Patent Application
20250189118
The present disclosure relates generally to systems, methods, and apparatuses for producing high-pressure steam.
Reducing on-site emissions in the industrial sector is critical to achieving desired greenhouse gas targets. For example, one set of greenhouse gas targets are set forth in California's Air Resources Board's AB32 and SB 32 greenhouse gas reduction targets, although this particular set of greenhouse gas targets should not be deemed the only targets to meet in the industrial sector. Presently, industrial manufacturing plants burn natural gas in a steam boiler to evaporate water and produce steam. Once the thermal energy of the steam is advantageously used, the thermal energy is removed from the process via a cooling water loop. This increases the temperature of the cooling water. The warmed cooling water is then typically sent to a cooling tower where the thermal energy is rejected to atmosphere, i.e., thrown away, in order to reduce the temperature of the cooling water.
In an effort to reach greenhouse gas targets and become carbon neutral, it is desired to increase industrial electrification. This includes electrification of the gas-powered boilers in various industries. For example, industrial sectors where improvement has been specifically identified include natural gas boilers to produce steam in the chemical sector, in the pulp and paper sectors, in association with food production, and still other, diverse industrial sectors. It is believed that these sectors, and others, could come closer to meeting energy goals.
A barrier to achieving desired energy goals is a lack of efficient and economically attractive technologies to electrify the massive thermal energy demands associated with steam production in industry including the above-mentioned sectors. State-of-the-art industrial heat pumps today are unable to reach the temperatures required to produce medium-high pressure saturated steam required by many industrial facilities. State-of-the-art electric boiler technologies, on the other hand, are indeed able to reach required temperatures and pressures, but they do so with a low coefficient of performance (COP) of 1.0 or less. This results in excessive electricity consumption, making these systems uneconomical to operate. Additionally, the high electricity consumption may add undue strain on the electric power grid.
It would also be desirable that development of an alternative electric boiler technology to meet the demand for medium to high pressure saturated steam could be implemented in a manner that limits custom engineering and specialized, one-off field assembly. Custom engineering and specialized field assembly drastically limit availability and increase cost. This, in turn, is believed to affect perception by the industrial customer of reliability. Further, customized solutions with specialized field assembly typically could potentially encounter very expensive downtime, and thus industrial customers are reluctant to try new technologies that may be perceived as possibly failing and/or causing undesired downtime.
Presently available, state-of-the-art heat pumps typically use hydrofluorocarbon (HFC) or hydrofluoro-olefin (HFO) refrigerant to produce thermal energy at temperatures up to 320° F. These known systems are unable to produce steam directly, but rather must be used in combination with an unfired steam generator, which introduces a 20° F. nominal temperature drop. As a result, the maximum saturated steam pressure these systems can produce is 3.5 barg (50 psig), which is not high enough to address the median pressure (3.5-20 barg) applications that are in demand throughout the manufacturing industry. In addition, these systems have a relatively low coefficient of performance of <3.0, resulting in high electricity demand and high operating costs. HFC refrigerants have high global warming potential, and HFO refrigerants have low global warming potential but high cost.
CO2-based heat pumps also utilize a low-cost and low-global warming potential refrigerant (CO2) but are limited to temperatures of approximately 238° F. or less due to the very high pressures required by the refrigerant. Although 238° F. is above the atmospheric boiling point of water, CO2-based heat pumps are not able to generate steam because these CO2-based heat pumps require a low fluid return temperature of 203° F. or less, and it is the fluid return temperature that generally dictates the ability to drive a steam generator.
Ammonia-based heat pumps are a more mature technology, but like CO2-based heat pumps, the high-pressure characteristics of the systems are limited to a maximum output temperature of approximately 203° F., which is unsuitable for steam generation. Ammonia-based systems can produce lower temperatures, and therefore, the ammonia-based systems are complementary rather than competitive to the heat pump systems desired for steam generation. For example, ammonia-based systems are commonly used to provide low temperature refrigeration in the food production industry and typically reject waste heat at temperatures ranging from about 85° F. to 100° F.
A need exists for an improved arrangement that addresses at least one or more of the above-described disadvantages, in a manner that is cost-effective, efficient, reliable, scalable, etc., as well as providing still other features and benefits.
Given the above background, what is needed in the art are systems, methods, and apparatuses to electrify the production of high-pressure steam. Various implementations of this application are efficient in energy consumption and manufacturing cost.
Accordingly, various aspects of the present disclosure are directed to systems, methods, and apparatuses for producing high-pressure steam. For instance, in some embodiments, the systems, methods, and apparatuses of the present disclosure are configured as a heat pump. In some embodiments, the heat pump of the systems, methods, and apparatuses of the present disclosure is configured as an open-cycle mechanical vapor recompression, high-pressure steam production heat pump. In some embodiments, the systems, methods, and apparatuses of the present disclosure are configured to replace conventional fossil-fuel (e.g., natural gas) boilers and/or conventional evaporative cooling towers, which not only reduces overall energy consumption but also provides water savings. More particularly, in some embodiments, the systems, methods, and apparatuses of the present disclosure provide for a high-efficiency, high-pressure heat pump that provides high-pressure steam by receiving hot water, such as cooling water from a facility, into a flash vessel train that is maintained at a pressure below the saturation pressure of the hot water in order to simultaneously cool the hot water and generate vapor (e.g., low-pressure steam). The flash vessel train is configured to supply the low-pressure steam to a compressor train that is configured to compress the low-pressure steam produced by the flash vessel train to produce the high-pressure steam at a desired pressure of the facility. Accordingly, in some embodiments, the systems, methods, and apparatus of the present disclosure produce high-pressure steam having a temperature of at most 426 degrees Fahrenheit (° F.) (219 degrees Celsius (° C.)), at a pressure of at most 315 pounds per square inch gauge (PSI) (19.0 Barg), and temperature lift of at most 330° F. (166° C.).
Furthermore, in some embodiments, the systems, methods, and apparatuses of the present disclosure provide for a baseline heat pump system that is modularly configurable based on interchangeable sub-assemblies of the compressor train and/or the flash vessel train of the heat pump system. Accordingly, in some embodiments, the systems, methods, and apparatuses of the present disclosure provide a standalone heat pump that is not deeply integrated into a process associated with a facility. Rather, the systems, methods, and apparatuses of the present disclosure connect with the facility at standard portions, which include a hot water source and a steam header, while otherwise operating external to the process associated with the facility.
Turning to more specific aspects, one aspect of the present disclosure is directed to providing a system for producing high-pressure steam. The system includes a compressor train. The compressor train includes a series of at least two compressors. Moreover, the compressor train includes an inlet of the compressor train. Furthermore, the compressor train includes an outlet of the compressor train that is configured to provide high-pressure steam to a facility. The system further includes a flash vessel train. The flash vessel train includes a series of at least two flash vessels, in which the series of at least two flash vessels further includes a terminal flash vessel at one end of the flash vessel train. Moreover, a vapor outlet of the terminal flash vessel is fluidly coupled to the inlet of the compressor train. Additionally, the system includes vapor outlets of a remainder of the series of at least two flash vessels that are fluidly coupled between compressors of the series of at least two compressors.
In some embodiments, the flash vessel train further includes an inlet of the flash vessel train that is configured to receive hot water received from the facility or a different facility.
In some embodiments, the remainder of the series of at least two flash vessels each includes a liquid outlet that is fluidly coupled to an inlet of another one of the series of at least two flash vessels.
In some embodiments, the terminal flash vessel includes a liquid outlet that is fluidly coupled to an outlet of the system.
In some embodiments, the system further includes a controller that is configured to maintain a temperature range of the flash vessel train between a temperature of the high-pressure steam and a temperature of the outlet of the system.
In some embodiments, the series of at least two compressors includes a centrifugal compressor. In some embodiments, the controller is configured to maintain the centrifugal compressor from stonewalling or surging.
In some embodiments, the terminal flash vessel includes a liquid outlet that is fluidly coupled to a repressurization pump. The repressurization pump is coupled to an outlet of the system.
In some embodiments, each flash vessel in the series of at least two flash vessels is configured to be maintained at an internal pressure less than a saturation pressure of hot water input into the respective flash vessel. Moreover, each flash vessel in the series of at least two flash vessels is configured to expand the hot water to produce low-pressure steam.
In some embodiments, the terminal flash vessel further includes an inlet that is configured to receive hot water. The hot water is received from the facility or a different facility.
In some embodiments, the terminal flash vessel further includes the inlet configured to receive hot water received from the facility or the different facility. Moreover, the terminal flash vessel further includes the liquid outlet fluidly that is coupled to a repressurization pump. The repressurization pump is further coupled to an outlet of the system. Moreover, the outlet of the system is fluidically coupled to a heat exchange mechanism associated with the hot water received from the facility or the different facility.
In some embodiments, the system further includes a desuperheater train that includes at least one desuperheater. Each desuperheater in the desuperheater train includes an outlet that is configured to inject hot water received from the facility or a different facility into the compressor train.
In some embodiments, at least one desuperheater of the desuperheater train is configured to control a flow rate of fluid through the desuperheater.
In some embodiments, in accordance with a determination that a temperature and/or a pressure associated with the compressor train satisfies a first pressure and/or a first temperature, the controller is configured to modify the flow rate of fluid through the desuperheater.
In some embodiments, the system includes a coefficient of performance greater than 65 percent of a corresponding Carnot efficiency.
In some embodiments, a flash vessel in the flash vessel train includes a continuous blowdown. The continuous blowdown is configured to remove a contaminant accommodated by the flash vessel.
In some embodiments, the system further includes a boiler that is disposed interposing between and fluidly coupled to an output of a terminal compressor in the compressor train and the outlet of the compressor train.
In some embodiments, the system further includes a steam accumulator that is disposed interposing between and fluidly coupled to an output of a terminal compressor in the compressor train and the outlet of the compressor train.
In some embodiments, the compressor train includes between two and twenty compressors, inclusive.
In some embodiments, the compressor train includes m compressors, in which m is an integer greater than two. Moreover, m is selected in accordance with a temperature of the high-pressure steam and a temperature of hot water received from the facility or a different facility.
In some embodiments, each compressor in the compressor train and each flash vessel in the flash vessel train share a one-to-one relationship.
In some embodiments, the compressor train includes a first compressor and a second compressor. The first compressor includes a first size, and the second compressor includes a second size less than the first size. Moreover, the first compressor is coupled upstream of the second compressor in the compressor train.
In some embodiments, the compressor train includes a third compressor that is interposing between and fluidly coupled to the first compressor and the second compressor. The third compressor includes either the first size or the second size.
In some embodiments, each compressor in the compressor train includes a compression ratio of less than 2.5.
In some embodiments, the outlet of the compressor train is configured to provide the high-pressure steam at a pressure between 50 pounds per square inch gauge (PSIg) (3.4 Barg) and 315 PSIg (21.7 Barg), inclusive.
In some embodiments, the controller is configured to modify a rotational velocity of a respective compressor in the compressor train, thereby maintaining a pressure of the outlet of the compressor train.
In some embodiments, a flash vessel in the flash vessel train comprises a second liquid outlet fluidly configured to selectively remove fluid from a corresponding flash vessel.
In some embodiments, the system further includes a controller in electronic communication with the second liquid outlet. In some such embodiments, the controller is configured to control the selective removal of fluid from the flash vessel.
In some embodiments, in accordance with a determination that a temperature and/or a pressure associated with the compressor train satisfies a first pressure and/or a first temperature, the controller is configured to modify a flow rate of fluid through the desuperheater.
In some embodiments, the series of at least two compressors includes at least four compressors. In some such embodiments, the at least four compressors is disposed in a herringbone array configuration.
In some embodiments, the system further includes a water loop. In some embodiments, the water loop includes an upstream portion and a downstream portion. In some embodiments, the downstream portion is configured to receive the hot water from the same or a different facility. In some embodiments, the upstream portion configured to supply cooling water to the same or the different facility. Moreover, in some embodiments, the water loop is heated by the same or the different facility.
The systems, methods, and apparatuses of the present disclosure have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
Systems, methods, and apparatuses for producing high-pressure steam are provided. A compressor train includes a series of at least two compressors, an inlet of the compressor train, and an outlet of the compressor train. In some embodiments, each compressor of the compressor train is a centrifugal compressor. The outlet of the compressor train is configured to provide high-pressure steam to a facility, which allows for the compressor train to be coupled to the facility. In some embodiments, the compressor train is coupled (e.g., directly connected) to the facility. A flash vessel train includes a series of at least two flash vessels. The series of at least two flash vessels includes a terminal flash vessel at one end of the flash vessel train. In some embodiments, the flash vessel train is configured to transform heat associated with hot water received by the system into latent heat. Furthermore, a vapor outlet of the terminal flash vessel is fluidly coupled to the inlet of the compressor train. Additionally, the system includes vapor outlets of a remainder of the series of at least two flash vessels that are fluidly coupled between compressors of the series of at least two compressors. In this way, each flash vessel of the flash vessel train produces a low-pressure steam that is received by a respective compressor of the compressor train in order to increase a pressure of the low-pressure steam, such as in order to produce high-pressure steam.
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For instance, a first compressor could be termed a second compressor, and, similarly, a second compressor could be termed a first compressor, without departing from the scope of the present disclosure. The first compressor and the second compressor are both compressors, but they are not the same compressor.
The terminology used in the present disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The foregoing description included example systems, methods, techniques, instruction sequences, and computing machine program products that embody illustrative implementations. For purposes of explanation, numerous specific details are set forth in order to provide an understanding of various implementations of the inventive subject matter. It will be evident, however, to those skilled in the art that implementations of the inventive subject matter may be practiced without these specific details. In general, well-known instruction instances, protocols, structures, and techniques have not been shown in detail.
The foregoing description, for purpose of explanation, has been described with reference to specific implementations. However, the illustrative discussions below are not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The implementations are chosen and described in order to best explain the principles and their practical applications, to thereby enable others skilled in the art to best utilize the implementations and various implementations with various modifications as are suited to the particular use contemplated.
In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will be appreciated that, in the development of any such actual implementation, numerous implementation-specific decisions are made in order to achieve the designer's specific goals, such as compliance with use case- and business-related constraints, and that these specific goals will vary from one implementation to another and from one designer to another. Moreover, it will be appreciated that such a design effort might be complex and time-consuming, but nevertheless be a routine undertaking of engineering for those of ordering skill in the art having the benefit of the present disclosure.
As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
As used herein, the term “about” or “approximately” can mean within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which can depend in part on how the value is measured or determined, e.g., the limitations of the measurement system. For example, “about” can mean within 1 or more than 1 standard deviation, per the practice in the art. “About” can mean a range of ±20%, ±10%, ±5%, or ±1% of a given value. Where particular values are described in the application and claims, unless otherwise stated, the term “about” means within an acceptable error range for the particular value. The term “about” can have the meaning as commonly understood by one of ordinary skill in the art. The term “about” can refer to ±10%. The term “about” can refer to ±5%.
As used herein, the term “epoch” means a predefined period of time.
Furthermore, the terms “compressor” and “blower” are used interchangeably herein unless expressly stated otherwise.
The terms “flash vessel” and “knockout drum” are used interchangeably herein unless expressly stated otherwise.
The terms “steam” and “water vapor” are used interchangeably herein unless expressly stated otherwise.
Moreover, the term “stream” as used herein means any material moving or en route, directly or indirectly, from one location to another. In some embodiments, a stream is still a stream even if it is temporarily stationary for any epoch. In some embodiments, it will be understood that if the present disclosure refers to a particular stream, this does not necessarily refer to a single pipe or other physical conveyance.
Furthermore, when a reference number is given an “ith” denotation, the reference number refers to a generic component, set, or embodiment. For instance, a compressor termed “compressor i” refers to the ith compressor in a plurality of compressors (e.g., a compressor 204-i in a plurality of compressors 204).
In some embodiments, the system 104 is coupled to one or more facilities (e.g., first facility 102-1 of
Referring to
One of skill in the art of the present disclosure will appreciate that temperature rise and mechanical stresses within a respective compressor limit the maximum pressure differential provided by any stage of the respective compressor. Accordingly, in order to provide the high-pressure steam 140 that is utilizable by the facility 102, the compressor train 202 includes a series of at least two compressors (e.g., first compressor 204-1 of any of
In some embodiments, the compressor train 202 includes m compressors 204, in which m is an integer, such as an integer greater than two. In some embodiments, m is at least two and less than twenty-one. Moreover, in some embodiments, m is selected for the system 104 in accordance with one or more input parameters (e.g., parameters 916 of
In some embodiments, the series of at least two compressors 204 is configured such that the at least two compressors 204 in the series of at least two compressors 204 are fluidically coupled in series. In some embodiments, the series of at least two compressors 204 are coupled, at least in part, fluidically in series, which allows for a stream of medium to flow from a first compressor 204-1 in the series of at least two compressors 204 into a second compressor 204-2 in the series of at least two compressors 204. For instance, in some embodiments, the series of at least two compressors 204 includes a pathline through both the first compressor 204-1 and the second compressor 204-2 when the series of at least two compressors 204 are coupled, at least in part, fluidically in series. In some embodiments, the series of at least two compressors 204 is configured such that each compressor in the series of at least two compressors 204 is disposed in a straight line, a substantially straight line, an arc line, or a substantially arc line. In some embodiments, the series of at least two compressors 204 is configured such that each compressor in the series of at least two compressors 204 is disposed in an array, such as an array of two or more rows of parallel, or substantially parallel lines. For instance, in some embodiments, the series of at least two compressors 204 is configured such that each compressor in the series of at least two compressors 204 is disposed in a herringbone array, in which a first line associated with a first set of compressors 204 in the series of at least two compressors 204 has a first slope and a second set of compressors 204 in the series of at least two compressors 204 has a second slope opposite the first slope. As a non-limiting example, referring briefly to
Y=B+(A*sin(k*X)), in which Y is first position of a respective compressor 204 of the compressor train 202, B is a position of a terminal compressor 204 of the compressor train 202, A is the constant amplitude, k is the constant frequency, and X is a second position of the respective compressor. However, the present disclosure is not limited thereto.
In some embodiments, the compressor train 202 includes the first compressor 202-1 and the second compressor 202-2. The first compressor 202-1 includes a first optimal inlet volumetric flow rate. Moreover, in some such embodiment, the second compressor 202-2 includes a second optimal inlet volumetric flow rate that is greater than the first optimal inlet volumetric flow rate of the first compressor 202-1. Moreover, in some such embodiments, the first compressor 204-1 is coupled upstream of the second compressor 204-2 in the compressor train 202.
Referring to
In some embodiments, the compressor train 202 includes a third compressor 204-3 that is adjacent to and interposing between the first compressor 204-1 and the second compressor 204-2. As a non-limiting example, referring briefly to
In some embodiments, each compressor 204 in the compressor train 202 includes a compression ratio of less than 2.5. For instance, in some embodiments, the compression ratio of a respective compressor 204 is defined by a ratio of an absolute discharge pressure against the absolute suction pressure of the respective compressor 204. Said otherwise, in some such embodiments, the compression ratio of the respective compressor 204 is the ratio of a pressure at an inlet of the respective compressor 204 (e.g., inlet 224) and a pressure of an outlet of the respective compressor 204. Accordingly, a higher compression ratio yields a greater pressure increase when compressing a fluid via the respective compressor 204.
In some embodiments, the series of at least two compressors 204 includes one or more centrifugal compressors 204, one or more piston compressors 204, one or more rotary compressors 204, one or more screw compressors 204, or a combination thereof.
Furthermore, in some embodiments, each compressor 204 in the series of at least two compressors 204 of the compressor train 202 is a single-stage compressor 204. For instance, in some embodiments, each stage of each compressor 204 is associated with a corresponding motor (e.g., power supply 986 of
In some embodiments, the controller 1906 is configured to modify a rotational velocity of a respective compressor 204 in the series of at least two compressors 204 of the compressor train 202. For instance, in some embodiments, the controller 1906 is configured to modify the rotational velocity of each respective compressor 204 in the compressor train 202 in order to maintain a pressure of the outlet of the compressor train 202, such as in order to maintain an outlet pressure of the high-pressure steam 140 at a pressure of at least 80 PSI. However, the present disclosure is not limited there. For instance, in some embodiments, the controller is configured to increase a rotational velocity of the first compressor 202-1, decrease the rotational velocity of the first compressor 202-1, increase the rotational velocity of the second compressor 202-2, decrease the rotational velocity of the second compressor 202-2, or a combination thereof (e.g., both decrease the rotational velocity of the first compressor 202-1 and increase the rotational velocity of the second compressor 202-2, etc.). However, the present disclosure is not limited thereto.
Moreover, the compressor train 202 includes an inlet (e.g., first inlet 216-1 of any of
Furthermore, the compressor train 202 includes an outlet (e.g., outlet 208 of any of
Referring to
In some embodiments, the outlet of the compressor train 202 is configured to provide the high-pressure steam 140 at a pressure between 50 PSI (3.44 Bar) and 315 PSI (21.7 Bar). For instance, in some embodiments, the compressor train 202 is configured to provide the high-pressure steam 140 to an existing steam header of a facility 102 at a pressure between 50 PSI (3.44 Bar) and 300 PSI (20.7 Bar), between 50 PSI (3.44 Bar) and 275 PSI (19.0 Bar), between 50 PSI (3.44 Bar) and 250 PSI (17.2 Bar), between 50 PSI (3.44 Bar) and 225 PSI (15.5 Bar), between 50 PSI (3.44 Bar) and 200 PSI (13.8 Bar), between 50 PSI (3.44 Bar) and 175 PSI (12.1 Bar), between 50 PSI (3.44 Bar) and 150 PSI (10.3 Bar), between 50 PSI (3.44 Bar) and 125 PSI (8.62 Bar), between 50 PSI (3.44 Bar) and 100 PSI (6.89 Bar), between 110 PSI (7.58 Bar) and 315 PSI (21.7 Bar), between 110 PSI (7.58 Bar) and 300 PSI (20.7 Bar), between 110 PSI (7.58 Bar) and 275 PSI (19.0 Bar), between 110 PSI (7.58 Bar) and 250 PSI (17.2 Bar), between 110 PSI (7.58 Bar) and 225 PSI (15.5 Bar), between 110 PSI (7.58 Bar) and 200 PSI (13.8 Bar), between 110 PSI (7.58 Bar) and 175 PSI (12.1 Bar), between 110 PSI (7.58 Bar) and 150 PSI (10.3 Bar), between 110 PSI (7.58 Bar) and 125 PSI (8.62 Bar), between 170 PSI (11.7 Bar) and 315 PSI (21.7 Bar), between 170 PSI (11.7 Bar) and 300 PSI (20.7 Bar), between 170 PSI (11.7 Bar) and 275 PSI (19.0 Bar), between 170 PSI (11.7 Bar) and 250 PSI (17.2 Bar), between 170 PSI (11.7 Bar) and 225 PSI (15.5 Bar), between 170 PSI (11.7 Bar) and 200 PSI (13.8 Bar), between 170 PSI (11.7 Bar) and 175 PSI (12.1 Bar), between 230 PSI (15.6 Bar) and 315 PSI (21.7 Bar), 230 PSI (15.6 Bar) and 300 PSI (20.7 Bar), between 230 PSI (15.6 Bar) and 275 PSI (19.0 Bar), between 230 PSI (15.6 Bar) and 250 PSI (17.2 Bar), between 290 PSI (20.0 Bar) and 315 PSI (21.7 Bar), or between 290 PSI (20.0 Bar) and 300 PSI (20.7 Bar), inclusive. In some embodiments, the compressor train 202 is configured to provide the high-pressure steam 140 to an existing steam header of a facility 102 at a pressure of at least 50 PSI (3.44 Bar), at least 70 PSI (4.83 Bar), at least 90 PSI (6.21 Bar), at least 110 PSI (7.58 Bar), at least 130 PSI (8.96 Bar), at least 150 PSI (10.3 Bar), 170 PSI (11.7 Bar), at least 190 PSI (13.1 Bar), at least 210 PSI (14.5 Bar), at least 230 PSI (15.6 Bar), at least 250 PSI (17.2 Bar), at least 270 PSI (18.6 Bar), at least 290 PSI (20.0 Bar), or at least 310 PSI (21.4 Bar). In some embodiments, the compressor train 202 is configured to provide the high-pressure steam 140 to an existing steam header of a facility 102 at a pressure of at most 50 PSI (3.44 Bar), at most 70 PSI (4.83 Bar), at most 90 PSI (6.21 Bar), at most 110 PSI (7.58 Bar), at most 130 PSI (8.96 Bar), at most 150 PSI (10.3 Bar), 170 PSI (11.7 Bar), at most 190 PSI (13.1 Bar), at most 210 PSI (14.5 Bar), at most 230 PSI (15.6 Bar), at most 250 PSI (17.2 Bar), at most 270 PSI (18.6 Bar), at most 290 PSI (20.0 Bar), or at most 310 PSI (21.4 Bar). Accordingly, the system 104 is capable of providing high-pressure steam 140 to the facility 102 at a pressure sufficient such that the high-pressure steam 140 can be directly utilized by the facility 102. In some embodiments, all pressures in this paragraph are quotes as gauge pressures. In some embodiments, all pressures in the present disclosure are gauge pressures, unless expressly stated otherwise.
The system 104 further includes the flash vessel train (e.g., flash vessel train 210 of any of
In some embodiments, each compressor 204 in the compressor train 202 and each flash vessel 212 in the flash vessel train 210 share a one-to-one relationship. For instance, referring briefly to
Similar to the series of at least two compressors 204 of the compressor train 202, the series of at least two flash vessels 212 of the flash vessel train 210 are coupled, at least in part, fluidically in series, which allows for a stream of medium to flow from one flash vessels 212 in the series of at least two flash vessels 212 into another flash vessel 212 in the series of at least two flash vessels. For instance, in some embodiments, referring briefly to
Accordingly, the series of at least two flash vessels 212 includes a terminal flash vessel 212 at one end of the flash vessel train 210. For instance, referring briefly to
In some embodiments, each flash vessel 212 in the series of at least two flash vessels 212 is configured to be maintained (e.g., by control module 906 of
In some embodiments, one or more flash vessels 212 in the flash vessel train 210 is disposed above an inlet (e.g., second inlet 224-2 of any of
Accordingly, in some embodiments, each flash vessel 212 in the series of at least two flash vessels 212 includes two or more outlets. For instance, in some embodiments, a vapor outlet (e.g., vapor outlet 226-1 of flash vessel 212-1 of any of
Additionally, the system 104 includes vapor outlets 226 of a remainder of the series of at least two flash vessels 212 that are fluidly coupled between compressors 204 of the series of at least two compressors 204 of the compressor train 202. As a non-limiting example, referring briefly to
In some embodiments, the flash vessel train 210 further includes an inlet (e.g., second inlet 224-2 of first flash vessel 212-1 of
In some embodiments, the inlet 224 of the flash vessel train 210 is an inlet of the terminal flash vessel 212-1 of the flash vessel train 210. For instance, in some embodiments, a second inlet 224-2 of the terminal flash vessel 212-1 is configured to receive hot water received from hot water source 110, which is supplied to an interior of the terminal flash vessel 212-1.
In some embodiments, the remainder of the series of at least two flash vessels 212 each includes a liquid outlet (e.g., second liquid outlet 228-2 of any of
In some embodiments, the terminal flash vessel 212-1 includes a liquid outlet (e.g., first liquid outlet 228-1 of any of
In some embodiments, the liquid outlet 228-1 of the terminal flash vessel 212-1 is fluidly coupled to a repressurization pump (e.g., repressurization pump 220 of any of
In some embodiments, the system 104 includes one or more valves (e.g., first valve 218-1 of any of
In some embodiments, the system 104 further includes a controller (e.g., control module 906 of
In some embodiments, the controller 906 is configured to maintain a respective centrifugal compressor 204 in the compressor train 202 from stonewalling or surging. For instance, in some embodiments, the controller 906 is configured to determine if a mass flow rate associated with the respective centrifugal compressor 204 in the compressor train 202 satisfies a first threshold mass flow rate that is associated with a stonewall condition for flow within the respective centrifugal compressor 204 and/or a second threshold mass flow rate that is associated with a surge condition for flow within the respective centrifugal compressor 204. However, the present disclosure is not limited thereto. As a non-limiting example, each respective compressor 204 has a minimal mass flow rate that the respective compressor 204 is able to stably operate at, which is the surge condition.
In some embodiments, the system 104 further includes a desuperheater train (e.g., desuperheater train 230 of
Each desuperheater 232 in the desuperheater train 230 includes an outlet that is configured to inject hot water received from the facility 102 or a different facility 102 into the compressor train 202. For instance, in some embodiments, each desuperheater 232 in the desuperheater train 230 is configured to receive a portion of the hot water received from hot water source 110 supplied to the inlet 224-2 of the terminal flash vessel 212-1, which allows for the desuperheater train 230 to utilize the same source of the hot water received from hot water source 110. However, the present disclosure is not limited thereto. In some embodiments, each desuperheater 232 of the desuperheater train 230 is configured to remove heat (e.g., superheat) that is added to the low-pressure steam 206 by each compressor 204 of the compressor train 202 by injecting the hot water received from the hot water source 110 into the low-pressure steam 206 between compressors 204. Accordingly, in some such embodiments, the water injected by the desuperheater 232 evaporates, which removes the superheat from the low-pressure steam 206 and increases the mass flow of the low-pressure steam 206 through the system 104. In some embodiments, the desuperheater train 230 is configured such that each compressor 204 of the compressor train 202 does not require an interstage cooler. Moreover, in some embodiments, a high efficiency of the system 104 is enabled by utilizing the desuperheater train 230 to provide desuperheating of low-pressure steam 206 when compressed by the compressor 204, which allows the system 104 to operate at or approximately at to a water saturation line without heat loss that would otherwise be incurred due to intercoolers or entropy loss due from high amounts of superheat.
In some embodiments, each compressor 204 in the compressor train 202 and each desuperheater 232 in the desuperheater train 230 share a one-to-one relationship. For instance, referring briefly to
In some embodiments, the system 104 includes a coefficient of performance (COP) greater than 65 percent of a corresponding Carnot efficiency, in which the Carnot efficiency represents the highest possible efficiency of heat pump systems operating between a higher temperature source and a lower temperature source. For instance, in some embodiments, the system 104, as a heat pump system 104 operating between two sources of different thermal temperatures (e.g., higher temperature hot water source 110 and lower temperature cooling water source 120, lower temperature hot water source 110 and higher temperature high-pressure steam, higher temperature high-pressure steam and lower temperature cooling water source 120, or a combination thereof) has an associated efficiency rating, which is in determine in accordance with a coefficient of performance (COP), an energy efficiency ratio (EER), or the like. In some embodiments, the COP is determined in accordance with a value of heat transferred from a lower temperature source divided by network input, which is a value of heat transferred to a higher temperature source less a refrigerant effect value. For instance, in some embodiments, the COP of the system 104 is determined in accordance with a temperature of the high-pressure steam 140 produced by the system 104 and a temperature of the hot water source 110 that provides hot water received by the system. In some embodiments, the COP of the system 104 is determined in accordance with a ratio of an electrical power consumption of the system 104 against an output thermal power of the system 104. In some embodiments, the corresponding percentage Carnot efficiency was determined in accordance with a ratio of a Carnot COP against an actual COP of the system 104. Additional details and information regarding the COP and/or Carnot efficiency of a heat pump system is found at Sadegh, et al., 2018, “Marks' Standard Handbook for Mechanical Engineers,” McGraw-Hill Education., print, which is hereby incorporated by reference in its entirety for all purposes.
In some embodiments, a flash vessel 212 in the flash vessel train 210 includes a blowdown (e.g., blowdown 170 of
In some embodiments, the blowdown 170 is associated with a second liquid outlet of a corresponding flash vessel 212 in the flash vessel train 210. In some embodiments, the blowdown 170 is fluidly configured to selectively remove fluid from a corresponding flash vessel 212.
In some embodiments, the controller 906 is in electronic communication with the second liquid outlet of the corresponding flash vessel 212. In some embodiments, the controller is configured to control the selective removal of fluid.
In some embodiments, a flash vessel 212 in the flash vessel train 210 includes a deaerator (e.g., deaerator 240 of
In some embodiments, the system 104 further includes one or more boilers (e.g., boiler 236 of
In some embodiments, the system 104 further includes a steam accumulator (e.g., steam accumulator 238 of
The systems, methods, and apparatuses of the present disclosure have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
Furthermore, the systems, methods, and apparatuses of the present disclosure avoid an intermediate refrigerant and associated losses transferring heat to and/or from the intermediate refrigerant. Rather, the systems, methods, and apparatuses of the present disclosure generated high-pressure steam directly from the hot water source 110 and directly compressed with low-pressure steam generated by a flash vessel train 210 using a multi-stage mechanical vapor recompression (MVR) compressor train 202 having a series of at least two centrifugal compressors 204. In some embodiments, the system 104 included a desuperheater train 230 including a desuperheater 232 disposed between each compressor 204 of the compressor train 202.
Accordingly, in some embodiments, the systems, methods, and apparatuses of the present disclosure achieved high COP (e.g., a COP of 4.5, a COP of 4.0, etc.) by leveraging high efficiency associated with utilizing one or more centrifugal compressors 204 in the compressor train 202 and avoiding superheat losses associated with high compression ratio compressors 204 typically found in conventional high-temperature industrial heat pumps technology.
In some embodiments, primary competitive advantages of the systems, methods, and apparatuses of the present disclosure over conventional high-temperature industrial heat pump technology were the ability to produce steam at a higher pressure, produce the high-pressure steam with a higher coefficient of performance, use a more attractive refrigerant in the form of water, or a combination thereof.
In some embodiments, conventional high-temperature industrial heat pump technology using one or more hydrofluorocarbons (HFC) refrigerants and/or one or more hydrofluoroolefins (HFO) refrigerants that produced thermal energy at temperatures up to 320 degrees Fahrenheit (160° C.). In some embodiments, the conventional high-temperature industrial heat pump was unable to produce steam directly, but rather must be used in combination with an unfired steam generator, which introduces a 20° F. nominal temperature drop. As a result, the maximum saturated steam pressure the conventional high-temperature industrial heat pump can produce was 3.5 Barg (50 PSIg), which was not sufficient to address medium pressure (e.g., between 3.5 Barg and 20 Barg) applications common to industrial facilities 102. In addition, the conventional high-temperature industrial heat pump had a relatively low coefficient of performance of that is less than 3.0, resulting in high electricity demand and high operating costs.
Furthermore, the one or more HFC refrigerants have high global warming potential (GWP). In contrast, the one or more HFO refrigerants have low GWP but prohibitive cost. In contrast, the heat pump system 104 of the systems, methods, and apparatuses of the present disclosure directly produced high-pressure steam 140 at pressures up to 20 Barg (290 PSIg). Moreover, the heat pump system 104 of the systems, methods, and apparatuses of the present disclosure produced this high-pressure steam 140 with a COP that is 50% higher than the conventional high-temperature industrial heat pump when performing under the same operating conditions, which resulted in proportionally lower electric demand and operating costs for the heat pump system 104 of the systems, methods, and apparatuses of the present disclosure. Moreover, since the heat pump system 104 of the systems, methods, and apparatuses of the present disclosure used water as a refrigerant, the heat pump system 104 provided the benefits of being low-cost, safe, non-toxic, zero-GWP, or a combination thereof.
Moreover, conventional high-temperature industrial heat pump that were CO2-based utilized a low-cost and low-GWP refrigerant in the form of CO2. However, the conventional high-temperature industrial CO2 heat pump was limited to temperatures of 238° F. (114° C.) or less due to the high pressures required by the refrigerant. In this way, one of skill in the art will appreciate that, although 238° F. (114° C.) is above the atmospheric boiling point of water, the conventional high-temperature industrial CO2-based heat pump was not able to generate adequate high-pressure steam because the conventional high-temperature industrial CO2-based heat pump required a low fluid return temperature of 203° F. (95° C.) or less, which directly dictated an ability of the conventional high-temperature industrial CO2-based heat pump to drive a steam generator.
Furthermore, conventional high-temperature industrial heat pump that were ammonia-based heat pump have the high-pressure characteristics that limited the conventional high-temperature industrial ammonia-based heat pump to a maximum output temperature of 203° F. (95° C.), which was unsuitable for steam generation.
Referring to
In some embodiments, primary competitive advantages of the systems, methods, and apparatuses of the present disclosure over conventional electric boiler technology was a higher COP by the of the systems, methods, and apparatuses of the present disclosure, which led to lower operating costs. Furthermore, the conventional electric boiler technologies were determined to have a COP approaching 1.0 and required approximately 295 kilowatt hours (kWh) of electricity to produce 1 klb of steam. When the price of an industrial electricity was assumed to be 0.12 dollars ($) per kWh, the conventional electric boiler required $35.40 in energy costs per klb of steam generated by the conventional electric boiler technology.
In contrast, even though the COP of the systems, methods, and apparatuses of the present disclosure depended on the temperature of the hot water source 110 received by the system 104, the temperature of cooling water source 120 associated with the system 104, and a common operating condition that sourced 85° F. hot water from the facility and produced 10 Barg (130 PSIg) high-pressure steam 140. At these operating conditions, the systems, methods, and apparatuses of the present disclosure had a COP of 3.0. Moreover, the systems, methods, and apparatuses of the present disclosure required three times less electricity than the conventional electric boiler of 97 kWh per klb of high-pressure steam. Additionally, the systems, methods, and apparatuses of the present disclosure provided three times lower energy cost than the conventional electric boiler, at a cost of $11.80 per klb of high-pressure steam.
Furthermore, the operating costs of the systems, methods, and apparatuses of the present disclosure were comparable or lower than the conventional natural gas boiler technologies. For instance, new conventional natural gas boiler technologies with economizers have a COP of 0.85 and required approximately 11.8 therms (thm) of natural gas to produce 1 klb of high-pressure steam. At a natural gas price of $1.30 per thm, conventional natural gas boiler technologies require $15.34 of energy costs per klb of steam, which is greater than the $11.80/klb achieved by the systems, methods, and apparatuses of the present disclosure.
In some embodiments, the method 800 is conducted by a heat pump system 104 in
Referring to block 804 in
In some embodiments, the heat pump system 104 is connected to a hot water source (e.g., hot water source 110 of any of
Furthermore, in some embodiments, the heat pump system 104 is connected to a steam condensate return (e.g., steam condensate return 214 of any of
In some embodiments, the connecting the heat pump system 104 between the hot water source 110 of the facility 102 and the existing steam header of the same or the different facility 102 further connects the heat pump system 104 to one or more utilities of the facility 102. For instance, referring briefly to
It is noted that in various embodiments of this application, “connect” broadly means “directly connect” or “indirectly connected” via an additional structure.
Referring to block 806 in
In some embodiments, the system 104 further includes a water loop, such as closed water loop configured to. In some embodiments, the water loop includes an upstream portion and a downstream portion. In some embodiments, the downstream portion is configured to receive the hot water from the same or a different facility. In some embodiments, the upstream portion configured to supply cooling water to the same or the different facility. Moreover, in some embodiments, the water loop is heated by the same or the different facility.
Referring to block 808 in
For instance, in some embodiments, the heat pump system 104 includes a compressor train (e.g., compressor train 202 of any of
More particularly, in some embodiments, the passing the hot water through the heat pump system 104 to produce the high-pressure steam 140 includes expanding the hot water at a flash vessel (e.g., first flash vessel 212-1 of any of
In some embodiments, the method 800 is configured to produce the first low-pressure steam 206-1 a first pressure between 0.256 pounds per square inch (PSI) (17.7 milliBar (mBar)) and 3.72 PSI (257 mBar), between 0.256 PSI (17.7 mBar) and 3.2 PSI (221 mBar), between 0.256 PSI (17.7 mBar) and 2.7 PSI (186 mBar), between 0.256 PSI (17.7 mBar) and 1.2 PSI (82.7 mBar), between 0.256 PSI (17.7 mBar) and 0.7 PSI (48.3 mBar), between 0.35 PSI (24.1 mBar) and 3.72 PSI (257 mBar), between 0.35 PSI (24.1 mBar) and 3.2 PSI (221 mBar), between 0.35 PSI (24.1 mBar) and 2.7 PSI (186 mBar), between 0.35 PSI (24.1 mBar) and 1.2 PSI (82.7 mBar), between 0.35 PSI (24.1 mBar) and 0.7 PSI (48.3 mBar), between 0.85 PSI (58.6 mBar) and 3.72 PSI (257 mBar), between 0.85 PSI (58.6 mBar) and 3.2 PSI (221 mBar), between 0.85 PSI (58.6 mBar) and 2.7 PSI (186 mBar), between 0.85 PSI (58.6 mBar) and 1.2 PSI (82.7 mBar), between 1.35 PSI (93.1 mBar) and 3.72 PSI (257 mBar), between 1.35 PSI (93.1 mBar) and 3.2 PSI (221 mBar), between 1.35 PSI (93.1 mBar) and 2.7 PSI (186 mBar), between 1.85 PSI (128 mBar) and 3.72 PSI (257 mBar), between 1.85 PSI (128 mBar) and 3.2 PSI (221 mBar), between 1.85 PSI (128 mBar) and 2.7 PSI (186 mBar), between 2.35 PSI (162 mBar) and 3.72 PSI (257 mBar), between 2.35 PSI (162 mBar) and 3.2 PSI (221 mBar), between 2.35 PSI (162 mBar) and 2.7 PSI (186 mBar), between 2.85 PSI (197 mBar) and 3.72 PSI (257 mBar), between 2.85 PSI (197 mBar) and 3.2 PSI (221 mBar), or between 3.35 PSI (231 mBar) and 3.72 PSI (257 mBar), inclusive. In some embodiments, the first pressure is at least 0.256 PSI (17.7 mBar), at least 0.363 PSI (25 mBar), at least 0.35 PSI (24.1 mBar), at least 0.5 PSI (34.5 mBar), at least 0.7 PSI (48.3 mBar), at least 0.85 PSI (58.6 mBar), at least 1 PSI (68.9 mBar), at least 1.2 PSI (82.7 mBar), at least 1.3 PSI (89.6 mBar), at least 1.35 PSI (93.1 mBar), at least 1.5 PSI (103 mBar), at least 1.65 PSI (114 mBar), at least 1.85 PSI (128 mBar), at least 2 PSI (138 mBar), at least 2.2 PSI (152 mBar), at least 2.35 PSI (162 mBar), at least 2.5 PSI (172 mBar), at least 2.7 PSI (186 mBar), at least 2.85 PSI (197 mBar), at least 3 PSI (207 mBar), at least 3.2 PSI (221 mBar), at least 3.35 PSI (231 mBar), at least 3.5 PSI (241 mBar), or at least 3.72 PSI (257 mBar). In some embodiments, the first pressure is at most 0.256 PSI (17.7 mBar), at most 0.363 PSI (25 mBar), at most 0.35 PSI (24.1 mBar), at most 0.5 PSI (34.5 mBar), at most 0.7 PSI (48.3 mBar), at most 0.85 PSI (58.6 mBar), at most 1 PSI (68.9 mBar), at most 1.2 PSI (82.7 mBar), at most 1.3 PSI (89.6 mBar), at most 1.35 PSI (93.1 mBar), at most 1.5 PSI (103 mBar), at most 1.65 PSI (114 mBar), at most 1.85 PSI (128 mBar), at most 2 PSI (138 mBar), at most 2.2 PSI (152 mBar), at most 2.35 PSI (162 mBar), at most 2.5 PSI (172 mBar), at most 2.7 PSI (186 mBar), at most 2.85 PSI (197 mBar), at most 3 PSI (207 mBar), at most 3.2 PSI (221 mBar), at most 3.35 PSI (231 mBar), at most 3.5 PSI (241 mBar), or at most 3.72 PSI (257 mBar).
In some embodiments, the expanding of the hot water at the flash vessel 212 when passing the hot water through the heat pumps system 104 further produces cooled water (e.g., condensate) from the hot water. In some embodiments, the cooled water produced by the flash vessel 212 has a lower temperature than the hot water. Said otherwise, in some such embodiments, a third temperature of the cooled water produced by the flash vessel 212 is less than the first temperature of the first temperature of the hot water source 110. Moreover, in some embodiments, the third temperature of the cooled water is less than the second temperature of the low-pressure steam 206 produced by the flash vessel 212. Accordingly, by expanding the hot water at the flash vessel 212, the heat pump system 104 increases the thermal energy of a portion of the hot water received from the hot water source 110 by forming the low-pressure steam 206, which is transferred from the cooled water produced by the flash vessel 212. For instance, in some embodiments, the facility 102 is configured to utilize the high-pressure steam 140 produced by the system 104, which, in turn, produces the cooling water source 120 at the third temperature that is less than the first temperature of the hot water received from the hot water source 31-0. However, the present disclosure is not limited thereto.
Furthermore, in some embodiments, a pressure in the flash vessel 212 is less than a saturation pressure of the hot water. For instance, in some embodiments, the passing the hot water through the heat pumps system 104 further includes compressing the low-pressure steam 206 to a first higher-pressure steam having a pressure higher than the low-pressure steam. For instance, referring briefly to
In some embodiments, the passing the hot water through the heat pumps system 104 further includes introducing hot water into the first higher-pressure steam (e.g., first low-pressure steam 206-1 produced by first flash vessel 212-1 of any of
In some embodiments, the passing the hot water through the heat pumps system 104 further includes repeating the compressing and introducing steps a desired number of times to produce the high-pressure steam.
In some embodiments, the desired number of times is greater than one. In some embodiments, the desired number of times is greater than one but less than twenty-one. In some embodiments, the desired number of times is between two and twenty, between two and seventeen, between two and fifteen, between two and twelve, between two and nine, between two and six, between two and three, between three and twenty, between three and seventeen, between three and fifteen, between three and twelve, between three and nine, between three and six, between five and twenty, between five and seventeen, between five and fifteen, between five and twelve, between five and nine, between five and six, between seven and twenty, between seven and seventeen, between seven and fifteen, between seven and twelve, between seven and nine, between nine and twenty, between nine and seventeen, between nine and fifteen, between nine and twelve, between eleven and twenty, between eleven and seventeen, between eleven and fifteen, between eleven and twelve, between thirteen and twenty, between thirteen and seventeen, between thirteen and fifteen, between fifteen and twenty, between fifteen and seventeen, or between seventeen and twenty, inclusive. In some embodiments, the desired number of times is at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, at least ten, at least eleven, at least twelve, at least thirteen, at least fourteen, at least fifteen, at least sixteen, at least seventeen, at least eighteen, at least nineteen, or at least twenty. In some embodiments, the desired number of times is at most two, at most three, at most four, at most five, at most six, at most seven, at most eight, at most nine, at most ten, at most eleven, at most twelve, at most thirteen, at most fourteen, at most fifteen, at most sixteen, at most seventeen, at most eighteen, at most nineteen, or at most twenty.
Referring to block 810 in
In some embodiments, the high-pressure steam 140 is supplied from the heat pump system 104 to the same or a different facility 102 at a mass flow rate between 10 kilopounds per hour (klb/hr) and 300 klb/hr, between 10 klb/hr and 250 klb/hr, between 10 klb/hr and 200 klb/hr, between 10 klb/hr and 150 klb/hr, between 10 klb/hr and 100 klb/hr, between 10 klb/hr and 50 klb/hr, between 75 klb/hr and 300 klb/hr, between 75 klb/hr and 250 klb/hr, between 75 klb/hr and 200 klb/hr, between 75 klb/hr and 150 klb/hr, between 75 klb/hr and 100 klb/hr, between 150 klb/hr and 300 klb/hr, between 150 klb/hr and 250 klb/hr, between 150 klb/hr and 200 klb/hr, between 225 klb/hr and 300 klb/hr, or between 225 klb/hr and 250 klb/hr, inclusive. In some embodiments, the mass flow rate of the high-pressure steam produced by the heat pump system 104 is at least 10 klb/hr, at least 25 klb/hr, at least 50 klb/hr, at least 75 klb/hr, at least 100 klb/hr, at least 125 klb/hr, at least 150 klb/hr, at least 175 klb/hr, at least 200 klb/hr, at least 225 klb/hr, at least 250 klb/hr, at least 275 klb/hr, or at least 300 klb/hr. In some embodiments, the mass flow rate of the high-pressure steam produced by the heat pump system 104 is at most 10 klb/hr, at most 25 klb/hr, at most 50 klb/hr, at most 75 klb/hr, at most 100 klb/hr, at most 125 klb/hr, at most 150 klb/hr, at most 175 klb/hr, at most 200 klb/hr, at most 225 klb/hr, at most 250 klb/hr, at most 275 klb/hr, or at most 300 klb/hr.
In the present disclosure, unless expressly stated otherwise, descriptions of devices and systems will include implementations of one or more computers. For instance, and for purposes of illustration in
In some embodiments, the communication network 984 optionally includes the Internet, one or more local area networks (LANs), one or more wide area networks (WANs), other types of networks, or a combination of such networks. Examples of communication networks 984 include the World Wide Web (WWW), an intranet and/or a wireless network, such as a cellular telephone network, a wireless local area network (LAN) and/or a metropolitan area network (MAN), and other devices by wireless communication. The wireless communication optionally uses any of a plurality of communications standards, protocols and technologies, including Global System for Mobile Communications (GSM), Enhanced Data GSM Environment (EDGE), high-speed downlink packet access (HSDPA), high-speed uplink packet access (HSUPA), Evolution, Data-Only (EV-DO), HSPA, HSPA+, Dual-Cell HSPA (DC-HSPDA), long term evolution (LTE), near field communication (NFC), wideband code division multiple access (W-CDMA), code division multiple access (CDMA), time division multiple access (TDMA), Bluetooth, Wireless Fidelity (Wi-Fi) (e.g., IEEE 802.11a, IEEE 802.11ac, IEEE 802.11ax, IEEE 802.11b, IEEE 802.11g and/or IEEE 802.11n), voice over Internet Protocol (VoIP), Wi-MAX, a protocol for e-mail (e.g., Internet message access protocol (IMAP) and/or post office protocol (POP)), instant messaging (e.g., extensible messaging and presence protocol (XMPP), Session Initiation Protocol for Instant Messaging and Presence Leveraging Extensions (SIMPLE), Instant Messaging and Presence Service (IMPS)), and/or Short Message Service (SMS), or any other suitable communication protocol, including communication protocols not yet developed as of the filing date of this document.
In various embodiments, the computer system 900 includes one or more processing units (CPUs) 972, a network or other communications interface 974, and memory 992.
In some embodiments, the computer system 900 includes a user interface 976. The user interface 976 typically includes a display 978 for presenting media, such as a status of a respective instrument (e.g., first instrument 910-1, second instrument 910-2, . . . , instrument Q 912-Q of
In some embodiments, the computer system 900 presents media to a user through the display 978. Examples of media presented by the display 978 include one or more images, a video, audio (e.g., waveforms of an audio sample), or a combination thereof. In typical embodiments, the one or more images, the video, the audio, or the combination thereof is presented by the display 978 through a client application stored in the memory 992. In some embodiments, the audio is presented through an external device (e.g., speakers, headphones, input/output (I/O) subsystem, etc.) that receives audio information from the computer system 900 and presents audio data based on this audio information. In some embodiments, the user interface 976 also includes an audio output device, such as speakers or an audio output for connecting with speakers, earphones, or headphones.
The memory 992 includes high-speed random access memory, such as DRAM, SRAM, DDR RAM, or other random access solid state memory devices, and optionally also includes non-volatile memory, such as one or more magnetic disk storage devices, optical disk storage devices, flash memory devices, or other non-volatile solid state storage devices. The memory 992 may optionally include one or more storage devices remotely located from the CPU(s) 972. The memory 992, or alternatively the non-volatile memory device(s) within memory 992, includes a non-transitory computer readable storage medium. Access to memory 992 by other components of the computer system 900, such as the CPU(s) 972, is, optionally, controlled by a controller. In some embodiments, the memory 992 can include mass storage that is remotely located with respect to the CPU(s) 972. In other words, some data stored in the memory 992 may in fact be hosted on devices that are external to the computer system 900, but that can be electronically accessed by the computer system 900 over an Internet, intranet, or other form of network 984 or electronic cable using communication interface 974.
In some embodiments, the memory 992 of the computer system 900 for producing high-pressure steam stores:
As indicated above, an optional electronic address 904 is associated with the computer system 900. The optional electronic address 904 is utilized to at least uniquely identify the computer system 900 from other devices and components of the distributed system 900, such as other devices having access to the communication network 984 (e.g., facility 102). For instance, in some embodiments, the electronic address 904 is utilized to receive a request from a remote device associated with a first facility 102-1 to initiate producing high-pressure steam for utilization by a second facility 102-2 using the computer system 900. However, the present disclosure is not limited thereto. In some embodiments, the electronic address 904 is utilized to receive the request from the remote device associated with the first facility 102-1 to initiate producing high-pressure steam for utilization by the first facility 102-1 using the computer system 900.
In some embodiments, the computer system 900 includes a control module 906, hereinafter “controller,” that is configured to control one or more operations conducted when producing high-pressure steam. Specifically, the controller 906 is configured to control the one or more operations conducted when producing the high-pressure steam in accordance with a plurality of heuristic instructions. As a non-limiting example, in some embodiments, the plurality of heuristic instructions include one or more proportional, integral, and derivative (PID) loop instructions and/or one or more variable frequency drive (VFD) instructions. For instance, in some embodiments, the controller 906 is in electronic communication with one or more sensors (e.g., sensor 982 of
An instrument 910 is an apparatus, device, mechanism, or a combination thereof that conducts a specific function or functions in the system 104 for producing high-pressure steam, such as for producing a high-pressure steam product (e.g., high-pressure steam of method 800 of
In some embodiments, each task 914 is associated with a function, step, or process in the production of high-pressure steam 140 (e.g., function, step, or process of method 800 of
Moreover, each task 914 includes a set of parameters 916 used in the performance of a function by a respective instrument 910. In some embodiments, each task 914 is a logical dependency of operations that defines the function performed by the respective instrument 910. For instance, in some embodiments, the task 914 is a first operation to run a first instrument 910-1 with a first set of parameters 916 and a second task 914-2 is a second operation to run a second instrument 910-2. As a non-limiting example, in some embodiments, the parameters 916 include a temperature of hot water received from hot water source 110 by the system 104, a pressure of hot water received from hot water source 110 by the system 104, a mass flow rate of hot water received from hot water source 110 by the system 104, a temperature of low-pressure steam 206 produced by the system 104, a pressure of low-pressure steam 206 produced by the system 104, a mass flow rate of low-pressure steam 206 produced by the system 104, a temperature of high-pressure steam 140 produced by the system 104, a pressure of high-pressure steam 140 produced by the system 104, a mass flow rate of high-pressure steam 140 produced by the system 104, a temperature of cooling water received from cooling water source 120 produced by the system 104, a pressure of cooling water received from cooling water source 120 produced by the system 104, a mass flow rate of cooling water received from cooling water source 120 produced by the system 104, a temperature of steam condensate return 214 received by the system 104, a pressure of steam condensate return 214 received by the system 104, a mass flow rate of steam condensate return 214 received by the system 104, and/or the like. As a non-limiting example, in some embodiments, the computer system 900 configures one or more parameters 916 including configuring a flow rate parameter 916 associated with a respective instrument 910 (e.g., mass flow rate), a pressure parameter 916, a temperature parameter 916, a directional parameter 916, or the like in order to optimize production of the high-pressure steam 140 at the system 104. However, the present disclosure is not limited thereto.
Each of the above identified modules and applications correspond to a set of executable instructions for performing one or more functions described above and the methods described in the present disclosure (e.g., the computer-implemented methods and other information processing methods described herein, method 800 of
It should be appreciated that the computer system 900 of
Additional example implementations of the heat pump system 400 are described as follows:
In some embodiments, a heat pump system (e.g., heat pump system 104 of any of
In some embodiments, one or more components of the system 104 were disposed on modular skids or containers designed for easy shipping and final installation.
In some embodiments, the baseline heat pump system 104 was configured to address the edges of the operating parameters 916, such as a minimum hot water source 110 temperature, a minimum steam condensate return 214 temperature, a maximum high-pressure steam 140 temperature, a maximum high-pressure steam 140 pressure, a maximum high-pressure steam 140 flow rate, or a combination thereof. In some embodiments, one or more portions of the compressor train 202 and/or the flash vessel train 210 is depopulated from the baseline heat pump system 104 to accommodate higher heat source temperatures and/or lower steam outlet temperature and/or pressure. For instance, in some embodiments, the baseline heat pump system 104 was configured to address minimum hot water source 110 temperature received from the facility 102 at least 60 degrees Fahrenheit (° F.) (15.6 degrees Celsius (° C.)) or at least 80° F. (26.7° C.).
In some embodiments, in accordance with a determination that the hot water source 110 is above 80° F. (26.7° C.), the baseline heat pump system 104 was modified by increasing the pressure of the flash vessel train 210 and depopulating one or more compressors 204 at a front end portion of the compressor train 202.
In some embodiments, in accordance with a determination that the high-pressure steam 140 received by the facility is less than 290 PSIg (20 Bar), the baseline heat pump system 104 was modified by depopulating one or more compressors 204 at a rear end portion of the compressor train 202.
In some embodiments, in accordance with a determination that the high-pressure steam 140 required a flow rate below 50 kilopounds (klb) per hour, one or more flash vessels 212 of the flash vessel train 210 and/or one or more compressors 204 of the compressor train 202 are substituted for a corresponding one or more flash vessels 212 and/or one or more compressors 204 configured for lower flow rates.
Since the density of steam increases as pressure increases, mass flow for a given size of a compressor 204 also increases. Accordingly, in some embodiments, the systems, methods, and apparatus of the present disclosure utilize the upper boundary of operating parameters, such as a 20 Barg output pressure of the high-pressure steam 140, and determined the minimum flow rates (e.g., after desuperheating via the desuperheater train 230) that the compressor train 202 yields such pressure at high efficiency and maximal compression ratio. In some embodiments, at the minimum flow rates, the systems, methods, and apparatus of the present disclosure determined the inlet pressure of hot water received from the hot water source 110 needed to achieve the 20 Barg output pressure of the high-pressure stream produced thereto. In some embodiments, the systems, methods, and apparatus of the present disclosure iteratively repeated this process on the remaining compressors 204 of the compressor train 202, until 35 mBara inlet pressure of the hot water received by the system 104 is reached.
In some embodiments, the baseline heat pump system 104 was modified in accordance with a unique set of parameter requirements associated with performance of the heat pump system 104 and/or one or more processes performed at a facility. For instance, in some embodiments, the unique set of parameter 916 requirements included the temperature of the hot water source 110 received by the system 104, the pressure of the high-pressure steam 140 produced by the system 104, and the mass flow rate of the high-pressure steam 140 produced by the system 104. In some embodiments, the systems, methods, and apparatus of the present disclosure configured the baseline heat pump system 104 into two or more sub-assemblies. Each sub-assembly included one or more compressors 204 of the compressor train 202 that is configured to be removed from the front end portion and/or the rear end portion of the compressor train 202. In some embodiments, each sub-assembly included one or more flash vessels 212 of the flash vessel train 210. By modifying the baseline heat pump system 104 through the sub-assemblies, the compressor train 202 was modified to change the temperature of the hot water source 110 received by the system 104, the pressure of the high-pressure steam 140 produced by the system 104. Moreover, in some embodiments, alternative sub-assemblies included smaller lower-flow compressors 204 that were substituted into the baseline heat pump system 104 to change the mass flow rate of the high-pressure steam 140 produced by the system 104 while optimizing for COP, cost, and size of the system 104.
Accordingly, by providing the heat pump system 104 in the modular configuration, the present disclosure allows for pre-engineered (e.g., pre-configured) and/or factory-produced packaged systems 104 ready to connect to a pre-existing facility 102.
Moreover, in some embodiments, this modular configuration of the heat pump system 104 allowed the cost and layout footprint of the heat pump system 104 to be optimized for a given application associated with a facility 102, while simultaneously providing standardization needed to achieve economies of scale when manufacturing the heat pump system 104. Furthermore, in some embodiments, the modular configuration of the heat pump system 104 allowed for production-level quality and reliability assurance, which was accomplished by qualifying the two or more sub-assemblies in addition to qualifying incoming components of the heat pump system 104.
Additionally, in some embodiments, the modular configuration of the heat pump system 104 allowed for factory fabrication of the heat pump system 104 in one or more skids, allowed for transportation of the heat pump system 104 from a factory to the facility 102 via standard truck-based transport, allowed for simple, non-complex on-site installation of the one or more skids at defined interface points at the facility 102, allowed for a minimized footprint area, allowed for easy removal and/or substitution of a sub-assembly, or a combination thereof.
For instance, in some embodiments, the footprint (e.g., surface area beneath the system 104) was between 2,000 square feet (ft2) and 8,000 ft2, inclusive, such as 150 foot length by 50 foot width footprint of the system 104.
In some embodiments, the present disclosure provided computer systems, methods, and a non-transitory computer-readable storage mediums for configuring a heat pump system 104.
In some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure allow for selection and configuration of one or more sub-assemblies of the heat pump system 104 in order to optimally satisfy a given set of parameter 916 requirements associated with a facility 102.
In some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure provide a lookup table. In some embodiments, the lookup table was utilized to match one or more ranges of various parameter requires, such as a first temperature of hot water received from the facility 102 and/or an outlet pressure of the high-pressure steam received by the facility 102 from the system 104 with specific combinations of two or more sub-assembles that were configured to operating collectively.
In some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure evaluated the performance of the heat pump system 104 based on the given set of parameter 916 requirements associated with the facility 102. For instance, in some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure determined the given set of parameter 916 requirements in the lookup table, then used the lookup table to select two or more sub-assemblies. In some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure evaluated the performance of the heat pump system 104 that included the two or more sub-assemblies selected through the lookup table. In some embodiments, the computer systems, methods, and a non-transitory computer-readable storage mediums of the present disclosure display a report that includes a complete, pre-qualified configuration of the heat pump system and the two or more sub-assembles that is ready for fabrication, and a performance specification for that configuration.
Referring to
In some embodiments, the system 104 included a compressor train 202. The compressor train 202 includes a series of at least two compressors 204. In some embodiments, the series of at least two compressors 204 included at least four compressors 204. Moreover, the compressor train 202 included an inlet 216 of the compressor train 202. Furthermore, the compressor train 202 included an outlet 208 of the compressor train 202 that is configured to provide high-pressure steam 140 to a facility 102. In some embodiments, the series of at least two compressors 204 is disposed interposing between the inlet of the compressor train 202 and the outlet of the compressor train 202.
In some embodiments, the system further included a flash vessel train 210. The flash vessel train 210 included a series of at least two flash vessels 212, in which the series of at least two flash vessels further included a terminal flash vessel 212 at one end of the flash vessel train 210. In some embodiments, the series of at least two flash vessels 212 included at least four flash vessels 212. Moreover, a vapor outlet 226 of the terminal flash vessel 212 is fluidly coupled to the inlet 216 of the compressor train 202. Additionally, the system 104 included vapor outlets 226 of a remainder of the series of at least two flash vessels 212 that are fluidly coupled between compressors 204 of the series of at least two compressors 204.
In some embodiments, the system 104 was configured to receive hot water received from hot water source 110 at a temperature of 120° F. (48.9° C.). In some embodiments, the system 104 was configured to receive steam condensate return 214 at a temperature of 200° F. (93.3° C.).
In some embodiments, each flash vessel 212 in the series of at least two flash vessels 212 of the flash vessel train 210 was configured to be maintained at an internal pressure less than a saturation pressure of hot water input into the respective flash vessel 212, and is configured to expand the hot water to produce low-pressure steam. For instance, in some embodiments, the terminal flash vessel 212-1 was configured to be maintained at an internal pressure less than the saturation pressure of hot water at 120° F. (48.9° C.) (e.g., the saturation pressure of water at 120° F. is 116.9 mBar, which yields an internal pressure below 116.8 mbar(a) for the respective flash vessel), a second flash vessel 212-2 was configured to be maintained at an internal pressure less than the saturation pressure of hot water at 140° F. (60° C.), a third flash vessel 212-3 was configured to be maintained at an internal pressure less than the saturation pressure of hot water at 160° F. (71.1° C.), and a fourth flash vessel 212-4 was configured to be maintained at an internal pressure less than the saturation pressure of hot water at 180° F. (82.2° C.). Accordingly, in some embodiments, the internal pressure of a first terminal flash vessel (e.g., flash vessel 212-1 of any of
All references cited herein are incorporated herein by reference in their entirety and for all purposes to the same extent as if each individual publication or patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety for all purposes.
The present invention can be implemented as a computer program product that includes a computer program mechanism embedded in a non-transitory computer-readable storage medium. For instance, the computer program product could contain the program modules shown in any combination of the Figures. These program modules can be stored on a CD-ROM, DVD, magnetic disk storage product, USB key, or any other non-transitory computer readable data or program storage product.
Many modifications and variations of this invention can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. The specific embodiments described herein are offered by way of example only. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. The invention is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.
The present Application is a continuation of International Patent Cooperation Treaty Application No.: PCT/US2023/030626, entitled “Systems, Methods, and Apparatuses for Producing High-Pressure Steam,” filed Aug. 18, 2023, which claims priority to U.S. Provisional Patent Application No. 63/371,837, entitled “Steam Generating Mechanical Vapor Recompression Heat Pump,” filed Aug. 18, 2022, each of which is hereby incorporated by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63371837 | Aug 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2023/030626 | Aug 2023 | WO |
| Child | 19054613 | US |
