U.S. patent application number 13/859878 was filed with the patent office on 2013-09-05 for energy changer.
The applicant listed for this patent is Edward Robnik. Invention is credited to Edward Robnik.
Application Number | 20130227949 13/859878 |
Document ID | / |
Family ID | 45722756 |
Filed Date | 2013-09-05 |
United States Patent
Application |
20130227949 |
Kind Code |
A1 |
Robnik; Edward |
September 5, 2013 |
Energy Changer
Abstract
A self-contained energy converter, suitable for powering a
vehicle for example, includes an assembly for gasification of a
liquid fuel to produce a combustible gas. A number of burners are
provided burn the combustible gas in order to heat a heat exchanger
for heating water from a tank to produce wet steam. A superheated
steam generator is provided in communication with the heat
exchanger and includes a number of heating assemblies arranged to
heat cylindrical surfaces for converting the wet steam into a
superheated steam. Nozzles are provided to direct the superheated
steam to a turbine to produce mechanical motion.
Inventors: |
Robnik; Edward; (Queensland,
AU) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Robnik; Edward |
Queensland |
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AU |
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|
Family ID: |
45722756 |
Appl. No.: |
13/859878 |
Filed: |
April 10, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/AU2011/001108 |
Aug 26, 2011 |
|
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13859878 |
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Current U.S.
Class: |
60/653 ;
60/676 |
Current CPC
Class: |
F01D 15/02 20130101;
F02C 6/20 20130101; F01K 13/00 20130101; F01K 3/186 20130101; F01K
15/02 20130101; Y02E 20/14 20130101 |
Class at
Publication: |
60/653 ;
60/676 |
International
Class: |
F01K 13/00 20060101
F01K013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 27, 2010 |
AU |
2010903840 |
Claims
1. An apparatus for converting thermal energy to mechanical motion,
comprising: a heat exchanger configured to produce wet steam
comprising: a combustible fluid reservoir and a combustible fluid
pump to circulate a combustible fluid from the combustible fluid
reservoir to a gas generator; a first heater means to heat the
combustible fluid in the gas generator to produce gasification of
the combustible fluid; an ignition source and burner to burn the
combustible gas; a water reservoir and a water pump to circulate a
supply of water from the water reservoir to the heat exchanger; a
second heater means to heat the water in the steam generator; a
superheated steam generator comprising: at least one steam
separator to separate water droplets from the wet steam produced in
the heat exchanger; a cylindrical surface within the superheated
steam generator, the surface of which is heated by at least one
heater element such that when the steam contacts the cylindrical
surface a superheated steam with a higher temperature and no water
is produced; and wherein the gas from the gas generator is ignited
to provide a heat source to heat the water in the heat exchanger,
wherein the heat exchanger provides the wet steam source for the
superheated steam generator and the superheated steam generator
provides a superheated steam which is directed to a turbine to
produce mechanical motion.
2. An apparatus according to claim 1, further comprising a
condenser placed between the turbine and the water chamber to
condense the steam to a liquid state and provide a closed loop
system.
3. An apparatus according to claim 2, wherein the apparatus
comprises three superheated steam generators connected in an
end-to-end arrangement and each generator comprises three heater
elements to produce a dry superheated steam for driving the
turbine.
4. An apparatus according to claim 3, wherein each said superheated
steam generator comprises: a separator vessel presenting a
substantially cylindrical inside surface; an inlet for directing
incoming wet steam containing a mixture of steam and water into the
vessel in a manner to effect a swirling motion of the wet steam
around said cylindrical inside surface; a steam chamber in the
upper portion of the separator vessel for receiving the separated
dry steam which rises above the water; a generally cylindrical
baffle plate mounted in the steam chamber at a location spaced
apart from the cylindrical inside surface of the separator vessel
to form a partition which provides a surface which is heated by the
three heater elements to produce a superheated steam; and a steam
outlet conduit extending from the steam chamber for discharging
superheated steam.
5. An apparatus according to claim 3, wherein the outlet of the
first superheated steam generator is fed to the inlet of the second
superheated steam generator and the outlet of the second said
superheated steam generator is fed to the inlet of the third
superheated steam generator and the outlet of the third superheated
steam generator provides the superheated steam at a higher
temperature and with no water to the turbine to produce the
mechanical motion.
6. An apparatus according to claim 3, wherein the baffle plate and
cylindrical inside surface of the separator vessel are constructed
from copper.
7. An apparatus according to claim 1, wherein the combustible fluid
comprises any one of the group consisting of ethanol, methylated
spirits or LP gas.
8. An apparatus according to claim 1, further comprising an
electrical source to power the heater means and heater elements and
the ignition source.
9. An apparatus according to claim 1, wherein the mechanical motion
produced by the energy converter can be used as a power source for
any one of the group comprising: a generator; a house; an
automobile; a boat; a pump; or any steam driven vehicle.
10. An apparatus according to claim 1, wherein the saturated steam
is directed by nozzles onto a rotor of the turbine to cause the
rotor to turn and produce mechanical motion.
11. An apparatus according to claim 1, wherein the heat exchanger,
the gas generator, the at least one superheated steam generator and
the turbine further comprise a pressure relief valve to control or
limit the pressure at each stage of the apparatus.
12. An apparatus according to claim 1, wherein the gas generator
further comprises a gas regulator valve to automatically control
the flow of a gas at a pre-determined pressure.
13. An apparatus according to claim 1, wherein the apparatus
further comprises a one way valve between each stage of the
apparatus to allow a liquid or gas to flow through it in only one
direction.
14. A method of converting thermal energy to mechanical motion, the
method comprising: heating a combustible fluid to produce a
combustible gas; igniting the combustible fluid to heat water in
the heat exchanger to produce a wet steam; separating water
droplets from the wet steam produced by the heat exchanger using a
steam separator; heating the separated dry steam in a superheated
steam generator to produce a superheated steam; and using the
superheated steam to turn a turbine to produce mechanical
motion.
15. A method according to claim 14 performed with the apparatus of
claim
16. A self contained energy converter comprising: a gas generator
housed within a first container and comprising: a combustible fluid
reservoir and a combustible fluid pump to circulate a combustible
fluid from the combustible fluid reservoir to the gas generator; a
first heater means to heat the combustible fluid in the gas
generator to produce gasification of the combustible fluid; and an
ignition source to ignite and burn the combustible gas; a heat
exchanger housed within a second container comprising: a water
reservoir and a water pump to circulate a supply of water from the
water reservoir to the heat exchanger; and a second heater means to
heat the water in the steam generator to produce a wet steam; a
superheated steam generator housed in a third container and
comprising: at least one steam separator to separate water droplets
from the wet steam produced in the heat exchanger; and a
cylindrical surface within the at least one steam separator the
surface of which is heated by at least one heater element such that
when the steam contacts the cylindrical surface a superheated steam
with a higher temperature and containing no water is produced;
wherein the gas generator provides the gas and when ignited
provides a heat source to heat the water in the heat exchanger,
wherein the heat exchanger provides the wet steam source for the
superheated steam generator and the superheated steam generator
provides a superheated steam which is directed to a turbine to
produce mechanical motion.
17. A self contained energy converter according to claim 16
performed with the apparatus of claim 1.
18. An energy converter including: an assembly for delivery of a
combustible gas; at least one burner to burn the combustible gas; a
heat exchanger in communication with a water reservoir for
producing wet steam thereform, said heat exchanger located to be
heated by the at least one burner; a superheated steam generator in
communication with the heat exchanger including: at least one
heating assembly arranged to heat at least one cylindrical surface
for converting said wet steam into a superheated steam; and an
arrangement for directing the superheated steam to a turbine to
produce mechanical motion.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims the benefit
of International Application No. PCT/AU2011/001108 having an
international filing date of Aug. 26, 2011 under 35 U.S.C.
.sctn.120, and which in turn claims priority to Australian Patent
Application No. 2010903840 filed on Aug. 27, 2010.
FIELD OF THE INVENTION
[0002] This invention relates to an energy changer and to a method
of changing energy. The invention relates particularly but not
exclusively to the conversion of thermal energy into mechanical
motion or electrical energy.
BACKGROUND TO THE INVENTION
[0003] The reference to any prior art in this specification is not
and should not be taken as an acknowledgement or any form of
suggestion that the referenced prior art forms part of the common
general knowledge in any place in the world.
[0004] It has been known to create devices which utilize a
temperature differential to create mechanical motion. Some of these
devices have been referred to as "heat engines" or "thermal
engines." A heat engine is a physical device that converts thermal
energy to mechanical output. The mechanical output is called work,
and the thermal energy input is called heat. Heat engines typically
run on a specific thermodynamic cycle, as such a heat engine
performs the conversion of heat energy to mechanical work by
exploiting the temperature gradient between a hot "source" and a
cold "sink".
[0005] Over the past one hundred years, Internal Combustion Engine
("ICE" or "IC engine") has been the major power source for
motorised vehicles. A typical IC engine comprises of a plurality of
piston-and-cylinder assembles. An air-fuel mixture is forced into
the cylinder during the intake stroke cycle, compressed and
subsequently ignited and generates high pressure to produce motion
energy and waste heat. Recent attempts have been made in the
automotive industries to incorporate alternative power sources such
as an electric motor, known as a hybrid vehicle. These types of
vehicles convert wasted mechanical work during brake or
deceleration into electricity for later driving.
[0006] With the world-wide depletion of fossil fuels, utilization
of other energy sources has become critical. Fossil fuels are
generally such fuels as oil, natural petroleum and coal. These
materials were derived from the fossilized remains of plants and
animals. As the years go on, the sources of these fuels have become
less and less. The problem with fossil fuels is they will someday
run out. It takes time for these energy sources to develop within
the crust of the earth. At the current rate of consumption, there
is no way that these fuels can develop naturally and not be used
up.
[0007] More efficient uses of these types of energy are being
produced and experimented with. Cars with better gas mileage are
being manufactured. Hybrid cars which use electricity as well as
gas are just one of the many products which have been developed to
sustain the use of fossil fuels. Still these fuels are being
depleted. Another problem with the use of fossils fuels is no
matter how safely and efficiently these fuels are being used, they
still have an impact on the environment. The combustion of these
fuels contributes pollutants to the atmosphere and contributes to
the greenhouse effect. Fossil fuels are not considered a renewable
energy source and aside from the environmental impact, the cost of
retrieving and converting them is beginning to demand notice.
[0008] These environmental concerns have prompted costly, complex
technological proposals in engine design. For instance, fuel cell
technology provides the benefit of running on clean burning
hydrogen. However, the expense and size of fuel cell engines, as
well as the cost of creating, storing, and delivering fuel grade
hydrogen disproportionately offsets the environmental benefits. As
a further example, clean running electric vehicles are limited to
very short ranges, and must be regularly recharged by electricity
generated from coal, diesel or nuclear fuelled power plants. And,
while gas turbines are clean, they operate at constant speed. In
small sizes, gas turbines are costly to build, run and overhaul.
Diesel and gas internal combustion engines are efficient,
lightweight and relatively inexpensive to manufacture, but they
produce a significant level of pollutants that are hazardous to the
environment and the health of the general population and are fuel
specific.
[0009] Steam engines which have previously been developed have
suffered the long-term endemic problems that have led to the demise
of steam power in a commercial environment; these include excessive
pollution, maintenance costs, labor intensive operation, low
power/weight ratio, low overall thermal efficiency. This applies
particularly to medium and small-scale installations where steam
power has generally now been superseded by the internal combustion
engine or by electrical power drawn from the National Grid.
[0010] Clearly it would be advantageous if a contrivance could be
devised that helped to at least ameliorate some of the shortcomings
described above. In particular it would be desirable if an
apparatus or a method could be devised for converting energy that
was cost effective and reduced the depletion of fossil fuels.
SUMMARY OF THE INVENTION
[0011] According to a first aspect, the present invention provides
an apparatus for converting thermal energy to mechanical motion,
comprising: a heat exchanger configured to produce wet steam
comprising: a combustible fluid reservoir and a combustible fluid
pump to circulate a combustible fluid from the combustible fluid
reservoir to a gas generator; a first heater means to heat the
combustible fluid in the gas generator to produce gasification of
the combustible fluid; an ignition source and burner to burn the
combustible gas; a water reservoir and a water pump to circulate a
supply of water from the water reservoir to the heat exchanger; a
second heater means to heat the water in the steam generator; a
superheated steam generator comprising: at least one steam
separator to separate water droplets from the wet steam produced in
the heat exchanger; a cylindrical surface within the superheated
steam generator, the surface of which is heated by at least one
heater element such that when the steam contacts the cylindrical
surface a superheated steam with a higher temperature and no water
is produced; and wherein the gas from the gas generator is ignited
to provide a heat source to heat the water in the heat exchanger,
wherein the heat exchanger provides the wet steam source for the
superheated 4 steam generator and the superheated steam generator
provides a superheated steam which is directed to a turbine to
produce mechanical motion.
[0012] The present invention does not suffer from the endemic
problems that have led to the demise of steam power in a commercial
environment to date. There is little or no pollution, due to the
recycling of the water and t e small number of moving parts means
maintenance costs have been significantly reduced. Due to the
adaptability and relative small size of the present invention means
that the energy converter may be used as part of a hybrid renewable
energy vehicle, for example an electric car. This means that the
drawback of having to regularly recharge an electric car can be
reduced due to the adaptability of the steam energy converter which
can be used to recharge the batteries while the car is still in use
thereby extending the time between charges of the batteries.
[0013] The above application of the present invention to a hybrid
renewable energy vehicle is but one possible use of the present
invention and will be used throughout the description of this
invention. However, the use of the present invention for a hybrid
vehicle should not be limited to only this use and a person skilled
in the art would be expected to apply this invention to many
possible uses.
[0014] Preferably, the apparatus for converting thermal energy to
mechanical motion may further comprises a condenser placed between
the turbine and the water chamber to condense the steam to a liquid
state and provide a closed loop system. The apparatus may comprise
three superheated steam generators connected in an end-to-end
arrangement and each generator comprises three heater elements to
produce a dry superheated steam for driving the turbine. Each said
superheated steam generator may comprise a separator vessel
presenting a substantially cylindrical inside surface; an inlet for
directing incoming wet steam containing a mixture of steam and
water into the vessel in a manner to effect a swirling motion of
the wet steam around said cylindrical inside surface; a steam
chamber in the upper portion of the separator vessel for receiving
the separated dry steam which rises above the water; a generally
cylindrical baffle plate mounted in the steam chamber at a location
spaced apart from the cylindrical inside surface of the separator
vessel to 5 form a partition which provides a surface which is
heated by the three heater elements to produce a superheated steam;
and a steam outlet conduit extending from the steam chamber for
discharging superheated steam.
[0015] Preferably, the outlet of the first superheated steam
generator may be fed to the inlet of the second superheated steam
generator and the outlet of the second said superheated steam
generator may be fed to the inlet of the third superheated steam
generator and the outlet of the third superheated steam generator
provides the superheated steam at a higher temperature and with no
water to the turbine to produce the mechanical motion.
[0016] Preferably, the baffle plate and cylindrical inside surface
of the separator vessel may be constructed from copper.
[0017] Preferably, the combustible fluid may comprise any one of
the group consisting of ethanol, methylated spirits or LP gas.
[0018] Preferably, the apparatus may further comprise an electrical
source to power the heater means and heater elements and the
ignition source. The mechanical motion produced by the energy
converter may be used as a power source for any one of the group
comprising: a generator; a house, an automobile; a boat; a pump; or
any steam driven vehicle.
[0019] Preferably, the saturated steam may be directed by nozzles
onto a rotor of the turbine to cause the rotor to turn and produce
mechanical motion.
[0020] Preferably, the heat exchanger, the gas generator, the at
least one superheated steam generator and the turbine may further
comprise a pressure relief valve to control or limit the pressure
at each stage of the apparatus. The gas generator may further
comprise a gas regulator valve to automatically control the flow of
a gas at a pre-determined pressure.
[0021] Preferably, the apparatus may further comprise a one way
valve between each stage of the apparatus to allow a liquid or gas
to flow through it in only one direction.
[0022] According to a further aspect, the present invention
provides a method of converting thermal energy to mechanical
motion, the method comprising: heating a combustible fluid to
produce a combustible gas; igniting the combustible fluid to heat
water in the heat exchanger to produce a wet steam; separating
water droplets from the wet steam produced by the heat exchanger
using a steam separator; heating the separated dry steam in a
superheated steam generator to produce a superheated steam; and
using the superheated steam to turn a turbine to produce mechanical
motion.
[0023] Preferably, the method may comprise any of the features of
the apparatus according to the first aspect.
[0024] According to a further aspect, the present invention
provides a self contained energy converter comprising: a gas
generator housed within a first container and comprising: a
combustible fluid reservoir and a combustible fluid pump to
circulate a combustible fluid from the combustible fluid reservoir
to the gas generator; a first heater means to heat the combustible
fluid in the gas generator to produce gasification of the
combustible fluid; and an ignition source to ignite and burn the
combustible gas; a heat exchanger housed within a second container
comprising: a water reservoir and a water pump to circulate a
supply of water from the water reservoir to the heat exchanger; and
a second heater means to heat the water in the steam generator to
produce a wet steam; a superheated steam generator housed in a
third container and comprising: at least one steam separator to
separate water droplets from the wet steam produced in the heat
exchanger; and a cylindrical surface within the at least one steam
separator the surface of which is heated by at least one heater
element such that when the steam contacts the cylindrical surface a
superheated steam with a higher temperature and containing no water
is produced; wherein the gas generator provides the gas and when
ignited provides a heat source to heat the water in the heat
exchanger, wherein the heat exchanger provides the wet steam source
for the superheated steam generator and the superheated steam
generator provides a superheated steam which is directed to a
turbine to produce mechanical motion.
[0025] Preferably, the self contained energy converter may comprise
any of the features of the apparatus according to the first
aspect.
[0026] According to a further aspect of the present invention there
is provided an energy converter including: an assembly for delivery
of a combustible gas; at least one burner to burn the combustible
gas; a heat exchanger in communication with a water reservoir for
producing wet steam thereform, said heat exchanger located to be
heated by the at least one burner; a superheated steam generator in
communication with the heat exchanger including: at least one
heating assembly arranged to heat at least one cylindrical surface
for converting said wet steam into a superheated steam; and an
arrangement for directing the superheated steam to a turbine to
produce mechanical motion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present invention will be understood more fully from the
detailed description given hereinafter and from the accompanying
drawings of the preferred embodiment of the present invention,
which, however, should not be taken to be limitative to the
invention, but are for explanation and understanding only.
[0028] FIG. 1 shows a perspective view of an energy converter in
accordance with an embodiment of the present invention;
[0029] FIG. 2 shows a line diagram of the process of converting a
combustible fluid to a heating source in accordance with an
embodiment of the present invention;
[0030] FIG. 3 shows a line diagram of the heat exchanger and the
superheated steam generator in accordance with an embodiment of the
present invention;
[0031] FIG. 4 shows an exploded perspective view of the superheated
steam generator in accordance with an embodiment of the present
invention; and
[0032] FIG. 5 shows an exemplary use of the energy converter in
accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] An apparatus for converting thermal energy to mechanical
motion and a method of converting thermal energy to mechanical
motion in accordance with this invention may manifest itself in a
variety of forms. It will be convenient to hereinafter describe
several embodiments of the invention in detail with reference to
the accompanying drawings. The purpose of providing this detailed
description is to instruct persons having an interest in the
subject matter of the invention how to carry 7 8 the invention into
practical effect. However it is to be clearly understood that the
specific nature of this detailed description does not supersede the
generality of the preceding broad description.
[0034] In FIGS. 1 to 5, reference numeral 10 generally designates
an embodiment of an apparatus for converting thermal energy to
mechanical motion.
[0035] The apparatus 10 includes a combustible gas producer and
burner system 20, in the form of an ethanol combustible fluid 21
and a heater element 28 which heats the ethanol fluid 21 to produce
gasification of the ethanol fluid 21 in a gas generator 26 to
provide ethanol gas for the burners 31. The gas is then burnt in
the burners 31 to produce a heat source for the steam producing
system 40. Water 41 is heated by the burners 31 in the heat
exchanger 47 to produce a wet steam which is then heated further in
the superheated steam system 50 to produce super heated steam at
the output of the superheated steam system 50. The superheated
steam is then utilized to drive a turbine system 60 in which the
superheated steam is directed by nozzles onto a rotor of the
turbine 61 to cause the rotor to turn and produce mechanical motion
which is transmitted to a drive shaft 62.
[0036] Each of the above systems of the energy converter 10 will be
described in more detail below.
[0037] The combustible gas producer and burner system 20 includes a
storage tank 22 for storing the combustible fluid 21. The
combustible fluid may include any fluid 21 which is capable of
igniting and burning. For example, ethanol, methylated spirits or
LP gas may be used. The invention relates particularly but not
exclusively to an energy converter that is suited to producing and
burning gaseous ethanol for use in heating water 41 in a heat
exchanger 47. It will therefore be convenient to hereinafter
describe the invention with reference to this application. However
it is to be understood that it is capable of broader
application.
[0038] The ethanol 21 is stored in a tank 22 and when required to
provide an ignition source for the burners 31 is drawn out of the
tank 22 by pump 24 and passes through a one-way valve 25 and into
the gas generator 26. The ethanol 21 is poured into the tank 22
through the filler point 23 and may be topped up as required. A
oneway valve or check valve is a mechanical device which allows
fluid (liquid or gas) to flow through it in only one direction. A
number of one-way valves are used in the energy converter 10 to
prevent either a gas or liquid from being fed back into the
previous process. One-way valves are typically two-port valves,
meaning they have two openings in the body, one for fluid to enter
and the other for fluid to leave.
[0039] The ethanol 21 is then heated in the gas generator 26 by
heating element 28. The heating element 28 may be a nichrome 80/20
(80% nickel, 20% chromium) wire, ribbon, or strip. A heating
element converts electricity from the battery 33 into heat through
the process of Joule heating. Electric current through the element
encounters resistance, resulting in heating of the element. The
ethanol fluid 21 undergoes the gasification process in a gas
generator 26 in which the ethanol or the carbonaceous material
undergoes several different processes.
[0040] Gasification is a process that converts carbonaceous
materials, such as coal, petroleum, or biofuel such as ethanol,
into carbon monoxide and hydrogen by reacting the raw material, at
high temperatures with a controlled amount of oxygen. The resulting
gas mixture is called synthesis gas or syngas.
[0041] The ethanol undergoes a pyrolysis (or devolatilization)
process which occurs as the carbonaceous particles heat up.
Volatiles are released and char is produced, resulting in up to 70%
weight loss of the carbonaceous material. The process is dependent
on the properties of the carbonaceous material and determines the
structure and composition of the char, which will then undergo
gasification reactions. The combustion process occurs as the
volatile products and some of the char reacts with oxygen to form
carbon dioxide and carbon monoxide, which provides heat for the
subsequent gasification reactions. Finally the gasification process
occurs as the char reacts with carbon dioxide and steam to produce
carbon monoxide and hydrogen, via the reaction.
[0042] In essence, a limited amount of oxygen or air is introduced
into the reactor to allow some of the organic material to be
"burned" to produce carbon monoxide and energy, which drives a
second reaction that converts further organic material to hydrogen
and additional carbon dioxide. Further reactions occur when the
formed carbon monoxide and residual water from the organic material
react to form methane and excess carbon dioxide. This third
reaction occurs more abundantly in reactors that increase the
residence time of the reactive gases and organic materials, as well
as heat and pressure. Catalysts are used in more sophisticated
reactors to improve reaction rates, thus moving the system closer
to the reaction equilibrium for a fixed residence time.
[0043] The ethanol gas or combined carbon dioxide, carbon monoxide
and methane gas are used in the burners 31. The gas in the burners
31 is ignited by the igniter 32 which may be an electric or
electronic igniter or a piezo igniter. Electronic ignition works
when the electronic module receives a signal from a switch or gas
knob. The module then outputs a series of sparks igniting the gas
burner. When the switch or gas knob is released, the ignition
stops. The electronic igniter is powered by a battery 33 or a power
supply (not shown).
[0044] Piezo ignition is a type of ignition that is used in
portable camping stoves, gas grills and some lighters. It consists
of a small, spring-loaded hammer which, when a button is pressed,
hits a crystal of lead zirconate titanate (PZT) or quartz crystal.
Lead zirconate titanate, also called PZT, is a ceramic perovskite
material that shows a marked piezoelectric effect. Quartz or PZT
are piezoelectric, which means that it creates a voltage when
deformed. This sudden forceful deformation produces a high voltage
and subsequent electrical discharge, which ignites the gas.
[0045] A pressure relief valve 27 or relief valve (RV) is used to
control or limit the pressure in the gas generator 26. The pressure
may build up by a process upset, instrument or equipment failure,
or fire and the pressure relief valve 27 is used to limit the
amount of pressure which can build up in the gas generator 26. The
gas which flows out of the gas generator 26 passes through a
one-way valve 34 and may 11 be switched on or off by open/close
valve 29. A pressure regulator 30 is used to automatically cut off
the flow of gas at a certain pressure. The gas is ignited in the
burners 31 and the heat source is used to heat the water 41 in the
heat exchanger 47 to produce the wet steam which passes from the
heat exchanger 47 and into the first tank 51 of the superheated
steam system 50.
[0046] The steam producing system 40 includes a tank 42 for storing
the water 41 which may be poured into the tank 42 through filler
point 43. A pressure relief valve 44 is used to limit and control
the pressure within the tank 42. The water 41 is drawn out of the
tank 42 by pump 45. The pump 45 is simply a device used to move
fluids, such as water 41 by displacing a volume by physical or
mechanical action. The water 41 then passes though a one-way valve
46 and into the heat exchanger 47 where the water 41 is heated by
the burners 31.
[0047] As the temperature increases and the water 41 approaches its
boiling condition, some molecules attain enough kinetic energy to
reach velocities that allow them to momentarily escape from the
liquid into the space above the surface, before falling back into
the liquid. Further heating causes greater excitation and the
number of molecules with enough energy to leave the liquid
increases. As the water 41 is heated by the burners 31 to its
boiling point, bubbles of steam form within it and rise to break
through the surface. Considering the molecular structure of liquids
and vapours, it is logical that the density of steam is much less
than that of water, because the steam molecules are further apart
from one another. The space immediately above the water surface
thus becomes filled with less dense steam molecules. When the
number of molecules leaving the liquid surface is more than those
re-entering, the water freely evaporates. At this point it has
reached boiling point or its saturation temperature, as it is
saturated with heat energy.
[0048] The heat exchanger 47 in its very basic form is a device
built for efficient heat transfer from one medium to another and in
this case from liquid to gas. The heat exchanger 47 in accordance
with this invention may manifest itself in a variety of forms. One
such form is a shell and tube heat exchangers 47 which consist of a
series of tubes. One set of these tubes contains the fluid that
must be heated by the burners 31. The second fluid runs over the
tubes that are being heated or cooled so that it can either provide
the heat or absorb the heat required. A set of tubes is called the
tube bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc. However it is to be clearly understood
that other types of heat exchanger 47 may be used, for example, a
plate heat exchanger or an adiabatic wheel heat exchanger may be
used without departing from the scope of the invention.
[0049] The heat exchanger 47 also includes a pressure relief valve
48 to limit and control the pressure within the heat exchanger 47.
If the pressure within the heat exchanger 47 remains constant,
adding more heat does not cause the temperature to rise any further
but causes the water to form saturated steam or wet steam. The
temperature of the boiling water and wet steam within the same
system is the same, but the heat energy per unit mass is much
greater in the wet steam. Therefore the steam that leaves the heat
exchanger 47 is a wet steam which is steam that contains water
droplets in suspension. The wet steam passes through a one-way
valve 49 before further processing in the superheated steam system
50.
[0050] The superheated steam system 50 consists of three steam
generator chambers 51 connected in an end-to-end arrangement,
separated and isolated from each other by three one-way valves 53.
Each steam generator chamber 51 comprises three heater elements 54
and a pressure relief valve 52 to control and limit the steam in
the generators 51.
[0051] Superheated steam is steam at a temperature higher than
water's boiling point. If wet or saturated steam is heated at
constant pressure, its temperature will rise, producing superheated
steam. This will occur if saturated steam contacts a surface with a
higher temperature. The steam is then described as superheated by
the number of degrees through which it has been heated above
saturation 30 temperature, put another way the temperature above
saturation temperature is called the degree of superheat of the
steam.
[0052] As each steam generator chamber 51 is identical in
construction we will only describe one unit and also describe how
each of the units interact to produce an output of superheated
steam for the turbine system 70. The steam generator is
substantially cylindrical in structure with end caps 58, 76 on
either end of the steam generator chamber 51. End cap 58 is
connected to an inlet 77 and end cap 76 is connected to the outlet
78. The inlet 77 into the first steam generator chamber 51 receives
the wet steam from the steam producing system 40. Each steam
generator chamber 51 is connected in series with the other steam
generator chambers 51, that is the outlet 78 of the first steam
generator chamber 51 is connected to the inlet 77 of the second
steam generator 51 and subsequently the output 78 of the second
steam generator chamber 51 is connected to the input 77 of the
third steam generator chamber 51 and the outlet 78 of the third
steam generator 51 is connected to the input of the turbine system
60. Each steam generator 51 has a pressure relief valve 52 for
controlling and limiting the pressure within each of the steam
generator chambers 51. In between each outlet 78 and inlet 77 a
one-way valve 53 is positioned to prevent the feedback of the steam
to the previous steam generator chamber 51.
[0053] Each steam generator chamber 51 is designed in such a way as
to ensure that no water or wet steam is transmitted to the turbine
system 60. Also, superheat cannot be imparted to the steam whilst
it is still in the presence of water, as any additional heat simply
evaporates more water. The saturated steam must be passed through a
heat exchanger or water separator. In this case each steam
generator 51 is designed with an internal cylindrical surface. The
wet steam containing a mixture of steam and water enters the steam
generator chamber 51 via the inlet 77 in a manner to effect a
swirling motion of the wet steam around said cylindrical inside
surface. This ensures that the water or water droplets are thrown
outwards separating the water from the steam.
[0054] A generally open cylindrical baffle plate 55 mounted in the
steam generator chamber 51 at a location spaced apart from the
cylindrical inside surface of the steam generator chamber 51 to
form a partition which provides a surface which is heated by the
three heater elements 54 to produce a superheated steam.
[0055] The baffle plate 55 has two ends 56, 57 which are located
within the end caps 75, 76. The baffle plate 55 does not form a
complete cylinder as there is an open slot in the surface which
allows any further moisture to drop to the bottom of the steam
generator chamber 51. A steam outlet conduit 78 extends from the
steam generator chamber 51 for discharging superheated steam. The
steam generator chamber has a separate steam chamber in the upper
portion of the steam generator chamber 51 for receiving the
separated dry steam which rises above the water and the dry steam
has the characteristics of a dry gas.
[0056] As described above the outlet of the first superheated steam
generator chamber 51 is fed to the inlet of the second superheated
steam generator chamber 51 "and the outlet of the second said
superheated steam generator chamber 51 is fed to the inlet of the
third superheated steam generator chamber 51 and the outlet of the
third superheated steam generator chamber 51 provides the
superheated steam at a higher temperature and with no water to the
turbine system 60 to produce the mechanical motion. The process of
passing the superheated steam from one steam generator chamber 51
to a next steam generator chamber 51 provides a superheated steam
at the output of the final steam generator chamber 51 which is more
efficient and with more energy due to the molecules having more
kinetic energy. Given that the superheated steam receives no
further moisture, but receives further heat energy from each of the
heater elements 54 in the steam generator chambers 51, it is
considered to be a dry steam.
[0057] Having a dry superheated steam is important because wet
steam reduces the thermal efficiency of the energy converter. It is
also important because water droplets in high velocity steam being
fed to the nozzles (or vanes) in a steam turbine system 60 can
impinge on and erode turbine internals such as turbine blades.
[0058] The baffle plate 55 and cylindrical heaters 54 in the steam
generator chambers 51 are constructed from copper but may be
constructed from any other material which allows for the transfer
of heat from the heater elements 54 to the baffle plate 55.
[0059] The steam is now in the form of a dry superheated steam
which is directed to the turbine system 60. In between the turbine
system 60 and the final stage of the superheated steam system 50 is
a one-way valve which prevents the feedback of dry superheated
steam to the final stage of the superheated steam system 50. The
turbine system 60 comprises a turbine 61 having a drive shaft 62
and a pressure relief valve 63. The turbine 61 is for example, a
turbine 61 where the superheated steam is directed by nozzles onto
a rotor. This causes the rotor to turn. The energy to make this
happen can only have come from the steam, so logically the steam
has less energy after it has gone through the turbine rotor.
Turbines typically have a number of stages; the exhaust steam from
the first rotor will be directed to a second rotor on the same
drive shaft 62. This means that the superheated steam could by the
time it reached the output of the turbine 61 have slightly
condensed and may have returned to a saturated or wet steam due to
it passing through the successive stages.
[0060] If the steam was not at a superheated stage and was only a
wet steam it could not only promote water hammer, but the water
particles would cause severe erosion within the turbine 61. Water
hammer is a pressure surge or wave resulting when a fluid (usually
a liquid but sometimes also a gas) in motion is forced to stop or
change direction suddenly. The solution as identified by the
applicant is to supply the turbine with superheated steam at the
inlet, and use the energy in the superheated portion to drive the
rotor until the temperature/pressure conditions are close to
saturation; and then exhaust the steam. At the output of turbine
system 60 is a one-way valve 64 which prevents the steam at the
output of the turbine feeding back into the turbine system 60.
[0061] In order to return the steam back to the system and to be
able to re-use a significant part of the steam, the steam is passed
through a condenser 70 and via a one-way valve 71 and back into the
water tank 42 for re-use. The energy converter 10 is formed
substantially as a closed loop system such that the water used to
convert to steam in the steam producing system 40 and then
converted to superheated steam in the superheated steam system 50
is fed back into the water tank 42. The condenser 70 is a device or
unit used to condense a substance from its 16 gaseous state to its
liquid state, typically by cooling it. In so doing, the latent heat
is given up by the substance, and will transfer to the condenser
coolant.
[0062] In the example illustrated in FIG. 5, the energy converter
10 may be stored in three separate containers and installed in a
motor vehicle 90. In this example the motor vehicle 90 has a
turbine system 60 which is connected to impart the mechanical
motion derived from the energy converter 10 to the front wheels 92
of the motor vehicle 90. Alternatively, the energy converter 10 may
be used to charge a set of storage batteries 91 an electric motor
(not shown) to operate the vehicle 90 as a hybrid vehicle combining
the energy converter 10 with an electric motor. The energy
converter 10 may be used to charge the batteries 91 while the
vehicle running on an electric motor (not shown). Obviously this is
but one possible use of many which may use the energy converter 10.
For example, the energy converter may be used to drive machinery
which would normally be driven by either a motor or
electricity.
[0063] As described above the energy converter 10 is conveniently
stored in three separate containers. The combustible gas producer
and burner system 20 is stored in the bottom or first container,
the steam producing system 40 is stored in the second or middle
container and finally the superheated steam generator 50 is stored
in the top container. Behind the containers the combustible fluid
tank 22 and the water tank 42 are conveniently placed to allow easy
access for refilling the tanks 22, 42 with their respective fluids.
The turbine system 60 and turbine 61 are located to the rear and to
one side of the three containers and conveniently attached to drive
the wheel 92 of the vehicle 90.
[0064] The present invention may also be used as a power source for
devices such as a boat, a motorcycle or a scooter. The size of the
present invention is dictated by the amount of mechanical energy
that is needed to power the individual devices. For example the
energy converter for a scooter is much smaller and is sized to fit
conveniently within the frame of a scooter, whereas the energy
converter for a boat can be significantly larger due to the extra
power required to drive a boat. The boat may be direct driven or
may be configured such that the energy converter is 17 connected to
a direct drive or shaft driven motor. The present invention is also
useful for powering a house in which the energy converter may power
a alternator or inverter device which uses the mechanical motion
from the energy converter to drive the inverter or alternator to
produce the electrical energy required to power a house or the
like. Another use of the energy converter may be to use the
mechanical motion developed by the energy converter to drive a pump
or motor for a number of uses. For example a water pump may be
driven by the energy converter for pumping water from a water tank
or for irrigation or any other similar use. The present invention
is not limited to only the above uses and a skilled person would
easily be able to devise many other suitable uses for the energy
converter of the present invention.
[0065] The present invention is also directed to a method of
converting thermal energy to mechanical motion. The method
comprises heating a combustible fluid 21 to produce a combustible
gas using the combustible gas producer and burner system 20. The
combustible fluid, in this case ethanol 21 is ignited using the
igniter 32 and the gas is burnt in the burners 31 and used to heat
water 41 in the heat exchanger 47 to produce a wet steam in the
steam producing system 40. In order to produce the superheated
steam the water droplets in the wet steam must be separated from
the steam using the superheated steam system 50 and a steam
separator. The wet steam once separated is heated further by the
steam generator 51 to produce a superheated steam which is used to
drive a turbine 61 in a turbine system 60 to produce the mechanical
motion or drive the drive shaft 62.
[0066] The applicant has found that the energy converter 10 has an
improved thermal efficiency over the prior art systems. The
efficiency of the best prior art heat engines is low; usually below
50% and often far below. So the energy lost to the environment by
heat engines is a major waste of energy resources. The present
invention has improved the thermal efficiency by using a closed
loop system which recycles some of the steam which is condensed and
fed back to the start of the process in the steam producing system
40.
[0067] The present invention advantageously allows the energy
converter 10 to be used in modern cogeneration, combined cycle and
energy recycling schemes which all provide an environmentally
friendly option using heat engines. By utilizing superheated steam
which is fed to a turbine system 60 the applicant is avoiding
causing blade erosion of the turbine 61.
[0068] The present invention does not suffer from the endemic
problems that have led to the demise of steam power in a commercial
environment to date. There is little or no pollution, due to the
recycling of the water and the small number of moving parts means
maintenance costs have been significantly reduced. Due to the
adaptability and relative small size of the present invention means
that the energy converter may be used as part of a hybrid renewable
energy vehicle, for example an electric car. This means that the
drawback of having to regularly recharge an electric car can be
reduced due to the adaptability of the steam energy converter which
can be used to recharge the batteries while the car is still in use
thereby extending the time between charges of the batteries.
[0069] In the specification the term "comprising" shall be
understood to have a broad meaning similar to the term "including"
and will be understood to imply the inclusion of a stated integer
or step or group of integers or steps but not the exclusion of any
other integer or step or group of integers or steps.
[0070] This definition also applies to variations on the term
"comprising" such as "comprise" and "comprises".
[0071] Although the present invention has been illustrated and
described with respect to exemplary embodiment thereof, it should
be understood by those skilled in the art that the foregoing and
various other changes, omissions and additions may be made therein
and thereto, without departing from the scope of the present
invention. Therefore, the present invention should not be
understood as limited to the specific embodiment set out above but
to include all possible embodiments which can be embodied within a
scope encompassed and equivalent thereof with respect to the
feature set out in the appended claims.
* * * * *