Patent Application
20160341187
The subject matter disclosed herein concerns improvements to reciprocating motor-compressors.
Reciprocating compressors are used in several industrial fields for boosting the pressure of a gas. Typical applications of reciprocating compressors are in refineries, e.g. in reformer, hydrocracker and hydrotreater plants. Typical applications of reciprocating compressors can be found also in the polymer industry, for manufacturing of ethylene and derivatives.
Reciprocating compressors are typically driven by electric motors, which are powered by electric energy from an electric power distribution grid. In some known embodiments, reciprocating compressors are driven by internal combustion engines, such as reciprocating Diesel or Otto engines. In other installations, steam turbines are used for driving the reciprocating compressors. A large amount of high-quality energy is thus usually needed for driving the compressors. Motor-compressors using Diesel or Otto internal combustion engines are particularly complex and expensive both from the point of view of manufacturing as well as from the viewpoint of maintenance.
The present disclosure suggests an improved reciprocating motor-compressor, which solves or alleviates at least some of the problems of known motor-compressors.
According to the present disclosure, the reciprocating motor-compressor includes a frame wherein a crankshaft is rotatingly housed. Compressor pistons are drivingly connected to the crankshaft and are reciprocatingly moved thereby in respective compressor cylinders. The crankshaft is driven into rotation by an embedded Stirling engine. The Stirling engine includes at least a hot cylinder and a cold cylinder, wherein a respective hot piston and a respective cold piston are reciprocatingly moving. Thermal power is provided to the hot cylinder and partially converted into mechanical power for driving the reciprocating compressor.
Integrating a Stirling engine in a reciprocating compressor as a driver for the reciprocating compressor allows using waste heat, e.g. from exhaust combustion gas of a gas turbine, or from any other source of waste heat in an industrial process, to drive the reciprocating compressor, thus saving high-quality energy, such as electric energy or fossil fuel. In some embodiments, solar energy can be used as a heat source. In some embodiments, a waste cold-flow stream can be used as a cold source, in combination with a hot source at ambient temperature or with a hot source at a temperature higher than ambient temperature.
Mechanical power is made available on the crankshaft for driving the compressor pistons by means of a thermodynamic cyclic transformation performed by a working fluid processed through the Stirling engine according to a closed cycle, the working fluid absorbing high-temperature heat at the hot source and discharging low-temperature heat at the cold source.
Stirling engines can be operated at a relatively low rotational speed, which is particularly useful in driving large reciprocating compressors, especially hyper-compressors.
Among the various potential benefits of a Stirling engine vs. an internal combustion engine, the following are worth noting: a simpler lubrication system is required; no spark plugs, air filters, timing chains and other components of the timing system are required; no fuel injection systems are used; costly, high-quality fossil fuel is not needed.
Additionally, since the size of Stirling cylinders bores can be larger than internal combustion cylinders, the same driving power needed to operate a reciprocating compressor can be generated with a smaller number of cylinders if a Stirling engine is used rather than an internal combustion engine. This makes the overall arrangement simpler and more compact. In some embodiments, the number of reciprocating compressor cylinders is equal to or even smaller than the number of Stirling engine cylinders. For instance, a two-cylinder Stirling engine can operate a two- or four-cylinder reciprocating compressor.
According to some embodiments, a reciprocating motor-compressor can be provided, which includes a frame; a crankshaft rotatingly supported in the frame and including a plurality of crank pins; at least one compression cylinder-piston arrangement, including a compression cylinder and a compression piston reciprocating therein and drivingly connected to a respective one of the crank pins; an embedded Stirling engine having at least one hot cylinder-piston arrangement including a hot cylinder with a hot piston slidingly housed in the hot cylinder; a hot source; at least one cold cylinder-piston arrangement comprised of a cold cylinder with a cold piston slidingly housed in the cold cylinder; a cold source; a fluid connection between the cold cylinder and the hot cylinder, where through a working fluid flows from the hot cylinder to the cold cylinder and vice-versa. The hot piston and the cold piston are drivingly connected to at least one of the crank pins, such that power generated by the Stirling engine drives the at least one compression cylinder-piston arrangement.
According to a further aspect, the subject matter disclosed herein concerns a method of driving a reciprocating compressor, including the steps of providing a crankshaft with a plurality of crank pins in a frame; drivingly connecting at least one reciprocating piston of at least one compression cylinder-piston arrangement to one of the crankshaft; providing a Stirling engine with a hot source, a cold source, a hot piston and a cold piston; drivingly connecting the hot piston and the cold piston of the Stirling engine to the crankshaft; providing thermal power to the Stirling engine; converting at least part of the thermal power into useful mechanical power in the Stirling engine, and driving the reciprocating piston with the mechanical power.
Features and embodiments are disclosed here below and are further set forth in the appended claims, which form an integral part of the present description. The above brief description sets forth features of the various embodiments of the present invention in order that the detailed description that follows may be better understood and in order that the present contributions to the art may be better appreciated. There are, of course, other features of the invention that will be described hereinafter and which will be set forth in the appended claims. In this respect, before explaining several embodiments of the invention in details, it is understood that the various embodiments of the invention are not limited in their application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which the disclosure is based, may readily be utilized as a basis for designing other structures, methods, and/or systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase “in one embodiment” or “in an embodiment” or “in some embodiments” in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
The cylinder-piston arrangements of the reciprocating-compressor section 1A can be connected in parallel or in series. In the exemplary embodiment shown in
In other embodiments only one cylinder-piston arrangement or more than two cylinder-piston arrangements can be provided in the reciprocating-compressor section 1A of machine 1.
The Stirling-engine section 113 of machine 1 includes a hot cylinder-piston arrangement 9 and a cold cylinder-piston arrangement 11.
Referring to
The cavity 15A has a head end and a crank end, which can be closed by respective closure elements 19A and 21A. The closure elements can be constrained to a cylindrical barrel 23A. The closure element 21A can be provided with a passage through which a piston rod 25A can extend. Packing cups 27A can provide a sealing around the piston rod 25A. The piston 17A divides the inner cavity 15A of the cylinder 23A into respective first, or head-end chamber 29A and second, or crank-end chamber 31A, respectively.
Each first chamber 29A and second chamber 31A is connected through respective suction valves and discharge valves to a suction duct and a discharge duct, not shown. In some embodiments the suction valves and the discharge valves can be automatic valves, for example so-called ring valves or the like. Suction valve arrangements for the first and second chambers 29A and 31A are shown at 33A and 35A, respectively. The number of suction and discharge valves for each one of the two chambers 29A and 31A can be different, depending upon the dimension and design of the reciprocating compressor.
The reciprocating movement of the piston 17A and of the piston rod 25A is controlled by crankshaft 5 through a respective connecting rod 37A. The connecting rod 37A can be hinged at 39A to a crosshead 41A, which can be provided with crosshead sliding shoes 43A in sliding contact with sliding surfaces 45A. The rotation movement of the crankshaft 5 is converted into reciprocating rectilinear movement of the crosshead 41A according to double arrow f41A. A first end of the piston rod 25A is connected to the crosshead 41A and a second end is connected to the piston 17A, such that the crosshead 41A and the piston 17A reciprocate integrally one with the other.
The big end of the connecting rod 37A is supported on a crank pin 5.1 of crankshaft 5. An adjacent crank pin 5.2 of crankshaft 5 can engage in the big-end hole of a connecting rod 51 of the hot cylinder-piston arrangement 9 of the Stirling-engine section 1B. The hot cylinder-piston arrangement 9 includes a hot-end cylinder 53 and a hot-end piston 55 slidingly housed in the hot-end cylinder 53, forming an expansion chamber 56. The hot-end piston 55 is connected through a hot-end piston rod 57 to a hot-end crosshead 59 in sliding contact through sliding shoes 61 with sliding surfaces 63. The crosshead 59 is pivotally connected at 65 with the small end of the connecting rod 51. When the crankshaft 5 rotates, the hot-end piston 55 reciprocates in the hot-end cylinder 53.
Referring now to
The cavity 15B has a head end and a crank end, which can be closed by respective closure elements 19B and 21B. The closure elements can be constrained to a cylindrical barrel 23B. The closure element 21B can be provided with a passage through which a piston rod 25B can extend. Packing cups 27B can provide a sealing around the piston rod 25B. The piston 17B divides the inner cavity 15B of the cylinder 23B into respective first or head end chamber 29B and second or crank-end chamber 31B.
Each first chamber 29B and second chamber 31B is connected through respective suction valves and discharge valves to a suction duct and a discharge duct, not shown. In some embodiments the suction valves and the discharge valves can be automatic valves, for example so-called ring valves or the like. Suction valve arrangements for the first and second chambers 29B and 31B are shown at 33B and 35B, respectively. The number of suction and discharge valves for each one of the two chambers 29B and 31B can be different, depending upon the dimension and design of the reciprocating compressor.
The reciprocating movement of the piston 17B and of the piston rod 25B is controlled by crankshaft 5 through a respective connecting rod 37B. The connecting rod 37B can be hinged at 39B to a crosshead 41B, which can be provided with crosshead sliding shoes 43B in sliding contact with sliding surfaces 45B. The rotation movement of the crankshaft 5 is converted into reciprocating rectilinear movement of the crosshead 41B according to double arrow f41B. The piston rod 25B can be connected to the crosshead 41B and to the piston 17B and transmits the movement from the crosshead 41B to the piston 17B.
The big end of the connecting rod 37B is supported on a crank pin 5.3 of crankshaft 5. An adjacent crank pin 5.4 of crankshaft 5 can engage in the big-end hole of a connecting rod 71 of the cold cylinder-piston arrangement 11 of the Stirling-engine section 1B. The cold cylinder-piston arrangement 11 includes a cold-end cylinder 73 and a cold-end piston 75 slidingly housed in the cold-end cylinder 73. A cold compression chamber 74 is formed between cold-end piston 75 and cold-end cylinder 73. The cold-end piston 75 is connected through a cold-end piston rod 77 to a cold-end crosshead 79 in sliding contact through sliding shoes 61 with sliding surfaces 83. The cold-end crosshead 79 is pivotally connected at 85 with the small end of the connecting rod 71. Thus, while the crankshaft 5 rotates, the cold-end piston 75 moves reciprocatingly in the cold-end cylinder 73.
A hot source, i.e. a source of thermal energy, schematically shown at 91 is combined with the hot cylinder-piston arrangement 9 and provides thermal energy at a high temperature to a working fluid which is cyclically moved from the hot-end cylinder 53 to the cold-end cylinder 73 and vice-versa while performing a thermodynamic Stirling cycle.
The hot source 91 can include a burner, where a fuel is burned to generate heat which is transferred, e.g. through a heat exchanger schematically shown at 92, to the working fluid of the Stirling engine.
In some embodiments the hot source can be a waste heat recovery system, where waste heat is transferred to the working fluid. For example, heat from the exhaust combustion gas of a gas turbine can be transferred to the working fluid of the Stirling engine. A separate heat-transfer loop (not shown) where a heat transfer fluid is circulated, can be used to transfer heat from the waste heat source to the Stirling engine. Diathermic oil, water or any other suitable heat transfer fluid can be circulated in the loop and exchange heat with the exhaust combustion gas from a gas turbine on one side and with the working fluid of the Stirling engine on the other.
A cold source or heat sink 93 is combined with the cold cylinder-piston arrangement 11. Low-temperature heat (i.e. thermal energy at a temperature lower than the temperature of the thermal energy provided by the hot source 91) is removed from the working fluid at the cold source 93. A passage or duct 94 connects the hot-end cylinder 53 to the cold-end cylinder 73. The cold source or heat sink 93 can include a heat exchanger, for example an air heat exchanger, where the working fluid of the Stirling engine is cooled by discharging low-temperature heat in ambient air. A water heat exchanger can also be used as a heat sink, whereby low-temperature heat is removed from the working fluid of the Stirling engine by circulating cold water. A heat regenerator 96 can be arranged along duct 94.
In some embodiments the heat sink can include a cold source where heat is removed at a temperature lower than the ambient temperature. For instance, a cold fluid from an expansion process, a refrigerant of a refrigeration circuit or the like can be used as a cold source. A cold source can be provided by a regasification process, where heat is removed from the cold source and used to gasify liquid natural gas (LNG). In this case heat removal from the cold source of the Stirling engine is provided by heat exchange with a flow of waste cold fluid.
In some embodiments, where the cold source is below ambient temperature, the hot source can be at ambient temperature. If the temperature of the cold source is sufficiently lower than the ambient temperature, the hot source can be ambient air itself.
Usually, a temperature drop between hot source and cold source of 200° C. or more is suitable for operating a Stirling engine embedded in an integrated reciprocating motor-compressor, as the one illustrated in
The angular positions of the crank pins 5.1-5.4 can be better appreciated from
As shown in
In the schematic of
The operation of a Stirling engine is known from the art and will not be described in detail herein. Suffice it to recall that once the reciprocating movement of the hot-end piston 55 in the hot-end cylinder 53 and of the cold-end piston 75 in the cold-end cylinder 73 is initiated, it will continue thanks to the thermal power delivered at the hot end, which is partly converted into mechanical power available on the crankshaft, while the non-converted thermal energy is discharged at the cold sink. Energy conversion is performed by the cyclic thermodynamic transformation undergone by the working fluid contained in the closed system formed by the two cylinder-piston systems 9, 11, heat regenerator 96, cooler 93, heater 92, as well as duct 94, connecting them to one another.
The mechanical power thus generated by the Stirling engine formed by the two cylinder-piston systems 9, 11 and relevant connection duct, hot source and cold source, is used to drive the crankshaft 5 and compress the gas in the reciprocating-compressor section 1A of the reciprocating machine 1. A flywheel (not shown) is provided on the crankshaft 5 and assists in keeping the crankshaft in continuous rotational motion.
Larger machines including a larger number of reciprocating-compressor pistons and Stirling-engine pistons can be designed, based on the same concept.
In
The structure of the crankshaft 5 in
In the schematic of
In a four-cylinder or eight cylinder machine, the crankshaft designed for the corresponding reciprocating compressor having four and respectively eight compression cylinder-piston arrangements can be used without redesigning the crankshaft.
In other embodiments, an integrated reciprocating machine with a Stirling-engine section and a reciprocating-compressor section can be designed, with a different number of cylinders. For example, a six-cylinder machine can be designed, having two Stirling-engine cylinder-piston arrangements in a Stirling-engine section and four reciprocating compressor cylinder-piston arrangements. In order to obtain the correct phasing of the Stirling-engine pistons, however, in this case a dedicated crankshaft has to be designed.
The embodiments of
Known reciprocating compressors exist, wherein one and the same crank pin drives two opposite cylinder-piston arrangements, which are phased at 180° one with respect to the other. Typically, embodiments where a single crank pin drives opposite pistons are used in hyper-compressors.
Referring to
As known to those skilled in the art of reciprocating compressors and specifically of reciprocating hyper-compressors, in other embodiments each crank pin can be drivingly connected to a pair of opposite, single-effect pistons by means of a single connecting rod, which reciprocates a central crosshead. Piston rods are connected at two opposed sides of the central crosshead and are reciprocated thereby. Additional auxiliary cross-heads can be arranged along the piston rod.
In some hyper-compressors the piston rod is slidingly housed in the cylinder and the end portion thereof forms the actual piston.
The cylinder-piston arrangements can be grouped in a reciprocating-compressor section 1A of the integrated reciprocating compressor.
The crankshaft 5 is driven into rotation by a Stirling-engine section which shares the same crankshaft and the same frame. The Stirling-engine section can include a hot cylinder-piston arrangement and a cold cylinder-piston arrangement substantially as known in the art. In
In some embodiments, the two cylinder-piston arrangements of the Stirling engine can be positioned one parallel to the other and driven by two different crank pins angularly shifted by 90° one with respect to the other.
Arrows H1 and H2 schematically represent the high-temperature thermal energy delivered to the hot-end of the Stirling engine and the low-temperature thermal energy removed at the cold-end of the Stirling engine.
In some embodiments, the crankshaft 5 can rotate at a speed comprised e.g. between 150 and 1500 rpm, lower speeds being particularly suitable for hyper-compressors.
In the above described embodiments, a starting motor can be provided, which starts rotation of the crankshaft 5. For instance, an electric starting motor can be provided at either one or the other of the free ends of the crankshaft, outside or inside the frame 5.
While the disclosed embodiments of the subject matter described herein have been shown in the drawings and fully described above with particularity and detail in connection with several exemplary embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without materially departing from the novel teachings, the principles and concepts set forth herein, and advantages of the subject matter recited in the appended claims. Hence, the proper scope of the disclosed innovations should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications, changes, and omissions. Different features, structures and instrumentalities of the various embodiments can be differently combined.
| Number | Date | Country | Kind |
|---|---|---|---|
| FI2014A000022 | Jan 2014 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2015/051907 | 1/30/2015 | WO | 00 |
