U.S. patent application number 12/658172 was filed with the patent office on 2011-08-04 for energy separation and recovery system for mobile application.
This patent application is currently assigned to CLEANPOWER TECHNOLOGY, INC.. Invention is credited to Michael Alan Burns, Paul Andrew Burns, Marco Cucinotta, Gareth Andew Storoszko.
Application Number | 20110185726 12/658172 |
Document ID | / |
Family ID | 44340411 |
Filed Date | 2011-08-04 |
United States Patent
Application |
20110185726 |
Kind Code |
A1 |
Burns; Michael Alan ; et
al. |
August 4, 2011 |
Energy separation and recovery system for mobile application
Abstract
An energy separation and recovery system wherein exhaust heat
from an automotive engine source which might otherwise be wasted is
employed in conjunction with a heat exchanger and a super heater to
generate steam in a substantially closed-loop system wherein the
heat supply is an open system. The superheated steam is transmitted
to an engine to generate power which may be used to supply
electrical energy. The electrical energy may be employed external
to the system or may be used to assist the motive engine in
providing motive power to the vehicle. Stepped diameter tubing
carries water, or other vaporizable fluids, through the heat
exchanger into the super heater while simultaneously exposing the
carried water or fluid to incrementally higher temperature heated
gas. Variable bellows, attached operatively to end plates
accommodate the differential expansion of the tubing. The energy
generation system includes a control module to permit the
generation of steam and electricity at such times as there is
sufficient heat to permit the generation of superheated steam. The
energy separation and recovery system may, alternatively, be
employed to provide the power to an engine or other device or may
provide an energy source to an alternative power consumption
device, such as a refrigeration unit on a vehicle or a cold plate
system.
Inventors: |
Burns; Michael Alan;
(Seaford, GB) ; Burns; Paul Andrew; (Seaford,
GB) ; Storoszko; Gareth Andew; (Eastbourne, GB)
; Cucinotta; Marco; (Worthing, GB) |
Assignee: |
CLEANPOWER TECHNOLOGY, INC.
|
Family ID: |
44340411 |
Appl. No.: |
12/658172 |
Filed: |
February 4, 2010 |
Current U.S.
Class: |
60/618 |
Current CPC
Class: |
F01K 23/10 20130101 |
Class at
Publication: |
60/618 |
International
Class: |
F01K 23/10 20060101
F01K023/10 |
Claims
1. An energy separation and recovery system to recover thermal
energy from a provided by an automotive power source comprising a
thermal energy transfer core for transferring the thermal energy
from the waste energy source to a fluid, vaporizable energy capture
medium, the energy capture medium being introduced into the
separation and recovery system at a point furthermost from the
entrance point of the thermal waste energy, said capture medium
being conveyed through a series of interconnected tubes within the
separation and recovery system to absorb incrementally the thermal
waste energy, wherein the thermal energy transfer core comprises a
first energy transfer array disposed towards the furthermost point
from the entrance point of the thermal waste energy and a second
energy transfer array disposed between the entrance point of the
thermal waste energy and the first energy transfer array, the first
and second energy transfer arrays being connected to permit
continuous flow of the capture medium from the first to the second
energy transfer arrays, said first energy transfer array separating
sufficient waste energy to vaporize the capture medium and said
second energy transfer array separating sufficient energy from the
thermal waste energy to superheat the vaporized capture medium.
2. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 1
wherein the recovered energy provides power to a refrigeration unit
associated with the mobile power source.
3. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 1
wherein the thermal waste energy consists of a gas which flows in
direction opposite to the capture medium.
4. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 1
wherein the first transfer array is comprised of a plurality of
tubes parallel to one another.
5. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 4
wherein second transfer array is comprised of a plurality of tubes
parallel to one another.
6. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 5
wherein the first and second transfer arrays each have the
longitudinal axis of each tube disposed substantially perpendicular
to the direction of flow of the thermal waste energy gas.
7. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 6
wherein the first and second transfer arrays are disposed so as to
minimize the back pressure upon the thermal waste energy gas.
8. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 6
wherein successive tubes are connected by a virtual pipe bend
assembly.
9. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 6
wherein a plurality of successive tubes are connected by means of a
head comprise of at least one virtual pipe bend assembly.
10. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 6
wherein the plurality of tubes are rigidly affixed to a tube plate
to maintain them in substantially parallel alignment.
11. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 10
wherein the heads are attached to the tube plates and the head and
tube plate assembly is flexibly attached to the heat exchanger
casing to permit differential expansion of the tubes without loss
of energy captured by the fluid capture medium or loss of
fluid.
12. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 10
wherein the head and tube assembly is flexibly attached by a
bellows arrangement attached between the assembly and the heat
exchange casing.
13. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 10
wherein the heads and tube plates may be comprised of materials
having different rates of expansion to further seal upon
application of heat transfer from the energy capture fluid.
14. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 4
wherein the first transfer array having affixed to at least one
tube thereof a vortex fin disposed proximate to the rearmost
section of the tube to promote turbulent flow of the thermal waste
energy gas.
15. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 14
wherein the turbulent flow thereby permits substantially uniform
heat transfer across the first array.
16. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 14
wherein the turbulent flow increases the heat transfer from the gas
to the rear of the tube.
17. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 4
wherein the first transfer array having affixed to a plurality of
tubes a fin array by thermal brazing or other technique to maximize
heat transfer there between.
18. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 5
wherein a dryer is interposed between the first and second transfer
arrays.
19. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 1
wherein the recovered energy provides power to the automotive power
source.
20. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 19
wherein the recovered energy provides power by driving at least one
power element of the power source.
21. An energy separation and recovery system to recover thermal
energy from an automotive power source as claimed in claim 1
wherein system provides emission control capabilities for the
automotive power source.
22. An energy separation and recovery system to recover thermal
energy from an automotive power source comprising a thermal energy
transfer core for transferring the thermal energy from the waste
energy source to a fluid, vaporizable energy capture medium, the
energy capture medium being introduced into the thermal energy
transfer core of the separation and recovery system at a point
furthermost from the entrance point of the thermal waste energy,
said capture medium being conveyed through multiple series of tubes
within the separation and recovery system to absorb incrementally
the thermal waste energy, wherein the thermal energy transfer core
comprises at least two first energy transfer arrays disposed
towards the furthermost point from the entrance point of the
thermal waste energy and at least two second energy transfer arrays
disposed between the entrance point of the thermal waste energy and
the at least two first energy transfer arrays, one of the first and
one of the second energy transfer arrays being connected to form a
first recovery unit to permit continuous flow of the capture medium
from said one first energy array to said one second energy transfer
array of the first recovery unit, and the other first energy
transfer array and the other second energy array arrays being
connected to form a second recovery unit to permit continuous flow
of the capture medium from said other first energy array to said
other second energy transfer array of the second recovery unit,
each first energy transfer array separating sufficient waste energy
to vaporize the capture medium flowing there through and said
second energy transfer array separating sufficient energy from the
thermal waste energy to superheat the vaporized capture medium
flowing there through.
23. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the recovered energy from one of the two recovery units
provides power to a refrigeration unit associate with the mobile
power source.
24. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the recovered energy from one of the two recovery units
provides power to the automotive power source.
25. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the recovered energy from one of the two recovery units
provides power to assist in providing motive energy to the mobile
device associated with the power source.
26. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the recovered energy from one of the two recovery units
provides power by driving at least one of the power elements of the
power source.
27. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the recovered energy from one or both of the two recovery
units provides power, alternatively and selectively according to
the needs of each system, to the automotive power source or
provides motive power to the mobile device or drives at least one
of the power elements of the power source.
28. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein the thermal waste energy consists of a gas which flows in
direction opposite to the capture medium.
29. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 22
wherein each of the first transfer arrays is comprised of a
plurality of tubes parallel to one another.
30. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 29
wherein each of the second transfer arrays is comprised of a
plurality of tubes parallel to one another.
31. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 30
wherein each of the first and second transfer arrays each have the
longitudinal axis of each tube disposed substantially perpendicular
to the direction of flow of the thermal waste energy gas.
32. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 31
wherein each of the first and second transfer arrays are disposed
so as to minimize the back pressure upon the thermal waste energy
gas.
33. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 31
wherein successive tubes within each array are connected by a
virtual pipe bend assembly.
34. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 31
wherein a plurality of successive tubes for each array are
connected by means of a head comprise of at least one virtual pipe
bend assembly.
35. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 31
wherein the plurality of tubes are rigidly affixed to a tube plate
to maintain them in substantially parallel alignment.
36. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 35
wherein the heads are attached to the tube plates and the head and
tube plate assembly is flexibly attached to the heat exchanger
casing to permit differential expansion of the tubes without loss
of energy captured by the fluid capture medium or loss of
fluid.
37. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 35
wherein the head and tube assembly is flexibly attached by a
bellows arrangement attached between the assembly and the heat
exchange casing.
38. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 35
wherein the heads and tube plates may be comprised of materials
having different rates of expansion to further seal upon
application of heat transfer from the energy capture fluid.
39. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 29
wherein each first transfer array has affixed to at least one tube
thereof a vortex fin disposed proximate to the rearmost section of
the tube to promote turbulent flow of the thermal waste energy
gas.
40. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 39
wherein the turbulent flow thereby permits substantially uniform
heat transfer across each first array.
41. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 39
wherein the turbulent flow increases the heat transfer from the gas
to the rear of the tube.
42. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 29
wherein each of the first transfer arrays has affixed to a
plurality of tubes a fin array by thermal brazing or other
technique to maximize heat transfer there between.
43. An energy separation and recovery system to recover thermal
energy from a thermal waste energy source as claimed in claim 30
wherein a dryer is interposed between at least one of the first and
second transfer arrays.
44. An energy separation and recovery system to recover thermal
energy from a motive power source as claimed in claim 21 wherein
the system further contains at least one additional burner element
to flame off emissions.
45. An energy separation and recovery system to recover thermal
energy form a motive power source as claimed in claim 12 wherein
the system in interposed proximate to the motive power source to
provide emission control capability for the mobile power
source.
46. An energy separation and recovery system to recover thermal
energy form a motive power source as claimed in claim 16 wherein
the system in interposed proximate to the motive power source to
provide emission control capability for the mobile power
source.
47. An energy separation and recovery system to recover thermal
energy form a motive power source as claimed in claim 17 wherein
the system in interposed proximate to the motive power source to
provide emission control capability for the mobile power
source.
48. An energy separation and recovery system to recover thermal
energy form a motive power source as claimed in claim 18 wherein
the system in interposed proximate to the motive power source to
provide emission control capability for the mobile power source.
Description
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains
material which is subject to copyright protection. The copyright
owner has no objection to the facsimile reproduction by anyone of
the patent document or the patent disclosure, as it appears in the
Patent and Trademark Office patent file or records, but otherwise
reserves all copyright whatsoever in all forms currently known or
otherwise developed.
BACKGROUND OF THE INVENTION
[0002] This invention relates to energy separation and recovery
systems and heat exchangers and more particularly to a novel
compact, low back pressure heat exchanger for use in conjunction
with an engine that provides motive power. The system employs a
novel exchanger/super heater configuration to generate superheated
steam and a steam engine which operates in conjunction with the
motive power source by use of the exhaust waste gas generated by
the motive engine to provide a source of waste exhaust gas having
energy which is of sufficient magnitude to generate commercially
viable quantities of power from the steam engine.
[0003] Over the years there have been numerous attempts to utilize
the waste heat generated by the internal combustion engine to
augment the power of the engine or supplement it by using the waste
steam to run a steam turbine or other power plant. The inventions
known in the prior art include utilizing the exhaust emitted by the
internal combustion engine to heat water which will result in the
creation of steam to run a steam turbine or other similar device to
generate power which will augment or otherwise supplement that
generated by the internal combustion engine.
[0004] Generally, the prior art discloses the use of waste heat
from either or both of the primary sources of heat from the
internal combustion engine, those being the hot exhaust gases that
are vented from the engine by means of the exhaust pipe system and
the heat vented by the engine block through the radiator system by
means of the liquid cooled or air cooled systems generally employed
in today's automobiles and trucks. Additional heat is vented by the
block and moving parts of the engine, but inasmuch as that heat is
not captured by either the radiation system or the exhaust system,
it is effectively lost for purposes of motive power generation.
[0005] Heat can be recovered from a high temperature source and
converted into work utilizing the well-known Rankine cycle. The
heat is extracted from a high temperature heat source, for example
a combustion exhaust gas stream, into a working fluid. The working
fluid, which is initially liquid, is evaporated and the resulting
pressurized working fluid vapor passes into an expansion turbine
where work is generated to recover at least some of the heat energy
extracted from the high temperature source. By using very high
temperatures for the heat source and very low temperatures for the
heat sink, high efficiency can be achieved for the heat recovery
step.
[0006] The expansion turbine vapor exhaust, which is at a reduced
temperature and pressure, passes to a condenser which is in thermal
contact with a low temperature heat sink, typically a very large
body of water or ambient air. The heat of condensation is rejected
to the low temperature heat sink typically by cooling water, which
is discharged into a large body of water or into the atmosphere by
means of a cooling tower. Alternatively, air cooling is used with
the heated air being discharged directly into the atmosphere. The
ultimate heat sink remains at an essentially constant temperature
relative to the thermal load rejected by condensation of the
turbine exhaust. The heat thus rejected is not used for any
beneficial purpose and cannot be utilized within the process which
provides the source of the high temperature heat. It is therefore
lost.
[0007] In U.S. application Ser. No. 12/214,835, there is disclosed
accumulated energy system. Heat is employed in conjunction with a
super heater/evaporator to generate steam, which is then stored in
an energy accumulator which retains the stored energy by way of a
heated water containment unit. The heated water containment unit
accretes the energy and, upon attainment of a predetermined
pressure and liquid level, steam is transmitted to a steam engine
to generate power which may be used to run a generator and supply
electricity. The heat may be from an internal combustion engine or
other instrumentality which generates a sufficient quantity of
heated exhaust gas to generate the requisite steam.
[0008] Separation and recovery may also be employed in connection
with a hydrocarbon stream to vaporize it and thereby modify it. An
example of such a system is described in United States Patent
Application No. 2009/0324488 to Goodman, Wayne. The system includes
a heat exchanger configured to transfer heat from the exhaust
stream to a hydrocarbon stream. The heat exchanger may be a
separate device from the catalyst element, or the heat exchanger
and the catalyst element may be the same device. The heat exchanger
described may be configured to allow heat exchange with the exhaust
stream during some periods of operation and to block heat exchange
with the exhaust stream during other periods of operation and may
include a control to permit a fraction of the exhaust stream
flowing to the heat exchanger, allowing a controllable fraction of
heat from the exhaust stream to exchange with the hydrocarbon
stream and/or catalyst element.
[0009] It is generally agreed that in an internal combustion
engine, the energy generated by the combustion of the hydrocarbon
fuel results in the use of approximately one third of the total for
motive power. Approximately one third is transferred to the cooling
system and is lost from a propulsion perspective, while the
remaining one third is lost through the exhaust pipe. If one were
able to save a portion of the lost energy and convert it into
motive power, it would provide a realistic fuel saving and could
provide cleaner emissions. By saving 25% of the waste heat it would
translate into a fuel saving of approximately 40%-50%.
Concurrently, an energy accumulator could also permit the use of
the vehicle under circumstance were it was required that there be
zero emissions, such as in congested areas.
[0010] By way of example, U.S. Pat. No. 5,191,766 describes a
hybrid engine which utilizes combustion gases of an internal
combustion engine to generate steam externally to the cylinders of
the engine. That steam is then employed to power turbines which are
stated to be connected to augment the power supplied by the
internal combustion engine. This calls for a second engine to be
powered by the steam, something which renders the overall system
not effective for automotive locomotion.
[0011] Similarly, U.S. Pat. No. 5,708,306 describes a supplementary
power system which uses the exhaust gas heat to create steam and
drive a steam engine which, in turn, drives an air compressor,
which in turn drives a pneumatic motor to ostensibly provide a
power output to the engine shaft of the automobile. Again, multiple
engines are suggested to permit the use of the waste heat from the
exhaust.
[0012] Other illustrations of multiple engines and the use of waste
heat to operate the additional engine are described in U.S. Pat.
Nos. 4,590,766; 4,406,127; 4,300,353; and, 5,148,668 among
others.
[0013] None of those inventions, and others which convert the heat
from the exhaust gases into steam, has yet resulted in a
commercially viable power source which can be employed with today's
automobiles or trucks.
[0014] Systems are also known and described for accumulating steam
by using the waste heat generated by a power plant and then using
the steam to power a turbine or other power generation device. An
example of such a system is described in U.S. Pat. No. 4,555,905
and the patents and literature set forth therein. None of those
systems, however, are adaptable for providing motive power or
auxiliary power in an automotive vehicle.
[0015] In the past, systems have been suggested which describe the
use of steam to run one or more special cylinders which are
integrated into an internal combustion engine and either provide
compressive force to create high pressure steam or are linked,
through gear reduction systems, to the drive shaft of the motor
vehicle. Examples of such systems are disclosed in U.S. Pat. Nos.
4,442,673; 4,433,548; and, 4,706,462 among others.
[0016] Today, in many areas of the world, pollution and related
environmental concerns in conjunction with the congestion created
by high population density in many urban areas, has resulted in the
implementation of severe pollution controls on automotive vehicles
both for passenger and commercial use. Because almost all vehicles
are currently propelled, as the primary mode of locomotion, by
burning a hydrocarbon fuel, these vehicles will become the subject
of greater control and legislation and, in certain areas, will be
banned unless they can reduce the emitted pollution to zero in
populated areas.
[0017] Currently, the only available solution for a totally
pollution free power source available for vehicles is an electric
fuel cell. Hydrogen fuel cells are currently in the prototype phase
and are not commercially available. Thus the electric battery is
the only current source for a pollution free energy reservoir and
source.
[0018] However, battery performance has not improved markedly in
the past 100 years. The major advancements which were used to
propel underwater vehicles have not been improved upon measurably
to provide a low weight/low mass propulsion means that could be
employed in motor vehicles. The specific energy, or energy per unit
of weight, of the most common lead-acid batteries is about 50
watt-hours per kilogram compared with 12,000 watt-hours for a
kilogram of petroleum fuel. Similarly, the specific power, or power
per unit of weight, for a battery is only about 10% of the output
from an internal combustion engine. At the same time, such
batteries as are charged by the use of the internal combustion
engine are actually parasitic and may actually augment the amount
of pollution generated by the inefficiency of the engine during the
time that is required to operate in order charge the batteries.
[0019] There are no current radical advances for batteries on the
horizon and, in recognition of this, Los Angeles, one of the urban
centers setting standards for the world wide anti-pollution
incentive, has reduced the required range of electric cars by over
50% and have postponed the implementation date for anti-pollution
legislation.
SUMMARY OF THE INVENTION
[0020] To overcome one or more of the drawbacks in the current
energy technology and methods of employing waste heat exhaust
gases, the current invention employs a dual core system comprised
of a super heater and a heat exchanger. A finned tube array is
disposed in connection with the heat exchanger to heat water and
generate steam. A continuous tubing matrix directs a flow of fluid
in a direct transverse to the direction of the waste heat and
toward incrementally higher temperature of the waste heat. Waste
heat exhaust gases are first passed over the tubing array of the
super heater to superheat the steam within the super heater core.
The waste heat exhaust gases are then passed over the heat
exchanger segment of the unit to heat the water within the heat
exchanger. The tubing array from the heat exchanger to the super
heater is incrementally stepped up in diameter to achieve the open
core flow and provide the superheated steam output. The superheated
steam is transmitted to a steam engine to generate power which may
be used to run a generator and supply electricity. The engine
includes a control system to permit the generation of steam and
electricity at such times as there is sufficient heat to permit the
generation of superheated steam. The energy separation and recovery
system may also be employed to drive an engine or other device or
may provide an energy source to an alternative power consumption
device.
[0021] The energy separation and recovery system may,
alternatively, be employed to provide the power to one or more
energy consumption portions of the overall energy generation
system. By way of example only, a portion of the power may be used
within the electrical system of the heat exchanger itself in order
to keep it operational during periods of time where startup is
required via supplemental battery power.
[0022] The energy separation and recovery system may,
alternatively, be employed to provide the power to additional
energy consumption items within the vehicle or to provide power to
supplemental systems such as refrigeration, cold plate or motive
assistance units.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
[0023] The foregoing summary, as well as the following detailed
description of preferred embodiments of the invention, will be
better understood when read in conjunction with the appended
drawings. For purposes of illustrating the invention, there is
shown in the drawings embodiments which are presently preferred. It
should be understood, however, that the invention is not limited to
the precise arrangements and instrumentalities shown. In the
drawings:
[0024] FIG. 1 illustrates a block flow diagram for an exemplary
system for separating, recovering, and storing or transferring the
electricity generated by the use of the waste heat exhaust gases by
a mobile engine source, in accordance with one embodiment of the
present invention.
[0025] FIG. 1A is a detailed exemplary and diagrammatic view of an
automotive waste energy separation and recovery system, in
accordance with one embodiment of the present invention.
[0026] FIG. 1B is a detailed exemplary and diagrammatic view of an
automotive waste energy separation and recovery system directly
coupled to the automotive power plant, in accordance with one
embodiment of the present invention.
[0027] FIG. 1C is a detailed exemplary and diagrammatic view of an
automotive waste energy separation and recovery system in which the
output drives a piston of the automotive power plant, in accordance
with one embodiment of the present invention.
[0028] FIG. 2A is an illustrative view of an exemplary heat
exchanger/super heater system for the separation and recovery of
waste heat energy in which the system is interposed after the waste
exhaust gas has undergone emissions treatment, in accordance with
one embodiment of the present invention.
[0029] FIG. 2B is an illustrative view of an exemplary heat
exchanger/super heater system for the separation and recovery of
waste heat energy in which the system is interposed before the
waste gas has undergone emissions treatment, in accordance with
another embodiment of the present invention.
[0030] FIG. 2C is an illustrative view of an exemplary heat
exchanger/super heater system for the separation and recovery of
waste heat energy in which the system incorporates emissions
treatment within the separation and recovery, in accordance with an
embodiment of the present invention wherein the system also serves
as a muffler.
[0031] FIG. 3 is an illustrative view of an exemplary heat
exchanger/super heater system showing representative cores for the
separation and recovery of the waste heat energy, in accordance
with one embodiment of the present invention.
[0032] FIG. 4 is a detailed view of an exemplary arrangement of the
continuous tubing employed in connection with the heat exchanger
and super heater configuration, in accordance with one embodiment
of the present invention.
[0033] FIG. 5 is a detailed interior top view of a vortex fin
assembly of the heat exchanger, before vacuum brazing, in
accordance with one embodiment of the present invention.
[0034] FIG. 6 is a detailed sectional view of tube and vortex fin
interface, after vacuum brazing, in accordance with one embodiment
of the present invention.
[0035] FIG. 7 is a plan view of a single illustrative vortex fin
plate structure for disposition within the heat exchanger, in
accordance with one embodiment of the present invention.
[0036] FIG. 7A is a detailed interior view of a segment of a vortex
fin plate of the heat exchanger, in accordance with one embodiment
of the present invention.
[0037] FIG. 8 is an illustrative view of the gas flow pattern
around a tube within the heat exchanger configuration, in
accordance with one embodiment of the present invention.
[0038] FIG. 9 is an interior view of two corresponding heads for
linking adjacent piping structures of the heat exchanger and super
heater to form the continuous path in accordance with one
embodiment of the present invention.
[0039] FIG. 10 is a detailed sectional view of the heat exchanger
and super heater structure illustrating the adjacent hole
structures through which the heat exchanger and super heater piping
is disposed, in accordance with one embodiment of the present
invention.
[0040] FIG. 11 is a diagrammatic representation illustrating the
introduction of exhaust heat through the decrement staged piping of
the system and the water input and superheated steam output for a
single illustrative segment in accordance with one embodiment of
the present invention.
[0041] FIG. 12 is a cross-sectional view illustrating the super
heater structure and the head and end plate assemblies for linking
adjacent segments of piping in accordance with one embodiment of
the present invention.
[0042] FIG. 13 is a detail view taken of a corner of FIG. 12
illustrating the expandable section between the main core casing
structure and the head and end plate assemblies for linking
adjacent segments of piping in accordance with one embodiment of
the present invention.
[0043] FIG. 14 is an illustrative view of an expandable bellows
segment operatively associated with the head and end plate
assemblies depicting the differential expansion as the result of
the introduction of waste heat into the system in accordance with
one embodiment of the present invention.
[0044] FIG. 15 is an illustrative view of the head to end plate
interface showing the interlocking head with expanded tube detail
in accordance with one embodiment of the present invention
[0045] FIG. 16 is an exploded illustrative view of the head to end
plate interface showing the illustrative gaskets depicted thereon
in accordance with one embodiment of the present invention.
[0046] FIG. 17 is an illustrative view of the assembled heat
exchanger, fin assembly and superheater cores in association with
the expandable bellows segment operatively disposed with the head
and end plate assemblies and illustrative gaskets depicted thereon
in accordance with one embodiment of the present invention.
[0047] FIG. 18 is an illustrative view of an assembled multi-core
heat exchanger and super heater assembly in accordance with one
embodiment of the present invention.
[0048] FIG. 19 is an illustrative view of an assembled multi-core
heat exchanger and super heater assembly having vertically stacked
tubing to provide multiple heat exchangers and super heaters to
provide steam to multiple engines or other applications in
accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0049] Certain terminology may be used in the following description
for convenience only and is not limiting. The words "lower" and
"upper" and "top" and "bottom" designate directions only and are
used in conjunction with such drawings as may be included to fully
describe the invention. The terminology includes the above words
specifically mentioned, derivatives thereof and words of similar
import.
[0050] Where a term is provided in the singular, the inventors also
contemplate aspects of the invention described by the plural of
that term. As used in this specification, the singular forms "a",
"an", and "the" include plural references unless the context
clearly dictates otherwise, e.g. "a waste heat source". Thus, for
example, a reference to "a method" includes one or more methods,
and/or steps of the type described therein and/or which will become
apparent to those persons skilled in the art upon reading this
disclosure.
[0051] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning or meanings as commonly
understood by one of ordinary skill in the art to which this
invention belongs. Although any methods and materials similar or
equivalent to those described herein can be used in the practice or
testing of the present invention, the preferred methods, constructs
and materials are described herein. All publications mentioned
herein, whether in the text or by way of numerical designation, are
incorporated herein by reference in their entirety. Where there are
discrepancies in terms and definitions used by reference, the terms
used in this application shall have the definitions given
herein.
[0052] Referring to FIG. 1, FIG. 1A and FIG. 2A, in a preferred
embodiment of the invention, the energy separation and recovery
system 20 is located proximate to an mobile engine 10 which is
generating waste exhaust gas 18. The exhaust gas 18 is transferred
from the mobile engine 10 to the input duct 12 of the energy
separation and recovery system 20. The mobile engine 10 produces
motive power for the vehicle and waste heat exhaust gases 18. The
motive power is used to drive the vehicle. The waste heat exhaust
gases 18 are passed through from the input duct 12 to the output
duct 14 of the energy separation and recovery system 20 and is
utilized by the separation and recovery system 20 to generate
electrical power 22 which may be used, alternatively, to provide
additional motive power, supply power to a supplemental system to
power a refrigeration system or cold plate system, or supply power
to power parasitic elements which would normally be powered via an
alternator, or, if not needed otherwise, to be stored for future
use by the vehicle systems.
[0053] The separation and recovery system 20 and the electrical
power generating systems may be positioned either in close
proximity to one another or may be distributed throughout the
vehicle. As is shown in FIG. 1A, a steam engine 42 is drivingly
connected to an electrical generator, and a condenser and a
condensate recovery system all of which will be further delineated
and exemplified in an embodiment of the invention. As is shown in
FIG. 1B, the steam engine 42 is drivingly coupled to the primary
motive engine to supplement it. As is shown in FIG. 1C, the output
of the energy separation and recovery system 20 is directly applied
to the primary motive engine. It will be appreciated that those
skilled in the art can apply the output through various means such
as direct application to a cylinder or through a coupling mechanism
which may be attached to the shaft of the primary motive
engine.
[0054] In the exemplary embodiment of the invention, hot waste
exhaust gases 18 are flowed through the intake super heater side of
the separation and recovery system 20 thereby reduce the
temperatures of the waste heat exhaust gases 18 from approximately
1000.degree. F. (620.degree. C.) to approximately 600.degree. F.
(350.degree. C.). The 600.degree. F. waste heat exhaust gas 18 is
continually flowed through the heat exchange elements of the
separation and recovery system 20. Upon exiting the heat exchanger
30 the balance of the now cooled waste heat exhaust gas 18 is
appropriately vented.
[0055] It is to be understood that the temperatures set forth above
are merely illustrative and may be altered to optimize the
particular separation and recovery system or the use to which the
superheated steam is ultimately put.
[0056] Referring to FIG. 1, FIG. 1A and FIG. 4, the waste heat
exhaust gases 18 from the mobile engine 10 are directed via an
exhaust piping system 12 to the super heater 26. A portion of the
waste heat exhaust gases 18 may be diverted from the system if the
temperatures are in excess of that which is required to provide
superheated steam. A leading tube section 25 of the super heater 26
is that area proximate to the super heater steam outflow 40, as is
best seen in FIG. 4.
[0057] The waste heat exhaust gases 18 are sequentially passed from
the leading tube section 25 of the super heater 26 through to
trailing tube section 27 of super heater 26 and traverse
sequentially a leading tube section 29 and a trailing tube section
31 portion of the heat exchanger 30. As is best illustrated in FIG.
11, the heat exchanger 30 is comprised of decreasing diameter
tubing 33 such that, in the illustrated embodiment, approximately
one half of the heat exchanger 30 nearest the leading tube section
25 is comprised of one diameter tubing and the second portion of
the heat exchanger 30 nearest the trailing tube section 31 is
comprised of a smaller diameter tubing.
[0058] Continuing to refer to FIG. 1A and FIGS. 2A, 2B, 2C and 3,
the waste heat exhaust gases 18 from which the energy has been
separated then travel out of the energy separation and recovery
system 20. As is shown in FIG. 2A, the waste heat exhaust gas 18 is
exhausted to the atmosphere. As is shown in FIG. 2B, the waste heat
exhaust gas 18 is travels through the emissions treatment system 21
before it is exhausted into the atmosphere. As is shown in FIG. 2C,
the energy separation and recovery system 20 incorporates one or
more aspects of the emission treatment system 21. Although the
following description will refer to water as the fluid being
employed, it is understood by those skilled in the art that other
fluids may be employed to achieve similar results. Accordingly, as
is illustrated in FIG. 1A, a water pump 50 takes water 51 from
water tank 52 and causes it to flow through an initial series of
one or more pre-heater sections 300, consisting of tubing 301
having a diameter which is substantially similar to the diameter of
the trailing tube section 31 of the heat exchanger 30. The
pre-heater sections 300 may be employed to heat the water or other
fluid to a predetermined initial temperature which is, ideally,
just below the boiling point of the fluid medium used. As can be
seen from FIG. 1A, the pre-heater sections 300 may have a control
valve system 302 to permit selective activation or deactivation of
one or more of the sections 300. This permit the predetermined
temperature to be accurately maintained based upon the initial
temperature of the fluid.
[0059] In the event that less than all of the pre-heater sections
300 are employed, a by-pass tubing section 303 is interposed to
permit the fluid to be introduce into the trailing tube section 31
of the heat exchanger 30 at input port 305. As is best seen in FIG.
1A and FIG. 10, the water 51 travels through a first series of
tubes 304, which are the smallest diameter tubes employed in the
system. In one embodiment of the heat exchanger 30, a number of
spaced 3/8'' stainless steel tubes 304 are longitudinally disposed
in an array which is transverse to the direction of flow of the gas
18. The array is designed to simultaneously maximize the tube area
which is exposed to the flow of gas, while at the same time the
array is arranged to minimize the effect which it has on
back-pressure of the gas 18. The array may vary according to the
specific embodiment and application for the energy separation and
recovery system. This first series of tubes 304 are positioned such
that the longitudinal axis of each tube is substantially
perpendicular to the gas 18 flow.
[0060] Continuing to refer to FIGS. 1A and 10, the water 51 travels
through the first series of tubes 304 into a second series of tubes
306 which are of a larger diameter then the first series of tubes
304. The first and second series of tubes form the heat exchanger
30 core. The gases 18 encounter the second series of tubes 306 at a
higher temperature than they encounter the first series of tubes
304. It can be seen that the temperature gradient for the water 51
which has been pumped into the tubes 304 at inlet 305 is such that
the temperature of the water within the second series of tubes 306
is higher then that in the first series of tubes at 304.
[0061] Continuing to refer to FIGS. 1A and 10 and FIG. 4, the water
51, which has now been turned to steam 58 by the action of the
energy separation and recovery system 20, travels through the
leading tube section 29 of the heat exchanger 30 into the trailing
tube section 27 of the super heater 26 via connecting tube 307.
Depending on the particular application and the temperature of the
gas, a steam dryer assembly 310 may be advantageously interposed
between the leading tube section 29 and the trailing tube section
27. The steam dryer assembly 310 constitutes a drying stage where,
in the event that the steam from the heat exchanger 30 is wet, it
may be appropriately dried and made ready for super heating.
[0062] Continuing to refer to FIGS. 1A, 3, 4 and FIG. 11, the dry
steam enters into the super heater 26 of the separation and
recovery system 20, such that the temperature of the gas 18 at the
trailing tube section 27 of the super heater 26 is a lower
temperature than at the leading tube section 25 of the super heater
26. Accordingly, the steam 58 encounters increasingly hotter gases
18 as it travels from the trailing tube section 27 to the leading
tube section 25 of the super heater 26. It can be appreciated that
the temperature gradient for the steam 58 as it enters the super
heater 26 is such that the steam 58 at the superheated steam exit
port 308 is at substantially higher temperature than the steam at
the entrance port 307 of the super heater 26.
[0063] During the travel of the steam 58 from the trailing tube
section 27 to the leading tube section 25 of the super heater 26,
the steam 58 becomes superheated steam 59. The superheated steam 59
is directed via a superheated steam exit port 308 to a steam engine
42. In general, the reciprocating steam engine 42 produces
rectilinear motion in a piston by the supply of high-pressure, high
temperature steam to a cylinder. In the instant invention,
superheated steam 59 is employed to drive the cylinder (not shown).
In most reciprocating piston engines the steam reverses its
direction of flow at each stroke (counter flow), entering and
exhausting from the cylinder by the same port. In the steam engine
42 illustratively employed in connection with the instant
invention, the superheated steam 59 enters from an entry port 44
and exits from an exit port 45 in proximity to the entry port 44
and both located on the head section 100 of the steam engine 42, in
order to complete the engine cycle, which occupies one rotation of
the crank and two piston strokes. The cycle comprises several
events--admission, expansion and exhaust. The steam engine 42 then
changes the rectilinear motion of the pistons into rotary motion
using a crank shaft (not shown) and rotates a driveshaft 47. A
reciprocating steam engine 42 may also reverse the rectilinear
motion direction of the piston using the inertial force of a
flywheel installed at the crank shaft unit.
[0064] Because the superheated steam 59 loses heat as the energy is
being taken from it, the superheated steam 59 sequentially becomes
dry steam, wet steam and eventually water 51. In order to
accommodate the decrease in temperature and the increase in
moisture content the various steam components (also referred to as
phases) can be drawn off at various points from the steam engine
42. By way of example reference is again made to FIG. 1A which
shows the transfer of the various steam components in various
phases. Dry steam 70 is collected from the piston blowby 71 and is
conducted via tubing 72 to a tank 84. Wet steam 73 is collected
from the oil sump 74 and conducted via tubing 75 to the tank 84.
Additional wet steam 76 and water 51 are collected from the reserve
oil reservoir 77 and conducted via tubing 78 to the tank 84. The
steam 70, 73 and 76, after being conducted to tank 84, is conducted
via ducting 79 to the water tank 52 where it is employed to
recharge the energy separation and recovery system 20.
[0065] The superheated steam 59 exits from the exit port 45 as
depleted steam 130 through a discharge pipe 48 which is connected
to and passes through the reserve oil reservoir 77. The depleted
steam 130 still contains sufficient energy to be employed to heat
the oil within the reserve oil reservoir 77 to maintain it at a
predetermined temperature. The depleted steam 130 continues through
discharge pipe 48 to a condenser 80 where it is cooled by a fan
assembly 82 and the resultant water 51 is transferred through
piping 49 and returned to the water tank 52. As a part of the
recapture mechanism, water from the several steam draw points is
captured in tank 84 and is re-circulated to the water tank 52.
[0066] Referring to FIGS. 2A, 2B and 2C there is shown various
illustrative configurations of the energy separation and recovery
system 20 in combination with an illustrative energy source 10,
wherein the separation and recovery system 20 is interposed at
various different points along the flow path of the gas 18. The
energy separation and recovery system 20 shown in FIG. 2A is
disposed after the emissions treatment system 21. The gas 18
travels first through the emissions system 21, then through the
separation and recovery system 20 and is then exhausted to the
atmosphere. FIG. 2C illustrates the energy separation and recovery
system 20 in combination with an illustrative energy source 10
where the system 20 is operatively to either provide or supplement
the emissions treatment system 21 which is required for the mobile
engine. In such a configuration, the energy separation and recovery
system 20 may be advantageously used to provide sufficient noise
abatement and thereby eliminate the use of a muffler.
[0067] Referring again to FIG. 1A there is shown an expanded and
detailed view of certain operative portions of the separation and
recovery system 20. The steam engine 42 is, in the preferred
embodiment a Voith steam expander. The steam engine 42 is drivingly
associated with a generator 90. The steam engine 42, which is
powered by the superheated steam derived by the separation and
recovery system 20, rotationally engages the generator 90. In the
preferred embodiment the generator 90 is an alternating current
generator which provides electrical energy. The alternating current
is passed to a power control module 92 which then converts the
electrical energy into various forms which are suitable for
powering various electrical consuming items such as a refrigeration
unit, a cold plate system, a supplemental motive power source or
the vehicle's low voltage power system, by way of example only.
[0068] Referring again to FIG. 4 in conjunction with FIGS. 5, 6, 7
and 7A, there is shown a preferred embodiment of a vortex fin array
200 which is disposed perpendicular to the heat exchange tubing 304
and 306. The vortex fin array 200 is comprised of a series of
circular apertures 202 through which the heat exchange tubing 304
and 306 extends. The heat exchange tubing 304 and 306 is affixed to
the vortex fin array 200. In a preferred embodiment of the
invention, the vortex fin array 200 and the heat exchange tubing
304 and 306 are braised to further increase the heat transfer
between the waste heat exhaust gas 18 and the water 51 traveling
through the respective heat exchange tubing 304 and 306.
[0069] Referring to FIG. 7A there is shown a view of one portion of
a representative section of heat exchange tubing 304 or 306 and a
pair of associated vortex fins 204. The heat exchange tubing 304 or
306 extends in a substantially perpendicular orientation relative
to the fin array 200. The vortex fins 204 are in an orientation
substantially parallel the longitudinal axis of the heat exchange
tubes 304 or 306 and at a 45.degree. orientation relative to the
flow direction of the waste gas 18. Referring to FIG. 6, there is
shown a sectional view of the interface between tubes 304 or 306
and the fin array 200. A braze 206 is circumferentially disposed
around the entire tube 304 or 306 to bond the respective tube to
the vortex fin array 200.
[0070] The fins 204 are elevated from the surface of the vortex fin
array 200 in a direction substantially parallel to the longitudinal
axis of the respective heat exchange tubes 304 and 306 and are
advantageously disposed on the rear section 210 of each heat
exchange tube 304 and 306, where the rear section 210 is defined as
that portion of the heat exchange tube 304 and 306 which is down
stream from the direction of flow of the waste heat exhaust gases
18. In a preferred embodiment of the invention twin fins 204 are
punched into the vortex fin array 200 such that each fin 204 is
substantially perpendicular to the vortex fin array 200. Each fin
204 is disposed at an angle which is approximately 45.degree. from
the direction of flow of the exhaust heat gases 18. Each fin 204
extends upwardly and has an upper edge 207 which is substantially
similar in length to the length of the fin 204 where each of the
fins 204 is affixed to the vortex fin array plate 200. The purpose
of the fins 204 is to disturb the airflow around the rear section
210 of each of the heat exchanger tubes 304 and 306 for increased
heat transfer.
[0071] Referring to FIG. 8 there is shown a diagrammatic
representation of the flow of waste heat exhaust gases 18 around
the heat exchanger pipes 304 and 306. With the introduction of the
fins 204, the flow is disturbed on the rear section 210 represented
by arrow Fd such that the flow is diverted approximately 45.degree.
causing the waste heat exhaust gas 18 to curl backward and further
contact the heat exchanger pipes 304 and one 306.
[0072] Referring to FIG. 9 there is shown an interior view of a
pair of heads 400 which comprises two corresponding heads 402A and
402B for linking adjacent piping structures within the heat
exchanger 30 and within the super heater 26 to form a continuous
path through each and therefore through both, in accordance with
one embodiment of the present invention. Each of the corresponding
heads 402A and 402B is comprised of a series of semicircular
virtual pipe bends 404, each of which straddles sequential sections
of straight heat exchanger tubes 304 and 306 or super heater tubes
308, to provide the travel channel for the fluid within each tube
and the travel path for the fluid through all of the tubes 304, 306
and 308. As is best seen in FIG. 9, the inlet 405, in the upper
left most corner of head 402A has inserted therein representative
tube 304-A1. The insertion and expansion of the tubes 304, 306 and
308 into each head 402 will be discussed hereinafter.
Representative tube 304-A1 extends through the heat exchanger 30
and the other end is inserted into the upper right most corner of
head 402B at virtual pipe bend 404-A1/A2. A second representative
tube 304-A2 is inserted at the left most section of virtual pipe
bend 404-A1/A2 and extends into the left most section of virtual
pipe bend 404-A2/A3 located on head 402A. As can be best
appreciated by referring to FIG. 9 and FIG. 12, the tubes extend
between the two heads 402A and 402B in a substantially parallel
configuration to permit the fluid to flow from one to the other
with minimal obstruction.
[0073] The configuration shown and describe above, when viewed with
reference to FIG. 10, illustrates the internal pumping system which
permits the fluid to travel though the piping structure in the heat
exchanger 26 and the super heater 30 without the necessity of any
additional mechanical pumping mechanism deployed within either the
heat exchanger 30 or the super heater 26. FIG. 10 illustrates the
parallel piping structure of the heat exchanger 30 and the super
heater 26 in which the heads 402 has been removed to permit the
viewing of the tubes 304, 306 and 308. In the illustrative
embodiment shown in FIG. 10, the super heater 30 and the heat
exchanger 26 are each shown as a square core structure. It will be
appreciated that the core configuration can be adapted to optimize
the energy separation and recovery which is accomplished by the
system and will generally be a function of, among other things, the
input gas temperature and the desired output super heated steam
which is being delivered for end use. In FIG. 10, it can be seen
that the super heater 30 and the heat exchanger 26 are each
situated with the system cabinet 160 such that the gas 18 is
required to pass around the tubes 308 of the super heater 30, and
the tubes 304 and 306 of the heat exchanger 26 rather than being
able to circumvent the tubes 304, 306 and 308. As the result of the
configuration of the heat exchanger 26 and the super heater 30
which are shown in FIG. 10, and are in close proximity to the upper
and lower portions of the system cabinet 160 the gas 18 is caused
to flow over the tubes 304 and 306 of the heat exchanger 26 and
over tubes 308 of the super heater 30.
[0074] The virtual pipe bends 404 provide numerous advantages over
traditional pipe bends which would otherwise be used to connect
sequential sections of straight pipe 304, 306 and 308 as is
illustratively shown in FIG. 11 and FIG. 12. A traditional pipe
bend radius on a 3/4'' tube is approximately 1.75 inches. When
bending a tube or pipe, the material is generally thinner on the
out side surface and crumpled on the inside edge thereby creating
weaknesses. Additionally once fluid is forced to change direction
rapidly, as would occur when it is forced around a tight bend,
water hammer can occur and over time eat into the tube bend and
causing a failure. By providing a virtual pipe bend 404, thicker
material can be employed to provide greater strength and less
likelihood of failure at the pipe bend juncture. Another advantage
of employing virtual pipe bends 404 on a separation and recovery
system 20 is that each head 402 can be removed in order to permit
the full disassembly of the heat exchanger 30 and the super heater
26 and thereby access the straight tube sections 304 and 306 or
308, respectively to permit cleaning or repair of those sections as
well as the virtual pipe bends 404. Another advantage is that the
internal straight sections 304, 306 and 308 can be changed to give
greater heat exchange 30 volume or super heater 26 area as is
required in any particular application.
[0075] Referring to FIGS. 10, 11, 12, 13 and 17, there is shown a
preferred embodiment of the heads 402 and a gasket 420 arrangement
in order to provide a fluid return route through the virtual pipe
bends 404 in the heat exchanger 30 and super heater 26 elements of
the separation and recovery system 20. A gasket 420 is interposed
between the head 402 of the heat exchanger 30 core and the tube
plate 422 which carries the tubes 304, 306 or 308. As is shown
illustratively in FIG. 17, two parallel and sequential heat
exchanger tubes 304 or 306 (or super heater tubes 308) are
juxtaposed to each virtual pipe bend 404, which provides the fluid
return conduit between sequential sections of straight pipe 304,
306 or 308. Viewing the sequential piping designations shown in
FIG. 9 and the cross-section shown in FIG. 12, is can be
appreciated that the flow path of the fluid medium used to separate
and recover the energy from the gas 18 is in substantially
continuous contact with the energy carrying gas 18. At the same
time the tubes 304, 306 and 308 are situated behind one another to
minimize the back pressure from the heat exchanger 26 and the super
heater 30.
[0076] It is to be appreciated that although water has been used as
an example above, the system may also be employed with other
liquids/fluids/plasmas which are able to be vaporized and transmit
energy thereby.
[0077] As is best illustrated in FIGS. 12, 14 and 17, each head 402
is affixed to the tube plate 422 with a gasket 420 interposed there
between and two parallel and sequential heat exchanger tubes 304 or
306 are secured to the tube plates 422 such that each virtual pipe
bend 404 provides the fluid return conduit between sequential
sections of straight pipe 304 and 306. A bellows 430 is welded to
the external casing 432 and extends outwardly therefrom to provide
a flexible segment to accommodate lateral displacement due to heat
expansion of the pipes 304 or 306 which are connected to the two
tube plates 422. The exterior edge of the bellows 430 has affixed
thereto a flange 434 to which the head 402 is affixed. Because the
heating differential between the input side of the separation and
recovery system 20 and the output side may vary by over 300.degree.
C., the expansion of the tubes 304, 306 and 308 and related
assemblies is not equal throughout the flow area of the gas 18. In
the area closest to the input of the gas 18 where the temperature
is approximately 650.degree. C., the tubes 308 will tend to expand
more along the longitudinal axis at the entrance area of the super
heater 26. Similarly the leading area of the heat exchanger 30 will
be at a higher temperature than the trailing portion of the heat
exchanger 30. In order to accommodate the differential expansion of
the tubes 304, 306 and 308, the bellows 430 permits the heads 402
to accommodate the differential expansion by lateral movements at
either end to accommodate expansion along the longitudinal axis of
the tubes 304, 306 and 308.
[0078] Referring to FIG. 14 there is shown illustratively the
operation of the bellows system 430 as the result of the
application of energy carrying gas 18 from a heat source through
the super heater 26 and the heat exchanger 30. As can be
appreciated, the greater the heat the more the individual tubes are
likely to expand along their respective longitudinal axis. The
bellows system 430 is designed to allow for that uneven expansion
without causing a reduction in the efficiency of the unit or leaks
of the superheated steam. At the same time by permitting the
expansion it maintains the tubes 304, 306 and 308 in parallel
alignment thereby permitting the steam to enter and exit the
virtual pipe bends 404 of the heads 402 with minimal distortion or
backflow problems.
[0079] Referring to FIG. 15 there is shown a graphic representation
of the head 402 interlocked to the tube plate 422 with the gasket
420 interposed between the head 402 and the tube plate 422. As is
illustrated in FIG. 15, each tube 304, 306 or 308 sits
approximately 0.5 mm proud of the exterior most edge of the tube
plate 422 in the area of the virtual pipe bend 404. A series of
tube role grooves 424 are circumferentially disposed within each
hole in the tube plate 422. Each tube 304, 306 and 308 is pressure
fitted into the respective hole such that the metal is compressed
in the area where the tube and the tube plate meet. The resultant
radial pressure results in the formation of tube role expansions
426 in the location of each tube which is adjacent to a
corresponding tube role groove 424. Thus, as can be seen
graphically in FIG. 15, a mating and sealing arrangement is thereby
obtained to hold each tube 304, 306 or 308 to the head without the
need for welding.
[0080] Referring to FIG. 17 there are shown in diagrammatic
representation form the core which houses the tubes 304 and 306 or
308 of either the heat exchanger 30 or the super heater 26 to the
heads 402 with illustrative bellows 430 at either end of the heads
404. It is also illustratively depicted that the bellows 430 are
secured to the outer portion 432 of the housing so as to provide a
secure seal and prevent any escape of gas 18, while provide the
angular movement necessary to accommodate the differential
expansion of the tubes 304, 306 and 308. This can be appreciated to
be a representation which shows the separation and recovery system
20 in a non-heated mode where substantially equal temperature is
maintained throughout. In such a state the tubes 304, 306 and 308
would remain approximately of equal length and the bellows 430
would not be required to perform any differential movement of the
heads 404. In contradistinction, by referring to FIG. 14 there are
shown the variable expansion which occurs during operation of the
separation and recovery system 20 and the manner in which the
bellows 430 is differentially moved in accordance with the relative
expansion along the lateral axis of each of the tubes 304, 306 and
308.
[0081] Referring to FIG. 18, there is shown an illustrative example
of a multi-core energy separation and recovery system 20, in
accordance with another embodiment of the invention. The housing
contains a series of super heaters 30 which contact the gas 18
before the heat exchangers 26 contact the gas 18. The number of
heat exchangers 26 and super heaters 30 may be varied depending
upon the particular application, the input temperatures and the
desired output temperatures and use to which the superheated steam
is to be put. Similarly, the tubing system may run from one or more
heat exchangers into a single super heater or from a single heat
exchanger into one or more super heaters. As is shown in FIG. 19,
it is a further object of this invention to provide the capability
of dividing the core structure of either the heat exchanger, super
heater or both so that the energy which has been separated and
recovered can be used to run separate steam engines on independent
or coordinated steam circuits or be use for several applications
simultaneously.
Test Data from a System Test
TABLE-US-00001 Waste Heat Engine Power Torq Exhaust KW RPM Nm Temp
C. 273 1344 1914 620 Steam Expander KW Steam inlet Steam Inlet Elec
RPM Temp C. Pressure BAR 18.3 1216 364 34.3 Compact Heat Exchanger
Water In Outlet l/min Temp Diff in/out Temp C. 4.5 367 253
[0082] For the purposes of promoting an understanding of the
principles of the invention, reference has been made to the
embodiments illustrated in the drawings and specific language used
to describe the same. It will nevertheless be understood that no
limitation of the scope of the invention is thereby intended. Any
alterations and further modifications in the described embodiments,
and any further applications of the principles of the invention as
described herein are contemplated as would normally occur to one
skilled in the art to which the invention relates.
[0083] Any experimental (including simulation) results are
exemplary only and are not intended to restrict any inventive
aspects of the present application. Any theory, mechanism of
operation, proof, or finding stated herein is meant to further
enhance understanding of the present invention and is not intended
to make the present invention in any way dependent upon such
theory, mechanism of operation, proof, or finding. It should be
understood that while the use of the word preferable, preferably or
preferred in the description above indicates that the feature so
described may be more desirable, it nonetheless may not be
necessary and embodiments lacking the same may be contemplated as
within the scope of the invention, that scope being defined by the
claims that follow. In reading the claims it is intended that when
words such as "a," "an," "at least one," "at least a portion" are
used there is no intention to limit the claim to only one item
unless specifically stated to the contrary in the claim. Further,
when the language "at least a portion" and/or "a portion" is used
the item may include a portion and/or the entire item unless
specifically stated to the contrary. While the invention has been
illustrated and described in detail in the drawings and foregoing
description, the same is to be considered as illustrative and not
restrictive in character, it being understood that only the
selected embodiments have been shown and described and that all
changes, modifications and equivalents that come within the spirit
of the invention as defined herein or by any claims that follow are
desired to be protected.
[0084] Although the control systems have been described generally,
aspects of the control algorithm and the interrelationship between
the algorithm, the sensed parameters and the controlled elements
are also a part of the invention. By way of example, valve designs
and controls form important inventive concepts that have
applicability in other separation and recovery and steam generation
systems.
[0085] In addition, although a methane landfill incinerator may be
employed as a source of gas to power the engine which is providing
the gas 18, it is merely one example to describe the inventive
concepts set forth herein. It is understood that a conventional
incinerator or other source of high temperature waste heat may be
employed, as well as a source of waste heat from burning of such
material as natural gas, particularly flash gas at well head
locations.
[0086] Although the description herein recites water as the fluid,
that is not meant to limit the scope of this invention and is used
for illustrative purposes only. Those skilled in the art may
substitute other appropriate fluids, depending on circumstances and
applications, consistent with the inventive concepts disclosed
herein.
[0087] It will be appreciated also by those skilled in the art that
changes could be made to the embodiments described above without
departing from the broad inventive concepts thereof. It is
understood, therefore, that this invention is not limited to the
particular embodiments disclosed but it is intended to cover
modifications within the spirit and scope of the present invention
as defined by the appended claims.
* * * * *