Patent Application
20250043748
The present disclosure relates to a power generation system, for example for producing electricity to be fed into an electricity grid.
Power generation systems are known. Various governments have made ambitious commitments to reduce carbon emissions. For example, the UK government has made a commitment to reduce carbon emissions to “net zero” by 2050. Whilst renewable energy will play a large role in achieving that aim, so will improving the efficiency of combustion-based power generation systems.
According to a first aspect there is provided: a power generation system comprising: at least one combustion engine; a power generation arrangement that is constructed and arranged to generate electricity from waste energy from the at least one combustion engine; and wherein the power generation arrangement comprises: an electro-turbo compounding engine; a high temperature turbine engine; and a low temperature turbine engine.
According to some examples, each of the electro-turbo compounding engine; the high temperature turbine engine; and the low temperature turbine engine can be switched on and off independently of each other.
According to some examples, the electro-turbo compounding engine is constructed and arranged to be driven by kinetic and/or thermal energy from the at least one combustion engine.
According to some examples, the high temperature turbine engine is constructed and arranged to be driven by flue gas from the at least one combustion engine.
According to some examples, the system comprises a heat exchanger fluidly connected to the high temperature turbine, wherein the flue gas enters the heat exchanger at about 380° C.
According to some examples, the low temperature turbine engine is constructed and arranged to be driven by water heated from the at least one combustion engine.
According to some examples, the water enters the low temperature turbine engine at about 90° C. to 120° C.
According to some examples, the at least one combustion engine comprises two or more combustion engines.
According to some examples, at any one time, at least one of the two or more combustion engines is switched off and at least one of the two or more combustion engines is switched on.
According to some examples, the at least one combustion engine comprises four combustion engines, and at any one time at least one of the combustion engines is switched on.
According to some examples, at any one time three of the combustion engines are switched on and one of the combustion engines is switched off.
According to some examples, the system comprises at least one electricity generator driven by the at least one combustion engine.
According to some examples, an output shaft of the at least one combustion engine is operatively connected to both the electricity generator driven by the at least one combustion engine and one of: an input shaft of the electro-turbo compounding engine; an input shaft of the high temperature turbine engine; an input shaft the low temperature turbine engine.
According to some examples, an output shaft of the at least one combustion engine is operatively connected to both the electricity generator driven by the at least one combustion engine and an input shaft of the low temperature turbine engine.
According to some examples, the system comprises a clutch for selectively transmitting drive from the output shaft of the at least one combustion engine to the input shaft of the low temperature turbine engine.
According to some examples, the clutch is arranged to transmit drive from the output shaft of the at least one combustion engine to the input shaft of the low temperature turbine engine, when an operating temperature of the low temperature turbine engine is reached.
According to some examples the system comprises: an electricity generator driven by the electro-turbo compounding engine; an electricity generator driven by the high temperature turbine engine; and an electricity generator driven by the low temperature turbine engine.
According to some examples, the system comprises an emissions unit for handling emissions from the system.
According to some examples, the emissions unit comprises a carbon capture unit.
According to some examples, the carbon capture unit is constructed and arranged to output one or more of: food-grade carbon dioxide; carbon black.
According to some examples, the emissions unit comprises a carbon-oxygen separation unit which is constructed and arranged to receive below food-grade carbon dioxide from the carbon capture unit, and to provide oxygen and carbon black as an output.
According to some examples, the emissions unit comprises a NOx/SOx cleaner.
According to some examples, the system is controlled by a control system.
According to some examples, the power generation system is arranged to output electrical power to an electrical grid.
According to an aspect there is provided a power generation system comprising: two or more combustion engines; a power generation arrangement that is constructed and arranged to generate electricity from waste energy from the two or more combustion engines; and wherein the power generation arrangement comprises: an electro-turbo compounding engine; a high temperature turbine engine; and a low temperature turbine engine; wherein each of the electro-turbo compounding engine; the high temperature turbine engine; and the low temperature turbine engine can be switched on and off independently of each other; and wherein the power generation system comprises an emissions handling unit, the emissions handling unit comprising a carbon capture unit.
Promotion of renewable energy has been a cornerstone of policy in reducing carbon emissions. However, there are some drawbacks with renewables. For example, renewable power sources have their own carbon footprint from the construction and installation of infrastructure, which is often greater than the carbon footprint of constructing (or maintaining) a traditional power plant. The energy supply from renewables is also insecure. For example, changing weather conditions cause fluctuations in generation output. Also, there is a lack of inertia from renewable energy supplies, which contrasts with the spinning momentum that provides system stability when a large power station goes off-line unexpectedly.
Considering these drawbacks, the present disclosure identifies that non-renewable power generation (such as gas-powered generation) is vital to complement the growth of renewables. Moreover, the present disclosure identifies that gas-powered generation can be accompanied by emissions handling such as carbon capture techniques, to comply with tightening emissions standards.
Therefore, in overview, the present disclosure relates to energy production using non-renewable sources, with improved efficiency. The present disclosure also discloses ways of capturing and cleaning the waste products from a combustion engine. The disclosed system complements the growth in renewables and helps to ensure there is sufficient supply to meet demand by at least: balancing the fluctuating output from intermittent renewable generation; support system stability by providing inertia in the grid; relieving stress on local and national power networks through dynamic, flexible generation providing additional power when it is needed. The result is dependable, clean energy that helps the UK and other countries meet their energy targets, and assists with the production of industrial grade CO2.
An overview of a proposed system, according to an example, is shown with respect to
The power generation system 100 comprises at least one combustion engine 102. According to some examples, the combustion engine 102 comprises a fossil fuel powered combustion engine. According to some examples, the combustion engine 102 is a gas-fired reciprocating engine. By way of example, the at least one combustion engine 102 comprises a Rolls Royce® MTU engine. For example, the MTU 20V4000 GS engine may be used. The at least one combustion engine 102 may be considered a base load generator. The at least one combustion engine 102 powers an electricity generator turbine shown schematically at 140. Electricity converted by generator 140 can be fed into an electrical grid shown schematically at 150. For example, grid 150 may comprise the National Grid.
A power generation arrangement is shown schematically at 104. The power generation arrangement 104 is constructed and arranged to generate electricity from waste energy from the at least one combustion engine 102. For example, the waste energy may comprise waste heat and/or kinetic energy. For example, the at least one combustion engine 102 may be considered a primary generator of electricity, and the power generation arrangement 104 is considered to be a secondary generator of electricity.
As shown in
According to some examples, the ETC comprises a Bowman® (www.bowmanpower.com) ETC.
According to some examples, the high temperature turbine engine 114 comprises a high temperature organic Rankine cycle engine (HT ORC). For example, the high temperature turbine engine 114 may comprise a HT ORC provided by Turboden® (www.turboden.com). In some examples the high temperature turbine engine 114 may operate at inlet temperature of over 300° C. In some examples, inlet temperature may be 380° C. or about 380° C., or higher.
According to some examples, the low temperature turbine engine 116 comprises a low temperature organic Rankine cycle engine (LT ORC). For example, the low temperature turbine engine 116 may comprise a LT ORC provided by Climeon® (www.climeon.com). In some examples, the inlet temperature of the low temperature turbine engine 116 is in a range of about 80° C. to about 120° C. In some examples, inlet temperature of the low temperature turbine engine 116 is 90° C. or about 90° C.
Generally speaking, it will be understood that the high temperature turbine engine 114 is arranged to operate at a first temperature, and the low temperature turbine engine is arranged to operate at a second temperature. The first temperature is higher than the second temperature. Thus, in some examples the high temperature turbine engine 114 may be considered a first-temperature turbine engine 114, and the low temperature turbine engine 116 may be considered a second-temperature turbine engine 116, where the second temperature is lower than the first temperature.
According to some examples, the ETC engine 112 is constructed and arranged to be driven by kinetic and/or and thermal energy from the at least one combustion engine 102. For example, kinetic energy from the flow of engine exhaust gases from the combustion engine 102 may be captured by the ETC 112. For example, heat may enter the ETC at 420° C. or about 420° C. ETC comprises an electrical generator shown schematically at 142. Electricity converted by generator 142 can be fed into grid 150. The incorporation of the ETC 112 into the system 100 produces a net efficiency increase for the system 100 due to the increase in total electrical output without any additional fuel input.
According to some examples, the high temperature turbine engine 114 is constructed and arranged to be driven by flue gas from the at least one combustion engine 102. According to some examples, a heat exchanger 160 is fluidly connected to the high temperature turbine 114. In some examples, the flue gas enters the heat exchanger 160 at about 380° C. In some examples, flue gas exits the heat exchanger at about 180° C.
The high temperature turbine engine 114 comprises an electrical generator turbine shown schematically at 144. Electricity converted by generator 144 can be fed into grid 150. In some examples the high temperature turbine engine 114 contributes up to 10% extra power and increases system efficiency to over 50%, by utilising waste heat in the exhaust gases of the combustion engine 102.
According to some examples, the low temperature turbine engine 116 is constructed and arranged to be driven by heat energy from the combustion engine 102. For example, the heat energy may be captured in the form of hot water heated by the at one combustion engine 102. According to some examples, the hot water is fed via a heat exchanger or engine cooling jacket 162. According to some examples, water enters the low temperature turbine engine (via heat exchanger 162) at a temperature of about 90° C. to 120° C. According to some examples, the water then re-enters the heat exchanger 162 at a temperature of about 80° C. This can additionally provide cooling to combustion engine 102, to improve efficiency. Use of waste heat from the combustion engine 102 contributes additional power without increased fuel consumption. In some examples, the combustion engine 102 has a thermal output of 1411 kWt, from which the LT ORC 116 can produce 85 to 116 kWe, depending on the ambient temperature. This may equate to a 3.4 to 4.5% increase in overall power output from the combustion engine 102 with no increase in fuel demand.
The low temperature turbine engine 116 comprises an electrical generator turbine shown schematically at 146. Electricity converted by generator 146 can be fed into grid 150.
According to some examples, each of the electro-turbo compounding engine 112; the high temperature turbine engine 114; and the low temperature turbine engine 116 can be switched on and off independently of each other. This enables maintenance of individual elements without having to completely shut down power generation arrangement 104.
The combination of the combustion engine 102, with ETC 112; high temperature turbine engine 114; and low temperature turbine engine 116; all feeding electricity in to grid 150, is considered to provide improved efficiency over known power generation system arrangements.
According to some examples, one or more of the ETC 112; high temperature turbine engine 114; and low temperature turbine engine 116 is provided in a modular fashion, for example on skids or in a container. This means they can be added/retrofitted to the system 100 in a plug-and-play fashion.
According to some examples, the at least one combustion engine 102 comprises two or more combustion engines. According to some examples, at any one time at least one of the two or more combustion engines is switched off and at least one of the two or more combustion engines is switched on. This introduces a level of redundancy in the system. For example, one combustion engine can be taken off-line for maintenance whilst the system 100 can still run effectively via the at least one combustion engine that is still switched on.
According to some examples, the at least one combustion engine comprises four combustion engines, and at any one time at least one of the combustion engines is switched on. According to some examples, at any one time one combustion engine is switched off while three combustion engines remain running.
According to some examples, each combustion engine comprises a 2.5 MW engine. Therefore, where four combustion engines are used, that provides a 10 MW plant.
According to some examples, the at least one combustion engine 102 is referred to as a base generator. According to some examples, each of the ETC 112, the high temperature turbine engine 114, and the low temperature turbine engine 116 may be referred to as downstream elements.
According to some examples, the system comprises an emissions handling unit 110 for handling emissions from the system 100. Emissions handling unit 110 may also be referred to as a Stack Gas Recovery (SGR) unit. In some examples, the emissions handling unit 110 is constructed and arranged to handle emissions from the at least one combustion engine 102. According to some examples, the emissions unit is also constructed and arranged to handle emissions from any one or more of: ETC 112; high temperature turbine engine 114; low temperature turbine engine 116.
In some examples, the emissions are drawn into emissions unit 110 by an induced draught fan. In some examples, a diverter damper or valve can be used to divert the exhaust gases to the emissions handling unit 110. The emissions handling unit 110 is described in more detail with respect to
As shown in
As shown in
According to some examples, the emissions unit comprises a carbon capture unit 124. The carbon capture unit is arranged to capture carbon. In some examples, carbon capture unit 124 is arranged to capture carbon from carbon dioxide. According to some examples, carbon capture unit 124 is arranged to output one or more of: food grade carbon dioxide; carbon black. According to some examples, the food grade carbon dioxide can be bottled and then provided to users of carbon dioxide e.g. the beverage industry.
According to some examples, the emissions unit 110 comprises carbon-oxygen separation unit 128. According to some examples, the carbon-oxygen separation unit 128 is constructed and arranged to receive below food-grade carbon dioxide from the carbon capture unit 124, and to provide oxygen and carbon black as an output.
Overall, about 90 to 95% of carbon emitted by one or more combustion engines 102 can be removed/captured.
According to some examples, each of the components of the emissions handling unit 110 (e.g. NOx/SOx cleaner 122; carbon capture unit 124; carbon oxygen separation unit 128) is skid mounted. This means they can be constructed in a factory and then transported to site for easy installation, for example in a plug-and-play fashion.
In some examples, the presence of the emissions handling unit 110 enables the at least one combustion engine 102 to be operated at a relatively high temperature (for example, higher than would typically be used without emissions handling). This is because any increased carbon dioxide output caused by the higher operational temperatures of the at least one combustion engine 102 is captured downstream in the emissions handling unit 110. Running the at least one combustion engine 102 at higher temperatures may increase electrical output from the downstream generators.
Some alternative arrangements for the layout of system 100 are shown in
Turning to
The same principle applies in
Turning to
Turning to
Turning to
In some examples, similar arrangements to
Table 1 below provides a comparison between a standard peaking power or “peaker” plant (first column); against a plant configuration or system 100 as disclosed in the present application, not including emissions handling unit 110 (second column); and a plant configuration or system 100 as disclosed in the present application, including the emissions handling unit 110 (third column). In some examples, the system 100 disclosed in the present application is referred to as “flex-power plus” (FPP).
Of particular note is the overall efficiencies of the systems. A standard 10 MW peaker plant has an efficiency of about 42%. FPP configuration of system 100 without the emissions handling has an efficiency of about 51%. With emissions handling, this efficiency rises still further to about 51.5%. Moreover, typically a standard peaker plant will run for about 1,500 hours per year. Because of the benefits of carbon capture, and the redundancy provided within the system (e.g. by running multiple combustion engines, and/or the ETC, low temperature turbine and high temperature turbine which can be turned on and off independently of each other), the system 100 can run for approximately 8,000 hours per year. This also helps mitigate inefficiencies caused by turning the system on and off. Therefore, it will be appreciated that the components of the system operate synergistically to improve overall efficiency.
From the foregoing it will be appreciated that a new plant configuration is provided that: increases the efficiency of a reciprocating gas engine power plant; removes carbon and NOx from the resultant emissions; and purifies these emissions to produce valuable industrial gases such as CO2.
According to examples, the combustion engine 102 acts as the base from which the other technologies (e.g. ETC, HT ORC, LT ORC) operate. However, the at least one combustion engine 102 remains inherently independent from the ETC, HT ORC and LT ORC, thereby limiting operational risk. If one of the downstream elements (e.g. ETC, HT ORC, LT ORC) requires maintenance, this can be turned off individually while allowing the plant to continue to generate to fulfil its contractual commitments. In examples, the downstream elements rely on simple inputs from the engine 102 to start, and in some examples will do so automatically when the correct input levels are reached. In some examples, the downstream elements require only field instrument inputs to start and stop. According to some examples, this can be automatically controlled by the control system 170.
According to some examples, each of the ET ORC, HT ORC, LT ORC may be considered a heat recovery unit. Collectively, the ET ORC, HT ORC and LT ORC may be considered a heat recovery arrangement. In some examples, a specific way in which exhaust heat is fed from each of the combustion engine(s) to the heat recovery arrangement is not limited. For example, heat from one or more combustion engines may be accumulated before being fed to the heat recovery unit, where it is then split between each heat recovery unit. In some examples, where there are two or more combustion engines, then one combustion engine may feed one or more of the heat recovery units whilst another combustion engine feeds another of the one or more heat recovery units. In some examples, and as previously mentioned, each of the heat recovery units can be turned off whilst the other units keep operating. For example, it is possible to feed one LT ORC from two engines, and if one of the two engines is down, the LT and HT ORC can operate at half load and flue gas can be fed to the CCU at half rate.
According to some examples, the system 100 is controlled by a control system 170. According to some examples, the control system 170 comprises at least one memory 172 and at least one processor 174. According to some examples, control software is stored in memory 172. According to examples, control system 170 comprises a controller. The control system is arranged to control elements of system 100, such as when elements (e.g. at least one combustion engine 102; ETC 112; HT ORC 114; LT ORC 116) are turned off and on. According to some examples, system 100 can run automatically according to the control software. According to some examples, the control system 170 comprises a user interface enabling an operator to control elements of the system 100.
The disclosed system can be implemented on new build sites. In some examples, the system or elements of the system can be retrofitted to existing plants that are looking to adapt to comply with increasingly demanding environmental standards, market changes and regulations.
The examples described herein are to be understood as illustrative examples of embodiments of the invention. Further embodiments and examples are envisaged. Any feature described in relation to any one example or embodiment may be used alone or in combination with other features. In addition, any feature described in relation to any one example or embodiment may also be used in combination with one or more features of any other of the examples or embodiments, or any combination of any other of the examples or embodiments. Furthermore, equivalents and modifications not described herein may also be employed within the scope of the invention, which is defined in the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2118285.2 | Dec 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/085897 | 12/14/2022 | WO |
