U.S. patent application number 13/236240 was filed with the patent office on 2012-03-22 for high efficiency power production methods, assemblies, and systems.
This patent application is currently assigned to Palmer Labs, LLC. Invention is credited to Rodney John Allam, Jeremy Eron Fetvedt, Miles Palmer.
Application Number | 20120067054 13/236240 |
Document ID | / |
Family ID | 45816489 |
Filed Date | 2012-03-22 |
United States Patent
Application |
20120067054 |
Kind Code |
A1 |
Palmer; Miles ; et
al. |
March 22, 2012 |
HIGH EFFICIENCY POWER PRODUCTION METHODS, ASSEMBLIES, AND
SYSTEMS
Abstract
The present disclosure provides methods, assemblies, and systems
for power production that can allow for increased efficiency and
lower cost components arising from the control, reduction, or
elimination of turbine blade mechanical erosion by particulates or
chemical erosion by gases in a combustion product flow. The
methods, assemblies, and systems can include the use of turbine
blades that operate with a blade velocity that is significantly
reduced in relation to conventional turbines used in typical power
production systems. The methods and systems also can make use of a
recycled circulating fluid for transpiration protection of the
turbine and/or other components. Further, recycled circulating
fluid may be employed to provide cleaning materials to the
turbine.
Inventors: |
Palmer; Miles; (Chapel Hill,
NC) ; Allam; Rodney John; (Chippenham, GB) ;
Fetvedt; Jeremy Eron; (Raleigh, NC) |
Assignee: |
Palmer Labs, LLC
|
Family ID: |
45816489 |
Appl. No.: |
13/236240 |
Filed: |
September 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61385039 |
Sep 21, 2010 |
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61385047 |
Sep 21, 2010 |
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61437330 |
Jan 28, 2011 |
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Current U.S.
Class: |
60/772 ;
415/182.1; 415/200; 60/805 |
Current CPC
Class: |
F05D 2220/32 20130101;
F01D 5/085 20130101; F01D 5/182 20130101; F01D 25/14 20130101; F02C
3/34 20130101; F01D 5/282 20130101; F01D 5/183 20130101; F05D
2300/702 20130101; F05D 2230/22 20130101; F05D 2260/95 20130101;
F05D 2260/203 20130101 |
Class at
Publication: |
60/772 ; 60/805;
415/200; 415/182.1 |
International
Class: |
F02C 3/04 20060101
F02C003/04; F01D 25/24 20060101 F01D025/24; F01D 1/04 20060101
F01D001/04 |
Claims
1. A method of power generation comprising: introducing a fuel,
O.sub.2, and a circulating fluid into a combustor; combusting the
fuel in the combustor to provide a combustion product stream
including the circulating fluid and a content of particulates, the
combustion product stream flowing at a defined velocity; and
expanding the combustion product stream across a turbine comprising
a plurality of turbine blades to generate power and output a
turbine discharge stream, the turbine being operated such that the
turbine blades rotate at a blade velocity of less than about 500
mph.
2. The method of claim 1, further comprising passing the turbine
discharge stream through a filter configured to remove
substantially all of the particulates contained in the turbine
discharge stream and form a filtered turbine discharge stream.
3. The method of claim 2, further comprising passing the filtered
turbine discharge stream through a heat exchanger to provide a
cooled turbine discharge stream; treating the cooled turbine
discharge stream to withdraw one or more components of the turbine
discharge stream; and passing the treated turbine discharge stream
back through the heat exchanger to provide a heated, recycled
circulating fluid stream.
4. The method of claim 3, further comprising directing at least a
portion of the heated, recycled circulating fluid stream to the
combustor.
5. The method of claim 3, further comprising directing at least a
portion of the heated, recycled circulating fluid stream to the
turbine.
6. The method of claim 3, further comprising directing at least a
portion of the heated, recycled circulating fluid stream to a
cleaning material unit wherein the heated, recycled circulating
fluid stream is combined with a cleaning material to form a
cleaning material stream, the cleaning material in the cleaning
material stream being configured to remove deposits on the turbine
blades arising from the content of particulates present in the
combustion product stream.
7. The method of claim 6, wherein the cleaning material stream is
input directly into the turbine.
8. The method of claim 6, wherein the cleaning material stream is
combined with the combustion product stream to form a combined
combustion product and cleaning material stream that is directed
into the turbine.
9. The method of claim 1, wherein the circulating fluid comprises
CO.sub.2.
10. The method of claim 9, wherein the CO.sub.2 is provided in a
supercritical state.
11. The method of claim 1, further comprising combining the
filtered turbine discharge stream with a particulate sold fuel to
form an additional fuel in the form of a slurry; and introducing
the additional fuel to the combustor.
12. The method of claim 3, further comprising using at least a
portion of the circulating fluid that is recycled as a
transpiration fluid.
13. The method of claim 12, wherein using the circulating fluid
that is recycled as the transpiration fluid comprises transpiring
the transpiration fluid to an exterior surface of the turbine
blades.
14. The method of claim 13, wherein transpiring the transpiration
fluid to the exterior surface of the turbine blades comprises
transpiring the transpiration fluid through a porous sintered
material.
15. A power generation system comprising: a combustor configured
for receiving a fuel, O.sub.2, and a circulating fluid, and having
at least one combustion stage that combusts the fuel and provides a
combustion product stream including the circulating fluid and a
content of particulates; a turbine in fluid communication with the
combustor, the turbine having an inlet for receiving the combustion
product stream, an outlet for release of a turbine discharge
stream, and a plurality of turbine blades of sufficient dimensions
such that the turbine operates at a blade velocity of less than
about 500 mph; and a filter in fluid communication with the outlet
of the turbine and configured to produce a filtered turbine
discharge stream.
16. The power generation system of claim 15, further comprising a
heat exchanger in fluid communication with the filter and
configured to receive the filtered turbine discharge stream.
17. The power generation system of claim 16, further comprising a
cleaning material unit in fluid communication with the heat
exchanger, the cleaning material unit being configured to combine a
cleaning material with a fluid stream received from the heat
exchanger to form a cleaning material stream.
18. The power generation system of claim 17, further comprising a
flow combiner switch configured to combine the cleaning material
stream with the combustion product stream to form a combined
combustion product and cleaning material stream and direct the
combined combustion product and cleaning material stream to the
turbine.
19. The power generation system of claim 15, wherein the blades
comprise a porous sintered material, the porous sintered material
configured to direct a transpiration fluid to an exterior surface
of the blades.
20. The power generation system of claim 19, wherein the porous
sintered material defines the entirety of the exterior surface of
the blades.
21. The power generation system of claim 19, wherein the turbine
comprises a rotor, and wherein the rotor comprises the porous
sintered material and the porous sintered material is configured to
direct the transpiration fluid to an exterior surface of the
rotor.
22. A method of power generation comprising: introducing a fuel,
O.sub.2, and a CO.sub.2 circulating fluid into a combustor;
combusting the fuel to provide a combustion product stream
comprising CO.sub.2; expanding the combustion product stream across
a turbine to generate power and output a turbine discharge stream;
processing the turbine discharge stream to recycle at least a
portion of the CO.sub.2 circulating fluid into the combustor;
withdrawing a portion of the CO.sub.2 circulating fluid that is
recycled; and using the recycled CO.sub.2 circulating fluid as a
transpiration fluid.
23. The method of claim 22, wherein using the recycled CO.sub.2
circulating fluid as the transpiration fluid comprises transpiring
the recycled CO.sub.2 circulating fluid in the turbine.
24. The method of claim 22, wherein using the recycled CO.sub.2
circulating fluid as the transpiration fluid comprises transpiring
the recycled CO.sub.2 circulating in the combustor.
25. The method of claim 22, further comprising directing the
combustion product stream from the combustor through a conduit to
the turbine, wherein using the recycled CO.sub.2 circulating fluid
as the transpiration fluid comprises transpiring the recycled
CO.sub.2 circulating fluid in the conduit.
26. The method of claim 22, further comprising conditioning the
recycled CO.sub.2 circulating fluid to a temperature that is less
than a temperature of the combustion product stream.
27. The method of claim 22, further comprising conditioning the
recycled CO.sub.2 circulating fluid to a temperature that is
substantially equal to a temperature of the combustion product
stream.
28. The method of claim 22, further comprising conditioning the
recycled CO.sub.2 circulating fluid to a temperature that is
greater than a temperature of the combustion product stream.
29. A power generation system comprising: a combustor configured
for receiving a fuel, O.sub.2, and a CO.sub.2 circulating fluid
stream, and having at least one combustion stage that combusts the
fuel in the presence of the CO.sub.2 circulating fluid stream and
provides a combustion product stream comprising CO.sub.2; a turbine
in fluid communication with the combustor, the turbine having an
inlet for receiving the combustion product stream, an outlet for
release of a turbine discharge stream comprising CO.sub.2, and a
plurality of turbine blades; one or more components configured for
processing the turbine discharge stream to form a recycled CO.sub.2
circulating fluid stream, wherein one or more components of the
system are configured for using a portion of the recycled CO.sub.2
circulating fluid stream as a transpiration fluid.
30. The power generation system of claim 29, wherein the one or
more components configured for processing the turbine discharge
stream to form the recycled CO.sub.2 circulating fluid stream
comprise a filter.
31. The power generation system of claim 30, wherein the one or
more components configured for processing the turbine discharge
stream to form the recycled CO.sub.2 circulating fluid stream
further comprise a heat exchanger.
32. The power generation system of claim 31, wherein the one or
more components configured for processing the turbine discharge
stream to form the recycled CO.sub.2 circulating fluid stream
further comprise a separator.
33. The power generation system of claim 32, wherein the one or
more components configured for processing the turbine discharge
stream to form the recycled CO.sub.2 circulating fluid stream
further comprise a compressor.
34. The power generation system of claim 29, wherein the one or
more components configured for using the portion of the recycled
CO.sub.2 circulating fluid stream as the transpiration fluid
comprise a porous sintered material configured for receiving the
transpiration fluid therethrough.
35. The power generation system of claim 29, wherein the turbine
blades have a blade height less than about 0.275 m.
36. The power generation system of claim 29, wherein the turbine
comprises less than about 2000 of the turbine blades.
37. The power generation system of claim 29, wherein a ratio of a
length of the turbine to an average diameter of the blades is
greater than about 4.
38. A turbine assembly, comprising: a plurality of components
including: a casing defining: an inlet configured to receive a
combustion product stream, and an outlet; a rotor positioned in the
casing; and a plurality of blades extending from the rotor, wherein
one or more of the components comprise a porous sintered material,
the porous sintered material configured to direct a transpiration
fluid therethrough.
39. The turbine assembly of claim 38, wherein the porous sintered
material defines the entirety of the exterior surface of the
blades.
40. The turbine assembly of claim 38, wherein the casing comprises
the porous sintered material and the porous sintered material is
configured to direct the transpiration fluid to an interior surface
of the casing.
41. The turbine assembly of claim 38, wherein the rotor comprises
the porous sintered material and the porous sintered material is
configured to direct the transpiration fluid to an exterior surface
of the rotor.
42. The turbine assembly of claim 38, wherein the rotor comprises
an annular flow diverter configured to divert the combustion
product stream around the rotor.
43. The turbine assembly of claim 38, further comprising an inlet
conduit coupled to the inlet of the casing and configured to couple
to an outlet of a combustor assembly and receive the combustion
product stream therefrom, wherein the inlet conduit comprises the
porous sintered material and the porous sintered material is
configured to direct the transpiration fluid to an interior surface
of the inlet conduit.
44. The turbine assembly of claim 38, wherein the inlet of the
casing is configured to couple directly to an outlet of a combustor
assembly.
45. The turbine assembly of claim 44, wherein the inlet of the
casing is configured to receive the combustion product stream from
a plurality of combustors radially disposed with respect to a major
axis defined by the rotor.
46. The turbine assembly of claim 38, wherein the blades comprise
the porous sintered material, the porous sintered material
configured to direct the transpiration fluid to an exterior surface
of the blades.
47. The turbine assembly of claim 46, wherein the blades
respectively further comprise at least one reinforcement
member.
48. The turbine assembly of claim 47, wherein the reinforcement
member comprises a rod that extends through the porous sintered
material in each of the blades.
49. The turbine assembly of claim 48, wherein the reinforcement
member comprises a core, wherein the porous sintered material
extends around the core.
50. The turbine assembly of claim 49, wherein the core defines one
or more channels configured to receive the transpiration fluid and
direct the transpiration fluid into the porous sintered
material.
51. The turbine assembly of claim 46, wherein one or more channels
are defined in the blades, and wherein the channels are configured
to receive the transpiration fluid and direct the transpiration
fluid into the porous sintered material.
52. The turbine assembly of claim 46, wherein each of the blades
extends from a leading edge to a trailing edge, and wherein the
blades are configured to define a flow of the transpiration fluid
at the leading edge that is greater than a flow of the
transpiration fluid at the trailing edge.
53. The turbine assembly of claim 52, wherein each of the blades
defines a transpiration fluid inlet area at the leading edge that
is greater than a transpiration fluid inlet area at the trailing
edge.
54. The turbine assembly of claim 52 wherein each of the blades
defines a wall thickness that is greater at the trailing edge than
at the leading edge.
55. The turbine assembly of claim 46, wherein each of the blades
extends from a root at the rotor to a tip, and wherein the porous
sintered material defines a porosity that varies between the root
and the tip.
56. The turbine assembly of claim 55, wherein the porosity of the
porous sintered material is configured to define a flow of the
transpiration fluid at the tip that is greater than a flow of the
transpiration fluid at the root.
57. The turbine assembly of claim 55, wherein the porosity of the
porous sintered material is configured to define a flow of the
transpiration fluid at the tip that is substantially equal to a
flow of the transpiration fluid at the root.
58. The turbine assembly of claim 55, wherein the porous sintered
material defines a plurality of layers, wherein the porosity of the
layers increases from the root to the tip.
59. The turbine assembly of claim 46, wherein the blades each
respectively define an integral structure comprising a plurality of
internal ribs.
60. The turbine assembly of claim 38, wherein the components
further comprise a plurality of stators, wherein the stators
comprise the porous sintered material and the porous sintered
material is configured to direct the transpiration fluid to an
exterior surface of the stators.
61. The turbine assembly of claim 38, further comprising one or
more seals, wherein one or more of the components are configured to
direct the transpiration fluid to the seals.
62. The turbine assembly of claim 61, wherein the seals comprise
the porous sintered material.
63. A turbine assembly, comprising: a casing defining: an inlet
configured to receive a combustion product stream, and an outlet; a
rotor positioned in the casing; and a plurality of blades extending
from the rotor, wherein a ratio of a length of the turbine assembly
to an average diameter of the blades is greater than about 4.
64. The turbine assembly of claim 63, wherein the turbine blades
have a blade height less than about 0.275 m.
65. The turbine assembly of claim 63, wherein the turbine assembly
comprises less than about 2,000 of the blades.
66. The turbine assembly of claim 63, wherein the blades are
transpiration protected.
67. The turbine assembly of claim 66, wherein the blades comprise a
porous sintered material configured to direct a transpiration fluid
to an exterior surface of the blades.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/385,039, which was filed on Sep. 21,
2010, U.S. Provisional Patent Application No. 61/385,047, which was
filed on Sep. 21, 2010, and U.S. Provisional Patent Application No.
61/437,330, which was filed on Jan. 28, 2011. The disclosures of
the referenced applications are hereby incorporated herein in their
entirety by reference.
FIELD OF THE ENDEAVOR
[0002] The present disclosure provides turbine and combustor
components that may be used in power production methods and
systems. The disclosure also provides methods of using such turbine
and combustor components in power production.
BACKGROUND
[0003] Gas turbines are routinely used in power production systems
and methods to extract energy from a flow of combustion gases that
is directed across blades present in the turbine to spin a turbine
shaft. Energy may be extracted from the rotating shaft by an
electrical generator to provide power in the form of electricity.
Due to the extreme conditions (e.g., high temperatures and presence
of erosive and/or corrosive materials) under which gas turbines are
operated in typical power production plants (e.g., coal burning
power plants), gas turbine components are typically formed of high
performance materials. Thus, gas turbines often are high cost
components of power production facilities.
[0004] Existing turbines may operate with inlet temperatures from
about 1200.degree. C. to about 1400.degree. C. with blade
temperatures from about 900.degree. C. to about 1000.degree. C.
Thus, gas turbines operating in power production facilities
typically require the use of superalloy materials to withstand the
high temperatures. Moreover, for most advanced applications, blade
cooling also is required along with the use of advanced fabrication
technology, such as directionally solidified materials and even
single crystal blade technology. Blade cooling is used to help
improve turbine temperature tolerance, and thus efficiency, but
this process has been limited by the fact that only air, or in some
cases steam, has been available for cooling. The quantity of air
available for cooling is limited by the amount of energy available
to compress and pump the air and sometimes steam through the
turbine blades. Moreover, the air typically is provided at a
limited pressure--e.g., close to atmospheric pressure--and thus has
limited heat transfer capabilities, even at high flow rates.
Further, air contains large amounts of oxygen, which is highly
reactive at high temperatures, and this is another factor that
tends to require that turbine blade metallurgy be restricted to
highly oxidation resistant materials, such as superalloys. Thus,
despite the use of advanced materials and cooling, gas turbine
blades still are plagued by oxidative and in some cases steam
degradation.
[0005] While fossil fuel sources are being depleted, there remain
vast reserves of coal that could be used in power production, but
combustion of such solid fuels results not only in pollution but
also particulates that can cause damage to components of power
production systems, particularly turbine blades. Such damage
particularly arises from particles in combustion product flows
impacting turbine blades at high velocities--e.g., up to and
exceeding 600 mph (268 m/s). Previous attempts to mitigate such
damage have included the requirement for filtration systems to
remove particulates from combustion product flows prior to passage
through the turbine, as well as the use of high performance
materials in blade construction, as noted above. Such requirements,
however, increase the cost of power production systems. Moreover,
such requirements increase the complexity of power production
systems and can reduce efficiency of the power production methods.
Accordingly, there is a need for improved gas turbine blade
technology that overcomes at least the foregoing limitations in the
art.
SUMMARY OF THE DISCLOSURE
[0006] The present disclosure provides methods, assemblies, and
systems for power production that can allow for increased
efficiency and lower cost components arising from the control,
reduction, or elimination of turbine blade chemical degradation by
air and steam and by mechanical erosion by particulates in a
combustion product flow. The methods, assemblies, and systems can
comprise the use of higher pressure fluid flows and/or turbine
blades with increased total blade area that allow for a required
power generation with a substantial reduction in blade velocity and
in blade temperature. The disclosure particularly provides for
turbines that are significantly smaller in at least one dimension
and with cooler blades in comparison to turbines used in
conventional power production systems. Such turbines particularly
can be incorporated into a power production method or system. For
example, the method or system can be one that incorporates the use
of a high pressure, high recycle ratio circulating or working
fluid, such as a CO.sub.2 circulating fluid. Moreover, blade
cooling technology can be combined with the blade design, operation
pressure, and operation velocity to allow for customization of
turbine operation within a range of temperatures, pressures, and
speeds that control, reduce, or eliminate erosion arising from
particle impingement or chemical degradation of the turbine blades.
Particularly, the turbine blades can incorporate transpiration
protection via passage of a transpiration fluid (e.g., the recycled
working fluid) through the turbine blades. Such transpiration
protection can include blade cooling, depending upon the
temperature of the transpiration fluid used. Since the turbine
blades can rotate at a significantly reduced velocity in relation
to turbine blades in conventional power production systems, the
disclosure may provide for reduction in erosion, increased blade
lifetime, and reduction in blade strength requirements. Moreover,
the inventive turbines may operate at higher efficiency and lower
temperatures, which enables lower operating costs, longer
in-service time, and lower fuel use.
[0007] In one particular embodiment, a method of power generation
is provided. The method may comprise introducing a fuel, O.sub.2,
and a circulating fluid into a combustor, combusting the fuel in
the combustor to provide a combustion product stream including the
circulating fluid and a content of particulates, the combustion
product stream flowing at a defined velocity, and expanding the
combustion product stream across a turbine comprising a plurality
of turbine blades to generate power and output a turbine discharge
stream, the turbine being operated such that the turbine blades
rotate at a blade velocity of less than about 500 mph.
[0008] The method may further comprise passing the turbine
discharge stream through a filter configured to remove
substantially all of the particulates contained in the turbine
discharge stream and form a filtered turbine discharge stream. The
method may also comprise passing the filtered turbine discharge
stream through a heat exchanger to provide a cooled turbine
discharge stream, treating the cooled turbine discharge stream to
withdraw one or more components of the turbine discharge stream,
and passing the treated turbine discharge stream back through the
heat exchanger to provide a heated, recycled circulating fluid
stream. The method may additionally comprise directing at least a
portion of the heated, recycled circulating fluid stream to the
combustor. Further, the method may comprise directing at least a
portion of the heated, recycled circulating fluid stream to the
turbine. Also, the method may comprise directing at least a portion
of the heated, recycled circulating fluid stream to a cleaning
material unit wherein the heated, recycled circulating fluid stream
is combined with a cleaning material to form a cleaning material
stream, the cleaning material in the cleaning material stream being
configured to remove deposits on the turbine blades arising from
the content of particulates present in the combustion product
stream.
[0009] The cleaning material stream may be input directly into the
turbine. Further, the cleaning material stream may be combined with
the combustion product stream to form a combined combustion product
and cleaning material stream that may be directed into the turbine.
The circulating fluid may comprise CO.sub.2, which may be provided
in a supercritical state. Additionally, the method may include
combining the filtered turbine discharge stream with a particulate
sold fuel to form an additional fuel in the form of a slurry, and
introducing the additional fuel to the combustor. Also, the method
may include using at least a portion of the circulating fluid that
is recycled as a transpiration fluid. Using the circulating fluid
that is recycled as the transpiration fluid may comprise
transpiring the transpiration fluid to an exterior surface of the
turbine blades. Transpiring the transpiration fluid to the exterior
surface of the turbine blades may comprise transpiring the
transpiration fluid through a porous sintered material.
[0010] In another embodiment a power generation system is provided.
The power generation system may comprise a combustor configured for
receiving a fuel, O.sub.2, and a circulating fluid, and having at
least one combustion stage that combusts the fuel and provides a
combustion product stream including the circulating fluid and a
content of particulates, a turbine in fluid communication with the
combustor, the turbine having an inlet for receiving the combustion
product stream, an outlet for release of a turbine discharge
stream, and a plurality of turbine blades of sufficient dimensions
such that the turbine operates at a blade velocity of less than
about 500 mph, and a filter in fluid communication with the outlet
of the turbine and configured to produce a filtered turbine
discharge stream.
[0011] The power generation system may further comprise a heat
exchanger in fluid communication with the filter and configured to
receive the filtered turbine discharge stream. The power generation
system may also comprise a cleaning material unit in fluid
communication with the heat exchanger, the cleaning material unit
being configured to combine a cleaning material with a fluid stream
received from the heat exchanger to form a cleaning material
stream. The power generation system may additionally include a flow
combiner switch configured to combine the cleaning material stream
with the combustion product stream to form a combined combustion
product and cleaning material stream and direct the combined
combustion product and cleaning material stream to the turbine.
[0012] The blades may comprise a porous sintered material, and the
porous sintered material may be configured to direct a
transpiration fluid to an exterior surface of the blades. The
porous sintered material may define the entirety of the exterior
surface of the blades. Further, the turbine may comprise a rotor,
and the rotor may comprise the porous sintered material and the
porous sintered material may be configured to direct the
transpiration fluid to an exterior surface of the rotor.
[0013] In another embodiment a method of power generation is
provided. The method may comprise introducing a fuel, O.sub.2, and
a CO.sub.2 circulating fluid into a combustor, combusting the fuel
to provide a combustion product stream comprising CO.sub.2,
expanding the combustion product stream across a turbine to
generate power and output a turbine discharge stream, processing
the turbine discharge stream to recycle at least a portion of the
CO.sub.2 circulating fluid into the combustor, withdrawing a
portion of the CO.sub.2 circulating fluid that is recycled, and
using the recycled CO.sub.2 circulating fluid as a transpiration
fluid.
[0014] Using the recycled CO.sub.2 circulating fluid as the
transpiration fluid may comprise transpiring the recycled CO.sub.2
circulating fluid in the turbine. Using the recycled CO.sub.2
circulating fluid as the transpiration fluid may comprise
transpiring the recycled CO.sub.2 circulating in the combustor. The
method may further comprise directing the combustion product stream
from the combustor through a conduit to the turbine, and using the
recycled CO.sub.2 circulating fluid as the transpiration fluid may
comprise transpiring the recycled CO.sub.2 circulating fluid in the
conduit. The method may also include conditioning the recycled
CO.sub.2 circulating fluid to a temperature that is less than a
temperature of the combustion product stream. The method may
additionally include conditioning the recycled CO.sub.2 circulating
fluid to a temperature that is substantially equal to a temperature
of the combustion product stream. Also, the method may include
conditioning the recycled CO.sub.2 circulating fluid to a
temperature that is greater than a temperature of the combustion
product stream.
[0015] In another embodiment a power generation system is provided.
The system may comprise: a combustor configured for receiving a
fuel, O.sub.2, and a CO.sub.2 circulating fluid stream and having
at least one combustion stage that combusts the fuel in the
presence of the CO.sub.2 circulating fluid stream so as to provide
a combustion product stream comprising CO.sub.2; a turbine in fluid
communication with the combustor, the turbine having an inlet for
receiving the combustion product stream, an outlet for release of a
turbine discharge stream comprising CO.sub.2, and a plurality of
turbine blades, wherein the combustion product stream acts on the
turbine blades to rotate the turbine and generate power; and one or
more components configured for processing the turbine discharge
stream to form a recycled CO.sub.2 circulating fluid stream;
wherein one or more components of the system are configured for
using a portion of the recycled CO.sub.2 circulating fluid stream
as a transpiration fluid.
[0016] The one or more components configured for processing the
turbine discharge stream to form the recycled CO.sub.2 circulating
fluid stream may comprise a filter, a heat exchanger, a separator,
and/or a compressor. The one or more components configured for
using the portion of the recycled CO.sub.2 circulating fluid stream
as the transpiration fluid may comprise a porous sintered material
configured for receiving the transpiration fluid therethrough. The
turbine blades may have a blade height less than about 0.275 m. The
turbine may comprise less than 2000 of the turbine blades. A ratio
of a length of the turbine to an average diameter of the blades may
be greater than 4.
[0017] In another embodiment a turbine assembly is provided. The
assembly may comprise a plurality of components including a casing
defining an inlet configured to receive a combustion product
stream, and an outlet. The components may further comprise a rotor
positioned in the casing, and a plurality of blades extending from
the rotor, wherein one or more of the components comprise a porous
sintered material, the porous sintered material configured to
direct a transpiration fluid therethrough.
[0018] The porous sintered material may define the entirety of the
exterior surface of the blades. The casing may comprise the porous
sintered material and the porous sintered material may be
configured to direct the transpiration fluid to an interior surface
of the casing. The rotor may comprise the porous sintered material
and the porous sintered material may be configured to direct the
transpiration fluid to an exterior surface of the rotor. The rotor
may comprise an annular flow diverter configured to divert the
combustion product stream around the rotor. The assembly may
further comprise an inlet conduit coupled to the inlet of the
casing and configured to couple to an outlet of a combustor
assembly and receive the combustion product stream therefrom, and
the inlet conduit may comprise the porous sintered material and the
porous sintered material may be configured to direct the
transpiration fluid to an interior surface of the inlet conduit.
The inlet of the casing may be configured to couple directly to an
outlet of a combustor assembly. The inlet of the casing may be
configured to receive the combustion product stream from a
plurality of combustors radially disposed with respect to a major
axis defined by the rotor.
[0019] The blades may comprise the porous sintered material, and
the porous sintered material may be configured to direct the
transpiration fluid to an exterior surface of the blades. The
blades may respectively further comprise at least one reinforcement
member. The reinforcement member may comprise a rod that extends
through the porous sintered material in each of the blades. The
reinforcement member may comprise a core, and the porous sintered
material may extend around the core. The core may define one or
more channels configured to receive the transpiration fluid and
direct the transpiration fluid into the porous sintered material.
One or more channels may be defined in the blades, and the channels
may be configured to receive the transpiration fluid and direct the
transpiration fluid into the porous sintered material. Each of the
blades may extend from a leading edge to a trailing edge, and the
blades may be configured to define a flow of the transpiration
fluid at the leading edge that is greater than a flow of the
transpiration fluid at the trailing edge. Each of the blades may
define a transpiration fluid inlet area at the leading edge that is
greater than a transpiration fluid inlet area at the trailing edge.
Each of the blades may define a wall thickness that is greater at
the trailing edge than at the leading edge. Each of the blades may
extend from a root at the rotor to a tip, and the porous sintered
material may define a porosity that varies between the root and the
tip. The porosity of the porous sintered material may be configured
to define a flow of the transpiration fluid at the tip that is
greater than a flow of the transpiration fluid at the root. The
porosity of the porous sintered material may be configured to
define a flow of the transpiration fluid at the tip that is
substantially equal to a flow of the transpiration fluid at the
root. The porous sintered material may define a plurality of
layers, wherein the porosity of the layers increases from the root
to the tip. The blades may each respectively define an integral
structure comprising a plurality of internal ribs.
[0020] The components of the turbine assembly may further comprise
a plurality of stators, wherein the stators comprise the porous
sintered material and the porous sintered material may be
configured to direct the transpiration fluid to an exterior surface
of the stators. The turbine assembly may further comprise one or
more seals, wherein one or more of the components are configured to
direct the transpiration fluid to the seals. The seals may comprise
the porous sintered material.
[0021] In another embodiment a turbine assembly is provided. The
turbine assembly may comprise a casing defining an inlet configured
to receive a combustion product stream, and an outlet. The assembly
may further comprise a rotor positioned in the casing, and a
plurality of blades extending from the rotor, wherein a ratio of a
length of the turbine assembly to the average diameter of the
plurality of blades is greater than 4.
[0022] The turbine blades may have a blade height less than about
0.275 m. The turbine assembly may comprise less than 2000 of the
blades. The blades may be transpiration protected. Further, the
blades comprise a porous sintered material configured to direct a
transpiration fluid to an exterior surface of the blades.
[0023] Other aspects and advantages of the present invention will
become apparent from the following.
BRIEF DESCRIPTION OF THE FIGURES
[0024] Having thus described the disclosure in general terms,
reference will now be made to the accompanying figures,
wherein:
[0025] FIG. 1 provides a flow diagram of a combustion cycle and
system according to one example embodiment;
[0026] FIG. 2 provides a flow diagram of a combustion cycle and
system according to a further example embodiment;
[0027] FIG. 3 provides a sectional view through a combustor in
accordance with one example embodiment;
[0028] FIG. 4 provides a sectional view through a turbine including
an inlet conduit in accordance with one example embodiment;
[0029] FIG. 5 provides a longitudinal sectional view through a
turbine and a plurality of radially disposed combustors in
accordance with one example embodiment;
[0030] FIG. 6 provides a lateral sectional view through the turbine
and combustor system of FIG. 5;
[0031] FIG. 7 provides a lateral sectional view through a turbine
including a core in accordance with one example embodiment;
[0032] FIG. 8 provides a partial sectional view through an inlet
conduit comprising first and second layers in accordance with one
example embodiment;
[0033] FIG. 9 provides a partial sectional view through an inlet
conduit comprising four layers in accordance with one example
embodiment;
[0034] FIG. 10 provides a sectional view between the leading and
trailing edges of a turbine blade comprising reinforcement rods and
channels configured to receive a transpiration fluid in accordance
with one example embodiment;
[0035] FIG. 11 illustrates a sectional view between a leading edge
and a trailing edge of a turbine blade including integral internal
ribs defining channels configured to receive a transpiration fluid
in accordance with one example embodiment;
[0036] FIG. 12 illustrates a sectional view between the tip and
base member of the turbine blade of FIG. 11;
[0037] FIG. 13 illustrates a perspective view of the turbine blade
of FIG. 11;
[0038] FIG. 14 illustrates a sectional view between a leading edge
and a trailing edge of a turbine blade defining differing material
thicknesses between the leading and trailing edges in accordance
with one example embodiment;
[0039] FIG. 15A illustrates a partial sectional view between the
root and tip of a turbine blade including layers of material
defining differing porosities between the root and tip in
accordance with one example embodiment;
[0040] FIG. 15B illustrates a partial sectional view between the
root and tip of a turbine blade defining a porosity gradient
between the root and tip in accordance with one example
embodiment;
[0041] FIG. 16 illustrates a calculated particle trajectory for a
particle in a turbine in accordance with one example
embodiment;
[0042] FIG. 17 provides a graphical illustration of radial travel
distance of particulates in a combustion product flow in a
combustor as a function of axial travel distance in accordance with
one example embodiment;
[0043] FIG. 18 illustrates a lengthwise cross-section of a
conventional turbine for use in conventional natural gas power
plant; and
[0044] FIG. 19 illustrates a lengthwise cross-section of a turbine
according to example embodiments that is generally smaller in size
than a conventional turbine.
DETAILED DESCRIPTION
[0045] The disclosure now will be described more fully hereinafter
through reference to various embodiments. These embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the disclosure to those skilled in
the art. Indeed, the disclosure may be embodied in many different
forms and should not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so that this
disclosure will satisfy applicable legal requirements. As used in
the specification, and in the appended claims, the singular forms
"a", "an", "the", include plural referents unless the context
clearly dictates otherwise.
[0046] The present disclosure in one embodiment relates to turbine
blade designs and methods of use that can reduce or even eliminate
turbine blade erosion arising from chemical degradation by air or
steam or by particle impingement. The disclosure also provides
power production methods and systems that can provide high
efficiency operation while reducing or even eliminating turbine
blade erosion arising from particulates in a combustion product
flow without the requirement of filtration prior to passage through
the turbine. The reduction and/or elimination of blade erosion can
simplify power production systems and increase possible feedstocks
since it allows for the turbines to process combustion product flow
with higher total particulate concentration and is thus
particularly beneficial in combustion processes using feedstocks,
such as coal, that include a relatively high concentration of
particulates in the combustion product.
[0047] The terms "particulates" and "particles" (including such
terms in the singular form) as used in relation to components of
the combustion product stream specifically encompass solid and
liquid materials present in the combustion product stream in a
relatively small unit size typically understood to be
characteristic of particles, specifically in relation to the
overall volume of the combustion product stream. In some
embodiments, particles or particulates may comprise any material in
the combustion product stream that is in a non-gaseous state.
Liquid particulates specifically may encompass materials that are
liquid at the temperature of the combustion product stream but that
are solid at a temperature that is less than the temperature of the
combustion product stream, such as at least 10.degree. C., at least
15.degree. C., at least 20.degree. C., at least 30.degree. C., at
least 50.degree. C., or at least 100.degree. C. less than the
temperature of the combustion product stream. Such liquid
particulates may have a freezing point that is at least ambient
temperature, at least about 40.degree. C., at least about
50.degree. C., at least about 60.degree. C., at least about
80.degree. C., at least about 100.degree. C., or at least about
200.degree. C. In specific embodiments, the liquid particles may
have a freezing point falling within any combination of the
above-listed temperatures (e.g., within the range that is at least
10.degree. C. less than the temperature of the combustion product
stream and at least ambient temperature).
[0048] In particular embodiments, the present disclosure realizes
that particle impact damage on turbine blades is related to blade
velocity. In particular, a damage rate arising from particle impact
can change as approximately the cube of blade velocity relative to
particle velocity. In this regard, the standard alternating current
frequency employed in the United States is 60 Hz. Further, power
production systems in the United States typically drive synchronous
alternating current generators that operate at either 1,800 rpm
(30.times.60 Hz) or 3,600 rpm (60.times.60 Hz), although it should
be understood that the turbines may rotate within other rpm ranges.
In this regard, other countries may employ differing standard
alternative current frequencies. For example, the United Kingdom
operates at a frequency of 50 Hz. Further, generator systems may
employ permanent magnet direct current generators driven at any
speed such that the direct current is converted to alternating
current having a desired frequency. Accordingly, it should be
understood that the frequencies discussed herein are provided for
example purposes only.
[0049] However, known gas turbines used in power production systems
and methods including synchronous alternating current generators
typically operate at blade speeds of 600 mph (268 m/s) or greater.
At blade speeds typical in existing steam and gas turbines, the
presence of even very small particulates in a combustion product
flow can cause blade erosion. The present disclosure, however, has
recognized the ability to overcome blade erosion through
alterations in blade structure and operation that allows for
decreased blade velocities. In specific embodiments, blade velocity
according to the present disclosure may be from about 20 m/s to
about 340 m/s at the blade tip. More specifically, the blade
velocity may be below 200 m/s, below 100 m/s, or from about 50 m/s
to about 75 m/s. In one embodiment, the disclosure can provide for
turbine operation at a blade velocity that is about 3 times lower
than typical (i.e., 200 mph (89 m/s)), which may result in a
decrease in blade erosion rate of 27 fold or more. In one
embodiment, a blade velocity of 150 mph (67 m/s)--i.e., a four-fold
decrease from typical blade velocities--can provide approximately a
64 fold decrease in blade damage rate.
[0050] The ability to operate the turbine in a power production
system at a lower velocity can arise from a variety of factors that
can be embodied singularly or in multiple combinations. For
example, the turbine blades can be designed with dimensions that
can allow for the blade velocity to be slowed to a speed where
particle impingement no longer causes erosion of the turbine
blades. More specifically, the operating blade speed can be reduced
below the critical velocity at which erosion occurs. In this
regard, the blade speed at any given point on a blade is provided
by the following formula:
v=(rpm/60)*2*.pi.*r (Formula 1)
[0051] where: [0052] v=blade speed (m/s), [0053] rpm=rotations of
the blade per minute, [0054] .pi.=pi, and [0055] r=distance (m)
between a center of the rotor and a point on the blade at which the
blade velocity is to be determined (e.g., radius).
[0056] Note further that the blade speed at the tip of a blade is
provided by the following formula:
v.sub.t=(rpm/60)*2*.pi.*(a+b) (Formula 2)
[0057] where: [0058] v.sub.t=blade speed (m/s) at the tip of the
blade, [0059] rpm=rotations of the blade per minute, [0060]
.pi.=pi, [0061] a=radius (m) of the rotor at the blade, and [0062]
b=blade height (m).
[0063] Thus, the maximum blade speed for each blade may be reduced
by decreasing the distance to which the blades extend from the
center of the rotor. As discussed below, use of turbines having
blades extending to relatively smaller radii may be enabled by
employing a supercritical fluid having relatively high fluid
density and high pressure at a moderate flow velocity in the
turbine of the present disclosure. Further, employing a high
density working fluid in the turbine may provide for significantly
reduced turbine blade temperature by improving the ability of
transpiration to cool the blades.
[0064] Blade height (i.e., the distance from a root at the outer
surface of the turbine shaft (e.g. rotor) to the blade tip)
preferably is less than about 0.275 m. In specific embodiments,
average blade height can be about 0.05 m to about 0.25 m, about
0.075 m to about 0.225 m, about 0.1 m to about 0.2 m, or about
0.125 m to about 0.175 m. In specific embodiments, actual blade
heights could vary from the turbine inlet to the turbine outlet.
For example, blade height at the inlet could be lower than the
average and increase toward the outlet such that blade height at
the outlet is higher than the average. Average blade width can be
about 0.025 m to about 0.125 m, about 0.04 m to about 0.11 m, about
0.05 m to about 0.1 m, or about 0.06 m to about 0.09 m. In other
embodiments, blade height and width can be further dimensions that
allow for operation at a velocity as described herein.
[0065] The inventive turbines and methods of operation also can be
characterized by overall turbine dimensions. For example, a turbine
according to the disclosure can have an overall length of less than
about 11 m, less than about 10 m, or less than about 9 m. In
further embodiments, overall turbine length can be about 6 m to
about 10 m, about 6.5 m to about 9.5 m, about 7 m to about 9 m, or
about 7.5 m to about 8.5 m. A turbine according to the disclosure
can have an average diameter of less than about 3.5 m, less than
about 3 m, or less than about 2.5 m. In further embodiments,
average turbine diameter can be about 0.25 m to about 3 m, about
0.5 m to about 2 m, or about 0.5 m to about 1.5 m. The ratio of
turbine length to turbine average diameter (i.e., diameter of the
turbine blades) can be greater than about 3.5, greater than about
4, greater than about 4.5, or greater than about 5. In specific
embodiments, the ratio of turbine length to turbine average
diameter can be about 3.5 to about 7.5, about 4 to about 7, about
4.5 to about 6.5, or about 5 to about 6. The above ratios
specifically can relate to the total length of the turbine. In some
embodiments, total length may refer to the length of the casing
from inlet to outlet. In certain embodiments, total length may
refer to the distance within the casing from the turbine blade
immediately adjacent the inlet to the turbine blade immediately
adjacent the outlet.
[0066] The inventive turbines and methods of operation likewise can
be characterized by average blade radius (center of the rotor to
tip of the turbine blade). Preferably, the turbines operate with an
average blade radius of less than about 1.2 m, less than about 1.1
m, less than about 1 m, less than about 0.9 m, less than about 0.8
m, less than about 0.7 m, or less than about 0.6 m. Turbine blade
radius specifically can be about 0.25 m to about 1 m, about 0.275 m
to about 0.8 m, about 0.3 m to about 0.7 m, about 0.325 m to about
0.6 m, about 0.35 m to about 0.5 m, or about 0.375 m to about 0.475
m.
[0067] In certain embodiments, a turbine useful according to the
disclosure can have a total number of turbine blades that is
significantly less than present in typical gas turbine systems.
Specifically, the inventive turbines may have less than about 3,000
blades, less than about 2,500 blades, or less than about 2,000
blades. In further embodiments, the number of blades in a turbine
can be about 500 to about 2,500, about 750 to about 2,250, about
1,000 to about 2,000, or about 1,250 to about 1,750.
[0068] In some embodiments, the turbines according to the
disclosure particularly can provide high efficiency power
production with reduced blade velocity through operation at
significantly increased inlet pressure, and/or significantly
increased outlet pressure, and/or significantly increased pressure
drop from inlet to outlet in relation to typical gas turbine power
production systems. In specific embodiments, the turbine can be
operated at an inlet pressure of at least about 25 bars (2.5 MPa),
at least about 50 bars (5 MPa), at least about 100 bars (10 MPa),
at least about 150 bars (15 MPa), at least about 200 bars (20 MPa),
or at least about 250 bars (25 MPa). In further embodiments, inlet
pressure can be about 50 bars (5 MPa) to about 500 bars (50 MPa),
about 100 bars (10 MPa) to about 450 bars (45 MPa), about 150 bars
(15 MPa) to about 400 bars (40 MPa), about 200 bars (20 MPa) to
about 400 bars (40 MPa), or about 250 bars (25 MPa) to about 350
bars (35 MPa).
[0069] In further embodiments, the turbine can be operated with an
outlet pressure of at least about 5 bars (0.5 MPa), at least about
10 bars (1 MPa), at least about 15 bars (1.5 MPa), at least about
20 bars (2 MPa), or at least about 25 bars (2.5 MPa). The outlet
pressure particularly may be about 10 bars (1 MPa) to about 50 bars
(5 MPa), about 15 bars (1.5 MPa) to about 45 bars (4.5 MPa), about
20 bars (2 MPa) to about 40 bars (4 MPa), or about 25 bars (2.5
MPa) to about 35 bars (3.5 MPa).
[0070] In other embodiments, the ratio of turbine inlet pressure to
turbine outlet pressure can be at least about 6, at least about 7,
at least about 8, at least about 9, or at least about 10. In
specific embodiments, the ratio of turbine inlet pressure to
turbine outlet pressure can be about 6 to about 15, about 7 to
about 14, about 8 to about 12, or about 9 to about 11.
[0071] In yet other embodiments, the turbines according to the
disclosure can be operated in a power production system at a
significantly increased flow density in relation to operation of
turbines in typical power production systems. For example, the
inventive turbines can be operated at a flow density of at least
about 20 kg/m.sup.3, at least about 50 kg/m.sup.3, at least about
100 kg/m.sup.3, at least about 150 kg/m.sup.3, at least about 200
kg/m.sup.3, or at least about 300 kg/m.sup.3, at least about 400
kg/m.sup.3, at least about 500 kg/m.sup.3, or at least about 600
kg/m.sup.3.
[0072] In contrast to the turbines in accordance with the present
disclosure, existing gas turbine compressors may operate with
outlet pressures from about 1 Bar (0.1 MPa) to about 15 Bar (1.5
MPa), with gas densities in the compressor section ranging from 1
kg/m.sup.3 to about 15 kg/m.sup.3 (assuming adiabatic compression
heating). Erosion and other problems may not be severe in the
compressor due to the relatively low temperatures therein. However,
in the hot section, the gas temperature may vary from a peak of
roughly 1727.degree. C. to about 527.degree. C. The density of the
gas in the hot section may vary from a high of about 5 kg/m.sup.3
to a low of about 0.5 kg/m.sup.3. Thus, the conditions inside
existing turbines may vary considerably from those within the
turbines in accordance with the present disclosure.
[0073] The use of higher pressures at lower flow rates and higher
temperatures may increase the torque on the turbine blades.
Accordingly, the turbine may include features configured to reduce
the torque applied to the blades. In particular, the turbine may
include a larger number of blades, discs, and/or stages than
conventional turbines, which distributes the torque therebetween to
reduce the torque applied to the individual blades. Further, the
blades may define an angle of attack configured to exert less force
and torque on the blades. In particular, the blades may define a
decreased angle with respect to the flow through the turbine, which
induces less drag and increases the lift to drag ratio.
Accordingly, these features may reduce the torque exerted on each
of the blades so that they may be formed from relatively less
strong and relatively less expensive materials.
[0074] In some embodiments, blade erosion also may be controlled,
reduced, or eliminated by combining any of the above-described
characteristics with one or more methods of blade cooling. Any
method of turbine blade cooling could be combined with the present
disclosure, including transpiration blade cooling, as more fully
described below. In this regard, transpiration cooling may be
employed to cool any of the various components of the turbine,
combustor, and related apparatuses disclosed herein. With
particular regard to the turbine, the case, stators (e.g., stator
blades), seals, blades (e.g., turbine blades), rotor, and various
other internal components may be transpiration cooled through, for
example, employing the porous materials disclosed herein. In this
regard, the stators may comprise the porous sintered material and
the porous sintered material may be configured to direct the
transpiration fluid to an exterior surface of the stators.
Additionally, one or more of the components of the turbine assembly
may be configured to direct transpiration fluid to the seals. The
seals may comprise the porous sintered material in some
embodiments. Example embodiments of seals and stators that may be
transpiration cooled in accordance with embodiments of the
disclosure are described in U.S. Pat. App. Pub. 2009/0142187, which
is incorporated herein by reference in its entirety. However,
various other embodiments of components of turbines, combustors,
and related apparatuses may also be transpiration cooled in
accordance with the present disclosure.
[0075] Further, the transpiration cooling techniques disclosed
herein may provide improved cooling relative to existing
transpiration cooling techniques. Current blade cooling is
typically conducted with bleed air from the compressor of the
turbine. This air has a limited heat capacity due to its relatively
low density (e.g., 0.5-5 kg/m.sup.3) set by the relatively low
operating pressure of the turbine hot section in existing turbines,
as described above. This limits the heat transfer rates. In
contrast, as discussed below, the present disclosure provides for
transpiration cooling through use of CO.sub.2, which may provide
improved heat transfer.
[0076] The heat transfer rates for existing embodiments of turbines
are also limited by the relatively large stress placed on the
turbine blades due to the long length of the blades resulting in
high centrifugal forces during rotation thereof. The cooling
passages in existing turbines thus must be kept relatively small
and they must not define more than a relatively small fraction of
the blade overall cross-sectional area in order to limit the
reduction in longitudinal strength of the blades caused by the
cooling passages.
[0077] The inventive turbines are particularly useful in systems
and methods for power production in that the turbines not only
provide for reduced blade erosion but also can significantly reduce
total turbine cost. In specific embodiments, total turbine cost in
relation to turbines used in typical power production systems can
be reduced by at least 20%, at least 30%, at least 40%, at least
50%, at least 60%, at least 70%, or at least 75% without any
significant loss in electrical power output (i.e., loss of less
than 5%, less than 4%, less than 3%, less than 2%, less than 1%, or
less than 0.8%). Reductions in cost may occur by avoiding the need
for superalloys and/or other expensive materials in the blades due,
for example, to a reduction in the centrifugal forces applied
thereto. Further, reductions in power output may be minimized
despite reduced rotating speeds by employing high inlet
temperatures in the turbine as well as high operating pressures
relative to existing embodiments of turbines.
[0078] In specific embodiments, the present disclosure can comprise
systems and methods for power production that can incorporate the
present turbine blade designs and modes of operation. For example,
the inventive systems and methods allow for power production
through use of a high efficiency fuel combustor (such as a
transpiration cooled combustor), optionally with an associated
circulating fluid (such as a CO.sub.2 circulating fluid).
Specifically, the use of a high pressure circulating fluid (or
working fluid) that has a high CO.sub.2 recycle ratio provides the
ability to direct a portion of the CO.sub.2 circulating fluid to
the turbine blades for transpiration cooling.
[0079] The combination of transpiration cooling with the blade
designs and modes of operation of the present disclosure
particularly can be useful since erosion can be a function of
turbine blade temperature and blade material composition. The
combination of turbine blade design and operation with blade
operation temperature can provide for a wide range of possible
blade operation velocities and blade operation temperatures wherein
blade erosion can be controlled, reduced, or eliminated. At lower
blade temperatures, erosion is lower, and the blade velocity at
which erosion starts can be higher. The ability to choose operation
conditions is beneficial in that it can allow for the use of metal
alloys that can resist erosion at higher blade velocities but
otherwise would not be available for use at higher operating
temperatures. In this regard, at lower temperatures, high strength
steels are relatively immune to impact damages. As an example,
rolled homogenous armor used on military vehicles is not damaged by
solid steel bullets traveling at up to speeds of 400 mph (179
m/s).
[0080] In other embodiments, however, as more fully described
below, transpiration may effect blade protection by preventing
solidification of combustion product stream components (e.g.,
liquid ash). In such embodiments, transpiration cooling may be
defined as cooling the blades (and/or other components) to a
temperature below the temperature of the combustion product stream.
More particularly, such cooling may be configured to have a lower
limit that is greater than the temperature at which a component of
the combustion product stream (e.g., liquid ash) will freeze (or
solidify) and thus become deposited upon the turbine blades. For
example, ash softening may begin at 590.degree. C., and melting may
occur at 870.degree. C. Without transpiration cooling, the turbine
would need to operate well below 590.degree. C. to avoid ash
buildup on the blades, which is too low for efficient operation.
With transpiration protection, the turbine can operate above
870.degree. C., where the ash is liquid, but the liquid droplets do
not touch or stick to the surface because of the transpiration
vapor layer covering substantially all surfaces that are internal
to the turbine and thus subject to contact with components of a
stream flowing through the turbine (e.g., the internal surface of
the turbine housing, the external surfaces of the turbine blades
within the turbine, etc.). Thus, transpiration protection may
reduce or eliminate not only degradation due to mechanical erosion
by particle impingement, but also chemical degradation by keeping
the blades cooler, and by replacing air or air/steam as the coolant
with CO.sub.2 as the coolant in the form of a transpiration
fluid.
[0081] In some embodiments, it can be useful for the turbines to be
operated at blade velocities that are relative to the velocity of
the combustion product flow. In such embodiments, it can be
particularly beneficial for flow velocity to be significantly less
than flow velocities in typical combustion processes. For example,
flow velocity according to the disclosure can be less than about
400 mph (179 m/s), less than about 350 mph (156 m/s), less than
about 300 mph (134 m/s), less than about 250 mph (112 m/s), less
than about 200 mph (89 m/s), less than about 150 mph (67 m/s), or
less than about 100 mph (45 m/s). The ratio of blade tip velocity
to flow velocity preferably is greater than 1, greater than 1.5,
greater than 2, greater than 2.5, or greater than 3. Specifically,
the ratio of blade tip velocity to flow velocity can be about 1 to
about 5, about 1.5 to about 4.75, about 1.75 to about 4.5, about 2
to about 4.25, or about 2.5 to about 4.
[0082] As a result of erosion, turbines may experience degradation
in performance over time (e.g., through reduced efficiency and/or
power output). For example, a conventional turbine may experience
operational degradation of 10% power loss over a two to three year
period. An overhaul to repair the turbine may cost approximately
50% of the purchase cost of the turbine. Accordingly, over a 20
year lifetime, existing turbines may be overhauled a total of eight
times, which may cost a total of 4 times the initial purchase price
of the turbine.
[0083] This degradation may be due to erosion caused by residual
dust particles that get past an air filtration system positioned
between the combustor and the turbine. Increasing the particulate
removal effectiveness of the filters may not be a viable option
because this may restrict air flow and reduce efficiency of the
turbine. Thus, the turbines of the present disclosure may provide
significant cost savings by minimizing or eliminating the need for
overhauls by minimizing or eliminating damage from erosion. In this
regard, the rate of dissipation of impact energy associated with
collision between the particles and blades is approximately
proportional to the cube of the relative velocity therebetween. In
this regard, erosion of turbine blades tends to be approximately
proportional to the rate of impact energy dissipation ("Impact
Power"), as illustrated below:
IP=kV.sup.3/X (Formula 3)
[0084] where: [0085] IP=impact power, [0086] k=a variable factor
based on the particle material, the blade material, the ambient
temperature, and the impact angle, [0087] v=relative velocity
between the turbine blades and particles, and [0088]
X=characteristic length of the impact interaction.
[0089] By reducing the speed of the blades and providing
transpiration protection, impacts may be minimized or reduced below
a threshold at which erosion occurs and chemical damage may also be
reduced or eliminated. Accordingly, expenses associated with
overhauls due to erosion may be reduced or eliminated, and thus
embodiments of the turbines provided herein may provide significant
cost savings. Further, as noted above, by eliminating the need for
use of expensive superalloys, the turbines in accordance with the
present disclosure may be relatively less expensive than existing
turbines.
[0090] In various known embodiments of power plants, efficiency is
critically dependent on turbine inlet temperatures. For example,
extensive work has been done at great cost to achieve turbine
technology allowing for inlet temperatures as high as about
1,350.degree. C. The higher the turbine inlet temperature, the
higher the plant efficiency, but also the more expensive the
turbine is, and potentially, the shorter its lifetime. Because of
the relatively high temperature of the combustion product stream,
it can be beneficial for the turbine to be formed of materials
capable of withstanding such temperatures. It also may be useful
for the turbine to comprise a material that provides good chemical
resistance to the type of secondary materials that may be present
in the combustion product stream.
[0091] In certain embodiments, the present disclosure can
particularly provide for the use of a cooling fluid with the
turbine components. As more fully described below, for example, the
inventive systems and methods allow for power production through
use of a high efficiency fuel combustor (e.g., a transpiration
cooled combustor) and an associated circulating fluid (such as a
CO.sub.2 circulating fluid). Specifically, a portion of the
circulating fluid can be directed to the turbine components,
particularly the turbine blades, to be used in turbine cooling,
such as through transpiration cooling.
[0092] For example, in some embodiments, a portion of a CO.sub.2
circulating fluid can be withdrawn from the cycle (e.g., from a
portion of the cycle where the circulating fluid is under
conditions useful for a transpiration cooling fluid) and directed
to a turbine for cooling of the components, particularly the
turbine blades. The blade cooling fluid can be discharged from
holes (or perforations) in the turbine blade and be input directly
into the turbine flow. Thus, rather than using air as a
transpiration cooling fluid (which is limited in its cooling
ability as described above, and hampered by safety concerns), the
methods and systems of the disclosure provide for the use of very
large quantities of high pressure CO.sub.2, supercritical CO.sub.2,
and even liquid CO.sub.2 as a turbine blade cooling medium. This is
highly useful because it increases the cooling capacity available
for the turbine blades by large ratios in relation to known blade
cooling methods. The disclosure also is particularly useful because
the CO.sub.2 circulating fluid can be present in the system in very
large quantities, which allows for a very large quantity of cooling
fluid to be moved through the turbine blades. This high volume
and/or high mass flow of CO.sub.2 cooling fluid through the turbine
blades not only protects the turbine blades from the extreme heat
that is useful for high efficiency power production methods, but it
also assists in protecting the turbine blades from the corrosive
and erosive effects of the high temperature gases and unfiltered
particulate material flowing through the turbine by transpiration
of the CO.sub.2 cooling fluid out through the entire surface of the
blade. In one embodiment transpiration cooling may provide for
operational blade temperatures from about 200.degree. C. to about
700.degree. C. despite the significantly higher turbine inlet
temperatures described above (e.g., 1350.degree. C.), which may
thus allow for use of turbine blades comprising relatively less
expensive materials than those which are presently employed and/or
higher turbine inlet temperatures may be employed, which may lead
to greater efficiency. The foregoing transpiration cooled turbine
components can be used in any power production method and system
wherein high pressure CO.sub.2 (or other fluid which is less
corrosive than air or steam, such as N.sub.2) can be made available
as a high recycle ratio circulating fluid.
[0093] In specific embodiments, the use of a CO.sub.2 circulating
fluid as a turbine blade cooling medium allows for the turbine
blades to be fabricated from much lower cost materials than known
turbine blades used in high efficiency power production methods
because use of the CO.sub.2 cooling medium prevents the blades in
the present disclosure from being heated to the extreme
temperatures of the surrounding combustion product flow and reduces
the corrosive and erosive effects of the combustion product flow.
For example, according to the present disclosure, turbine blades
could be fabricated from a wide variety of high strength steels, or
even relatively low cost steels. Likewise, the blades could be
fabricated from carbon composites or even low temperature
materials, such as aluminum. Any material recognized as useful in
the art for gas turbine components, even for turbines used in low
temperature conditions and/or low erosive or low corrosive
conditions, could be used for fabricating turbine components
according to the present disclosure.
[0094] Transpiration cooling of turbine blades with a portion of a
CO.sub.2 circulating fluid according to the present disclosure
further is useful because it can facilitate the safe passage of
combustion gasses containing ash (or other particulate matter
and/or incombustibles) through the turbine without the need for an
intervening filtration step and component. This can greatly
simplify the design of power production facilities and increase the
types of materials that may be used as the fuel source for
combustion.
[0095] The use of a CO.sub.2 circulating fluid in transpiration
cooling of turbine components according to the present disclosure
also is advantageous in relation to the thermodynamics of the power
production cycle. Because of the vastly improved cooling ability of
the CO.sub.2 circulating fluid in relation to known transpiration
media for turbine blades, it is possible to operate the combustor
at increased temperatures without the limitation of the heat
tolerance of the turbine. Thus, combustors capable of operation at
extremely high temperatures (e.g., transpiration cooled combustors)
can be operated according to the present disclosure at near maximum
operating temperatures since the combustion product flow can be
passed through the CO.sub.2 cooled turbine without damage to the
turbine components. This increases the potential thermodynamic
efficiency of the power production cycle to approaching 100%.
[0096] Any combination of turbine blade design, overall turbine
design, and transpiration cooling of the turbine blades can be used
in any power production method where turbine blade life is
desirably extended, such as methods and systems where combustion
results in formation of particulates. In some embodiments, the
methods and systems particularly can be those wherein a circulating
fluid can be used. For example, high pressure CO.sub.2 can be made
available as a high recycle ratio circulating fluid.
[0097] For example, a turbine as described herein may be used in a
method and system wherein a CO.sub.2 circulating fluid is provided
in a combustor along with an appropriate fuel, any necessary
oxidant, and any associated materials that may be useful for
efficient combustion. Such systems and methods can comprise a
combustor that operates at very high temperatures (e.g., in the
range of about 1,600.degree. C. to about 3,300.degree. C., or even
greater), and the presence of the circulating fluid can function to
moderate the temperature of a fluid stream exiting the combustor so
that the fluid stream can be utilized in energy transfer for power
production. Specifically, a combustion product stream can be
expanded across at least one turbine to generate power. The
expanded gas stream can be cooled to remove various components from
the stream, such as water, and heat withdrawn from the expanded gas
stream can be used to heat the CO.sub.2 circulating fluid. The
purified circulating fluid stream can then be pressurized and
heated for recycle through the combustor. Exemplary power
production systems and methods that may incorporate the turbine
blade designs of the present disclosure (with or without associated
blade transpiration cooling) are described in U.S. Pat. App. Pub.
2011/0179799, which is incorporated herein by reference in its
entirety.
[0098] The incorporation of a turbine according to the disclosure
in a combustion power cycle is particularly useful in relation to
combustion of fuels that result in a particulate component. Various
types of coal, for example, can be combusted in a power production
cycle to produce a combustion stream having a content of ash and/or
other particulates. Beneficially, when a turbine according to the
disclosure is incorporated into the combustion cycle, the full
combustion product stream (i.e., including the full content of
particulates) can be introduced into the turbine without the need
of a preliminary filtering step. This enables the use of higher
turbine inlet temperature which in turn increases combustion
efficiency in relation to processes requiring filtration of the
combustion product prior to passage through the turbine. This is
possible according to the disclosure since the inventive turbines
can be subjected to particle impingement without significant
erosion. Particulate materials then can be filtered from the stream
exiting the turbine.
[0099] One embodiment of a combustion cycle provided according to
the present disclosure is illustrated in the flow diagram of FIG.
1. In the illustrated embodiment, an air separation unit 100 is
provided to intake ambient air 10 and output an enriched oxygen
stream 120. The oxygen stream 120 may comprise oxygen having a
molar purity of at least about 50%, at least about 60%, at least
about 70%, at least about 80%, at least about 85%, at least about
90%, or at least about 95%. The oxygen stream 120 may be supplied,
for example, by any air separation system/technique known in the
art, such as, for example, a cryogenic air separation process, or a
high temperature ion transport membrane oxygen separation process
(from air), could be implemented. In specific embodiments, an
enriched oxygen stream may be produced by the operation of a
cryogenic air separation process in which the oxygen is pressurized
in the process by pumping liquid oxygen that is efficiently heated
to ambient temperature conserving refrigeration. Such a cryogenic
pumped oxygen plant can have two air compressors, both of which can
be operated adiabatically with no inter-stage cooling. In specific
embodiments, it may be useful to include components useful for
recovering heat produced by the air separation unit and
transferring the heat to a component of the presently described
system where heat input may be desirable.
[0100] The cycle illustrated in FIG. 1 can be useful for combustion
of any fuel source that includes particulate matter (e.g., ash) as
a component of the combustion product. Non-limiting examples of
fuels that are useful according to the disclosure include various
grades and types of coal, wood, oil, tar from tar sands, bitumen,
biomass, algae, graded combustible solid waste refuse, asphalt, and
used tires. In particular, any solid fuel material may be used in
the disclosure, and such fuels particularly may be ground,
shredded, or otherwise processed to reduce particles sizes, as
appropriate. A fluidization or slurrying medium can be added, as
necessary, to achieve a suitable form and to meet flow requirements
for high pressure pumping. For example, referring to FIG. 1, the
solid fuel 15 can be passed through a mill apparatus 200 to provide
a powdered fuel. In other embodiments, the solid fuel 15 could be
provided in a particularized condition to forego the need for
on-site milling. In specific embodiments, the solid fuel 15 may
have an average particle size of about 10 .mu.m to about 500 .mu.m,
about 25 .mu.m to about 400 .mu.m, or about 50 .mu.m to about 200
.mu.m. In other embodiments, the solid fuel 15 may be described in
that greater than 50%, 60%, 70%, 80%, 90%, 95%, or 99% of the solid
fuel particles have an average size of less than about 500 .mu.m,
400 .mu.m, 300 .mu.m, 200 .mu.m, or 100 .mu.m.
[0101] The solid fuel 15 can be suitably processed to allow for
injection into a combustion apparatus at sufficient rates and at
pressures above the pressure within the combustion chamber. To
provide such characteristic, the solid fuel 15 may be in liquid,
slurry, gel, or paste form with appropriate fluidity and viscosity
at ambient temperatures or at elevated temperatures. For example,
the solid fuel 15 may be provided at a temperature of about
30.degree. C. to about 500.degree. C., about 40.degree. C. to about
450.degree. C., about 50.degree. C. to about 425.degree. C., or
about 75.degree. C. to about 400.degree. C. When the solid fuel 15
is in a ground, shredded, or otherwise processed condition so that
particle size is appropriately reduced, a fluidization or slurrying
medium can be added, as necessary, to achieve a suitable form and
to meet flow requirements for high pressure pumping. As illustrated
in the embodiment of FIG. 1, the particulate solid fuel 220
produced from the solid fuel 15 by the mill apparatus 200 can be
mixed with a fluidizing substance to provide the coal in the form
of a slurry. In particular, the particulate solid fuel 220 is
combined in a mixer 250 with a CO.sub.2 side draw 562 from a
recycled CO.sub.2 circulating fluid stream 561. The CO.sub.2 side
draw 562 may be provided in a supercritical, high density state. In
specific embodiments, the CO.sub.2 used to form the slurry can have
a density of about 450 kg/m.sup.3 to about 1,100 kg/m.sup.3. More
particularly, the CO.sub.2 side draw 562 may cooperate with the
particulate solid fuel 220 to form a slurry 255 having, for
example, from about 10 weight % to about 75 weight % or from about
25 weight % to about 55 weight % of the particulate coal. Moreover,
the CO.sub.2 from the side draw 562 used to form the slurry 255 may
be at a temperature of less than about 0.degree. C., less than
about -10.degree. C., less than about -20.degree. C., or less than
about -30.degree. C. In further embodiments, the CO.sub.2 from the
side draw 562 used to form the slurry may be at a temperature of
about 0.degree. C. to about -60.degree. C., about -10.degree. C. to
about -50.degree. C., or about -18.degree. C. to about -40.degree.
C. Although the slurrying step is described in terms of using
CO.sub.2 as a slurry medium, it is understood that other slurrying
mediums could be used.
[0102] The slurry 255 can be transferred from the mixer 250 via a
pump 270 to a combustion apparatus 300. In specific embodiments,
the combustion apparatus 300 can be a high efficiency combustor
capable of providing substantially complete combustion of a fuel at
a relatively high combustion temperature. High temperature
combustion can be particularly useful to provide for substantially
complete combustion of all combustible components of the fuel and
thus maximize efficiency. In various embodiments, high temperature
combustion can mean combustion at a temperature of at least about
1,000.degree. C., at least about 1,200.degree. C., at least about
1,500.degree. C., at least about 2,000.degree. C., or at least
about 3,000.degree. C. In further embodiments, high temperature
combustion can mean combustion at a temperature of about
1,000.degree. C. to about 5,000.degree. C. or, about 1,200.degree.
C. to about 3,000.degree. C.
[0103] In certain embodiments, the combustion apparatus 300 may be
a transpiration cooled combustor. One example of a transpiration
cooled combustor that may be used in the disclosure is described in
U.S. Pat. App. Pub. No. 2010/0300063 and U.S. Pat. App. Pub. No.
2011/0083435, the disclosures of which are incorporated herein by
reference in their entirety. In some embodiments, a transpiration
cooled combustor useful according to the disclosure may include one
or more heat exchange zones, one or more cooling fluids, and one or
more transpiration fluids.
[0104] The use of a transpiration cooled combustor according to the
present disclosure is particularly advantageous over the known art
around fuel combustion for power production. For example, the use
of transpiration cooling can be useful to prevent corrosion,
fouling, and erosion in the combustor. This further allows the
combustor to work in a sufficiently high temperature range to
afford complete or at least substantially complete combustion of
the fuel that is used. These, and further advantages, are further
described herein.
[0105] In one particular aspect, a transpiration cooled combustor
useful according to the disclosure can include a combustion chamber
at least partially defined by a transpiration member, wherein the
transpiration member is at least partially surrounded by a pressure
containment member. The combustion chamber can have an inlet
portion and an opposing outlet portion. The inlet portion of the
combustion chamber can be configured to receive the carbon
containing fuel to be combusted within the combustion chamber at a
combustion temperature to form a combustion product. The combustion
chamber can be further configured to direct the combustion product
toward the outlet portion. The transpiration member can be
configured to direct a transpiration substance therethrough toward
the combustion chamber for buffering interaction between the
combustion product and the transpiration member. In addition, the
transpiration substance may be introduced into the combustion
chamber to achieve a desired outlet temperature of the combustion
product. In particular embodiments, the transpiration substance can
at least partially comprise the circulating fluid. The walls of the
combustion chamber may be lined with a layer of porous material
through which the transpiration substance, such as CO.sub.2 and/or
H.sub.2O, is directed and flows.
[0106] The flow of the transpiration substance through this porous
transpiration layer, and optionally through additional provisions,
can be configured to achieve a desired total exit fluid stream
outlet temperature from the combustion apparatus 300. In some
embodiments, as further described herein, such temperature can be
in the range of about 500.degree. C. to about 2,000.degree. C. This
flow may also serve to cool the transpiration member to a
temperature below the maximum allowable operational temperature of
the material forming the transpiration member. The transpiration
substance may also serve to prevent impingement of any liquid or
solid ash materials or other contaminants in the fuel which might
corrode, foul, or otherwise damage the walls. In such instances, it
may be desirable to use a material for the transpiration member
with a reasonable thermal conductivity so that incident radiant
heat can be conducted radially outwards through the porous
transpiration member and then be intercepted by convective heat
transfer from the surfaces of the porous layer structure to the
fluid passing radially inwards through the transpiration layer.
Such a configuration may allow the subsequent part of the stream
directed through the transpiration member to be heated to a
temperature in a desirable range, such as about 500.degree. C. to
about 1,000.degree. C. or from about 200.degree. C. to about
700.degree. C., while simultaneously maintaining the temperature of
the porous transpiration member within the design range of the
material used therefor. Suitable materials for the porous
transpiration member may include, for example, porous ceramics,
refractory metal fiber mats, hole-drilled cylindrical sections,
and/or sintered metal layers or sintered metal powders. A second
function of the transpiration member may be to ensure a
substantially even radially inward flow of transpiration fluid, as
well as longitudinally along the combustor, to achieve good mixing
between the transpiration fluid stream and the combustion product
while promoting an even axial flow of along the length of the
combustion chamber. A third function of the transpiration member
can be to achieve a velocity of diluent fluid radially inward so as
to provide a buffer for or otherwise intercept solid and/or liquid
particles of ash or other contaminants within the combustion
products from impacting the surface of the transpiration layer and
causing blockage, erosion, corrosion, or other damage. Such a
factor may only be of importance, for example, when combusting a
fuel, such as coal, having a residual inert non-combustible
residue. The inner wall of the combustor pressure vessel
surrounding the transpiration member may also be insulated to
isolate the high temperature transpiration fluid stream within the
combustor.
[0107] In certain embodiments, a mixing arrangement (not
illustrated) may be provided to combine the materials to be
introduced into the combustion apparatus 300 prior to such
introduction. Specifically, any combination of two or all three of
the fuel, O.sub.2, and circulating fluid (e.g., CO.sub.2
circulating fluid) may be combined in the optional mixing
arrangement prior to introduction into the combustion apparatus
300.
[0108] The fuel 15 introduced to the combustion apparatus 300 (as
the slurry stream 255) along with the O.sub.2 120 and a recycled
circulating fluid 503 is combusted to provide a combustion product
stream 320. In specific embodiments, the combustion apparatus 300
is a transpiration cooled combustor, such as described above.
Combustion temperature can vary depending upon the specific process
parameters--e.g., the type of fuel used, the molar ratio of
circulating fluid to carbon in the fuel as introduced into the
combustor, and/or the molar ratio of CO.sub.2 to O.sub.2 introduced
into the combustor. In specific embodiments, the combustion
temperature is a temperature as described above in relation to the
description of the transpiration cooled combustor. In particularly
preferred embodiments, combustion temperatures in excess of about
1,000.degree. C., as described herein, may be advantageous.
[0109] It also can be useful to control combustion temperature such
that the combustion product stream leaving the combustor has a
desired temperature. For example, it can be useful for the
combustion product stream exiting the combustor to have a
temperature of at least about 700.degree. C., at least about
900.degree. C., at least about 1,200.degree. C., or at least about
1,600.degree. C. In some embodiments, the combustion product stream
may have a temperature of about 700.degree. C. to about
1,600.degree. C. or about 1,000.degree. C. to about 1,500.degree.
C.
[0110] Specifically, the pressure of the combustion product stream
320 can be related to the pressure of the circulating fluid that is
introduced into the combustion apparatus 300. In specific
embodiments the pressure of the combustion product stream 320 can
be at least about 90% of the pressure of the circulating fluid
introduced into the combustion apparatus 300.
[0111] The chemical makeup of the combustion product stream 320
exiting the combustion apparatus 300 can vary depending upon the
type of fuel used. Importantly, the combustion product stream will
comprise the major component of the circulating fluid (e.g.,
CO.sub.2) that will be recycled and reintroduced into the
combustion apparatus 300 or further cycles. In further embodiments,
the combustion product stream 320 may comprise one or more of water
vapor, SO.sub.2, SO.sub.3, HCl, NO, NO.sub.2, Hg, excess O.sub.2,
N.sub.2, Ar, incombustibles and/or other particulate matter, and
possibly other contaminants that may be present in the fuel that is
combusted. These materials present in the combustion product stream
may persist in the CO.sub.2 circulating fluid stream unless
removed, such as by processes described herein.
[0112] Advantageously, according to the present disclosure, the
combustion product stream 320 can be directed to a turbine 400
without the necessity of first filtering out any particulate
material in the combustion product stream 320. In the turbine 400,
the combustion product stream 320 is expanded to generate power
(e.g., via a generator 400a to produce electricity). The turbine
400 can have an inlet for receiving the combustion product stream
320 and an outlet for release of a turbine discharge stream 410.
Although a single turbine 400 is shown in FIG. 1, it is understood
that more than one turbine may be used, the multiple turbines being
connected in series or optionally separated by one or more further
components, such as a further combustion component, a compressing
component, a separator component, or the like.
[0113] The turbine 400 specifically can be a turbine having a blade
design and/or overall design as otherwise described herein.
Further, the turbine may incorporate transpiration cooling or other
cooling technology, as described herein. In particular, the turbine
design can be one with such low blade velocity and ash particle
impingement velocity such as to enable the turbine to endure
impingement without significant erosion. Transpiration cooling of
the turbine further can protect against particle erosion by
creating a continuous flow barrier layer of the transpiration fluid
between the blade surface and the particulate material passing
through the turbine.
[0114] Returning to FIG. 1, the exemplary system and cycle further
comprises a filter 5 downstream from the turbine 400. The turbine
discharge stream 410 can be passed through the filter 5 to remove
the particulate materials therefrom. The placement of the filter 5
downstream of the turbine 400, instead of upstream of the turbine,
is an advantageous characteristic of the disclosure since the
combustion product stream 320 can be expanded across the turbine at
the higher temperature and pressure when immediately exiting the
combustor apparatus 300 and thus power production may be maximized.
The lower pressure and cooler turbine discharge stream 410 can then
be filtered in the filter 5 to remove the particulate materials
therefrom as particulate stream 7. The filtered turbine discharge
stream 420 thus is provided substantially free from particulate
material for further processing in the combustion cycle.
[0115] In specific embodiments, the filter 5 preferably can
comprise a configuration that is effective for removing
substantially all of the particulate material present in the
combustion product stream 320. The filter 5 may comprise a cyclone
filter and/or a candle filter in some embodiments, and filtration
may occur from about 300.degree. C. to about 775.degree. C. in some
embodiments. In particular embodiments, removal of substantially
all of the particulates can encompass removal of at least 95%, at
least 96%, at least 97%, at least 98%, at least 99%, at least
99.5%, or at least 99.8% by volume of the particulates present in
the combustion product stream. Such particulate removal efficiency
of the filter can be related to particle size. For example, the
noted percentage of particles removed can relate to the ability of
the filter to retain particles having a diameter of at least about
0.1 .mu.m, at least about 0.5 .mu.m, at least about 1 .mu.m, at
least about 5 .mu.m, at least about 10 .mu.m, at least about 25
.mu.m, at least about 50 .mu.m, at least about 100 .mu.m, or at
least about 500 .mu.m. In one embodiment the particles produced by
combustion may be in the range from about 0.1 .mu.m to about 100
.mu.m, and the filter may be configured to remove substantially all
particles above about 1 .mu.m, above about 5 .mu.m, above about 10
.mu.m, above about 15 .mu.m, or above about 20 .mu.m and reduce the
total particulate levels to less than about 10 mg/m.sup.3, less
than about 5 mg/m.sup.3, less than about 1 mg/m.sup.3, or less than
about 0.5 mg/m.sup.3.
[0116] In particular embodiments (i.e., wherein CO.sub.2 is used as
a circulating fluid), the filtered turbine discharge stream 420 can
be passed through a heat exchanger unit 500 (which may be a series
of heat exchangers) to form an unprocessed recycle stream 501. This
unprocessed recycle stream 501 can be passed through a cold water
heat exchanger 520 to form stream 521, which is passed to a
separator 540 for removal of secondary components (e.g., H.sub.2O,
SO.sub.2, SO.sub.4, NO.sub.2, NO.sub.3, and Hg) as a stream 542. In
specific embodiments, the separator 540 can comprise a reactor that
provides a contactor with sufficient residence times such that the
impurities can react with water to form materials (e.g., acids)
that are easily removed. A purified circulating fluid stream 541
from the separator 540 can be passed through a compressor 550 to
form stream 551, which can be further cooled with a cold water heat
exchanger 560 to provide a supercritical, high density CO.sub.2
circulating fluid 561. In certain embodiments, the purified
CO.sub.2 circulating fluid 541 can be compressed to a pressure of
at least about 7.5 MPa or at least about 8 MPa. A portion of stream
561 can be withdrawn as stream 562 for use as the fluidizing medium
in the mixer 250 to form the slurry stream 255. The supercritical,
high density CO.sub.2 circulating fluid stream 561 otherwise is
further pressurized in compressor 570 to form the pressurized,
supercritical, high density CO.sub.2 circulating fluid stream 571.
A portion of the CO.sub.2 in stream 571 may be withdrawn as stream
572 to a CO.sub.2 pipeline or other means of sequestration. The
remaining portion of the CO.sub.2 can proceed as pressurized,
supercritical, high density CO.sub.2 circulating fluid stream 573,
which can be passed back through the heat exchanger 500 (or series
of heat exchangers) to heat the stream. In specific embodiments,
the CO.sub.2 circulating fluid can be provided at a density of at
least about 200 kg/m.sup.3, at least about 300 kg/m.sup.3, at least
about 500 kg/m.sup.3, at least about 750 kg/m.sup.3, or at least
about 1,000 kg/m.sup.3 after discharge from the cold water heat
exchanger 560 (and prior to passage through the heat exchanger unit
500 for heating). In further embodiments, the density may be about
150 kg/m.sup.3 to about 1,100 kg/m.sup.3. Passage of the stream 551
through the cold water heat exchanger 560 can cool the CO.sub.2
circulating fluid to a temperature of less than about 60.degree.
C., less than about 50.degree. C., or less than about 30.degree. C.
The CO.sub.2 circulating fluid in stream 561 entering the second
compressor 570 can be provided at a pressure of at least about 12
MPa. In some embodiments, the stream can be pressurized to a
pressure of about 15 MPa to about 50 MPa. Any type of compressor
capable of working under the noted temperatures and capable of
achieving the described pressures can be used, such as a high
pressure multi-stage pump.
[0117] The heated, pressurized, supercritical, high density
CO.sub.2 circulating fluid can exit the heat exchanger 500 as first
stream 503 to be provided as the recycled circulating fluid. In
some embodiments, the heated, pressurized, supercritical, high
density CO.sub.2 circulating fluid can exit the heat exchanger 500
as a second recycled circulating fluid stream 504 to be provided as
a transpiration fluid for the turbine blades. Preferably, the
second recycled circulating fluid stream 504 can be controllable
such that the total mass or volume of circulating fluid in the
stream can be increased or decreased as demand requires increasing
or decreasing the protection provided by the transpiration fluid.
Specifically, a system according to the disclosure can include flow
control means such that the second recycled circulating fluid
stream 504 can be completely stopped when desired.
Note that in some embodiments the recycled circulating fluid (e.g.,
CO.sub.2) provided to the turbine 400 may bypass the heat exchanger
500 prior to being provided to the turbine. In this regard, the
recycled CO.sub.2 may be compressed by the compressor 570 and then
a portion of circulating fluid stream 571 may bypass the heat
exchanger 500 and enter the turbine 400. Thereby CO.sub.2 (or other
recycled circulating fluid) may be introduced into the turbine 400
without being warmed by the heat exchanger 500. Accordingly, the
CO.sub.2 (or other recycled circulating fluid) may be introduced
into the turbine at a temperature that is less than the temperature
of fluid warmed by the heat exchanger. In this regard, the CO.sub.2
(or other recycled circulating fluid) may be introduced into the
turbine at a temperature of less than about 300.degree. C., less
than about 200.degree. C., less than about 100.degree. C., less
than about 55.degree. C., or less than about 25.degree. C. and
thus, the CO.sub.2 (or other recycled circulating fluid) may be
employed to cool the turbine 400. In order to compensate for adding
relatively cooler circulating fluid to the turbine 400, O.sub.2 may
travel through the heat exchanger 500 to warm the O.sub.2 and then
the O.sub.2 may be combined with the recycled circulating fluid 503
directed to the combustor 300 to compensate for the loss in
efficiency that may otherwise occur. In certain embodiments,
circulating fluid leaving the cold end of the heat exchanger (or
the final heat exchanger in the series when two or more heat
exchangers are used) can have a temperature of less than about
200.degree. C., less than about 100.degree. C., less than about
75.degree. C., or less than about 40.degree. C.
[0118] In certain embodiments, it may thus be useful for the heat
exchanger receiving the turbine discharge stream to be formed from
high performance materials designed to withstand extreme
conditions. For example, the heat exchanger may comprise an
INCONEL.RTM. alloy or similar material. Preferably, the heat
exchanger comprises a material capable of withstanding a consistent
working temperature of at least about 700.degree. C., at least
about 900.degree. C., or at least about 1,200.degree. C. It also
may be useful for one or more of the heat exchangers to comprise a
material that provides good chemical resistance to the type of
secondary materials that may be present in the combustion product
stream. INCONEL.RTM. alloys are available from Special Metals
Corporation, and some embodiments can include austenitic
nickel-chromium-based alloys. Suitable heat exchangers can include
those available under the tradename HEATRIC.RTM. (available from
Meggitt USA, Houston, Tex.).
[0119] As noted above, in addition to water, the CO.sub.2
circulating fluid may contain other secondary components, such as
fuel-derived, combustion-derived, and oxygen-derived impurities.
These secondary components of the CO.sub.2 circulating fluid (often
recognized as impurities or contaminants) can all be removed from
the cooled CO.sub.2 circulating fluid using appropriate methods
(e.g., methods defined in U.S. Patent Application Publication No.
2008/0226515 and European Patent Application Nos. EP1952874 and
EP1953486, which are incorporated herein by reference in their
entirety). For example, SO.sub.2 and SO.sub.3 can be converted 100%
to sulfuric acid, while >95% of the NO and NO.sub.2 can be
converted to nitric acid. Any excess O.sub.2 present in the
CO.sub.2 circulating fluid can be separated as an enriched stream
for optional recycle to the combustor. Any inert gases present
(e.g., N.sub.2 and Ar) can be vented at low pressure to the
atmosphere.
[0120] As described above, a power production cycle incorporating a
turbine that is configured according to the disclosure can operate
at a high efficiency in part because the combustion product stream
(e.g., arising from combustion of a solid fuel, such as coal) can
be inputted directly into the turbine without the need for first
filtering out particulate material present in the combustion
product stream. Particularly, the inventive turbine configurations
eliminate or greatly reduce blade erosion arising from impingement
of the non-combusted material. Even though the disclosure provides
such valuable protection of the turbine materials, there still may
be occasion for turbine impairment arising from interaction of the
turbine components with the particulate components of the
combustion product stream.
[0121] For example, liquid ash sticking and freezing (or
solidifying) onto the turbine blades can cause slagging, loss of
efficiency, and/or loss of rotor balance. Accordingly, in certain
embodiments, the present disclosure provides for incorporation of
specific components into a combustion cycle for alleviating and/or
at least partially removing buildup or chemical deposits from
turbine components, particularly turbine blades. Although ash
buildup is exemplified herein, it is understood that the cleaning
provided by embodiments of the present disclosure would be expected
to be effective in at least partially removing or completely
removing any type of deposit on the turbine components arising from
materials present in the combustion product stream, particularly
particulate materials. Thus, various types of ash, ash derived
material, and carbon may be removed by the cleaning provided
herein.
[0122] Buildup of chemical deposits on turbine components, such as
turbine blades, may be prevented by employing transpiration
protection techniques. For example, as seen in FIG. 1, hot recycled
working fluid (e.g., CO.sub.2) can be withdrawn from the hot end of
the heat exchanger 500 as stream 504 and delivered to the turbine
400. For example, the hot recycled working fluid can be delivered
to the turbine rotor and then through the turbine blades to provide
transpiration protection of the turbine blades. In such
embodiments, the turbine blades can be perforated as necessary so
that a hot recycled working fluid exits the blades along
substantially the entire surface of the blades, or at least the
leading surface of the blades that is in the direct path of the
combustion product stream entering the turbine. In specific
embodiments, the greatest flow of transpiration fluid out of the
blades would be at the leading edges of the blades.
[0123] The transpiration fluid may be provided at various
temperatures. In some embodiments, the transpiration fluid for the
turbine may be at a temperature that is within about 10%, within
about 8%, within about 5%, or within about 2% of the temperature of
the combustion product stream entering the turbine. In such
embodiments, the temperature of the transpiration fluid for the
turbine may be characterized as being substantially similar to the
temperature of the combustion product stream entering the turbine.
In other embodiments, the transpiration fluid directed to the
turbine for transpiration protection may be 15% to about 90% less
than, about 15% to about 60% less than, about 15% to about 50% less
than, or about 20% to about 40% less than the temperature of the
combustion product stream entering the turbine. In such
embodiments, the temperature of the transpiration fluid for the
turbine may be characterized as being substantially less than the
temperature of the combustion product stream entering the
turbine.
[0124] In some embodiments, the use of the transpiration fluid with
the turbine blades can perform multiple functions. For example, the
transpiration fluid can be effective for protecting the turbine
blades as it can essentially prevent particulate materials in the
combustion product stream from actually contacting the blade
surface. Rather, the protective barrier formed by the transpiration
fluid can deflect or otherwise redirect the particulate materials
around the turbine blades. The hot recycled working fluid also can
function to heat the blades, particularly the blade surfaces on the
outlet side of the turbine. This additional heating can prevent the
blade surfaces, on the outlet side and/or the inlet side, from
cooling to a temperature wherein liquid ash (or other materials
that are liquid at the temperature of the combustion product stream
and have a freezing (or solidification) point that is less than the
temperature of the combustion product stream but greater than
ambient temperature) will solidify (i.e., the freezing temperature
of the material). This prevents the liquid particles that actually
contact the surface of the turbine blade from freezing (or
solidifying) and thus depositing on the blade surfaces.
[0125] Transpiration protection can eliminate particle freezing (or
solidifying) in some embodiments. In this regard, all ash may
remain molten above approximately 870.degree. C.-980.degree. C. in
some embodiments. In other embodiments, particle freezing can be
reduced in relation to identical cycles and systems that do not
incorporate transpiration protection. To the extent particle
freezing is reduced but not eliminated, periodic cleaning of the
turbine components may be necessary. In specific embodiments,
cleaning of turbine components, such as turbine blades, may be
effected through incorporation of cleaning components into a
combustion cycle or system.
[0126] The cycle shown in FIG. 2 illustrates a system wherein
turbine blade cleaning materials can be directed through the
turbine to effect cleaning of the turbine blades. Beneficially, the
cleaning materials may be directed through the turbine in parallel
with the combustion product stream. Thus, cleaning can be effected
without interrupting the power production combustion cycle. In some
embodiments, it may be desirable to alter one or more of the cycle
parameters discussed herein to facilitate the cleaning process
(e.g., to alter the temperature of the combustion product stream,
to increase the ratio of recycle fluid to fuel, or the like). In
embodiments wherein the turbine blade is being transpiration
protected, it may be desirable to cease the transpiration fluid
flow to facilitate contact of the cleaning material with the
turbine blades. However, combustion and power generation may
continue during the cleaning process.
[0127] Referring to FIG. 2, a combustion cycle can proceed
substantially as described above in relation to FIG. 1. In the
present embodiments, however, a third recycled circulating fluid
stream 506 can exit the heat exchanger 500 and pass through a
cleaning material junction 600 wherein the cleaning material is
combined with the third recycled circulating fluid stream 506 to
form the cleaning material stream 610. The cleaning material
junction 600 can comprise any structure, unit, or device suitable
for combining the third recycled circulating fluid stream 506 with
the cleaning material wherein the cleaning material is provided in
a continuous flow or is provided batchwise. Preferably, the
cleaning material junction is configured such that the cleaning
material is combined with and flows with the third recycled
circulating fluid stream 506. As also described above in relation
to the second recycled circulating fluid stream 504, the third
recycled circulating fluid stream 506 can be controlled such that
the flow rate can be zero or can be any rate necessary to
effectively transfer the cleaning material to the turbine.
[0128] The cleaning material can be any material effective to
contact the surface of the turbine blades and physically or
chemically remove solid deposits therefrom. Preferably, the
cleaning material comprises a material that is effective to remove
the deposits with minimal to no erosion of the blade surfaces
themselves. Solid cleaning materials may include carbon particles,
alumina particles, or other hard particles configured to not melt
at the flow temperatures. Erosion of ash but not the blades may
occur at the low impact velocities because the ash may define a
lower fracture strength than the blade. Liquid cleaning materials
may include potassium compounds such as potassium oxide, carbonate,
or hydroxide. The potassium compounds may act as a flux to lower
the melting point of the ash so it may melt off the blades. Gaseous
cleaning materials may include oxygen which may oxidize deposits
such as carbon. Solid or liquid cleaning materials combined with
the third recycled circulating fluid stream 506 at the cleaning
material junction 600 may define less than about 0.5%, less than
about 0.1%, or less than about 0.01% of the total mass flow rate of
the cleaning material stream 610 and from about 0.001% to about
0.1%, from about 0.1% to about 1%, or from about 0.0001% to about
0.01% of the total mass flow rate of the cleaning material stream.
Gaseous cleaning materials combined with the third recycled
circulating fluid stream 506 at the cleaning material junction 600
may define less than about 5%, less than about 2%, or less than
about 1% of the total mass flow rate of the cleaning material
stream 610 and from about 0.1% to about 2%, from about 0.01% to
about 1%, or from about 0.01% to about 5% of the total mass flow
rate of the cleaning material stream. In one embodiment the
cleaning cycle may be initiated whenever the power output by the
generator 400a drops from about 2% to about 5%, from about 5% to
about 10%, or from about 1% to about 2%. For example, the cleaning
operation may be conducted from about once per week to about once
every three years. The cleaning cycle may last from about five
minutes to about one hour in some embodiments.
[0129] The cleaning material stream 610 may flow directly into the
turbine 400. In such embodiments, the cleaning material stream may
mix with the combustion product stream 320 in a common inlet to the
turbine 400, or the cleaning material stream 610 and combustion
product stream 320 may have individual inlets into the turbine such
that the streams mix at a point interior to the turbine 400. In the
illustrated embodiment, the cleaning material stream 610 is first
mixed with the combustion product stream 320 in a flow combiner
switch 650. Thus, in a cleaning cycle, the combined combustion
product and cleaning material stream 326 exits the flow combiner
switch 650 and enters the turbine 400.
[0130] In some embodiments, continuous cleaning may be used wherein
some minimal flow of the third recycled circulating fluid stream
506 can be maintained such that an amount of cleaning material is
continuously introduced into the turbine. The flow of the third
recycled circulating fluid stream 506 could be adjusted up or down
periodically to increase or reduce the cleaning capacity of the
cycle. In other embodiments, the third recycled circulating fluid
stream 506 can be closed so that no cleaning material passes from
the cleaning material junction 600 into the flow combiner switch
650. In this mode of operation, the combustion product stream 320
may bypass the flow combiner switch 650 and pass directly into the
turbine, as illustrated in FIG. 1. Alternately, the combustion
product stream 320 may continue to flow through the combiner switch
650 but, in the absence of an incoming cleaning material stream
610, the stream exiting the combiner switch 650 would be
essentially the combustion product stream 320 and not the combined
combustion product and cleaning material stream 326.
[0131] In embodiments wherein the cleaning cycle is active, the
deposits or residue removed from the turbine blades can be removed
from the cycle via the filter 5 in the manner described in relation
to FIG. 1. Likewise, when solid cleaning materials are used, the
solid cleaning materials can be removed from the cycle via the
filter 5. In some embodiments, the filter 5 may be a multi-unit
filter wherein a first filter media or unit is used in the normal
course of the combustion cycle, and a second filter media or unit
can be used during the cleaning cycle to collect the cleaning
material and the removed blade deposits without unnecessarily
fouling the filter used in the normal combustion cycle. The
inventive system could incorporate the appropriate devices to
facilitate such switching between filters.
Example Embodiments
[0132] The present disclosure will now be described with specific
reference to the following examples, which are not intended to be
limiting of the disclosure and are rather provided to show
exemplary embodiments.
[0133] FIG. 3 illustrates an example embodiment of a combustor 1000
that may be employed in accordance with the systems and methods
disclosed herein. The combustor 1000 may define a combustion
chamber 1002 into which fuel and O.sub.2 are directed through a
fuel inlet 1004 and an O.sub.2 inlet 1006. Accordingly, the fuel
may be combusted to form a combustion product stream 1008. The
combustor 1000 may comprise a casing comprising an outer casing
1010 and an inner casing 1012. The inner casing 1012 may comprise a
transpiration material such as a porous sintered material (e.g., a
porous sintered metal material) that is configured to receive a
transpiration fluid 1014 and transpire the fluid therethrough to
define a transpiration layer 1016 configured to reduce the heat
incident on the casing. The transpiration fluid 1014 may be
received in some embodiments through an inlet 1026, although the
transpiration fluid may be received from a turbine attached to the
combustor in some embodiments, as described below. Accordingly, the
combustor 1000 may be configured to withstand the heat produced in
the combustion chamber 1002 without employing expensive heat
resistant materials such as superalloys and/or the combustor may
operate at increased combustion temperatures.
[0134] As described above, the combustion product stream produced
by a combustor may be employed to drive a turbine. In this regard,
FIG. 4 illustrates an example embodiment of a turbine 2000. In one
embodiment the turbine 2000 may include an inlet conduit 2002
configured to couple to an outlet of a combustor (e.g., combustor
1000) and direct a combustion product stream (e.g., combustion
product stream 1008) to an inlet of a casing 2004 of the turbine.
The turbine 2000 may comprise a rotor 2006 to which a plurality of
blades 2008 are attached. The rotor 2006 may comprise an annular
flow diverter 2010 configured to divert the combustion product
stream around the rotor. Accordingly, the combustion product stream
1008 may be expanded while traveling through the turbine 2000,
thereby causing the blades 2008 to rotate the rotor 2006 and a
power shaft 2011 (which may be integral with the rotor, or coupled
thereto) before a turbine discharge stream 2012 is discharged
through one or more outlets 2014. Thus, the turbine 2000 may drive
a generator, or other device.
[0135] As further illustrated in FIG. 4, the inlet conduit 2002 may
comprise an inner casing 2016 and an outer casing 2018. Further,
the casing 2004 of the turbine 2000 may comprise an inner casing
2020 and an outer casing 2022. A transpiration fluid 2024 may be
directed from an inlet 2026 between the inner casings 2016, 2020
and the outer casings 2018, 2022 of the inlet conduit 2002 and the
turbine 2000. The inner casings 2016, 2020 may comprise a
transpiration material such as a porous sintered material (e.g., a
porous sintered metal material) that is configured to receive the
transpiration fluid 2024 and transpire the fluid therethrough.
Thereby a transpiration layer 2028 may be defined between the
combustion product stream 1008 and the inner surface of the inlet
conduit 2002 and a transpiration layer 2030 may be defined between
the blades 2008 and an inner surface of the inner casing 2020 and
the inner casings may be cooled or otherwise protected by the
transpiration fluid 2024. In some embodiments the transpiration
fluid provided to the turbine may also be provided to the combustor
for transpiration cooling. In this regard, for example, the inlet
conduit may mate to the combustor such that the transpiration fluid
is provided thereto in some embodiments. However, transpiration
fluid provided to the combustor may additionally or alternatively
be provided from a separate inlet 1026 in some embodiments.
[0136] Further, transpiration fluid 2024 may also be introduced
into the turbine 2000 through a second inlet 2032, which may be
defined in the power shaft 2011 in some embodiments. Accordingly,
the transpiration fluid 2024 may travel through the power shaft
2011 into the rotor 2006. The rotor 2006 and/or the blades 2008 may
comprise a transpiration material such as a porous sintered
material (e.g., a porous sintered metal material) that is
configured to receive the transpiration fluid 2024 and transpire
the fluid therethrough to outer surfaces thereof. Accordingly, the
rotor 2006 and/or the blades 2008 may be cooled or otherwise
protected from the combustion product stream 1008 and particulates
therein by the transpiration fluid 2024.
[0137] FIGS. 5 and 6 illustrate an alternate embodiment of a
turbine 2000'. As illustrated, a plurality of combustors 1000' may
be configured to drive the turbine 2000'. In particular, the
combustors 2000' may be radially disposed with respect to a major
axis defined by the rotor 2006', as illustrated in FIG. 6. As shown
in FIG. 5, the turbine 2000' may be substantially similar to the
embodiment of the turbine 2000 illustrated in FIG. 4, except the
combustors 1000' may supply combustion product streams 1008' around
the circumference of the rotor 2006'. Accordingly, an annular flow
diverter may not be needed to divert the combustion product streams
1008' around the rotor 2006'. Each of the combustors 1000' may be
substantially similar to the combustor 1000 described above except
for the placement of the combustors around the rotor 2006'.
[0138] FIG. 7 illustrates a lateral sectional view through an
embodiment of a turbine blade 2008A that may be employed in the
turbines disclosed herein. The turbine blade 2008A may comprise an
outer layer 3002 and a core 3004. The core 3004 may define a
relatively strong metal, or other material configured as a
reinforcement member. A strong metal, as used herein, refers to a
metal with a strength greater than about 10,000 PSI, greater than
about 20,000 PSI or greater than about 30,000 PSI at appropriate
elevated temperatures and that is chemically resistant at
appropriate temperatures. Examples include stainless steel alloys
and high nickel alloys such as Inconel, etc. Thus, the present
disclosure allows lower cost alloys such as stainless steel (e.g.,
316 stainless steel) or other alloys with lower nickel and cobalt
contents to be used instead of the typical superalloys which have
relatively very high nickel and cobalt contents, and are thus very
expensive. In this regard, a polycrystalline 316 stainless steel
can be as much as twenty times less expensive per pound than a
polycrystalline superalloy, and two-thousand times cheaper per
pound than single crystal superalloy blades.
[0139] Further, the core 3004 may define one or more channels 3006.
The channels 3006 may be configured to receive transpiration fluid
and direct the transpiration fluid into the outer layer 3002. The
outer layer 3002 may define a portion, or the entirety, of an
exterior surface 3008 of the blade 2008A in some embodiments.
Further, the outer layer 3002 may comprise a porous material such
as a porous sintered metal material. Accordingly, the channels 3006
in the core 3004 may be configured to receive transpiration fluid
and direct the transpiration fluid into the outer layer 3002. Thus,
the transpiration fluid may flow through the outer layer 3002 of
the turbine blade 2008A and provide a transpiration layer around
the exterior surface 3008 of the turbine blade which may protect
the turbine blade from heat and/or impacts with particulates. In
this regard, it should be understood that a turbine blade and/or
other components of the systems disclosed herein may be
transpiration protected, meaning a transpiration fluid is directed
to at least a portion of a surface thereof, regardless of whether
the transpiration cools the component. For example, a component may
be transpiration protected by a transpiration fluid that protects a
surface of the component from impact with particulates or other
matter regardless of the temperature of the transpiration fluid.
Conversely, a component may additionally or alternatively be
transpiration protected by a transpiration fluid that cools the
component or acts as a barrier that reduces heating of the
component.
[0140] As described above, transpiration fluid may additionally or
alternatively be employed in other components associated with the
systems and assemblies described herein. In this regard, FIG. 8
illustrates a sectional view through a portion of an inlet conduit
2002A configured to deliver a combustion product stream from a
combustor to a turbine. The inlet conduit 2002A may comprise an
inner layer 4002 and an outer layer 4004. The outer layer 4004 may
comprise a shell, which may comprise a strong metal as described
above, configured to provide strength to the inlet conduit 2002A.
Further, the outer layer 4004 may define one or more channels 4006.
The channels 4006 may be configured to receive transpiration fluid
and direct the transpiration fluid into the inner layer 4002. The
inner layer 4002 may define a portion, or the entirety, of an inner
surface 4008 of the inlet conduit 2002A in some embodiments.
Further, the inner layer 4002 may comprise a porous material such
as a porous sintered metal material. Accordingly, the channels 4006
in the outer layer 4004 may be configured to receive transpiration
fluid and direct the transpiration fluid into the inner layer 4002.
Thus, the transpiration fluid may flow through the inner layer 4002
of the inlet conduit 2002A and provide a transpiration layer at the
inner surface 4008 of the inlet conduit which may protect the inlet
conduit from heat and/or impacts with particulates.
[0141] As illustrated in FIG. 9, in one embodiment of an inlet
conduit 2002B, an insulation layer 4010 and a second outer layer
4012 may additionally be provided. The insulation layer 4010 and
the second outer layer 4012 may surround the inner layer 4002 and
the outer layer 4004 in some embodiments. The insulation layer 4010
may insulate the inlet conduit 2002B so as to retain more heat
therein, which may increase the efficiency of the system in which
it is employed. Further, the second outer layer 4012 may provide
additional strength to the inlet conduit 2002B. However, the
various material layers and features described above may
additionally or alternatively be employed in other components of
the systems and assemblies described herein, such as in a
combustor.
[0142] FIG. 10 illustrates a longitudinal sectional view through a
turbine blade 2008B in accordance with an alternate embodiment. The
turbine blade 2008B may comprise one or more reinforcement members
such as one or more rods 5014. The rods 5014 may comprise a metal
material, or other material configured to provide strength to the
turbine blade 2008B.
[0143] The turbine blade 2008B may further define one or more
channels 5006. The channels 5006 may be configured to receive
transpiration fluid and direct the transpiration fluid into the
material defining the turbine blade 2008B. In this regard, the
turbine blade 2008B may comprise a porous material such as a porous
sintered metal material. Accordingly, the channels 5006 in the
turbine blade 2008B may be configured to receive transpiration
fluid and direct the transpiration fluid through the turbine blade
to provide a transpiration layer at an outer surface 5008 of the
turbine blade which may protect the turbine blade from heat and/or
impacts with particulates.
[0144] In some embodiments the turbine blade 2008B may be
configured to define a flow of transpiration fluid at a leading
edge 5016 of the turbine blade that is greater than a flow of the
transpiration fluid at a trailing edge 5018 of the turbine blade.
This may provide the leading edge with greater protection, which
may be desirable since the leading edge may otherwise be more prone
to impacts with particles than the remainder of the turbine blade.
In this regard, one or more channels 5006 in the turbine blade
2008B may define a transpiration fluid inlet area at the leading
edge 5016 (see, e.g., channel 5006A) that is greater than a
transpiration fluid inlet area of one or more channels at the
trailing edge 5018 (see, e.g., channel 5006B). Alternatively, a
greater number of channels may be defined at the leading edge than
at the trailing edge.
[0145] FIGS. 11-13 illustrate an alternate embodiment of a turbine
blade 2008C. As illustrated, the turbine blade 2008C may define an
integral structure comprising one or more internal ribs 6020. The
internal ribs 6020 may function as a reinforcement member
configured to provide strength to the turbine blade 2008C. The
internal ribs 6020 may be integrally formed with an outer layer
6002 and/or a base member 6022 of the turbine blade 2008C.
[0146] The turbine blade 2008C may include one or more channels
6006 that may be separated by the internal ribs 6020. The channels
6006 may be configured to receive transpiration fluid (e.g., from a
rotor to which the base member 6022 attaches) and direct the
transpiration fluid through the outer layer 6002. In this regard,
the turbine blade 2008C may comprise a porous material such as a
porous sintered metal material. Accordingly, the channels 6006 in
the turbine blade 2008C may be configured to receive transpiration
fluid and direct the transpiration fluid through the outer layer
6002 of the turbine blade to provide a transpiration layer at an
outer surface 6008 of the turbine blade which may protect the
turbine blade from heat and/or impacts with particulates. As
further illustrated, the channels 6006 in the turbine blade 2008C
may define a transpiration fluid inlet area at the leading edge
6016 (see, e.g., channel 6006A) that is greater than a
transpiration fluid inlet area of one or more channels at the
trailing edge 6018 (see, e.g., channel 6006B). Accordingly, in some
embodiments the turbine blade 2008C may be configured to define a
flow of transpiration fluid at a leading edge 6016 of the turbine
blade that is greater than a flow of the transpiration fluid at a
trailing edge 6018 of the turbine blade.
[0147] FIG. 14 illustrates a lateral cross-sectional view through
an additional embodiment of a turbine blade 2008D. As illustrated,
the turbine blade 2008D may comprise an outer layer 7002 that
defines a wall thickness at the trailing edge 7018 that is greater
than a wall thickness at the leading edge 7016. In this regard, the
turbine blade 2008D may comprise a porous material such as a porous
sintered metal material. Accordingly, transpiration fluid may be
directed through the turbine blade 2008D such that it travels
through the outer layer 7002 to provide a transpiration layer at an
outer surface 7008 of the turbine blade which may protect the
turbine blade from heat and/or impacts with particulates. Since the
wall thickness of the outer layer 7002 is greater at the trailing
edge 7018 than at the leading edge 7016, the turbine blade 2008D
may define a flow of transpiration fluid at the leading edge that
is greater than a flow of the transpiration fluid at the trailing
edge.
[0148] Further, the turbine blades in accordance with the various
embodiments disclosed herein may define a porosity that varies
between the root and tip of a turbine blade (see, e.g., the root
6026 and tip 6028 of the turbine blade 2008C illustrated in FIG.
13). In this regard, in some embodiments the turbine blades
disclosed herein may be configured to define a flow of the
transpiration fluid at the tip of the turbine blade that is greater
than a flow of the transpiration fluid at the root of the turbine
blade. This may provide the turbine blades with additional
protection which may be desirable since the tip of the turbine
blade moves at a greater velocity than any other point on the
turbine blade.
[0149] For example, FIG. 15A schematically illustrates a
longitudinal sectional view through a turbine blade 2008E. As
illustrated, the turbine blade 2008E defines a porosity that
differs between the root 8026 and the tip 8028. In particular, the
turbine blade 2008E is more porous at the tip 8028 than the root
8026 such that relatively more transpiration fluid may flow out of
the tip of the turbine blade than the root of the turbine blade. In
this regard, the turbine blade 2008E may comprise a porous material
such as a porous sintered metal material configured to transpire a
transpiration fluid therethrough, as discussed above. As
illustrated, in some embodiments the porous material may define a
plurality of layers 8030A-D, wherein the porosity of the layers
increases from root to tip. The layers 8030A-D may be defined by
different materials or by the same material which has been sintered
to various extents, and hence the porosity thereof varies. In some
embodiments the layers may be laminated together, although the
layers may be attached in various other manners.
[0150] In another embodiment, as illustrated in FIG. 15B, the
turbine blade 2008E' defines a porosity that differs between the
root 8026' and the tip 8028', as described above with respect to
FIG. 15B. However, as illustrated, in some embodiments the porous
material may define a porosity gradient, wherein, for example, the
porosity of the material increases from the 8026' to the tip 8028'.
In this regard, the porosity of the material may change at various
locations without there being distinct layers defining different
porosities in some embodiments.
[0151] Various other configurations for the turbine blades may be
employed. For example, in some embodiments the turbine blades may
be configured to define a flow of transpiration fluid at the
leading edge that is substantially equal to, or less than, the flow
of transpiration fluid at the trailing edge of the turbine blades.
Further, in some embodiments the turbine blades may be configured
to define a flow of transpiration fluid at the tip that is
substantially equal to, or less than, the flow of transpiration
fluid at the root of the turbine blade. Further, variations in
porosity between the leading edge and trailing edge may also be
used to control the flow of transpiration fluid out of the blades
in a similar manner as described with respect to controlling
transpiration flow between the root and tip.
[0152] Thus, for example, the porosity of the material defining the
turbine blade (or other component) may increase between the root
and tip, decrease between the root and tip, be relatively higher or
lower in the center relative to outer portions of the blade,
increase or decrease from the leading edge to the trailing edge,
etc. The porosity gradient or porosity layers may increase or
decrease from about 10% porosity to about 90% porosity, about 25%
porosity to about 75% porosity, or about 1% porosity to about 25%
porosity.
[0153] Accordingly, transpiration fluid may be configured to cool
and/or otherwise protect various components of the systems and
assemblies disclosed herein. In this regard, FIG. 16 illustrates a
calculated trajectory 900 for a 100 .mu.m ash particle 902 relative
to an outer surface 904 of a turbine blade 906. The ash particle
trajectory 900 is modeled based on the ash particle 902 initially
traveling at 75 m/s toward the turbine blade 906 with a flow of
CO.sub.2 transpiration fluid 908 transpiring from the outer surface
904 of the turbine blade at 2 m/s. Circulating fluid in the turbine
may be at 300 Bar (30 MPa) and 700.degree. C. As illustrated, the
transpiration fluid 908 prevents the ash particle 902 from coming
into contact with the turbine blade 906. In particular, the ash
particle 902 is calculated to come about 0.2 mm from the outer
surface 904 of the turbine blade. Accordingly, erosion of the
turbine blade 906 may be avoided.
[0154] Similarly, FIG. 17 illustrates one example according to the
present disclosure of a calculated particle trajectory 1000 for a
50 .mu.m ash particle 1002 relative to an inner surface 1004 of a
combustor 1006. The ash particle trajectory 1000 is modeled based
on the ash particle 1002 initially traveling at a velocity of 50
msec perpendicular to the inner surface 1004 of the combustor 1006
with an axial flow velocity of the combustion gas of about three
meters per second, a combustion gas composition of over about 90%
CO.sub.2, a combustion gas temperature of about 1,500.degree. C., a
pressure of about 300 Bar (30 MPa), and a radial transpiration flow
rate of the transpiration fluid 1008 of about one meter per second
in the radial direction, (e.g., perpendicular to the axial
combustion gas flow). As illustrated, the transpiration fluid 1008
prevents the ash particle 1002 from coming into contact with the
inner surface 1004 of the combustor 1006. The ash particle 1002 is
calculated to come only about 0.2 mm from the inner surface 1004 of
the combustor 1006. Accordingly, erosion of the inner surface 1004
of the combustor 1006 may be avoided.
[0155] Table 1 below provides various parameters for operation of a
conventional power plant natural gas turbine design. A
cross-section of such typical turbine 1100 is shown in FIG. 18. As
a comparative, Table 2 below provides the same parameters for
operation of a high pressure, low velocity turbine according to the
present disclosure. A cross-section of an exemplary turbine 1200
according to the disclosure is shown in FIG. 19. As may be seen by
comparing the conventional turbine 1100 to the turbine 1200 of the
present disclosure, the turbine of the present disclosure may
define a relatively smaller diameter due to the turbine of the
present disclosure employing relatively shorter turbine blades
2008F as compared to the turbine blades 1108 of the conventional
turbine in some embodiments. In this regard, as shown in the
following tables, the turbine blades 2008F of the turbine 1200 of
the present disclosure may define a relatively smaller average
inner radius (i.e., from the center of the rotor 2006F to the root
of the turbine blade), average outer radius (i.e., from the center
of the rotor to the tip of the turbine blade), and average radius
(average of the inner and outer radii) as compared to the turbine
blades 1108 of the conventional turbine 1100 in some embodiments.
Also, the turbine 1200 of the present disclosure may define a
relatively greater length to diameter ratio as compared to the
conventional turbine 1100. Further, the turbine 1200 of the present
disclosure may include a relatively larger number of turbine blades
2008F than the conventional turbine 1100. Additionally, the
diameter of the rotor 2006F of the turbine 1200 of the present
disclosure may be less than the diameter of the rotor 1106 of the
conventional turbine 1100.
TABLE-US-00001 TABLE 1 Conventional Design Parameter Value
Electrical Generator Power Requirement 2.5 .times. 10.sup.8 W
Turbine Inlet Pressure 15 bars (1.5 MPa) Turbine Outlet Pressure 1
bar (0.1 MPa) Combustion Product Flow Temperature 1,623 K
(1,350.degree. C.) Flow Density 0.75 kg/m.sup.3 Flow Velocity 700
mph (310 m/s) Turbine Length 10 m Turbine Diameter 4 m Number of
blades 200
TABLE-US-00002 TABLE 2 Inventive Design Parameter Value Electrical
Generator Power Requirement 2.5 .times. 10.sup.8 W Turbine Inlet
Pressure 300 bars (30 MPa) Turbine Outlet Pressure 30 bar (3 MPa)
Combustion Product Flow Temperature 1,400 K (1,127.degree. C.) Flow
Density 70 kg/m.sup.3 Flow Velocity 100 mph (44 m/s) Turbine Length
5 m Turbine Diameter 1.5 m Number of blades 1,000
[0156] Many modifications and other embodiments of the disclosure
set forth herein will come to mind to one skilled in the art to
which the disclosure pertains having the benefit of the teachings
presented in the foregoing descriptions. Therefore, it is to be
understood that the disclosure is not to be limited to the specific
embodiments disclosed and that modifications and other embodiments
are intended to be included within the scope of the appended
claims. Although specific terms are employed herein, they are used
in a generic and descriptive sense only and not for purposes of
limitation.
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