Most power plants utilize a water/steam boiler system to energize a generator turbine and produce electricity. Because of the extremely high pressures and temperatures involved in the process, dissolved gasses and solids in the system water dramatically increase the deleterious effect on boilers steel and other metallic components.
A boiler circuit is largely but not a completely closed system, specifically, because solids are introduced into the water through make-up water, erosion, corrosion and other means. They need to be removed periodically or continuously to prevent build up from negatively impacting the function and efficiency of the system. Main boiler blow down is used to flush out the solids but also releases a small percentage of water from the system that needs to be replaced. Further, a small amount of water is lost in the form of steam vented out of a deaerator and through soot blowers in coal fired plants.
Make-up water subsystems are employed to replace the flushed water.
Referring to
The condensed water is then fed into a deaerator 116 by one or more conduits 122. A small amount of the steam from the pressurized steam pipes 118 extending between the main boiler and the electric generator is diverted and piped into the deaerator. The deaerator includes a pressure release vent and through this maintains the pressure in it to a desired level of about 5-60 psi depending on the particular application. As the cool condensed water is received in the deaerator, the steam heats it to 250-300 F and deaerates it freeing and venting any previously dissolved oxygen and other gasses to atmosphere through the vent. The deaerated water pools at the bottom of the deaerator and is fed back into the boiler to repeat the cycle.
As mentioned above a small amount of water is lost from the otherwise closed boiler loop when steam is vented out of the deaerator's vent. A much larger amount of water is removed from the system through boiler blown down. Overtime, small amounts of solids, such as from the walls of the boiler and pipes, dissolve into the boiler water and steam. If the level of dissolved solids reaches too high a level the contaminants can accelerate the corrosion and erosion of internal surfaces within the closed system. Accordingly, a blown down valve 126 and associated piping 128 is provided near the base of the main boiler where any solids may collect. Periodically, and when sensors located in the system indicated that the solid level is close to or exceeds 250 ppm, the blow down valve is opened to release a portion of the water along with particulate and dissolved solid contained in it to atmosphere. In addition to a loss of system water, which must be made up and replaced, the heat energy contained in the water is lost. While the lost heat energy is low relative to the energy output of the system, the value of the energy over the course of months and years can represent a measurable and significant amount. Furthermore, the treatment of make-up water to remove dissolved solids and other contaminants therefrom represents a sizable and significant cost over time.
A typical prior art make-up water subsystem 130 utilizes water from a well 132 or other suitable source. As can be appreciated well water wherein chlorine and other additives have not been introduced into the water is preferred since any additives have to be removed by the make-up water subsystem before the water can be introduced into the boiler loop. The water make-up subsystem includes a means for pumping water from a well 132, a means for scrubbing the water to remove particulate and dissolved solids, and a pipe 134 or pipes coupled with the boiler loop to introduce the make-up water therein. In the illustrated prior art subsystem, the means for scrubbing the water comprises a series of tanks 136 & 138 filled with cation resins and anion resins through which the water passes and solids are removed. In other makeup water subsystems reverse osmosis membranes can be used in combination with or in place of the cation and anion tanks.
While the prior art systems are very effective, over time they can be expensive requiring tens of thousands of dollars in chemicals, lost water, or reverse osmosis filters and membranes annually for a small to medium-sized power plant. Additional inefficiencies occur from the loss of heat energy in the flushing of very high temperature water during boiler blow down.
Embodiments of the present invention comprise a novel processed vapor make-up water subsystem that uses steam from the main boiler loop and blow down water to heat and vaporize make-up water in a make-up water boiler. Upon vaporization, dissolved solids remain in the liquid water in the bottom of the make-up boiler and the solids-free steam is introduced into the main boiler loop through a deaerator. Periodically, the water in the bottom of the make-up boiler is blown down when the amount of dissolved solids in the water reach a predetermined level.
The use of a processed vapor make-up water subsystem that uses of heat energy already being generated by the boiler system including heat energy that would otherwise be lost reduces the need for a reverse osmosis or cation/anion subsystem and accordingly reduces the operating costs of the associated power plant. It is to be appreciated that a reverse osmosis and/or cation/anion subsystem may be utilized for initial fillings of the main boiler loop from a dry or drained state prior to commencing operation of the power plant.
Embodiments also comprise the methodology of operating the boiler system including the processed vapor make-up water subsystem
Terminology
The terms and phrases as indicated in quotation marks (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document, including in the claims, unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.
The term “or” as used in this specification and the appended claims is not meant to be exclusive; rather the term is inclusive, meaning either or both.
References in the specification to “one embodiment”, “an embodiment”, “another embodiment, “a preferred embodiment”, “an alternative embodiment”, “one variation”, “a variation” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment or variation, is included in at least an embodiment or variation of the invention. The phrase “in one embodiment”, “in one variation” or similar phrases, as used in various places in the specification, are not necessarily meant to refer to the same embodiment or the same variation.
The term “couple” or “coupled” as used in this specification and appended claims refers to an indirect or direct physical connection between the identified elements, components, or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.
The term “directly coupled” or “coupled directly,” as used in this specification and appended claims, refers to a physical connection between identified elements, components, or objects, in which no other element, component, or object resides between those identified as being directly coupled.
The term “approximately,” as used in this specification and appended claims, refers to plus or minus 10% of the value given.
The term “about,” as used in this specification and appended claims, refers to plus or minus 20% of the value given.
The terms “generally” and “substantially,” as used in this specification and appended claims, mean mostly, or for the most part.
The terms “removable”, “removably coupled”, “removably installed,” “readily removable”, “readily detachable”, “detachably coupled”, “separable,” “separably coupled,” and similar terms, as used in this specification and appended claims, refer to structures that can be uncoupled, detached, uninstalled, or removed from an adjoining structure with relative ease (i.e., non-destructively, and without a complicated or time-consuming process), and that can also be readily reinstalled, reattached, or coupled to the previously adjoining structure.
Directional or relational terms such as “top,” bottom,” “front,” “back,” “above,” “beneath,” and “below,” as used in this specification and appended claims, refer to relative positions of identified elements, components, or objects, where the components or objects are oriented in an upright position as normally installed or used.
The terms “conduit”, “pipe” and their plurals are used interchangeably herein and refer to any suitable means of conveying a fluid, which in the instant document comprise water and steam.
A First Embodiment of Steam Boiler System with a Processed Vapor Make-Up Subsystem
As illustrated in
The processed vapor make-up subsystem is typically incorporated into a steam boiler system, such as that which may be used in a power plant as shown in
The operation of the power plant and specifically the main boiler loop is generally similar to the operation of the prior art system of
The process vapor make-up subsystem of
The make-up boiler is heated by superheated and pressurized steam that is funneled through piping 258 from the main boiler when motorized valve 270 is opened response to sensors indicating the need for make-up water in the main boiler loop, through a pressure reducing valve 259 to reduce the steam to about 150 psi, and through heat exchanging piping 262 contained in the make-up boiler to heat the pooled make-up water. After exiting the make-up boiler the steam is condensed in a condenser tank 263 and passed to the deaerator 216 for deaeration and resupply to the main boiler. The piping from the condenser tank to the deaerator is not shown. Two separate and distinct condenser tanks 214 & 263 are shown in
The make-up water pooled in the make-up boiler 228 after being heated by the main boiler steam boils creating solid and dissolved gas free steam, which is typically maintained within the boiler at about 60 psi. The steam is passed through a pipe 264 and into the deaerator where it acts to help deaerate the condensed water being provided to the deaerator from the condenser 214, but additionally upon condensation adds water to the main boiler loop. As shown and as can be appreciated, since the make-up boiler is only operative when make-up water is needed in the main boiler loop other sources of steam for the deaerator are provided to permit continuous operation. A spur pipe 266 can be provided from the piping extending between the main boiler and the make-up boiler to supply super heated steam. Further, piping 268 can be provided from the flash tank, which is described below, to the deaerator to supply steam.
As can be appreciated, overtime as more of the make-up water is transformed into steam, the level of dissolved solids in the remaining make-up boiler water pool increases. Above a certain level of dissolved solids in the make-up water, dissolved solids can be carried with the resulting steam so it is imperative that a portion of the water in the make-up boiler 228 is periodically purged or blown down. Incidentally, to substantially eliminate the risk of the introduction of additional solids into the system by way of corrosion, the make-up boiler and many of the other components of the processed vapor make up system can be comprised of stainless steel. Components made of other steels can be used as well with suitable chemical treatment. One or more dissolved solids sensors 272 are provided in the boiler to measure the level of dissolved solids in the pooled make-up water. A pipe or pipes 274 are provided that extend between the bottom of the make-up boiler 228 and the make-up water heat exchanger 244 as described above. Additional pipes are provided on the heat exchanger to dispose of the blow down water. On these pipes, one or more motorized valves 276 & 278 are provided. At least one of these valves is activated when either (i) the conductance level of the water contained in the make-up boiler becomes too high as measured by the dissolved solids sensor(s) 272 or (ii) when the makeup boiler water level rises too high as measured by a level gauge 250. Ideally, the blow down water has a temperature of 60-100 F when discharged because most of its heat has been transferred to make-up water in the circulating loop 240.
As indicated above, on occasion it is also desirable to blow down a small percentage of the water in the main boiler 210 to remove dissolved solids in the boiler loop and lower the average amount of dissolved solids to below a desired level (usually less than 250 ppm but the level is ultimately dependent on the boiler pressure and the particular boiler). With reference to
A Second Embodiment of Steam Boiler System with a Processed Vapor Make-Up Subsystem
As illustrated in
In similar operation to the boiler loop of
The process vapor make-up subsystem of
The circulation loop includes make-up water heat exchanger 344 where high temperature blow down water from the main boiler 310 is fed into the exchanger through a conduit when control valve 384 is opened and its heat is transferred in part to the make-up water. The boiler blow down water is fed into the make-up boiler 328 after exiting the heat exchanger. A pressure reducing valve 386 is provided to lower the pressure of the blow down water to an amount similar to that of the softened make-up water (approximately 100 psi). A one way check valve 390 and a motorized valve 388 are also provided to control the flow of blow down water into the make-up boiler as needed or desired.
Normally, the pressurized softened make-up water circulates in the loop 340, which includes various valves to ensure the proper direction of flow and desired pressure are maintained including a one way check valve 346 and a 100 psi bypass valve 348. When make-up water is required by the make-up subsystem as is measured by a level gauge 350 in the makeup boiler 328, an associated signaling switch opens a motorized valve 352 located on a pipe spur 354 that extends from the heat exchanger and permits the flow of approximately 100 psi make-up water through a one way valve 356 and into the make-up boiler. The valve closes once the water level in the make-up boiler increases to a desired level.
The make-up boiler 328 is heated by a portion of the steam that is funneled through piping 392 after exiting the electric generator the main boiler and through heat exchanging piping 360 contained in the make-up boiler to heat the pooled make-up water. After exiting the make-up boiler the steam is fed into one of the condenser 314 or the piping 322 after the condenser leading to the deaerator 316. The destination of the piping after exiting the make-up boiler is not shown.
The make-up water pooled in the make-up boiler 328 after being heated by the main boiler steam boils creating solid and dissolved-gas free steam, which is typically maintained within the boiler at about 60 psi. The steam is passed through a pipe 364 and into the deaerator. As shown and as can be appreciated, since the make-up boiler is only operative when make-up water is needed in the main boiler loop other sources of steam for the deaerator are provided to permit continuous operation. A spur pipe 366 can be provided from the piping extending between the main boiler and the electric generator to supply super heated steam.
As can be appreciated, overtime as more of the make-up water is transformed into steam and as blown down water from the main boiler is pooled in the make-up boiler, the level of dissolved solids in the remaining makeup boiler water increases. Above a certain level of dissolved solids in the make-up water, dissolved solids can be carried with the resulting steam so it is imperative that a portion of the water in the make-up boiler 328 is periodically purged or blown down. One or more dissolved solids sensors 372 are provided in the boiler to measure the level of dissolved solids in the pooled make-up water. A pipe or pipes 394 are provided that when a motorized valve 396 is opened pump blow down water out of the boiler system. A one way check valve 398 is typically provided to prevent back flow. The amount of blow down water is typically small especially when compared to blow down from traditional prior art systems since a portion of the blow down from the main boiler is reintroduced into the boiler loop as solid-free steam created by the make-up boiler. However, depending on the economics much of the heat contained in the blow down make-up boiler water can be extracted by running the water through a heat exchanger, such as the heat exchanger 344 of the circulation loop.
It is appreciated that many variations and alternative embodiments of the process vapor make-up system are contemplated as would be obvious to one or ordinary skill in the art given the benefit of this disclosure. For instance, in its simplest form the make-up water subsystem can be provided without a circulation loop and associated heat exchanger. Rather well water or water from other sources can be softened (as necessary), pressurized and introduced directly into the make-up boiler. Energy would be lost as blow down water is purged from the system but with the economics of some power plants, the cost to install a heat exchanger and the associated circulation loop may not be cost effective. As can also be appreciated the source of steam used to heat the make-up boiler and boil the make-up water can be provided from various locations along the boiler loop whether tapped directly from the main boiler, directed from the electric generator or tapped from some other suitable point along the loop.
In an even more significant variation, the heat source for the make-up boiler can come from some other means. For instance, the make-up boiler can be electrically heated using electrical energy created by the electrical generator. While using electric resistance heating instead of steam may be less efficient, the reduced cost of installing such a system may be an overriding consideration for some power plants.
This application claims the benefit and priority to U.S. Provisional Patent Application No. 61/931,783 filed on Jan. 27, 2014 entitled Processed Vapor Make-up Process and System and having the same inventor as the present application.
Number | Name | Date | Kind |
---|---|---|---|
1564716 | Ruths | Dec 1925 | A |
1938366 | Armacost | Dec 1933 | A |
3194217 | Grabowski | Jul 1965 | A |
3243961 | Caracristi | Apr 1966 | A |
3264826 | Kane | Aug 1966 | A |
3298359 | West | Jan 1967 | A |
3769795 | Rostrom | Nov 1973 | A |
3953966 | Martz | May 1976 | A |
4453499 | Palmer | Jun 1984 | A |
4627386 | Duffy | Dec 1986 | A |
5048466 | Rudd | Sep 1991 | A |
5724814 | Ven | Mar 1998 | A |
20120048215 | Hicks | Mar 2012 | A1 |
20120144830 | Ellert | Jun 2012 | A1 |
20130263928 | Inoue | Oct 2013 | A1 |
Number | Date | Country |
---|---|---|
WO 2012108757 | Aug 2012 | WO |
Number | Date | Country | |
---|---|---|---|
20150211731 A1 | Jul 2015 | US |
Number | Date | Country | |
---|---|---|---|
61931783 | Jan 2014 | US |