Patent Grant
7958731
This invention relates to power generation, thermal energy recovery, and energy storage. More particularly, this invention relates to the combination of systems and processes that require heating and/or cooling, have excess heating and/or cooling capacity, and/or efficiently transfer thermal energy between locations with systems that store and recover electrical energy using compressed gas.
As the world's demand for electric energy increases, the existing power grid is being taxed beyond its ability to serve this demand continuously. In certain parts of the United States, inability to meet peak demand has led to inadvertent brownouts and blackouts due to system overload as well as to deliberate “rolling blackouts” of non-essential customers to shunt the excess demand. For the most part, peak demand occurs during the daytime hours (and during certain seasons, such as summer) when business and industry employ large quantities of power for running equipment, heating, air conditioning, lighting, etc. During the nighttime hours, demand for electricity is often reduced significantly, and the existing power grid in most areas can usually handle this load without problem.
To address the possible insufficiency of power supply at peak demand, users are asked to conserve where possible. Also, power companies often employ rapidly deployable gas turbines to supplement production to meet peak demand. However, these units burn expensive fuels, such as natural gas, and have high generation costs when compared with coal-fired systems and other large-scale generators. Accordingly, supplemental sources have economic drawbacks and, in any case, can provide only a partial solution in a growing economy. The most obvious solution involves construction of new power plants, which is expensive and has environmental side effects. In addition, because most power plants operate most efficiently when generating a relatively continuous output, the difference between peak and off-peak demand often leads to wasteful practices during off-peak periods, such as over-lighting of outdoor areas, as power is sold at a lower rate off peak. Thus, it is desirable to address the fluctuation in power demand in a manner that does not require construction of new plants and can be implemented either at a power-generating facility to provide excess capacity during peak, or on a smaller scale on-site at the facility of an electric customer (allowing that customer to provide additional power to itself during peak demand, when the grid is heavily taxed).
Additionally, it is desirable for solutions that address fluctuations in power demand to also address environmental concerns and support the use of renewable energy sources. As demand for renewable energy increases, the intermittent nature of some renewable energy sources (e.g., wind and solar) places an increasing burden on the electric grid. The use of energy storage is a key factor in addressing the intermittent nature of the electricity produced by some renewable sources, and more generally in shifting the energy produced to the time of peak demand.
Storing energy in the form of compressed air has a long history. Most methods for converting potential energy in the form of compressed air to electrical energy utilize turbines to expand the gas, which is an inherently adiabatic process. As gas expands, it cools off if there is no input of heat (adiabatic gas expansion), as is the case with gas expansion in a turbine. The advantage of adiabatic gas expansion is that it can occur quickly, thus resulting in the release of a substantial quantity of energy in a short time.
However, if the gas expansion occurs slowly relative to the time which it takes for heat to flow into the gas, then the gas remains at a relatively constant temperature as it expands (isothermal gas expansion). Gas stored at ambient temperature that is expanded isothermally provides approximately three times the energy of ambient-temperature gas expanded adiabatically. Therefore, there is a significant energy advantage to expanding gas isothermally.
In the case of certain compressed-gas energy-storage systems according to prior implementations, gas is expanded from a high-pressure, high-capacity source, such as a large underground cavern, and directed through a multi-stage gas turbine. Because significant, rapid expansion occurs at each stage of the operation, the gas cools at each stage. To increase efficiency, the gas is mixed with fuel and the mix is ignited, pre-heating it to a higher temperature and thereby increasing power and final gas temperature. However, the need to burn fossil fuel (or apply another energy source, such as electric heating) to compensate for adiabatic expansion substantially defeats the purpose of an emission-free process for storing and recovering energy.
A more efficient and novel design for storing energy in the form of compressed gas utilizing isothermal gas expansion and compression is shown and described in U.S. patent application Ser. No. 12/421,057 (the '057 application), the disclosure of which is hereby incorporated herein by reference in its entirety. The '057 application discloses a system for expanding gas isothermally in staged hydraulic/pneumatic cylinders and intensifiers over a large pressure range in order to generate electrical energy when required. The power output of the system is governed by how fast the gas can expand isothermally. Therefore, the ability to expand/compress the gas isothermally at a faster rate will result in a greater power output of the system.
While it is technically possible to attach a heat-exchange subsystem directly to a hydraulic/pneumatic cylinder (an external jacket, for example), such an approach is not particularly effective given the thick walls of the cylinder. An internalized heat exchange subsystem could conceivably be mounted directly within the cylinder's pneumatic (gas-filled) side; however, size limitations would reduce such a heat exchanger's effectiveness and the task of sealing a cylinder with an added subsystem installed therein would be significant, making the use of a conventional, commercially available component difficult or impossible.
A novel compressed-gas-based energy storage system incorporating an external heat transfer circuit is disclosed in U.S. patent application Ser. No. 12/481,235 (the '235 application), the disclosure of which is hereby incorporated herein by reference in its entirety. The '235 application discloses a hydraulic/pneumatic converter component in a staged energy storage system that can store high-pressure gas at, for example, over 200 atmospheres (3000 psi) for use by the system. A pressure vessel or cylinder defining a gas chamber (pneumatic side) and a fluid chamber (hydraulic side) has a piston or other mechanism that separates the gas chamber and fluid chamber, preventing gas or fluid migration from one chamber to the other while allowing the transfer of force/pressure between the chambers. Both the gas chamber and the fluid chamber have primary ports that interface with the respective pneumatic and hydraulic components of the overall energy storage and recovery system. The gas chamber/pneumatic side of the cylinder has additional ports. The additional gas exit port is in fluid communication with an inlet to a circulation device (for example, a pneumatic pump or fan impeller), the exit of which is in fluid communication with the gas inlet of a heat exchanger. The gas exit port of the heat exchanger is in fluid connection with the additional gas chamber inlet port. The heat exchanger has corresponding fluid ports that support a flow of ambient-temperature fluid through the heat exchanger in a direction counter to the flow of gas in the heat exchanger. Thus, due to the heat exchange with the flowing fluid, the gas exiting the heat exchanger is returned to the gas chamber at ambient or near ambient temperature. (The term “ambient” is used to represent the temperature of the surrounding environment, or another desired temperature at which efficient performance of the system may be achieved.) The circulation of gas in the gas chamber through the heat exchange subsystem thereby maintains the gas in the gas chamber at ambient or near-ambient temperature. The entire gas circuit in the heat exchanger is sealed and capable of handling high pressures (e.g., 200 atmospheres) encountered within the pneumatic side of the cylinder. The fluid side of the heat exchanger communicates with an appropriate reservoir of ambient fluid.
However, the prior art does not disclose systems and methods for increasing efficiency and power density in isothermal compressed-gas-based energy storage systems having heat exchangers by heating or cooling the heat-transfer fluid.
The invention overcomes the disadvantages of the prior art by combining systems for thermal energy recovery, extraction, and/or usage with a system and method for compressed-gas energy storage to allow for cost-effective and efficient energy storage. In the invention, the heat-exchange subsystem of a novel compressed-gas energy conversion system, a staged hydraulic/pneumatic system as described in U.S. Provisional Patent Application No. 61/043,630 with heat transfer circuit as described in U.S. Provisional Patent Application No. 61/059,964—both applications of which are hereby incorporated by reference in their entireties—is combined with thermal systems to increase power density and efficiency by utilizing said thermal systems to chill or heat the transfer medium (e.g., water). In one application, excess thermal energy (e.g., waste heat) from power plants or industrial processes is used to preheat the heat-exchange fluid in the compressed-gas energy conversion system's heat-exchange subsystem. In such instances, the power density of the energy conversion system can be increased by coupling this excess thermal energy with the system while expanding stored gas. Similarly, chilled water that may be available from the natural local environment (e.g., a river) can be used to pre-cool the heat exchange fluid to decrease power requirements during compression. In the absence of such heating or cooling sources, both pre-heated and pre-chilled water can be efficiently generated through the use of heat pumps. Alternatively, hot and cold water generated during compression and expansion cycles, respectively, can be used as a heating or cooling source. Heated water (from the heat exchange subsystem during compression) can be used for process heat or building conditioning, and cooled water (from the heat exchange subsystem during expansion) can be used for cooling systems and/or building conditioning. In all instances, the combination of systems for thermal energy recovery, extraction, and/or usage with a compressed-gas energy conversion system improves performance and cost effectiveness.
In one application, excess thermal energy (e.g., waste heat) from power plants or industrial processes is used to preheat the heat exchange fluid and/or the compressed gas in the compressed-gas energy conversion system's heat-exchange subsystem. In such instances, the power density of the energy conversion system may be increased by coupling this excess thermal energy with the system during expansion of stored gas. Similarly, chilled water, such as may be available from the natural local environment (e.g., from a river), may be used to pre-cool the heat exchange fluid, the stored compressed gas prior to further compression, and/or the compressed gas during compression to decrease power requirements during compression. In the absence of such heating or cooling sources, heated and chilled water may be efficiently generated using ground loops, water loops, heat pumps, or other means. Alternatively, hot and cold water generated during compression and expansion cycles, respectively, may be used as a heating or cooling source. Heated water (from the heat exchange subsystem during compression) may be used for process heat or building conditioning, and cooled water (from the heat exchange subsystem during expansion) may be used for cooling systems and/or building conditioning. In all instances, the combination of systems for thermal energy recovery, extraction, and/or usage with a compressed-gas energy conversion system improves performance and cost effectiveness.
In one aspect, the invention relates to a combined thermal and compressed-gas energy conversion system. The system includes a compressed-gas energy conversion system, a source of recovered thermal energy, and a heat-exchange subsystem in fluid communication with the compressed-gas energy conversion system and the source of recovered thermal energy. The compressed gas energy conversion system is configured for substantially isothermal storage and recovery of energy. Examples of compressed-gas energy conversion systems are described in U.S. patent application Ser. No. 12/639,703 (the '703 application), the disclosure of which is hereby incorporated herein by reference in its entirety. The term “isothermal,” as used herein, denotes any non-adiabatic expansion or compression process that confers increased efficiency or other energetic benefit through the deliberate transfer of heat to or from the quantity of gas subject to the expansion or compression process. The term “recovered thermal energy,” as used herein denotes the transfer or recycling of thermal energy between at least two sources. The source of recovered thermal energy can include at least one of a fossil fuel power plant, a heat engine power plant, a solar thermal source, a geothermal source, an industrial process with waste heat, a heat pump, a heat source, a heat sink, or a source of environmentally chilled water.
In various embodiments of the foregoing aspect, the heat-exchange subsystem utilizes the recovered thermal energy to heat the compressed gas prior to and/or during expansion thereof. Additionally, the heat-exchange subsystem can use the recovered thermal energy to cool the compressed gas during and/or after compression thereof. In this scenario, the source of recovered thermal energy is being used as a heat sink for accepting the thermal energy transferred from the gas under compression. Generally, the source of thermal energy can be a source of fluid at a non-ambient temperature (either warmer or cooler), where the heat-exchange subsystem utilizes the temperature differential offered by the fluid source either to recover thermal energy by heating gas during expansion or to dispose of thermal energy by cooling gas during compression, as described above.
The source of recovered thermal energy can also include thermal well, where the thermal well can be used as a means of storing recovered energy from, for example, the compressed-gas energy conversion system. This stored thermal energy can be used, for example, to provide heating or other building conditioning. Additionally, thermal energy from another source can be used to preheat the thermal well prior to an expansion stage of the compressed-gas energy conversion system.
The heat exchange subsystem can include a circulation apparatus in fluid communication with the energy conversion system for circulating a fluid through the heat-exchange subsystem and a heat exchanger. The heat exchanger can include a first side in fluid communication with the circulation apparatus and the energy conversion system, where the circulation apparatus circulates the fluid from the energy conversion system, through the heat exchanger, and back to the energy conversion system, and a second side circulating a heat-exchange fluid through the source of recovered thermal energy. In one embodiment, the heat-exchange fluid transfers at least a portion of the recovered thermal energy for use as at least one of process heat, cooling, or building conditioning.
In one embodiment, the compressed-gas energy conversion system includes a cylinder assembly including a staged pneumatic side and a hydraulic side. The sides are separated by a mechanical boundary mechanism that transfers energy therebetween. In this embodiment, the heat exchange subsystem is in fluid communication with the pneumatic side of the cylinder assembly and the circulation apparatus circulates the fluid from the pneumatic side of the cylinder assembly, through the heat exchanger, and back to the pneumatic side of the cylinder assembly. The fluid can include a gas being compressed or expanded in the pneumatic side of the cylinder assembly. The heat exchange subsystem can include a spray mechanism disposed in the pneumatic side of the cylinder assembly and the fluid is a heat-exchange fluid introduced into the cylinder assembly through the spray mechanism. The spray mechanism can include at least one of a spray head disposed at an end of the cylinder assembly or a spray rod running through at least a portion of the cylinder assembly.
In additional embodiments, the cylinder assembly can be at least one of an accumulator or an intensifier. Additionally, the cylinders assembly can be at least one pneumatic cylinder mechanically coupled to at least one hydraulic cylinder. In one embodiment, the compressed-gas energy conversion system can include a second cylinder assembly including a staged pneumatic side and a hydraulic side separated by a boundary mechanism that transfers mechanical energy therebetween in fluid communication with the cylinder assembly. In a particular example of the foregoing embodiment, the first cylinder assembly is an accumulator that transfers the mechanical energy at a first pressure ratio and the second cylinder assembly is an intensifier that transfers the mechanical energy at a second pressure ratio greater than the first pressure ratio.
The compressed-gas energy conversion system can also include one or more pressure vessels for storage of the compressed gas, where a heat-exchange subsystem is in fluid communication with the pressure vessel. In one embodiment, a circulation apparatus of the heat exchange subsystem circulates the fluid from the pressure vessel, through a heat exchanger, and back to the pressure vessel(s). The fluid can include a gas being stored in the pressure vessel. The pressure vessel can also include a spray mechanism for introducing a heat-exchange fluid into the pressure vessel. In one embodiment, the existing heat exchange subsystem is in fluid communication with the pressure vessel(s) via appropriate valves and piping. Furthermore, the heat exchange subsystem can include an additional heat exchanger and/or circulation apparatus configured for use with the pressure vessel(s), as necessary. Alternatively, a second, dedicated heat exchange subsystem can be used with the pressure vessel(s).
In another aspect, the invention relates to a system for substantially isothermal expansion and compression of a gas. The system includes a source of recovered thermal energy, a cylinder assembly and a heat-exchange subsystem. The cylinder assembly can include a staged pneumatic side and a hydraulic side, where the sides are separated by a mechanical boundary mechanism that transfers energy therebetween. The heat exchange subsystem is in fluid communication with the pneumatic side of the cylinder assembly and the source of recovered thermal energy.
In yet another aspect, the invention relates to a method of substantially isothermal compressed-gas energy storage utilizing a source of recovered energy. The method includes the steps of at least one of substantially isothermally expanding or compressing a gas in a compressed-gas energy conversion system and utilizing thermal energy from a source of recovered thermal energy to at least one of cool the gas during or after compression or heat the gas prior to or during expansion.
These and other objects, along with the advantages and features of the present invention herein disclosed, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.
In the drawings, like reference characters generally refer to the same parts throughout the different views. In addition, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
In the following, various embodiments of the present invention are generally described with reference to a single hydraulic cylinder (for example, an accumulator or an intensifier) and simplified valve arrangements. It is, however, to be understood that embodiments of the present invention may include any number and combination of accumulators, intensifiers, and valve arrangements. In addition, any dimensional values given are exemplary only, as the systems according to the invention are scalable and customizable to suit a particular application. Furthermore, the terms pneumatic, gas, and air are used interchangeably and the terms hydraulic and fluid are also used interchangeably.
The temperature of the compressed air stored in the system can be related to its pressure and volume through the ideal gas law and thus to the power output of the system during expansion. Therefore, pre-heating (before or during expansion) or pre-cooling (during compression) of the compressed gas and/or heat-exchange medium (e.g., water) in the heat-transfer circuit described in the '235 application may be used to increase power output (or decrease power input) of the compressed-air energy conversion system, improving overall effective efficiency (potentially exceeding 100% efficiency for electric input to electric output). Potential sources of pre-heating of the stored or expanding compressed gas and/or heat exchange medium include waste heat from installations such as power plants and industrial processes and heat obtained from heat pumps, ground loops, solar thermal devices, and geothermal heating. Potential sources of pre-cooling for the heat-exchange medium include heat pumps, ground loops, and cold water from the local environment.
In lieu of pre-heating or pre-cooling, the heat exchange medium (e.g., water) in the heat transfer circuit described in the '235 application becomes cooler (provides thermal energy to the compressed air) during expansion and hotter (removes thermal energy from the compressed air) during compression. This movement of thermal energy may be used in combined heating or cooling applications such as space conditioning.
Combining thermal systems with compressed-gas energy storage may improve efficiency, cost-effectiveness, and performance. In some instances, compressed-gas energy conversion systems will be located at power generation sites (e.g., coal, nuclear, solar thermal) that use heat engines producing substantial excess thermal energy. In others, the system may be located at industrial sites with substantial waste process heat or otherwise freely available excess thermal energy. In all these instances, the power density of the system may be increased by preheating the stored compressed gas and/or coupling excess thermal energy with the gas during expansion. In other instances, cooled water from this system may be used for cooling systems and/or building conditioning. Conversely, local cooling sources such as ground loops or cold water from the local environment may be used to promote cooling during compression by cooling the stored compressed gas or the gas being compressed, thus increasing the efficiency of the process. Moreover, during compression, excess thermal energy is generated by the compressed-air energy conversion system. If extracted by an appropriate thermal system, this excess thermal energy may be used for process heat or building conditioning. Cooling from environmental sources may be combined with harvesting of excess storage-system heat by using the later for preheating of cold-water inputs to the installation being served. In all of these instances, performance and/or value of the storage system may be markedly improved.
In various embodiments, the recovered thermal energy from the power plant 102 is used in the heat-exchange subsystem of the compressed-gas energy conversion system 110 to preheat the heat exchange fluid during expansion, increasing the work done by a given volume of pressurized gas, thus improving system efficiency and/or performance. Likewise, cooled water from heat exchange with cold environments or other low-temperature reservoirs may be used in the heat-exchange subsystem of the compressed-gas energy conversion system 110 to improve efficiency and/or performance during compression. In lieu of using pre-chilled heat exchange fluid, excess thermal energy generated during air compression may be used for process heat or building conditioning. Similarly, in lieu of using pre-heated heat exchange fluid, during expansion the cooled exchange fluid may be used to cool the surroundings, e.g., for building conditioning.
In other embodiments, the recovered thermal energy from the power plant 102 is used in the heat-exchange subsystem of the compressed-gas pressure vessels 120 (or other pressurized storage) to preheat the stored compressed gas and to heat the heat-exchange fluid and gas during expansion, increasing the work done by a given volume of pressurized gas and so improving system efficiency and/or performance. Likewise, water cooled by heat exchange with cold environments, ground loops, or water loops, or other low-temperature reservoirs may be used in the heat-exchange subsystem to pre-cool and continually cool the compressed gas prior to and during further compression, improving system efficiency and/or performance. In all of these instances, performance and/or value of the system may be markedly improved.
As shown in
The system 300 also includes two heat-exchange subsystems 350 in fluid communication with the air chambers 340, 341, 344, 345 of the accumulators and intensifiers 316-319 and the high pressure storage tanks 302: these heat-transfer subsystems provide the improved isothermal expansion and compression of the gas. A simplified schematic of one of the heat exchange subsystems 350 is shown in greater detail in
The basic operation of the system 350 is described with respect to
As shown in
The selection of the various components will depend on the particular application with respect to, for example, fluid flows, heat transfer requirements, and location. In addition, the pneumatic valves may be electrically, hydraulically, pneumatically, or manually operated. In addition, the heat exchange subsystem 350 may include at least one temperature sensor 322 that, in conjunction with the controller 360 (
In one exemplary embodiment, the heat exchange subsystem is used with a staged hydraulic-pneumatic energy conversion system as shown and described in the '057 application, where the two heat exchangers are connected in series. The operation of the heat-transfer subsystem is described with respect to the operation of a 1.5 gallon capacity piston accumulator having a 4-inch bore. In one example, the system is capable of producing 1-1.5 kW of power during a 10 second expansion of the gas from 2900 psi to 350 psi. Two tube-in-shell heat exchange units one with a heat exchange area of 0.11 m2 and the other with a heat exchange area of 0.22 m2, are in fluid communication with the air chamber of the accumulator. Except for the arrangement of the heat exchangers, the system is similar to that shown in
During operation of the systems 300, 350, high-pressure air is drawn from the accumulator 316 and/or 317 and circulated through the heat exchangers 354 by the circulation apparatus 352. Specifically, once the accumulator(s) 316, 317 is filled with hydraulic fluid and the piston is at the top of the cylinder, the gas circulation/heat exchanger sub-circuit and remaining volume on the air side of the accumulator is filled with high-pressure (e.g., 3000 psi) air. The shut-off valves 307G-307J are used to select which, if any, heat exchanger to use. Once this is complete, the circulation apparatus 352 is turned on as is the heat exchanger counter-flow.
During gas expansion in the accumulator 316 the three-way valves 356 are actuated as shown in
The overall work output and thermal efficiency may be controlled by adjusting the hydraulic fluid flow rate and the heat exchanger area.
Referring back to
The accumulator fluid chambers 338, 339 are interconnected to a hydraulic motor/pump arrangement 330 via a hydraulic valve 328a. The hydraulic motor/pump arrangement 330 includes a first port 331 and a second port 333. The arrangement 330 also includes several optional valves, including a normally open shut-off valve 325, a pressure relief valve 327, and three check valves 329 that may further control the operation of the motor/pump arrangement 330. For example, check valves 329a, 329b, direct fluid flow from the motor/pump's leak port to the port 331, 333 at a lower pressure. In addition, valves 325, 329c prevent the motor/pump from coming to a hard stop during an expansion cycle.
The hydraulic valve 328a is shown as a three-position, four-way directional valve that is electrically actuated and spring returned to a center closed position, where no flow through the valve 328a is possible in the unactuated state. The directional valve 328a controls the fluid flow from the accumulator fluid chambers 338, 339 to either the first port 331 or the second port 333 of the motor/pump arrangement 330. This arrangement allows fluid from either accumulator fluid chamber 338, 339 to drive the motor/pump 330 clockwise or counter-clockwise via a single valve.
The intensifier fluid chambers 346, 347 are also interconnected to the hydraulic motor/pump arrangement 330 via a hydraulic valve 328b. The hydraulic valve 328b is also a three-position, four-way directional valve that is electrically actuated and spring returned to a center closed position, where no flow through the valve 328b is possible in the unactuated state. The directional valve 328b controls the fluid flow from the intensifier fluid chambers 346, 347 to either the first port 331 or the second port 333 of the motor/pump arrangement 330. This arrangement allows fluid from either intensifier fluid chamber 346, 347 to drive the motor/pump 330 clockwise or counter-clockwise via a single valve.
The motor/pump 330 may be coupled to an electrical generator/motor and that drives and is driven by the motor/pump 330. As discussed with respect to the previously described embodiments, the generator/motor assembly may be interconnected with a power distribution system and may be monitored for status and output/input level by the controller 360.
In addition, the fluid lines and fluid chambers may include pressure, temperature, or flow sensors and/or indicators 322, 324 that deliver sensor telemetry to the controller 360 and/or provide visual indication of an operational state. In addition, the pistons 336, 337, 342, 343 may include position sensors 348 that report their present position to the controller 360. The position of the piston may be used to determine relative pressure and flow of both gas and fluid.
The cylinder 501 has one or more gas circulation outlet ports 510 that are connected via piping 511 to the gas circulator 552. Note that, as used herein, the terms “pipe,” “piping” and the like shall refer to one or more conduits that are rated to carry gas or liquid between two points. Thus, the singular term should be taken to include a plurality of parallel conduits where appropriate. The gas circulator 552 may be a conventional or customized low-head pneumatic pump, fan, or any other device for circulating a gas. The gas circulator 552 should be sealed and rated for operation at the pressures contemplated within the gas chamber 502. Thus, the gas circulator 552 creates a predetermined flow (arrow 530) of gas up the piping 511 and therethrough. The gas circulator 552 may be powered by electricity from a power source or by another drive mechanism, such as a fluid motor. The mass-flow speed and on/off functions of the circulator 552 may be controlled by a controller 560 acting on the power source for the circulator 552. The controller 560 may be a software and/or hardware-based system that carries out the heat-exchange procedures described herein. The outlet of the gas circulator 552 is connected via a pipe 514 to the gas inlet 515 of a heat exchanger 554.
The heat exchanger 554 of the illustrative embodiment may be any acceptable design that allows energy to be efficiently transferred between a high-pressure gas flow contained within a pressure conduit and another mass flow (fluid). The rate of heat exchange is based in part on the relative flow rates of the gas and fluid, the exchange-surface area between the gas and fluid, and the thermal conductivity of the interface therebetween. In particular, the gas flow is heated or cooled, depending on the stage of operation of the energy conversion system, in the heat exchanger 554 by the fluid counter-flow passing through piping 517 (arrows 526), which enters the fluid inlet 518 of heat exchanger 554 at ambient temperature and exits the heat exchanger 554 at the fluid exit 519 equal or approximately equal in temperature to the gas in piping 514. The gas flow at gas exit 520 of heat exchanger 554 is at ambient or approximately ambient temperature, and returns via piping 521 through one or more gas circulation inlet ports 522 to gas chamber 502. (By “ambient” is meant the temperature of the surrounding environment or any other temperature at which efficient performance of the system can be achieved.) The ambient-temperature gas reentering the cylinder's gas chamber 502 at the circulation inlet ports 522 mixes with the gas in the gas chamber 502, thereby bringing the temperature of the fluid in the gas chamber 502 closer to ambient temperature.
The controller 560 manages the rate of heat exchange based, for example, on the prevailing temperature (T) of the gas within the gas chamber 502 as determined using a temperature sensor 513B of conventional design that thermally communicates with the gas within the chamber 502. The sensor 513B may be placed at any location along the cylinder including a location that is at, or adjacent to, the heat exchanger gas inlet port 510. The controller 560 reads the value T from the cylinder sensor and compares it to an ambient temperature value (TA) derived from a sensor 513C located somewhere within the system environment. When T is greater than TA, the heat exchange subsystem 550 is directed to move gas (by powering the circulator 552) therethrough at a rate that may be partly dependent upon the temperature differential (so that the exchange does not overshoot or undershoot the desired rate of heat exchange. Additional sensors may be located at various locations within the heat-exchange subsystem to provide additional telemetry that may be used by a more complex control algorithm. For example, the outlet gas temperature (TO) from the heat exchanger may measured by a sensor 513A that is placed upstream of the inlet port 522.
The heat exchanger's fluid circuit may be filled with water, a coolant mixture, and/or any acceptable heat-transfer medium. In alternative embodiments, a gas, such as air or refrigerant, is used as the heat-transfer medium. In general, the fluid is routed by conduits to a large reservoir of such fluid in a closed or open loop. One example of an open loop is a well or body of water from which ambient water is drawn and the exhaust water is delivered to a different location, for example, downstream in a river. In a closed-loop embodiment, a cooling tower may cycle the water through the air for return to the heat exchanger. Likewise, water may pass through a submerged or buried coil of continuous piping where a counter heat-exchange occurs to return the fluid flow to ambient temperature before it returns to the heat exchanger for another cycle.
It should also be clear that the isothermal operation of embodiments of this invention works in two directions thermodynamically. The gas may be warmed toward ambient by the heat exchanger during expansion or cooled toward ambient by the heat exchanger during compression; in the latter case, without cooling, significant internal heat may build up via compression. The heat-exchanger components should therefore be rated to handle at least the temperature range likely to be encountered for entering gas and exiting fluid. Moreover, since the heat exchanger is external to the hydraulic/pneumatic cylinder, it may be located anywhere that is convenient and may be sized as needed to deliver a high rate of heat exchange. In addition, it may be attached to the cylinder with straightforward taps or ports that are readily installed on the base end of an existing, commercially available hydraulic/pneumatic cylinder.
In various preferred embodiments, the heat-exchange fluid may be conditioned (i.e., pre-heated and/or pre-chilled) or used for heating or cooling needs by connecting the fluid inlet 518 and fluid outlet 519 of the external heat exchange side of the heat exchanger 554 to an installation 570, such as heat-engine power plants, industrial processes with waste heat, heat pumps, and buildings needing space heating or cooling.
As described above, in one embodiment, installation 570 is merely a large water reservoir that acts as a constant temperature thermal fluid source for use with the system. Alternatively, the water reservoir may be thermally linked to waste heat from an industrial process or the like, as described above, via another heat exchanger contained within the installation 570. This allows the heat exchange fluid to acquire or expel heat from/to the linked process, depending on configuration, for later use as a heating/cooling medium in the compressed air energy storage/conversion system.
In
In
Reference is now made to
In
In
The spray droplets pass through the gas side 603, exchanging heat with the expanding gas. Liquid accumulates 610 in whatever portion of the gas side is bottommost; is conducted out of the gas side through a line 611 (herein illustrated as exiting through a center-drilled piston rod) to a heat exchanger 554 where it is heated; exits the heat exchanger to pass through a circulator 613; and is again introduced into the interior of the hollow spray rod 701. Heat is delivered to the heat exchanger 554 by a circuit 614 that communicates with a source of heat, e.g. an installation 570 as described above.
It should be clear that during compression of gas for delivery to a storage reservoir (not shown), as opposed to expansion of gas from the storage reservoir (shown), the identical mechanisms shown in
It should be noted that heat-transfer subsystems discussed above may also be used in conjunction with the high pressure gas storage systems (e.g., storage tanks 302) to thermally condition the pressurized gas stored therein, as shown in
The spray heat exchange may occur either as pre-heating prior to expansion or, when valve 906 is opened, pre-cooling prior to compression in the system. The heat exchanger 954 may be any sort of standard heat exchanger design; illustrated here is a tube-in-shell type heat exchanger with high-pressure water inlet and outlet ports 921a and 921b and low-pressure shell ports 922a and 922b (which may be connected to an external heating or cooling source, as described above). As liquid-to-liquid heat exchangers tend to be more efficient than air-to-liquid heat exchangers, heat exchanger size may be reduced and/or heat transfer may be improved by use of a liquid-to-liquid heat exchanger. Heat exchange within the pressure vessels 902 is expedited by active spraying of the liquid (e.g., water) into the pressure vessels 902.
As shown in
As gas expands in the gas side 1003 of the cylinder 1001, it pushes the piston 1004 downward, pressurizing the liquid in the hydraulic side 1002. This liquid exits to a hydraulic motor/pump, not shown but indicated by 1007, whose shaft drives an electric motor/generator (also not shown) to produce electricity. Liquid may be admitted to the hydraulic side 1002 from any source (e.g., the liquid outlet of the hydraulic motor/pump), not shown, but indicated by 1008.
The gas expanding in the pneumatic side 1003 tends to cool according to the ideal gas law. Greater effective efficiency is achieved if heat is transferred to the gas during expansion. This is achieved by the introduction of a heated liquid into the pneumatic side 1003 of the cylinder. The heated liquid (e.g., water) may be introduced as a spray 1008 through a spray head or heads 1009. This liquid falls as a spray or droplets through the pneumatic side 1003, exchanging heat with the expanding gas. The liquid accumulates 1010 in the bottom of the pneumatic side 1003 and is drawn out of the pneumatic side 1003 of the cylinder. As shown in
The heat exchanger 1012 passes through a thermal well 1014, shown here as a water reservoir. In use, this system will achieve substantially isothermal expansion of the compressed gas from the reservoir 1005, with resulting power output and total recoverable energy superior to that achievable otherwise. The thermal energy delivered by the heat-exchange circuit and liquid spray to the expanding gas may raise its temperature, thereby increasing mechanical work that is delivered by the cylinder to the motor/generator and the amount of electricity produced.
Similarly, during compression of the gas, thermal energy may be transferred from the compressing gas to the liquid spray and then to the thermal well. Overall, for equal power and duration expansion and compression cycles, equal amounts of thermal energy will be stored and returned from the thermal well. Due to inefficiencies in the energy conversion system, the thermal well will actually gain in thermal energy over the course of a full compression and expansion process. This gain in thermal energy may be dissipated by means such as an environmental heat exchanger or other heat transfer, such as losses through imperfect insulation. In some embodiments, the gain in thermal energy may be utilized as a heat source for process heat or building conditioning, as described above.
The cylinder 1110 has one or more gas circulation outlet ports 1117, which are connected via piping 1122 to a gas circulator 1120, which may be part of the heat exchange subsystem described in the '235 application. The gas circulator 1120 provides a flow (arrow 1121) of gas through the piping 1122. The outlet of the gas circulator 1120 is connected via a pipe to the gas inlet of the heat exchanger 1123. The heat exchanger 1123 may pass directly through the thermal well, or as shown here, other connections on the heat exchanger 1123 may bring an external heat exchange fluid (e.g., water) from the thermal well 1130 to the heat exchanger 1123 to provide or extract thermal energy from the circulating compressed gas, thereby maintaining the gas at nearly the temperature of the exchange fluid. In one embodiment, a fluid circulator 1124 is used to circulate the heat exchange fluid through the heat exchanger 1123. The system 1100 improves efficiency and power output of the compressed-gas energy conversion system.
The system includes a pneumatic cylinder 1200 divided into two compartments 1201, 1202 by a piston 1203. The cylinder 1200, which is shown in a vertical orientation in this illustrative embodiment, has one or more gas ports 1204 that may exchange gas with other devices through piping 1205. In the operating state shown in
In this embodiment of the invention, liquid sprays may be introduced into either of the compartments 1201, 1202 of the cylinder 1200. The liquid, sprayed downward, allows for expedited heat transfer with the high-pressure gas being expanded (or compressed) in the cylinder 1200, as described in detail above. In
Liquid 1213 accumulating at the bottom of the chamber 1201 is removed at a pressure substantially the same as that of the gas inside the expansion chamber (e.g., 3000 psi at the start of the expansion) through a port 1207 and conveyed via piping 1214 to a heat exchanger 1215 to raise its temperature, which has been reduced by heat exchange with the expanding gas. The heat exchanger 1215 is shown for illustrative purposes and may be located anywhere in the circuit; moreover, its function may be performed during system idle times through circulation of water at low pressure or with replacement from a larger water bath. Exiting the heat exchanger 1215, the liquid passes through a four-way, two-position valve 1216 that directs it to whichever of the two chambers of a double-acting hydraulic cylinder 1217 is presently being filled. In the state of operation shown in
Liquid pressurized by the hydraulic cylinder 1217 (i.e., in chamber 1221, in this state of operation) is directed through the valve 1216, through piping 1222, through a flexible hose 1223, and into a center-drilled channel 1224 in one side of a piston shaft 1233 of the pneumatic cylinder 1200. Channels 1225 formed within the body of the piston 1203 direct the heat-exchange liquid to the spray heads 1212. The arrangement of channels and spray heads shown here is illustrative only, as any number and disposition of channels and spray heads or other spray devices inside the cylinder 1200 and its piston 1203 may be selected to suit a particular application: such variations are expressly contemplated and within the scope of the invention. The concept is also independent of whatever pumping mechanism is used to pressurize the heat-exchange liquid in the hydraulic loop.
Reference is now made to
In
The heat-exchange liquid is passed through a flexible hose 1323, a heat exchanger 1315, a four-way, two-position valve 1316, and raised to injection pressure by a hydraulic cylinder 1317 driven by an actuator 1320. It is then passed through the valve 1316 again and returned to the spray heads 1303 for injection into chamber 1202, in a process similar to that described with respect to
If the electric motor/generator (not shown) coupled to the pneumatic cylinder is operated as a motor rather than as a generator, the mechanism shown in
Reference is now made to
As shown in
The system shown in
The system shown in
Embodiments of the invention disclosed herein may be utilized in a variety of applications, including extraction, sequestration, and subsequent use of gases emitted from power plants, such as carbon dioxide. Fossil fuel-based power generation, as of 2008, accounts for a large fraction of the world's generated energy. While pollution control equipment can successfully capture much of the criteria emissions (e.g., sulfur dioxide, nitrogen oxides, particulates) at low-percentage energy consumption and cost, carbon dioxide (CO2) sequestration systems for fossil fuel power plants remain prohibitively energy intensive (utilizing 20-40% of the total energy generated) and expensive.
One potential method of carbon dioxide fixation from power plants emissions is through the growth of plant-based biomass. One use of biomass growth for CO2 emission mitigation described in US Patent Application Publication No. 2007/0289206, the disclosure of which is hereby incorporated by reference in its entirety, in which high-growth-rate algae is grown in a carbon-dioxide-rich environment. The grown biomass (e.g., algae) has the potential to be used as an energy carrier through the extraction of oils (biodiesel) and/or processing for use as other biofuels (e.g. ethanol). In any of these cases, when the ultimate biofuel is used (typically combusted in an engine) the sequestered carbon dioxide will be released. Overall, through the biomass-based CO2 emission mitigation, the net effect is an approximate halving of the carbon dioxide emissions for both processes (power plant generation and biofuel usage (e.g., transportation).
There is one significant drawback to the approach described above. Most such biomass-based CO2 emission mitigation schemes require light to provide the activation energy necessary for photosynthesis. Therefore, power plant biomass-based carbon dioxide sequestration schemes generally only operate well during daytime hours.
Other types of carbon dioxide sequestration systems are described in PCT Application Publication No. WO02/092755, PCT Application Publication No. WO 2007/134294, PCT Application Publication No. WO 2006/108532, PCT Application Publication No. WO 2006/100667, U.S. Patent Application Publication No. 2008/0220486, U.S. Patent Application Publication No. 2008/0009055, and U.S. Patent Application Publication No. 2008/0252215, all of which are hereby incorporated by reference in their entireties.
As the compressed-gas energy-storage methods and systems described above are relatively indifferent to the species of gas involved, such systems can compress and later expand processed carbon dioxide-rich power plant exhaust gasses without adverse effect on their energy-storage efficiency. The combination of fossil fuel based power plants, compressed-gas energy storage, and biomass carbon dioxide fixation/sequestration allows for the storage of low-cost energy during nighttime off-peak hours for release during daytime peak hours simultaneously with the storage of nighttime power plant emissions for daytime release through a biomass carbon dioxide sequestration facility. This provides an economically feasible solution to both energy-storage needs and carbon dioxide sequestration. Embodiments of the present invention enable the temporary storage of nighttime power plant emissions by a compressed-gas energy conversion system for later release through a biomass sequestration system during daylight hours.
Embodiments of the invention overcome the disadvantages of the prior art by combining biomass carbon dioxide sequestration with compressed-gas energy storage to allow for a cost-effective means of both storing energy and sequestering carbon dioxide at all times, day and night. The gas emissions from a power plant are compressed and stored, primarily during nighttime hours, in effect storing both energy and carbon-dioxide-rich power plant gas emissions. At other times, primarily during daytime hours, carbon-dioxide-rich power plant gas emissions are directed to a biomass sequestration facility, such as algae ponds or bioreactors. Upon market or other demand for energy stored by the compressed gas system, primarily during daytime hours, compressed and stored carbon-dioxide-rich gas emissions are expanded, generating usable/saleable power; after expansion, these previously stored carbon dioxide-rich gas emissions may also be directed to the biomass sequestration facility.
Reference is now made to
In
In
Systems and methods of carbon dioxide extraction from power plants emissions in accordance with embodiments of the invention feature compression of the emission gases to high pressure such that a portion of the carbon dioxide present undergoes a phase change to liquid and/or a supercritical fluid state. For example, pure carbon dioxide undergoes a phase change from gas to liquid at approximately 30 atm (440 psi) at 20° C. and 71 atm (1050 psi) at 31° C. As 31° C. and 71 atm is the critical point for carbon dioxide, above 31° C. carbon dioxide will be a combination of gas, liquid, and/or supercritical fluid, depending on the pressure. Carbon dioxide in a gas mixture (i.e., impure carbon dioxide), such as in power plant emissions, will undergo phase changes in accordance to the partial pressure of the carbon dioxide in the mixture. For example, a portion of carbon dioxide at a 10% concentration (by volume) in gas emissions will liquefy at 20° C. when the overall pressure reaches 300 atm (4400 psi), thus bringing the partial pressure of carbon dioxide to 30 atm. To liquefy the majority of carbon dioxide in a gas emissions mixture, very high pressures or reduced temperature is generally needed. After the carbon dioxide is liquefied or in the form of a supercritical fluid, it will typically sink to the bottom of the storage vessel due to its higher density. Removal of the liquefied or supercritical carbon dioxide may then be accomplished mechanically. Example mechanical apparatus for separation of the liquefied or supercritical carbon dioxide, among others, are described in U.S. Pat. Nos. 5,690,828 and 5,866,004, the disclosures of which are hereby incorporated herein by reference in their entireties.
Systems and methods for carbon dioxide extraction from carbon dioxide-rich gas emissions may involve the chemical processing of carbon dioxide rich gas emissions, such as in U.S. Pat. No. 6,497,852, where the recovery is done by passing the emissions over a material such as a “liquid absorbent fluid comprising an organic amine absorbent,” or as in U.S. Pat. No. 6,235,092, where separation is accomplished by “contact . . . with carbon dioxide nucleated water under conditions of selective carbon dioxide clathrate formation.” The extracted carbon dioxide may be compressed after extraction to form a liquid or supercritical fluid where it may be sequestered at depth or sold as a useful solvent for such things as dry cleaning and contaminant removal. Additionally, among other applications, the extracted carbon dioxide may be used for biofuel production. The disclosures of U.S. Pat. Nos. 6,497,852 6,235,092 are hereby incorporated herein by reference in their entireties. Typically, carbon dioxide separation from air is accomplished via chemical extraction methods in part due to the high partial pressures and/or low temperatures required.
The compressed-gas energy conversion systems described herein may be used for further cooling of compressed gases and thus extraction of carbon dioxide at low pressures. By compressing power plant emissions gas to store energy, such systems can concurrently process the carbon dioxide-rich power plant gas emissions (e.g., 2-30% carbon dioxide) for partial extraction of the carbon dioxide from said emissions. The combination of fossil fuel-based power plants, compressed-gas energy storage, and compression-based carbon dioxide extraction provides an economically feasible solution to both energy storage needs and carbon dioxide extraction. The added benefit of carbon dioxide extraction through the compression process further increases the value of the compressed-gas energy conversion system, providing carbon dioxide in liquid or supercritical fluid form, both reducing carbon dioxide gas emissions and providing a potential resource for use as solvent or otherwise.
Embodiments of the invention combine mechanical carbon dioxide extraction systems and methods with compressed-gas energy storage to allow for a cost-effective means of both storing energy and extracting carbon dioxide. Gas emissions from a power plant are compressed to high pressures using any of the compressed-air energy-storage systems described above, and then a portion of the carbon dioxide is extracted mechanically, in effect both storing energy and extracting carbon dioxide from carbon dioxide-rich power plant gas emissions. At other times, upon market or other demand, primarily during daytime hours, the processed and compressed power plant gas emissions are expanded, recovering most of the stored energy, while the extracted carbon dioxide is sold, utilized, or sequestered.
In one embodiment, compressed-gas energy conversion systems are utilized to concurrently store energy and capture carbon dioxide at a coal-fired or other carbon-based power plant. Some of the energy produced by the power plant at night is used to compress the gas emissions from the power plant and, at the same time, some carbon dioxide is extracted through compression of the emission gases to high pressure such that a portion of the carbon dioxide present undergoes a phase change to liquid and/or supercritical fluid state; this liquefied carbon dioxide, due to its higher density, sinks to the bottom of the storage vessel and is removed mechanically. During daylight hours, where market or other demand exists for additional power, previously compressed and stored gas emissions, which have undergone carbon dioxide extraction, are expanded increasing power output to the grid. Overall, this method has the potential to offset the high costs of sequestration by combining with an energy conversion system that can add value to a power generation plant by allowing the matching demand and the reutilization of a portion of the energy used in carbon dioxide extraction. This method both provides shifting of the energy produced by the power plant and extraction of some of the carbon dioxide produced by the plant and storing it in liquid form. Among other applications, the extracted carbon dioxide may be used as a valuable solvent or in biofuel production and/or sequestered through deep-well injection or in biomass as described above.
Reference is now made to
In
Embodiments of the invention also feature even more efficient methods of extraction of carbon dioxide (and/or other gases) in tandem with compressed-gas energy storage. In one embodiment, the gas emissions from a power plant are compressed within the first stage of a compressed gas storage system to moderate pressures and within that stage of the energy conversion system the carbon dioxide is extracted, in effect both storing energy and pressurizing the power plant emissions for extracting carbon dioxide from carbon dioxide-rich power plant gas emissions. Following carbon dioxide extraction in the first stage of the compressed-gas energy conversion system, both the processed power plant emissions and the extracted carbon dioxide may be further compressed in the second stage of the energy conversion system. At other times, upon market or other demand, primarily during daytime hours, the processed and compressed power plant gas emissions are expanded, recovering most of the stored energy, while the extracted carbon dioxide is sold, utilized, or sequestered.
Reference is now made to
In
In
The cylinder 2510 has one or more gas circulation outlet ports (shown here as port 2517) that are connected via piping 2522 to a gas circulator 2520 which is part of a heat exchange subsystem like those described above with respect to
Additionally, the compressed gases may further be circulated through a carbon-dioxide extraction system 2550 depending on the state of the valve 2540. Reactivity in many carbon dioxide extraction systems, such as absorber-type extraction systems using MEA (monoethanolamine), improves with compression of the gases being processed. In the system herein described, energy used for the compression of the exhaust gases is mostly stored and recovered in the compressed-gas energy conversion system. As indicated in
Embodiments of the invention disclosed herein may also be utilized in wind-energy storage applications. The power generated by a wind turbine/generator is variable and proportional to the wind speed. Wind turbine installations not coupled with energy storage supply the grid with intermittent power, typically resulting in increased costs for the utility due to the need to increase standby reserves to compensate for short-term variability in generation.
In 2008, nearly all operational wind turbines include an electric generator mounted in the nacelle of a horizontal-axis wind turbine. The inclusion of an electric generator in each turbine adds cost and weight to the nacelle for wind turbines. Certain approaches have been proposed to reduce weight in the nacelle, by moving the electrical generator to the ground, and to reduce costs, by replacing separate electric generators for each turbine with one larger generator for an array of turbines.
The replacement of the electrical generator in a wind turbine nacelle with a hydraulic drivetrain allows for the reduction of weight (and potentially cost) for the turbine, a broader wind-speed efficiency range for operation, and the ability to replace electrical generators at each individual turbine with a larger central electrical generator. Additionally, by coupling the hydraulic system with an efficient energy conversion system (such as those described above), wind energy generation may become a baseline generator with constant output or even a source of dispatchable energy providing power based on market needs.
Further, in another embodiment, the hydraulic-pneumatic energy conversion system 2640 may be used to store energy from another power source, such as the electric grid 2630, by having generator 2622 driven as an electric motor and hydraulic motor 2621 as a hydraulic pump, in turn driving hydraulic pump/motor 2610 as a hydraulic motor to power the system 2640 to compress air to high pressures in energy conversion system 2640 and store in pressure vessels or caverns 2650.
The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions may be made without departing from the spirit and scope of this invention. Each of the various embodiments described above may be combined with other described embodiments in order to provide multiple features. Furthermore, while the foregoing describes a number of separate embodiments of the systems and methods of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. For example, the size, performance characteristics, and number of components used to implement the system are highly variable. For example, while a particular implementation of a heat exchanger is shown and described, the type and placement of components within the heat exchange subsystem may be highly variable. For example, in an alternative embodiment, the circulator 352, 552 (
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/145,860, filed on Jan. 20, 2009; U.S. Provisional Patent Application Ser. No. 61/145,864, filed on Jan. 20, 2009; U.S. Provisional Patent Application Ser. No. 61/146,432, filed on Jan. 22, 2009; U.S. Provisional Patent Application Ser. No. 61/148,481, filed on Jan. 30, 2009; U.S. Provisional Patent Application Ser. No. 61/151,332, filed on Feb. 10, 2009; U.S. Provisional Patent Application Ser. No. 61/227,222, filed on Jul. 21, 2009; U.S. Provisional Patent Application Ser. No. 61/256,576, filed on Oct. 30, 2009; U.S. Provisional Patent Application Ser. No. 61/264,317, filed on Nov. 25, 2009; and U.S. Provisional Patent Application Ser. No. 61/266,758, filed on Dec. 4, 2009; the disclosure of each of which is hereby incorporated herein by reference in its entirety.
This invention was made with government support under IIP-0810590 and IIP-0923633, awarded by the NSF. The government has certain rights in the invention.
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