electrical energy even while operating with hot sources at medium/low temperatures (e.g., on the order of 35 to 130° C.).
It is also a purpose of the present invention to make available a plant and a related process, e.g., of Rankine cycle type, that can be adapted to different working conditions so that the available heat sources can be effectively utilized and the maximum power can be delivered with excellent efficiencies.
It is then a purpose of the present invention to make available a plant and a related process, e.g., of Rankine cycle type, of simple and compact construction suitable for easy deployment and consequently exhibiting extremely low production, maintenance and assembly costs.
It is also an objective of the invention to provide a plant and related process, such as of Rankine cycle type, in which the working fluid pumping system is improved in efficiency.
It is also an additional purpose, to offer a plant and process that can achieve a self-sustaining cycle that therefore does not require power supply to the working fluid pumping system (or that requires minimal power supply) to operate.
An additional purpose of the invention is making available a plant and a related process, e.g., of Rankine cycle type, in which the working fluid pumping system does not show reliability problems and is well suited for use at pressure regimes of the cycle described here and with a working fluid present in both gaseous and liquid states.
It is also an ancillary purpose of the invention to make available a plant and process using a pumping system that minimizes cavitation issues.
Finally, it is an objective of the present invention to make available a plant and process for converting thermal energy into electrical and/or mechanical energy that is easily implemented and through which excellent energy conversion efficiencies can be achieved.
These purposes and others, which will appear more from the following description, are substantially achieved by a volumetric expander, a closed-loop plant, and a process for converting thermal energy to electrical energy according to one or more of the appended claims and/or the following aspects, taken alone or in any combination with each other or in combination with any one of the claims and/or in combination with any one of the additional aspects or features described below.
Aspects of the invention are described below.
In a 1st aspect, a plant (1) is provided comprising:
In a 2nd aspect, optionally according to the 1st aspect, a plant (1) is provided comprising:
In a 3rd aspect according to any one of the preceding aspects, the expander (4) is a volumetric expander with one or more pistons (reciprocating or rotating), screw, scroll, or other type.
In a 4th aspect according to any one of aspects 1st or 2nd the expander (4) is a reaction expander, including one or more gas turbines.
In a 5th aspect according to any one of the preceding aspects, the plant is configured for converting thermal energy to electrical and/or mechanical energy.
In a 6th aspect according to any one of the preceding aspects, the pump is configured for determining an increase in volume of the second compartment (21) following the entry of said working fluid in a gaseous state coming from the second portion (2b) into the same second compartment (21), and consequently promoting a reduction in the volume of the first compartment (20) causing the transfer of working fluid in a liquid state towards said evaporator (3).
In a 7th aspect according to any one of the preceding aspects, the first compartment (20) is selectively configurable in a respective first operating condition, wherein said first compartment (20) is in fluid communication with the first portion (2a) of the closed circuit (2), and in a respective second operating condition, wherein the first compartment (20) is in fluid communication with a third portion (2c) of the closed circuit (2), extending downstream of the condenser (16) and upstream of the pump (13), to receive working fluid in a liquid state from the condenser (16).
In an 8th aspect according to any one of the preceding aspects, the second compartment (21) is selectively configurable in a respective first operating condition, wherein said second compartment (21) is in fluid communication with the second portion (2b) of the closed circuit (2), and in a respective second operating condition, wherein the second compartment (21) is in fluid communication with the third portion (2c) of the closed circuit (2) upstream of the pump (13) to discharge working fluid in a gaseous state into said third portion (2c).
In a 9th aspect according to any one of the preceding two aspects, the plant is configured to hold the first compartment (20) in the respective first operating condition when the second compartment (21) is in the respective first operating condition and to hold the first compartment (20) in the respective second operating condition when the second compartment (21) is in the respective second operating condition.
In a 10th aspect according to any one of the preceding aspects, the plant includes at least one collection tank (17) operating at the or a third portion (2c) of the closed circuit (2) and interposed between the condenser (16) and the pump (13), said collection tank (17) being configured to receive working fluid from the condenser (16) and to contain working fluid in the liquid state in equilibrium with working fluid in the gaseous state.
In an 11th aspect according to the preceding aspect, the first compartment (20), in the respective second operating condition, is in fluid communication with a zone of the collection tank (17), in particular a lower zone (17a) of the collection tank, wherein working fluid in liquid state is present to receive working fluid in liquid state from the collection tank.
In a 12th aspect according to any one of the preceding two aspects, the second compartment (21), in the respective second operating condition, is in fluid communication with a zone of the collection tank (17), in particular an upper zone (17b) of the collection tank, wherein working fluid in gaseous state is present, to discharge working fluid in the gaseous state into the collection tank.
In a 13th aspect according to any one of the preceding aspects the pump (13) includes a casing and at least one piston operating within the casing.
In a 14th aspect according to the preceding aspect, the piston has a first head delimiting, in cooperation with said casing, the first compartment (20), and a second head delimiting, in cooperation with said casing, the second compartment (21).
In a 15th aspect according to the preceding aspect the first and second heads are connected to each other.
In a 16th aspect according to the preceding aspect the first and second heads are rigidly connected.
In a 17th aspect according to the 15th or 16th aspect the first and second heads are connected to each other so that:
In an 18th aspect according to the 15th or 16th or 17th aspect the first and second heads are connected to each other so that:
In a 19th aspect according to any one of the four preceding aspects, the pump includes a driving member, optionally including an electric motor or hydraulic motor or electric actuator or hydraulic actuator or pneumatic actuator, active on said piston to cause it to move back and forth along a predetermined stroke within said casing.
In a 20th aspect according to any one of aspects from the 15th to the 18th, the enclosure defines at least a first and a second working chamber hydraulically separated from each other and each defining a respective volume that can be occupied by the working fluid, and where the volumetry of the second chamber is greater than the volumetry of the first chamber.
In a 21st aspect according to the preceding aspect, the volumetry of the second chamber is at least 1.5 times greater than the volumetry of the first chamber, e.g. 1.5 times, 1.75 times, 2 times, 2.25 times, 2.5 times, 2.75 times, 3 times greater than the volumetry of the first chamber.
In a 22nd aspect according to the 20th or 21st aspect, the first and second chambers have equal axial extension, i.e., equal extension in the direction of piston motion, and different cross section.
In a 23rd aspect according to the 20th or 21st or 22nd aspect, the first piston head is slidingly housed in the first chamber and the second piston head is slidingly housed in the second chamber.
In a 24th aspect according to the preceding aspect, the first and second heads are rigidly connected, and the first head has an active cross-sectional area smaller than that the second head.
In a 25th aspect according to the preceding aspect, the first and second heads are rigidly connected by a rod extending transversely to the same first and second heads and passing fluid-tight through a separating wall between the first and second chambers.
In a 26th aspect according to any one of the aspects from the 20th to the 25th, the first piston head separates the first chamber into said first compartment (20) and into a third compartment (22) of the pump, said first and third compartments (22) extending on opposite sides of the first piston head and presenting variable volume as the position of the first head in the first chamber varies.
In a 27th aspect according to any one of the aspects from the 20th to the 26th, the second piston head separates the second chamber into said second compartment (21) and into a fourth compartment (23) of the pump, said second and fourth compartments (23) extending on opposite sides of the second piston head and presenting variable volume as the position of the second head in the second chamber varies.
In a 28th aspect according to any one of the 26th or 27th aspects the first compartment (20) is adjacent to the third compartment (22) which is adjacent to the fourth compartment (23) which in turn is adjacent to the second compartment (21).
In a 29th aspect according to any one of the 26th or 27th or 28th aspects, the third compartment (22) is in fluid communication with the third portion (2c) of the closed circuit (2) upstream of the pump (13), in particular with an upper zone of the collection tank (17), wherein working fluid in the gas phase is present.
In a 30th aspect according to any one of aspects 26th or 27th or 28th or 29th the fourth compartment (23) is selectively configurable in a respective first operating condition, wherein said fourth compartment (23) is in fluid communication with the second portion (2b) of the closed circuit (2), and in a respective second operating condition, wherein the fourth compartment (23) is in fluid communication with the third portion (2c) of the closed circuit (2) upstream of the pump (13), in particular with an upper zone of the collection tank (17), wherein working fluid in gaseous phase is present to discharge working fluid in gaseous state into said third portion (2c).
In a 31st aspect according to any one of aspects 26th or 27th or 28th or 29th or 30th the plant (1) is configured to hold the fourth compartment (23) in the respective second operating condition when the second compartment (21) is in the respective first operating condition and hold the fourth compartment (23) in the respective first operating condition when the second compartment (21) is in the respective second operating condition.
In a 32nd according to any one of the above aspects including at least one valve assembly (50) cooperating with the pump (13).
In a 33rd aspect according to the preceding aspect, the valve assembly (50) is configured to:
In a 34th aspect according to the preceding aspect, the valve assembly (50) is configured to place the first compartment (20) of the pump (13) in the respective first operating condition when the second compartment (21) is in the respective first operating condition and to place the first compartment (20) in the respective second operating condition when the second compartment (21) is in the respective second operating condition.
In a 35th aspect according to the 32nd or 33rd or 34th aspect the valve assembly (50) includes:
In a 36th aspect according to the preceding aspect, the valve assembly (50) includes:
In a 37th aspect according to the 35th or 36th aspect, the valve assembly (50) includes:
In a 38th aspect according to the 35th or 36th or 37th aspect, the valve assembly (50) includes:
In a 39th aspect according to any one of the aspects from the 32nd to the 34th, the valve assembly (50) is further configured to:
In a 39th-bis aspect according to any one of the aspects from the 32nd to 34th or the 39th aspect, the valve assembly (50) includes:
In a 40th aspect according to any one of the aspects from the 32nd to the 34th or the 39th or the 39th-bis aspect, the valve assembly (50) includes:
In a 41st aspect according to any one of the aspects from the 32nd to the 34th or the 39th or the 39th-bis or the 40th aspect the valve assembly (50) includes:
In a 42nd aspect according to any one of the preceding aspects, the plant includes a level sensor (3c) associated with the evaporator (3).
In a 43rd aspect according to any one of the preceding aspects, the plant includes a level sensor (17c) associated with the tank (17).
In a 44th aspect according to any one of the two preceding aspects comprising a control unit (100) communicatively connected with the level sensor (3c) associated with the evaporator, said level sensor sending at least a corresponding signal relative to the level of liquid in the evaporator (or of the level of liquid in a liquid collection compartment associated with the evaporator) to the control unit (100) which is configured to receive said signal and, depending on said signal, control or not the activation of the pump (13), for example by operating on the positioning of said selector (53) or by activating said driving member (70) on the basis of at least said signal.
In a 45th aspect according to any one of the three preceding aspects comprising a control unit (100) communicatively connected with the level sensor (17c) associated with the tank, said level sensor sending at least a corresponding signal relative to the level of liquid in the tank to the control unit (100) which is configured to receive said signal and, depending on said signal, to control or not the activation of the pump (13), for example by operating on the positioning of said selector (53) or activating said driving member (70) on the basis of at least said signal.
In a 46th aspect according to any one of the preceding aspects, the plant includes at least one end-stroke sensor (60) associated with said pump for detecting the attainment by said piston (15) of respective end-stroke positions.
In a 47th aspect according to the preceding aspect, the end-stroke sensor is configured to directly control the reversal of the motion of said piston, e.g. by sending a command signal to said selector or driving member.
In a 48th aspect according to the 46th or 47th aspect, the end-stroke sensor is configured to emit a corresponding command signal for a/the control unit (100) which is configured to command the reversal of the motion of said piston (15), for example, by operating on the positioning of said selector (53) or by commanding the activation of said driving member (70).
In a 49th aspect according to any one of the preceding aspects a/said control unit (100) is configured to control the reversal of the motion of said piston (15), for example by operating on the positioning of said selector (53) or by controlling the activation of said driving member (70), at predetermined regular time intervals.
In a 50th aspect according to any one of the preceding aspects said evaporator (3) includes at least a first heat exchanger having a side configured to receive heat from a hot source (H) and a side crossed by said second portion (2b) of the closed circuit.
In a 51st aspect according to any one of the preceding aspects, the condenser (16) includes at least a second heat exchanger having a side crossed by a section of a/the third portion (2c) of the closed circuit (2) interposed between the expander (4) and the pump (13), and a side configured to interact with a cold source (C) and allow condensation of the working fluid crossing said section, determining its passage from the gaseous state to the liquid state.
In a 52nd aspect according to the preceding two aspects, the plant includes at least a third heat exchanger (18) having a side crossed by a section of the closed circuit interposed between the expander (4) and the condenser (16) and a side crossed by a section of the first portion (2a) of the closed circuit, in order to determine a preheating of the working fluid in the liquid state exiting the pump (13) and directed towards the evaporator (3).
In a 53rd aspect according to any one of the preceding aspects, the plant is configured to implement a closed Rankine cycle.
In a 54th aspect according to any one of the preceding aspects, the plant is configured to drive a/the pump without the use of electricity.
In a 55th aspect according to any one of the preceding aspects, the plant is energy self-sustaining, in the sense that apart from the hot source and the cold source it does not use energy supply from other sources to operate.
In a 56th aspect according to any one of the preceding aspects, the plant includes at least one electric power generator (12) connected to a main shaft (11) of the volumetric expander (4), said generator (12) being configured to generate electric energy as a result of the rotation of the main shaft (11).
In a 57th aspect according to any one of the preceding aspects said volumetric expander (4) includes:
In a 58th aspect according to the preceding aspect said valve (8) is configured and controlled to allow at least:
A 59th aspect concerns a process for converting thermal energy into electrical energy using a plant according to any one of the preceding aspects.
A 60th aspect concerns a process for converting thermal energy into mechanical energy using a plant according to any one of the preceding aspects from the 1st to 58th.
In a 61st aspect, in particular according to the 59th or 60th aspect, a process is provided comprising:
In a 62nd aspect according to the 61st aspect, the working fluid in the gaseous state used by the pump for pumping working fluid in the liquid state comes from a portion of the circuit (2) upstream of the expander used for mechanical and/or electrical power generation.
In a 63rd aspect according to any one of the four preceding aspects the process includes:
In a 64th aspect according to the preceding aspect said pump uses working fluid in the gaseous state produced by the evaporator (3) and tapped from the evaporator (3) itself or from the second portion (2b) of the closed circuit (2) included between the evaporator (3) and the volumetric expander (4) to pump toward the evaporator (3) said liquid working fluid from the condenser (16).
In a 65th aspect according to any one of the 58th through 64th aspects the process includes:
In a 66th aspect according to any one of the 58th through 64th aspects the process includes:
Embodiments and aspects of the present invention will appear from the following description with reference to the accompanying drawings, which are provided by way of non-limiting example, wherein:
Note that in the present detailed description corresponding parts shown in the various figures are indicated with the same numerical references.
The figures may illustrate the object of the invention by means of representations not to scale; therefore, parts and components illustrated in the figures related to the object of the invention could relate only to schematic representations.
With the term working fluid is, for example, understood to mean an organic-type fluid (ORC fluid). In particular, the working fluid that may be used with the described plant includes a quantity of organic fluid comprised between 90% and 99%, in particular between 95% and 99%, even more in particular around 98%. The organic-type fluid is preferably mixed with at least one oil configured for allowing lubrication of moving elements inside the volumetric expander. For example, the organic fluids used may include at least one selected among the group of the following fluids: R134A, R245FA, R1234FY, R1234FZ, R245 sas 3G, R 744, R32, R420, R520 (single ASHRAE).
The possibility of using other working fluids suitable for being used in the plant and process described here is not excluded.
In the following description and claims, the terms upstream and downstream refer to a direction of circulation of the working fluid within the closed circuit 2 of plant 1.
Parts Common to the Exemplifying Installations of
The first part of the following description shown common aspects of the plant of
With reference to the accompanying Figures from 1 to 4, with reference 1 has been indicated a closed-cycle plant, e.g., Rankine cycle, for the conversion of thermal energy into electrical and/or mechanical energy. The plant 1 finds application, for example, in biogas/biomass plants for recovery of waste heat from the cogeneration process, in geothermal plants for the exploitation of medium/small heat sources, in industrial plants for the recovery of waste heat (conversion of waste heat from industrial processes), in households for the production of electric energy and the exploitation of heat for sanitary use. A further use of the plant 1 may concern systems, both domestic and industrial, wherein the heat source is provided by systems exploiting solar energy. Uses of the plant in the automotive sector may also be envisaged, e.g. such as for the recovery of heat from the engine, or from flue gas or dissipated by the radiator.
The plant 1 includes a closed circuit 2 within which the working fluid circulates. In particular, the working fluid is a fluid of the type defined above.
As can be seen from the schematics of
The working fluid entering pump 13 is in the liquid state at a predetermined pressure, in particular substantially corresponding to a circuit minimum pressure. The pump 13 is configured for imposing a predetermined pressure jump on the working fluid and bringing it substantially to a maximum pressure of the circuit 2. The pressure jump imposed by the pump 13 depends on the sizing of the pump 13 and is preferably greater than 5 bar, in particular comprised between 5 bar and 25 bar, even more in particular between 5 bar and 20 bar. Due to the pressure jump imposed by pump 13, the working fluid circulates in the circuit 2 and in particular exiting the latter reaches a first heat exchanger or evaporator 3 active on the circuit 2. In fact, the working fluid in the liquid state pushed by pump 13 is fed into evaporator 3, which is configured to heat the fluid to the point of determining its transition from the liquid to the gaseous state.
In more detail, the evaporator 3 is suitable for receiving in passage the working fluid and in addition receive heat from a hot source H suitable for allowing the heating of said fluid by allowing its change of state: at the outlet of the evaporator 3 the working fluid is in a vapor condition, in particular saturated vapor. Structurally, the evaporator 3 may comprise, for example, one or more collection tanks (suitable for containing the liquid phase) and one or more heat exchanger(s) suitable for exploiting, as a hot source H, an additional working fluid e.g., arriving from a different industrial plant (e.g., industrial waste liquids) for transforming the working fluid from a liquid to a gas. Alternatively, the evaporator 3 may include a boiler suitable for allowing the working fluid to change state by means of a hot source H obtained by combustion. The heating fluid from the hot source may have a temperature lower than 150° C., in particular comprised between 25° C. and 130° C. In the example illustrated, the evaporator 3 comprises a first exchanger, with the working fluid flowing through a first side 3a of the first exchanger and being progressively converted to gas by a hot fluid from the hot source H connected to a second side 3b of the first exchanger 3. As can be seen from the figures, the fluids move against each other in the nonlimiting examples illustrated.
To the evaporator 3, and in particular to a liquid collection area of the evaporator, may be associated a level sensor 3c that is capable of reporting the level of liquid in the evaporator (e.g., in a tank associated with it): e.g., the level sensor 3c may comprise one or more sensor elements suitable for activating when a respective level is reached, or a transducer suitable for emitting an electrical or electromagnetic signal proportional to the liquid level, or a simple mechanical floating device suitable for sensing the liquid level and activating an electrical or mechanical control. The signal(s) from the level sensor 3c may be sent to a control unit 100 (e.g., comprising one or more digital CPUs associated respective memories or comprising one or more analog units or comprising a combination of one or more digital units associated with respective memories and one or more analog circuitry) programmed with at least one respective program or configured to selectively command the activation or shutdown of the pump 13 for fluid circulation, depending on the liquid level in the evaporator. Alternatively, the control unit 100 may be configured to command a valve assembly 50 associated to the pump 13 for hydraulically connecting or isolating the pump itself from the circuit 2 depending on the level sensed by the sensor 3a, or to command a driving member 70 of the pump 13. If the level sensor 3a is a mechanical device such as a float, the device may be kinematically connected to a switch of the pump for controlling the switching on or off the pump 53 or of the aforementioned driving member 70, or of at least one valve assembly associated with the pump to hydraulically isolate or not the pump itself from the circuit 2, depending on the level sensed by the sensor 17c.
Along the direction of circulation of the working fluid in the circuit 2, it is worth noting how the working fluid in the gaseous state exiting the evaporator 3 enters a volumetric expander 4 configured to transform the thermal energy of the working fluid into mechanical energy.
The volumetric expander 4 is of known type and for example comprises at least one piston 5 suitable for defining at least one expansion chamber 6 with variable volume. The volumetric expander 4 may further comprise a transmission member for example a crank gear 7 connected on one side to the piston and on the other side to a main shaft 11 configured to rotate about a respective axis. The volumetric expander 4 preferably includes at least one valve 8 configured for selectively allowing the working fluid to enter the chamber 6 through at least one inlet 9, the expansion of the fluid in the chamber 6 and the discharging of the working fluid from the expansion chamber 6 through at least one outlet 10 and thus generating the movement of the piston 5: so that, it is possible to rotate the main shaft 11 about its axis. It should be noted that a transmission part (not shown) connected—on one side—to the valve 8 and—on the other side—to the main shaft 11 can be provided to synchronize the inlet condition, the expansion condition and the discharge condition of the working fluid with the rotation of the main shaft 11 (alternatively, the synchronization can be managed by electrical or electronic systems),
As can be seen, for example, from
The volumetric expander 4 can obviously include more than one piston and for example can be of the type described in patent applications WO2010102874 and WO2014141072.
Along the direction of travel of the working fluid in the circuit 2, it can be seen that plant 1 also includes at least a second heat exchanger or condenser 16 active on the circuit 2 itself. The condenser 16, as seen for example in
The following description and claims will indicate as:
According to a further aspect, the working fluid in the liquid state is directed to a collection tank 17 located on circuit 2 between the condenser 16 and the pump 13. The function of the collection tank 17 is to collect and contain the working fluid in a liquid state exiting the condenser 16 at a lower zone 17a of the tank itself so that the pump 13 draws in liquid without bubbles, as shown in the accompanying figures. In particular, the tank 17 prevents the pumping of working fluid laden with air bubbles which could result in malfunction of the entire plant 1. The gas phase is in fact contained in the tank 17, which is not connected with the external environment, but part of the closed circuit, at an upper zone 17b of the tank itself. A level sensor 17c may be associated with the tank 17, and in particular with the lower liquid collection area 17a of the tank, which is suitable for providing the level of liquid in the tank: for example, the level sensor 17c may comprise one or more sensor elements capable of activating when a respective level is reached, or a transducer capable of emitting an electrical or electromagnetic signal proportional to the liquid level, or a simple mechanical float device capable of sensing the liquid level and activating an electrical or mechanical command. The signal(s) from the level sensor 17c can be sent to the control unit 100 programmed or configured to selectively command on or off the fluid circulation pump 13 or the driving member 70 depending on the liquid level in the tank 17. Alternatively, the control unit 100 may be configured to control a valve assembly 50 associated with the pump 13 to hydraulically connect or isolate the pump itself from the circuit 2 depending on the level sensed by the sensor 17c; if the level sensor 17c is a mechanical device such as a float, the device may be kinematically connected to a pump switch to control on or off of the pump 13 or the aforementioned driving member 70, or to at least one valve associated with the pump to isolate or not the pump itself from the circuit 2 depending on the level sensed by the sensor 17c.
According to a further aspect, the plant 1 includes at least a third heat exchanger 18 having a first side 18a crossed by a section of the fourth portion 2d of the closed circuit interposed between the expander 4 and the condenser 16 and a second side 18b crossed by a section of the first portion 2a of the closed circuit, for determining a preheating of the working fluid in a liquid state exiting the pump 13 and directed to the evaporator 3 by hot gas from expander 4.
Turning now to a more detailed description of the pump 13 of
The pump 13 shown in
Inside the case 14 operates a piston 15 presenting a first head 15a and a second head 15b. The first head 15a of the piston is slidingly housed in the first chamber 14a and the second head 15b of the piston is slidingly housed in the second chamber 14b; the first and second heads are then rigidly connected to each other. In the specific case, the first and second heads are connected by a rod 15d extending transversely to the same first and second heads 15a, 15b and passing fluid-tight through a separation wall 40 between the first and second chambers. As can be seen in
The first head 15a of the piston delimits, in cooperation with the case 14, a first compartment 20, and a third compartment 22 opposed to the first compartment with respect to the same first head 15a (the first and third compartments 20, 22 are part of the first chamber 14a); in turn, the second head 15b delimits, in cooperation with said case, a second compartment 21 and a fourth compartment 23 opposed to the second compartment with respect to the second head 15b (the second and fourth compartments 21, 23 are instead part of the second chamber 14b). The separation wall 40 actually separates the third and fourth compartments 22, and 23 which are in the illustrated example adjacent to each other, but part of hydraulically distinct chambers i.e. the first chamber 14a and the second chamber 14b respectively. Summing up: the first head 15a of the piston separates the first chamber 14a into said first and third compartments 20, 22 of the pump which are in fact on opposite sides of the first piston head and having variable volume as the position of the first head in the first chamber varies, while the second head 15b of the piston separates the second chamber in the second and fourth compartments 21, 23 of the pump which are on opposite sides of the second piston head and also having variable volume as the position of the second head in the second chamber varies.
In the illustrated example, the pump 13 has piston 15 that optionally also includes a third head 15c rigidly connected to piston rod 15d and located opposite the first head (in practice, in the illustrated example, pump 13 and thus the piston 15 and the case 14 have symmetrical structure with the second head located in the middle of the piston between the first and third heads). The case 14 also defines a third chamber 14c in which the third head 15c operates, which divides the third chamber into a fifth and a sixth compartment 24 and 25, where the sixth compartment 25 is, for example, adjacent to the second compartment 21 and separated from the latter by an additional separation wall 41 through which the piston rod 15d fluid-tightly flows, and where the fifth compartment 24 is adjacent to the sixth compartment 25 and on opposite sides to the first compartment 20.
The first compartment 20 may be placed in fluid communication with a first portion 2a of the closed circuit 2 extending downstream the pump 13 and upstream the evaporator 3, to send working fluid in a liquid state to the same evaporator 3: for example, the first compartment 20 may present an outlet passage opening to which a line 30 of the first portion 2a of the circuit 2 is connected. The first compartment 20 is also connectable with a third portion 2c of the closed circuit 2: for example, the first compartment 20 may present an inlet passage opening connected to a line 31 of the third portion 2c of the circuit 2, upstream of the pump 13, to receive working fluid in a liquid state coming from the condenser 16 and more precisely from the lower zone 17a of the tank 17; in more detail, the first compartment is selectively configurable in a respective first operating condition (
The second compartment 21 can be placed in fluid communication with the second portion 2b of the closed circuit 2 by means of a line 32, in order to receive working fluid in a gaseous state generated by the evaporator 3 or by means of a line 33 with the upper zone 17b of the tank in order to discharge working fluid in the tank. In more detail, the second compartment 21 is selectively configurable in a respective first operating condition (
According to one aspect of the invention, the pump 13 is configured and controlled by the plant so that the first compartment 20 is in the respective first operating condition when the second compartment 21 is also in the respective first operating condition and so that the first compartment 20 is in the respective second operating condition when the second compartment 21 is also in the respective second operating condition; in this way, the pressurized gas coming from the second portion 2b and produced by the evaporator 3, which is therefore at high pressure (e.g., from 5 to 10 bar, typically around 20/25 bar higher than the liquid/gas pressure in the tank 17) tends, thanks to the larger size of the second piston 15b, to let the second pump compartment to expand and consequently cause a reduction in the volume of the first compartment pushing liquid working fluid to the evaporator. In practice, due to the above-described piston 15 and to the heads 15a and 15b, the pump 13 is configured so that changes of the internal volume of the first and second compartments are interconnected: in other words, following inlet of said working fluid in a gaseous state from the second portion 2b of the closed circuit into the second compartment 21 there is a movement of the second head (towards the right in
Thanks to this solution, it is possible to take advantage of a portion (actually relatively small) of the thermal energy of the hot, high-pressure gas present in the second portion 2b of the circuit to pump working fluid in a liquid state, significantly increasing the cycle efficiency, all without exploiting electric energy and thus improving the efficiency of the cycle.
As mentioned, according to one aspect, the first and second heads are connected to each other: in particular, in the non-limiting example of
In the illustrated example the pump 13 has the piston 15 that optionally also includes a third head 15c rigidly connected to rod 15d and placed opposite to the first head conferring to the pump 13, and thus to piston 15 and to the case 14, symmetrical structure with the second head placed in the middle of the piston between the first and third heads: the third head operates in the third chamber 14c and divides it into the fifth and a sixth compartment 24 and 25.
In an optional and currently preferred solution, the third compartment 22 is in fluid communication with the third portion 2c of the closed circuit 2 upstream the pump 13: in particular, a service line 34 places the third compartment 22 in fluid communication with the upper zone 17b of the collection tank to receive or discharge working fluid in a gaseous phase, depending on whether the piston 15 is respectively moving in a first direction (e.g., towards the right with reference to
Alternatively, in a currently less preferred solution, it is possible to provide for the third compartment 22 (and possibly the sixth compartment 25 if present) to be selectively connectable to the second portion 2b of the circuit when the first compartment 20 (or the fifth compartment 24 if present) is in the first operating condition and pushing liquid to the evaporator 3 and to the third portion of the circuit 2c when the first compartment (or the fifth compartment if present) is in the second operating condition and drawing liquid from the third portion 2c of the circuit 2.
Finally, similarly to the second compartment 21, the fourth compartment 23 is selectively configurable in a respective first operating condition, in which said fourth compartment is in fluid communication with the second portion 2b of the closed circuit 2, e.g., through the line 32 (as will be seen thanks to the intervention of a valve assembly described below-condition shown in
As shown in
If (as in
As the skilled person may understand, various systems can be provided to drive the pump 13 and impose the operating conditions of the various compartments as described above. In the nonlimiting example shown in
In detail, the valve assembly 50 exemplified in
The valve assembly 50 can also provide for the presence of a selector switch 53 having at least four ways and two positions, which can be selectively placed in a first position (
Coordination of the selector switch 53 and thus its switching between the various positions described above may be done by an electronic, an electromechanical or purely a mechanical control system.
For example, it can be provided that control unit 100 sends a command to the selector switch to position it in one of the positions described above. For example, an end-stroke sensor 60 associated with the pump 13 can detect the attainment by said piston 15 of respective end-stroke positions and emit a corresponding command signal to the control unit 100, which can be configured to command the switch from the first to the second position of the selector based on said signal from the end-stroke sensor 60. Alternatively, the end-stroke sensor 60 can directly command the selector switch 53 to move between the first and second positions and vice versa.
As already mentioned, the control unit 100 may also be configured to control the valve assembly 50 and, in particular, the selector switch 53 associated with the pump 13, to appropriately connect or hydraulically isolate the pump itself with respect to the circuit 2 depending on the level sensed by the sensor 17c and/or depending on the level sensed by the level sensor 3c operating at the evaporator 3: e.g., if the level sensor sensed by level sensor 3c indicates a high liquid level, the control unit can be configured to turn off the pump by, for example, turning the selector switch to the third hydraulic lock position. Furthermore, the control unit can be configured to restart the pump and then set the selector switch to the first or second position (alternately) for pumping fluid in a liquid state to the evaporator if the level sensor 3c indicates a liquid level in the evaporator itself that is too low. Similarly, if the level sensor detected by level sensor 17c indicates a high liquid level, the control unit can be configured to activate the pump by, for example, turning the selector switch from the third hydraulic lock position alternately to the first and second positions. In addition, the control unit can be configured to stop the pump 13 and then set the selector switch to the third operating position if the level sensor 17c indicates a liquid level in the collection tank 17 that is too low.
If the level sensor 3c or 17c is a mechanical device such as a float, the device can be kinematically connected to selector switch 53 to control its movement towards the third position or outwards the third position and isolate or not the pump itself from the circuit 2, depending on the level sensed by the sensor 3c or 17c, respectively.
Finally, in a further variant, the pump 13 can be controlled by the control unit simply on a time basis determining the switching of the selector switch at predetermined regular intervals.
With reference to
The first head 15a of the piston delimits, in cooperation with the case 14, a first compartment 20; in turn, the second head 15b delimits, in cooperation with said casing, a second compartment 21. Summing up: the first head 15a and the second head 15b define the compartments 20 and 21, which have variable volume as the position of piston 15 varies.
The first compartment 20 may be placed in fluid communication with a first portion 2a of the closed circuit 2 extending downstream the pump 13 and upstream the evaporator 3, for sending working fluid in a liquid state to the same evaporator 3: for example, the first compartment 20 may present an outlet passage opening to which a line 30 of the first portion 2a of the circuit 2 is connected. The first compartment 20 is also connectable with a third portion 2c of the closed circuit 2: for example, the first compartment 20 may present an inlet passage opening connected to a line 31 of the third portion 2c of the circuit 2, upstream the pump 13, to receive working fluid in a liquid state coming from the condenser 16 and more precisely from the lower zone 17a of the tank 17; in more detail, the first compartment is selectively configurable in a respective first operating condition (
The second compartment 21 can be placed in fluid communication, e.g., by means of a line 32, with the second portion 2b of the closed circuit 2 in order to receive working fluid in a gaseous state generated by the evaporator 3 or, e.g., by means of a line 33, with the third portion 2c and in particular with the upper zone 17b of the tank in order to discharge working fluid into the tank itself. In more detail, the second compartment 21 is selectively configurable in a respective first operating condition (
According to one aspect of the invention, the pump 13 is configured and controlled by the plant so that the first compartment 20 is in the respective first operating condition when the second compartment 21 is also in the respective first operating condition and so that the first compartment 20 is in the respective second operating condition when the second compartment 21 is also in the respective second operating condition; in this way, the pressurized gas from the second portion 2b and produced by the evaporator 3, which is at high pressure (e.g., at a pressure from 5 bar to 10 bar, typically from 20 bar to 25 bar higher than the pressure of the working fluid in the tank 17) entering the second compartment of the pump tends to equalize the pressure in the first compartment. Due to the aforementioned piston 15 and the heads 15a and 15b, the pump 13 is configured so that the internal volume variations of the first and second compartments are interconnected: in other words, a small force given by a driving member 70 associated with pump 13 (sufficient to overcome friction) is sufficient to cause the displacement of the piston 15 and, following entry of said working fluid in a gaseous state from the second portion 2b of the closed circuit in the second compartment 21, having a movement of the second head 15b (towards the right in
Thanks to this solution, it is possible to take advantage of a portion (actually relatively small) of the thermal energy of the hot, high-pressure gas present in the second portion 2b of the circuit for promoting pumping the working fluid.
As mentioned in the example in
Also in the example in
The valve assembly 50 may, for example, comprise a first non-return valve 51, which may be physically carried by the body of the pump 13 (e.g., also directly associated with an outlet opening in the first compartment) or operating on the first portion 2a of the closed circuit (e.g., located on the line 30), to allow working fluid in a liquid state to be supplied from the first compartment to said evaporator 3 (while preventing fluid from flowing back to the first compartment). The valve assembly 50 also includes, for example, a second non-return valve 52, which may be carried by the body of the pump, for example also directly associated with an inlet opening in the first compartment 20 or operate on the third portion 2c of the closed circuit (for example on the line 31), to allow working fluid in a liquid state from the same third portion 2c (in particular from the tank 17) to enter the first compartment, during a charging phase of the first compartment with working fluid.
The valve assembly 50 may also comprise a third non-return valve 56 which may be physically carried by the body of the pump 13 (e.g., directly associated with an inlet opening of the second compartment) or operate on the second portion 2b of the closed circuit (e.g., on the line 32), to allow working fluid in the gaseous state generated by said evaporator 3 to be supplied to the second compartment (while preventing fluid from flowing back to the evaporator). The valve assembly 50 also includes, for example, a fourth non-return valve 57, which may be carried by the body of the pump, for example, directly associated with an outlet opening from the second compartment 21 or operate on the third portion 2c of the closed circuit (for example, on the line 33), to allow working fluid in the gaseous state to flow outward the second compartment to the same third portion 2c (in particular towards the tank 17), during a discharge phase of working fluid from the second compartment.
Alternatively to the above, the valve assembly 50 could include a selector switch, e.g., a four way two position (or other valve selector), e.g., controlled by the unit 100, capable of enabling the positioning of the first and second compartments under the operating conditions described above.
Although a pump using a piston with multiple heads has been described in the examples shown above, it is possible to provide instead of the piston, the use of diaphragms or membranes (acting as the heads and defining the various compartments) kinematically connected to each other so that they can ensure similar pump functionality as described above with the compartments operating as illustrated above.
Furthermore, although a pump using a reciprocating type piston has been described in the examples above, it is not excluded the possibility of using a ‘rotary piston’ system.
Process of Producing Electrical and/or Mechanical Energy.
It is also an object of the present invention a process using one of the above-described plants or a plant according to any one of the accompanying claims for converting thermal energy into mechanical or electrical energy. The process includes a step of circulating the working fluid whose motion is given by the pump 13. The working fluid, pushed by the pump 13 reaches the evaporator 3 which, thanks to the hot source H heats the working fluid until it evaporates.
The process may also have a preheating phase for the working fluid by means of the economizer or third heat exchanger 18. For example, the preheating phase allows the working fluid to be heated without causing evaporation of the working fluid. The heat for preheating is taken from the expanded gas leaving the expander 4.
Following the evaporation phase, the working fluid in the gaseous state reaches the expander 4: here the fluid is expanded and causes the rotation of the motor shaft 11 with generation of mechanical energy that could be directly used. In detail, as a result of this expansion, the piston 5 of the expander is moved, in a known manner, in an alternating (reciprocating expander) or rotary (rotary expander) direction, thus rotating the shaft 11 which produces mechanical energy that, for example, can be directly used if the shaft 11 is connected to a user device or system. Alternatively, the shaft 11 can be connected with an electric generator 12 to produce electricity that can be appropriately stored, distributed to the grid, or used immediately. The flow of gas exiting the expander 4 then reaches the hot side of the economizer 18, if present, and then proceeds to the condenser 16 in which said fluid is condensed and sent to the tank 17.
The tank 17 is in fluid communication with the pump 13, which draws directly from the lower zone 17a of said tank to circulate the working fluid back into the circuit. In more detail, the tank 17 is interposed between the condenser 16 and the pump 13 and allows for the accumulation of working fluid in a liquid state: in this condition, the tank 17 ensures that the pump 13 draws in liquid while preventing any air bubbles from being drawn in, thus ensuring a continuous supply of liquid.
In the case of the example of
Once the end of stroke (the right end of stroke shown in
During the steps described, non-return valves 51, 52, 54 and 55 allow the fluid to move in one direction only:
In the case of the example of
Once the end of stroke (the right end of stroke shown in
During the steps described, non-return valves 51, 52, 56 and 57 allow the fluid to move in one direction only:
By means of the solutions described and claimed, it is possible to exploit some of the energy in the working fluid to determine or support the pumping of that fluid in the closed circuit 2, resulting in an increase in overall efficiency of the cycle.
In addition, the type of pump having a piston 13 described above is suitable for being reliably used as it is of simple design and capable of operating at high pressure jump values having no sealing problems, likewise requiring little maintenance.
It should also be noted how the plant and process are completely or almost completely self-sustained in terms of energy.
Furthermore, by means of an appropriate driving of the pump 13, cavitation issues can be totally avoided.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102021000019994 | Jul 2021 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/056916 | 7/27/2022 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2023/007380 | 2/2/2023 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4266404 | ElDifrawi | May 1981 | A |
| 5461858 | Johnson | Oct 1995 | A |
| 20040144093 | Hanna | Jul 2004 | A1 |
| 20170058701 | Guo | Mar 2017 | A1 |
| 20200308967 | Zampieri | Oct 2020 | A1 |
| Number | Date | Country |
|---|---|---|
| 102016113007 | Jan 2017 | DE |
| 102015224416 | Jun 2017 | DE |
| 3056694 | Aug 2016 | EP |
| WO 2016144233 | Sep 2016 | WO |
| WO 2017187112 | Nov 2017 | WO |
| Entry |
|---|
| International Search Report and Written Opinion for PCT/IB2022/056916 dated Dec. 22, 2022 (10 pages). |
| Number | Date | Country | |
|---|---|---|---|
| 20250075640 A1 | Mar 2025 | US |
