U.S. patent application number 13/909730 was filed with the patent office on 2013-12-12 for forming liquid sprays in compressed-gas energy storage systems for effective heat exchange.
This patent application is currently assigned to SUSTAINX, INC.. The applicant listed for this patent is SUSTAINX, INC.. Invention is credited to Alexander Bell, Benjamin R. Bollinger, Benjamin Cameron, David Chmiel, Patrick Magari, Troy O. McBride, Horst Richter, Andrew Shang.
Application Number | 20130327033 13/909730 |
Document ID | / |
Family ID | 45351205 |
Filed Date | 2013-12-12 |
United States Patent
Application |
20130327033 |
Kind Code |
A1 |
McBride; Troy O. ; et
al. |
December 12, 2013 |
FORMING LIQUID SPRAYS IN COMPRESSED-GAS ENERGY STORAGE SYSTEMS FOR
EFFECTIVE HEAT EXCHANGE
Abstract
In various embodiments, efficiency of energy storage and
recovery systems compressing and expanding gas is improved via heat
exchange between the gas and a heat-transfer fluid.
Inventors: |
McBride; Troy O.; (Norwich,
VT) ; Bell; Alexander; (Kensington, NH) ;
Bollinger; Benjamin R.; (Topsfield, MA) ; Shang;
Andrew; (Lebanon, NH) ; Chmiel; David; (West
Lebanon, NH) ; Richter; Horst; (Norwich, VT) ;
Magari; Patrick; (Plainfield, NH) ; Cameron;
Benjamin; (Hanover, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SUSTAINX, INC. |
SEABROOK |
NH |
US |
|
|
Assignee: |
SUSTAINX, INC.
SEABROOK
NH
|
Family ID: |
45351205 |
Appl. No.: |
13/909730 |
Filed: |
June 4, 2013 |
Related U.S. Patent Documents
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Application
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13105986 |
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8474255 |
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13909730 |
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7802426 |
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61148691 |
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Current U.S.
Class: |
60/517 |
Current CPC
Class: |
F15B 2211/216 20130101;
H02J 15/006 20130101; F15B 2211/3057 20130101; F15B 2211/212
20130101; F15B 2211/327 20130101; F15B 2211/214 20130101; F15B
2211/41554 20130101; F15B 2211/62 20130101; F15B 1/024 20130101;
F15B 2211/30575 20130101; F15B 11/032 20130101; F15B 2211/50581
20130101; F15B 2211/20569 20130101; F15B 21/08 20130101; F15B 15/00
20130101; F15B 2211/3111 20130101; F15B 2211/30505 20130101; F15B
2211/31594 20130101; F15B 2211/7058 20130101; F15B 2211/41509
20130101; F15B 2211/3058 20130101; F15B 2211/426 20130101; F15B
2211/6309 20130101; F15B 2211/45 20130101; F15B 2211/40515
20130101; F15B 2211/5153 20130101 |
Class at
Publication: |
60/517 |
International
Class: |
F15B 15/00 20060101
F15B015/00 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under
IIP-0810590 and IIP-0923633 awarded by the National Science
Foundation and DE-OE0000231 awarded by the Department of Energy.
The government has certain rights in the invention.
Claims
1.-33. (canceled)
34. A compressed-gas energy storage and recovery system comprising:
a cylinder assembly comprising a pneumatic chamber for compressing
gas to store energy and expanding gas to recover energy and a
hydraulic chamber, separated from the pneumatic chamber;
selectively fluidly connected to the pneumatic chamber, (i) a
compressed-gas reservoir for storage of gas after compression and
supply of compressed gas for expansion thereof, and (ii) a vent for
exhausting expanded gas to atmosphere and supply of gas for
compression thereof; a spray mechanism for introducing
heat-transfer fluid within the pneumatic chamber of the cylinder
assembly to exchange heat with gas therein, thereby increasing
efficiency of the energy storage and recovery, the spray mechanism
comprising a plurality of nozzles for collectively producing an
aggregate spray filling substantially an entire volume of the
pneumatic chamber; and a circulation apparatus for circulating the
heat-transfer fluid to the spray mechanism, wherein the aggregate
spray comprises a plurality of overlapping individual sprays each
produced by one of the plurality of nozzles.
35. The system of claim 34, wherein each individual spray is an
atomized spray of individual droplets.
36. The system of claim 35, wherein the individual droplets have an
average diameter ranging from approximately 0.2 mm to approximately
1 mm.
37. The system of claim 34, wherein the plurality of nozzles
maintains a Weber value of gas within the chamber of at least
40.
38. The system of claim 34, wherein each nozzle maintains a
pressure drop thereacross of less than approximately 50 psi.
39. The system of claim 34, wherein at least one nozzle has a
divergent cross-sectional profile.
40. The system of claim 34, wherein at least one nozzle comprises a
mechanism for breaking up a flow of heat-transfer fluid
therethrough.
41. The system of claim 40, wherein the mechanism comprises at
least one of a plurality of vanes or a corkscrew.
42. The system of claim 34, further comprising a control system for
controlling the introduction of heat-transfer fluid into the
pneumatic chamber such that the at least one of compression or
expansion of gas is substantially isothermal.
43. The system of claim 34, wherein the plurality of nozzles is
organized into at least two nozzle groups, at least one nozzle
group not being active during a portion of a single cycle of
compression or expansion.
44. A compressed-gas energy storage and recovery system comprising:
a cylinder assembly comprising (i) a first chamber for compressing
gas to store energy and expanding gas to recover energy, (ii) a
second chamber, (iii) a movable piston separating the first chamber
from the second chamber, and (iv) a piston rod connected to the
movable piston; selectively fluidly connected to the first chamber,
(i) a compressed-gas reservoir for storage of gas after compression
and supply of compressed gas for expansion thereof, and (ii) a vent
for exhausting expanded gas to atmosphere and supply of gas for
compression thereof; a spray mechanism for introducing
heat-transfer fluid within the first chamber of the cylinder
assembly to exchange heat with gas therein, thereby increasing
efficiency of the energy storage and recovery, the spray mechanism
comprising a plurality of nozzles for collectively producing an
aggregate spray filling substantially an entire volume of the first
chamber; and a circulation apparatus for circulating the
heat-transfer fluid to the spray mechanism, wherein (i) the
aggregate spray comprises a plurality of overlapping individual
sprays each produced by one of the plurality of nozzles, and (ii)
the movable piston and piston rod define a fluid passageway
selectively fluidly connected to the circulation apparatus.
45. The system of claim 44, wherein each individual spray is an
atomized spray of individual droplets.
46. The system of claim 45, wherein the individual droplets have an
average diameter ranging from approximately 0.2 mm to approximately
1 mm.
47. The system of claim 44, wherein the plurality of nozzles
maintains a Weber value of gas within the chamber of at least
40.
48. The system of claim 44, wherein each nozzle maintains a
pressure drop thereacross of less than approximately 50 psi.
49. The system of claim 44, wherein at least one nozzle has a
divergent cross-sectional profile.
50. The system of claim 44, wherein at least one nozzle comprises a
mechanism for breaking up a flow of heat-transfer fluid
therethrough.
51. The system of claim 50, wherein the mechanism comprises at
least one of a plurality of vanes or a corkscrew.
52. The system of claim 44, further comprising a control system for
controlling the introduction of heat-transfer fluid into the first
chamber such that the at least one of compression or expansion of
gas is substantially isothermal.
53. The system of claim 44, wherein the plurality of nozzles is
organized into at least two nozzle groups, at least one nozzle
group not being active during a portion of a single cycle of
compression or expansion.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Patent Application No. 61/334,722, filed May 14, 2010,
U.S. Provisional Patent Application No. 61/349,009, filed May 27,
2010, U.S. Provisional Patent Application No. 61/363,072, filed
Jul. 9, 2010, and U.S. Provisional Patent Application No.
61/393,725, filed Oct. 15, 2010, and is a continuation-in-part of
U.S. patent application Ser. No. 12/639,703, filed Dec. 16, 2009,
which (i) is a continuation-in-part of U.S. patent application Ser.
No. 12/421,057, filed Apr. 9, 2009, which claims the benefit of and
priority to U.S. Provisional Patent Application No. 61/148,691,
filed Jan. 30, 2009, and U.S. Provisional Patent Application No.
61/043,630, filed Apr. 9, 2008; (ii) is a continuation-in-part of
U.S. patent application Ser. No. 12/481,235, filed Jun. 9, 2009,
which claims the benefit of and priority to U.S. Provisional Patent
Application No. 61/059,964, filed Jun. 9, 2008; and (iii) claims
the benefit of and priority to U.S. Provisional Patent Application
Nos. 61/166,448, filed on Apr. 3, 2009; 61/184,166, filed on Jun.
4, 2009; 61/223,564, filed on Jul. 7, 2009; 61/227,222, filed on
Jul. 21, 2009; and 61/251,965, filed on Oct. 15, 2009. The entire
disclosure of each of these applications is hereby incorporated
herein by reference.
FIELD OF THE INVENTION
[0003] In various embodiments, the present invention relates to
pneumatics, power generation, and energy storage, and more
particularly, to compressed-gas energy-storage systems and methods
using pneumatic or pneumatic/hydraulic cylinders.
BACKGROUND
[0004] Storing energy in the form of compressed gas has a long
history and components tend to be well tested and reliable, and
have long lifetimes. The general principle of compressed-gas or
compressed-air energy storage (CAES) is that generated energy
(e.g., electric energy) is used to compress gas (e.g., air), thus
converting the original energy to pressure potential energy; this
potential energy is later recovered in a useful form (e.g.,
converted back to electricity) via gas expansion coupled to an
appropriate mechanism. Advantages of compressed-gas energy storage
include low specific-energy costs, long lifetime, low maintenance,
reasonable energy density, and good reliability.
[0005] If a body of gas is at the same temperature as its
environment, and expands slowly relative to the rate of heat
exchange between the gas and its environment, then the gas will
remain at approximately constant temperature as it expands. This
process is termed "isothermal" expansion. Isothermal expansion of a
quantity of high-pressure gas stored at a given temperature
recovers approximately three times more work than would "adiabatic"
expansion, that is, expansion where no heat is exchanged between
the gas and its environment--e.g., because the expansion happens
rapidly or in an insulated chamber. Gas may also be compressed
isothermally or adiabatically.
[0006] An ideally isothermal energy-storage cycle of compression,
storage, and expansion would have 100% thermodynamic efficiency. An
ideally adiabatic energy-storage cycle would also have 100%
thermodynamic efficiency, but there are many practical
disadvantages to the adiabatic approach. These include the
production of more extreme temperatures and pressures within the
system, heat loss during the storage period, and inability to
exploit environmental (e.g., cogenerative) heat sources and sinks
during expansion and compression, respectively. In an isothermal
system, the cost of adding a heat-exchange system is traded against
resolving the difficulties of the adiabatic approach. In either
case, mechanical energy from expanding gas must usually be
converted to electrical energy before use.
[0007] An efficient and novel design for storing energy in the form
of compressed gas utilizing near isothermal gas compression and
expansion has been shown and described in U.S. Pat. No. 7,832,207
(the '207 patent) and U.S. patent application Ser. No. 12/639,703
(the '703 application), the disclosures of which are hereby
incorporated herein by reference in their entireties. The '207
patent and the '703 application disclose systems and methods for
expanding gas isothermally in staged cylinders and intensifiers
over a large pressure range in order to generate electrical energy
when required. Mechanical energy from the expanding gas may be used
to drive a hydraulic pump/motor subsystem that produces
electricity. Systems and methods for hydraulic-pneumatic pressure
intensification that may be employed in systems and methods such as
those disclosed in the '207 patent and the '703 application are
shown and described in U.S. patent application Ser. No. 12/879,595
(the '595 application), the disclosure of which is hereby
incorporated herein by reference in its entirety.
[0008] In the systems disclosed in the '207 patent and the '703
application, reciprocal mechanical motion is produced during
recovery of energy from storage by expansion of gas in the
cylinders. This reciprocal motion may be converted to electricity
by a variety of means, for example as disclosed in the '595
application as well as in U.S. patent application Ser. No.
12/938,853 (the '853 application), the disclosure of which is
hereby incorporated herein by reference in its entirety. The
ability of such systems to either store energy (i.e., use energy to
compress gas into a storage reservoir) or produce energy (i.e.,
expand gas from a storage reservoir to release energy) will be
apparent to any person reasonably familiar with the principles of
electrical and pneumatic machines.
[0009] Gas undergoing expansion tends to cool, while gas undergoing
compression tends to heat. To maximize efficiency (i.e., the
fraction of elastic potential energy in the compressed gas that is
converted to work, or vice versa), gas expansion and compression
should be as near isothermal (i.e., constant-temperature) as
possible. Various techniques of approximating isothermal expansion
and compression may be employed.
[0010] For example, as described in U.S. Pat. No. 7,802,426 (the
'426 patent), the disclosure of which is hereby incorporated by
reference herein in its entirety, gas undergoing either compression
or expansion may be directed, continuously or in installments,
through a heat-exchange subsystem external to the cylinder. The
heat-exchange subsystem either rejects heat to the environment (to
cool gas undergoing compression) or absorbs heat from the
environment (to warm gas undergoing expansion). An isothermal
process may be approximated via judicious selection of this
heat-exchange rate.
[0011] However, compressed-gas-based systems may be simplified via
thermal conditioning of the gas within the cylinder during
compression and expansion, rather than via the above-described
conditioning external to the cylinder. There is a need for such
internal-conditioning systems that enable heat exchange with the
gas in an efficient manner.
SUMMARY
[0012] In accordance with various embodiments of the present
invention, droplets of a liquid (e.g., water) are sprayed into a
chamber of the cylinder in which gas is presently undergoing
compression (or expansion) in order to transfer heat to or from the
gas. As the liquid droplets exchange heat with the gas around them,
the temperature of the gas is raised or lowered; the temperature of
the droplets is also raised or lowered. The liquid is evacuated
from the cylinder through a suitable mechanism. The heat-exchange
spray droplets may be introduced through a spray head (in, e.g., a
vertical cylinder), through a spray rod arranged coaxially with the
cylinder piston (in, e.g., a horizontal cylinder), or by any other
mechanism that permits formation of a liquid spay within the
cylinder, as further detailed below. Droplets may be used to either
warm gas undergoing expansion or to cool gas undergoing
compression. An isothermal process may be approximated via
judicious selection of this heat-exchange rate.
[0013] Specifically, embodiments of the invention relate to devices
that form liquid sprays in a chamber containing either (i) low- to
mid-pressure (e.g., up to 300 pounds per square inch gauge [psig])
gas, (ii) high-pressure (e.g., between 300 and 3,000 psig) gas, or
(iii) both, to achieve significant heat transfer between the liquid
and the gas. The heat transfer between the liquid and the air
preferably enables substantially isothermal compression or
expansion of the gas within the chamber. An exemplary device may
include a plate or surface perforated at a number of points with
orifices or nozzles to allow the passage of liquid from one side of
the plate (herein termed the first side) to the other (herein
termed the second side). A volume of liquid impinges on the first
side of the plate: this liquid passes through the orifices or
nozzles in the plate into a volume of gas that impinges on the
second side of the plate and is at lower pressure than the liquid
on the first side. The liquid exiting each nozzle into the gas may
break up into droplets as determined by various factors, including
but not limited to liquid viscosity, surface tension, pressure,
density, and exit velocity; pressure and density of the gas; and
nozzle geometry (e.g., nozzle shape and/or size). Herein, the term
"nozzle" denotes any channel, orifice, or other device through
which a liquid may be made to flow so as to produce a jet or spray
at its output by encouraging the breakup of liquid flow into a
spray of droplets.
[0014] Spray formation may occur via several mechanisms. Liquid
(e.g., water) injected into gas at sufficient velocities will
typically break up due to the density of the gas into which it is
injected. However, it is generally desirable to minimize the
injection velocity to minimize the energy needed to create the
spray. Therefore, this type of breakup is especially pertinent at
mid- to high-pressures where gas density is high, allowing for
spray creation even with relatively low water-injection velocities.
Thus even simple nozzles (e.g., channels with substantially
parallel sides) which form a water jet at the nozzle exit will
generally form a spray as gas density causes the water jet to break
up into fine droplets.
[0015] In the low- to mid-pressure range, however, the air density
is typically not great enough to cause the viscous drag needed to
break a water jet up into a spray of small droplets. In this
regime, water that exits a nozzle as a jet may remain in a solid
jet and not form droplets. Thus, nozzles in accordance with
embodiments of the invention may be more complex and incorporate
mechanisms to break up water exiting the nozzle into droplets. For
example, internal vanes may impart a rotational velocity component
to the water as it exits the nozzle. This angular velocity causes
the exiting water to diverge from the axis of the water spray,
creating a cone of water droplets. Other nozzles may incorporate
mechanisms such as corkscrews (i.e., spiral-shaped profiled
surfaces) attached to and/or incorporated within the nozzles to
break up the exiting water jet and form a cone of water droplets.
These mechanisms enable atomized-spray formation for water injected
even into low- to mid-pressure gas.
[0016] The spray device may include other features that enable it
to function within a larger system. For example, a device may be
installed within a vertically oriented pneumatic cylinder
containing a mobile piston that divides the interior of the
cylinder into two discrete chambers, this piston being connected to
one or more shafts that transmit force between the piston and
mechanical loads outside the cylinder. An above-described spray
device, with all the features and components that it may include,
is herein termed the "spray head."
[0017] A spray head may be affixed to the upper interior surface of
a pneumatic cylinder or within a pneumatic chamber of another type
of cylinder, e.g., a pneumatic/hydraulic cylinder. The spray head
is generally perforated by one or more orifices having identical or
various sizes, spacings, internal geometries, and cross-sectional
forms, which produce droplet sprays within the gas-filled volume
below the spray head. At the point of spray formation, droplets
appear with velocity vectors scattered randomly over a certain
solid angle (.ltoreq.2.pi. steradians) centered on the vertical and
pointing generally downward, forming a spray cone. At any pressure
greater than zero and given a sufficiently large gas volume, the
horizontal component of any particular droplet's momentum will
eventually be dissipated by frictional interaction with the gas,
after which the droplet will, in the ideal case, begin to fall
vertically at a fixed terminal velocity. (The droplet may be
perturbed from vertical fall by motions of the gas, such as those
produced by convection or other turbulence.) For each droplet, both
the limit of horizontal travel and the terminal velocity during
vertical fall are determined largely by gas density and droplet
size.
[0018] As a consequence of limited horizontal travel and vertical
terminal velocity, the spray cone produced by each spray-producing
nozzle will typically, at some distance beneath the nozzle, become
a column of droplets falling at constant speed. Because the density
of a gas at high pressure gas is higher than that of the same gas
at low pressure (at a given temperature), the horizontal distance
traveled by a droplet of a given size and initial velocity is
smaller in high-pressure gas than in low-pressure gas. Likewise,
the droplet's terminal velocity is lower in high-pressure gas.
Therefore, in high-pressure gas, a column of droplets forming
beneath a spray orifice tends to be narrower and slower-falling
than a column that forms under the same orifice in low-pressure
gas.
[0019] In order to maximize heat transfer between the droplets and
the gas, embodiments of the invention preferably bring as much gas
as possible into contact with as much droplet surface area as
possible as the droplets fall through the gas. That is, the gas
volume is generally filled or nearly filled with falling droplets.
The spray cone or column of droplets produced by a single nozzle
will not, in general, be wide enough to fill the gas volume. For
mid- or high-pressure gas, the droplet column will generally be
narrower, tending to require a larger number of orifices: in
particular, the number of orifices required to fill or cover with
spray a given volume of gas will be approximately proportional to
the inverse of the square of the radius of the column. Thus, for
example, halving spray-column radius while keeping the spray-head
area constant will typically increase the number of orifices
required by a factor of about four.
[0020] Alternatively, the initial velocity of spray droplets at
each spray-head orifice, and consequently the width of the
resulting spray column, may be increased by injecting liquid
through the spray head at higher velocity. Injection of liquid at
increased velocity requires increased difference between the
pressure of the liquid on first side of the spray head and the
pressure on the second side (this difference being termed
.DELTA.P). Raising the liquid by larger .DELTA.P would consume more
energy. Higher-pressure injection will typically increase the
distance at which a spray cone transitions into a column of falling
droplets, therefore widening the column of spray droplets produced
by each nozzle, but will typically also consume more energy and
therefore will tend not to increase the energy efficiency of spray
generation.
[0021] Moreover, if the gas volume has the form of a straight-sided
torus due to the presence of a piston shaft within the cylinder, a
single nozzle cannot in principle cover the whole interior volume
with falling droplets due to the obstructive effect of the
shaft.
[0022] Maximization of heat transfer with simultaneous minimization
of energy consumed in generating the heat-transfer spray,
therefore, generally requires multiple spray nozzles. Consequently,
embodiments of the invention contain multiple spray nozzles and
substantially cover the upper surface of the gas-filled chamber
into which it injects spray. The spray-head surface may have an
annular shape in embodiments where it surrounds a piston shaft, may
be disc-shaped in embodiments where it is mounted on the end of a
mobile piston, and may be otherwise shaped depending on a
particular application.
[0023] Embodiments of the invention feature multiple simple or
complex nozzles on the upper surface of a pneumatic chamber such
that the spray cones or columns produced by these nozzles overlap
and/or interact with each other, and thus leave minimal gas volume,
if any, unfilled by spray. All or almost all of the gas volume is
thus exposed to liquid spray as gravity pulls the columns of
droplets downward from the spray head. In high-gas-pressure
embodiments, where horizontal travel of spray droplets is small
(e.g., due to high gas density), many close-spaced orifices may be
utilized to fill all or nearly all of the gas volume with falling
spray.
[0024] Generally, embodiments of the invention generate a
considerably uniform spray within a pneumatic chamber and/or
cylinder via at least one spray head with multiple nozzles, where
the pressure drop across the spray-head orifices does not exceed 50
psi and the spray volumetric flow is sufficient to achieve heat
exchange necessary to achieve substantially isothermal expansion or
compression. In one embodiment, the heat exchange power per unit
flow in kW per GPM (gallons per minute) per degree C. exceeds 0.10.
The geometry of each nozzle may be selected to produce droplets
having a diameter of about 0.2 mm to about 1.0 mm. Additionally,
the plurality of orifices may be configured to maintain a pressure
drop of the heat-transfer fluid at less than approximately 50 psi
during introduction thereof and/or at least a portion of the
plurality of orifices may have divergent cross-sectional profiles.
In high-pressure-gas embodiments, the orifices may be configured
and arranged in a manner to maintain a Weber value of the
high-pressure gas sufficient to maintain the spray in a form
comprising or consisting essentially of substantially individual
droplets. In one embodiment, the orifices are configured to
maintain the Weber value of the high-pressure gas at a value of at
least 40.
[0025] Embodiments of the invention include features that enable
efficient installation within a pneumatic chamber and/or cylinder,
and may also include features that enable efficient provision of
liquid from an exterior source to the interior of the device for
transmission through the orifices in the plate.
[0026] Embodiments of the invention also increase the efficiency
with which varying amounts of a heat-exchange liquid are sprayed
into a pneumatic compressor-expander cylinder, thus minimizing the
energy required to maintain substantially isothermal compression or
expansion of a gas within the cylinder. Various embodiments of the
invention enable the injection of heat-exchange liquid at two or
more distinct rates of flow into one or both chambers of a
pneumatic compressor-expander cylinder by equipping the spray
mechanism within each chamber with two or more groups of
spray-generating nozzles, where the flow of heat-exchange liquid
through each nozzle group may be actuated independently.
Recruitment of additional nozzle groups allows total flow rate to
be increased by a given amount without increasing the power used to
pump the liquid as much as would be required if the number of
nozzles were fixed.
[0027] During expansion of gas from storage in certain systems such
as those disclosed in the '207 patent and the '703 application, the
pressure of a quantity of gas within one chamber of a pneumatic or
pneumatic-hydraulic cylinder exerts a force upon a piston and
attached rod slidably disposed within the cylinder. The force
exerted by the gas upon the piston and rod causes the piston and
rod to move. As described by the Ideal Gas Law, the temperature of
the gas undergoing expansion tends to decrease. To control the
temperature of the quantity of gas being expanded within the
cylinder (e.g., to hold it constant, that is, to produce isothermal
expansion), a heat-exchange liquid may be sprayed into the chamber
containing the expanding gas. The spray may be generated by pumping
the heat-exchange liquid through one or more nozzles, as detailed
above. If the liquid is at a higher temperature than that of the
gas in the chamber, then heat will flow from the droplets the gas
in the chamber, warming the gas.
[0028] Similarly, when gas is compressed in the cylinder, as
described by the Ideal Gas Law, the temperature of the gas
undergoing compression tends to increase. Heat-exchange liquid may
be sprayed into the chamber containing the gas undergoing
compression. If the liquid is at a lower temperature than that of
the gas in the chamber, then heat will flow from the gas in the
chamber to the droplets, cooling the gas.
[0029] The maximum amount of heat Q to be added to or removed from
the gas in a chamber of the cylinder by a given mass m of
heat-exchange liquid spray is Q=mc.DELTA.T, where c is the specific
heat of the liquid and .DELTA.T is the difference between the
initial temperature of the liquid and the final temperature of the
liquid (i.e., temperature of the liquid when it has reached thermal
equilibrium with the gas). Assuming that c and .DELTA.T are fixed,
the only way to alter Q is to alter m. In particular, to exchange
more heat between the heat-exchange liquid and the gas in the
cylinder chamber, m is increased.
[0030] The mass m of heat-exchange liquid entering the cylinder
chamber in a given time interval is given by flow rate q and fluid
density .rho.. Here, m has units of kg, q has units of m.sup.3/s,
and p has units of kg/m.sup.3. Thus, to add or remove more heat
from the gas in the cylinder chamber for a heat-exchange liquid
with near-constant density .rho., the flow rate q of the
heat-exchange liquid is increased.
[0031] When liquid flows through a nozzle or orifice, it encounters
resistance. This resistance is associated with a pressure drop
.DELTA.p from the input side of the nozzle to the output side. The
pressure drop across (i.e., through) the nozzle depends on the
characteristics of a particular nozzle, including its shape, and on
the flow rate q. In particular, to increase flow rate q, the
pressure drop .DELTA.p is increased. The relationship between flow
rate q and pressure drop .DELTA.p has the general form q .varies.
p.sup.n; n is typically less than 0.50. (This may also be expressed
as p .varies. q.sup.1/n) Moreover, the spraying power P consumed by
forcing liquid at rate q through a nozzle with a constant pressure
drop .DELTA.p is P=.DELTA.p q. Substituting .DELTA.p .varies.
g.sup.1/n n for .DELTA.p in P=.DELTA.p q gives P .varies. q
q.sup.1/n =q.sup.1/n+1. If, for example, n=0.5, then P .varies.
q.sup.1/n+1=q.sup.1/0.5+1=q.sup.3. Thus, the power required to
achieve a given amount of flow through a single nozzle--and
therefore through any fixed number of nozzles--increases
geometrically with flow rate. As a consequence, doubling the flow
rate more than doubles the required spraying power.
[0032] The rate of heat transfer between the gas in the pneumatic
cylinder chamber and the heat-exchange liquid spray is proportional
to the flow rate and bears a similar relation to spraying power as
does the flow rate. Specifically, from Q=m c .DELTA.T we have
dQ/dt=p q c .DELTA.T, where t is time, .rho. is liquid density, q
is liquid flow rate, .DELTA.T is the difference between the initial
temperature of the liquid and the final temperature of the liquid,
and dQ/dt is rate of heat transfer. If .rho., c and AT are
constant, dQ/dt .varies. q. In the example where n=0.5, one has P
.varies. q.sup.3, which combined with dQ/dt .varies. q gives P
.varies. (dQ/dt).sup.3. The spraying power P is thus, for an
exemplary n of 0.5, proportional to the third power of the required
rate of heat transfer. This result holds for any fixed number of
nozzles.
[0033] For a required rate of spray heat transfer in a pneumatic
cylinder, it is desirable to minimize the spraying power.
Preferably, the spray power is minimized to just above the
operating point (spray pressure) where a spray of sufficient
quality continues to be generated at the output of each nozzle,
since, as described above, the rate of heat transfer between the
gas in the chamber and the heat-exchange liquid is greatly
increased by mixing the heat-exchange liquid with the gas in the
form of a spray, which maximizes the area of liquid-gas
contact.
[0034] The flow rate (and thus rate of heat transfer if spray
quality is maintained) may be increased with a less-than-geometric
accompanying increase in spraying power by raising the number of
active nozzles (i.e., nozzles through which heat-exchange liquid is
made to flow) as the flow rate is increased. For example, the flow
rate may be doubled by doubling the number of active identical
nozzles without changing the flow rate through any individual
nozzle. In this case, the spraying power P per nozzle remains
unchanged while the number of nozzles doubles, so total spraying
power doubles. In contrast, for a fixed number of identical
nozzles, if an exemplary n of 0.5 is assumed, doubling the rate of
heat transfer requires an eightfold increase in the spraying power
P.
[0035] Thus, embodiments of the invention decrease the spraying
power required while maintaining sufficient pressure drop in each
nozzle (i.e., sufficient to create a spray at the output) by making
the number of active nozzles proportional to the rate of flow. This
proportionality may be exact or approximate.
[0036] Embodiments of the invention allow an increased flow rate of
heat-exchange liquid through an arrangement of nozzles into a
chamber of a pneumatic cylinder without geometric increase in
spraying power. Various embodiments of the invention include
methods for the introduction of heat-exchange liquid into a chamber
of a pneumatic cylinder through a number of nozzles. One or more
spray heads, rods, or other contrivances for situating nozzles
within the chamber are equipped with two or more sets of nozzles.
Each set of nozzles contains one or more nozzles. The sets of
nozzles may be interspersed across the surface of the spray head,
spray rod, or other contrivance, or they may be segregated from
each other. The nozzles within the various sets may be of uniform
type, or of various types. When a relatively low flow rate of
heat-exchange liquid is desired, e.g. when the pressure of the gas
within the chamber is relatively low, one or more nozzle sets may
be employed to spray heat-exchange liquid into the chamber. At
higher flow rates, e.g., when the pressure of the gas within the
chamber is relatively high, two or more nozzle sets may be employed
to spray heat-exchange liquid into the chamber. The identity and
number of the nozzle sets employed to spray heat-exchange liquid at
any given time may be determined by a control system, an operator,
and/or an automatic arrangement of valves. When increased flow rate
of heat-exchange liquid is desired in order to increase the rate of
heat transfer, additional nozzle sets are activated.
[0037] In various embodiments of the invention, the heat-transfer
fluid utilized to thermally condition gas within one or more
cylinders incorporates one or more additives and/or solutes, as
described in U.S. patent application Ser. No. 13/082,808, filed
Apr. 8, 2011 (the '808 application), the entire disclosure of which
is incorporated herein by reference. As described in the '808
application, the additives and/or solutes may reduce the surface
tension of the heat-transfer fluid, reduce the solubility of gas
into the heat-transfer fluid, and/or slow dissolution of gas into
the heat-transfer fluid. They may also (i) retard or prevent
corrosion, (ii) enhance lubricity, (iii) prevent formation of or
kill microorganisms (such as bacteria), and/or (iv) include a
defoaming agent, as desired for a particular system design or
application.
[0038] Embodiments of the present invention are typically utilized
in energy storage and generation systems utilizing compressed gas.
In a compressed-gas energy storage system, gas is stored at high
pressure (e.g., approximately 3,000 psi). This gas may be expanded
into a cylinder having a first compartment (or "chamber") and a
second compartment separated by a piston slidably disposed within
the cylinder (or by another boundary mechanism). A shaft may be
coupled to the piston and extend through the first compartment
and/or the second compartment of the cylinder and beyond an end cap
of the cylinder, and a transmission mechanism may be coupled to the
shaft for converting a reciprocal motion of the shaft into a rotary
motion, as described in the '595 and '853 applications. Moreover, a
motor/generator may be coupled to the transmission mechanism.
Alternatively or additionally, the shaft of the cylinders may be
coupled to one or more linear generators, as described in the '853
application.
[0039] As also described in the '853 application, the range of
forces produced by expanding a given quantity of gas in a given
time may be reduced through the addition of multiple,
series-connected cylinder stages. That is, as gas from a
high-pressure reservoir is expanded in one chamber of a first,
high-pressure cylinder, gas from the other chamber of the first
cylinder is directed to the expansion chamber of a second,
lower-pressure cylinder. Gas from the lower-pressure chamber of
this second cylinder may either be vented to the environment or
directed to the expansion chamber of a third cylinder operating at
still lower pressure; the third cylinder may be connected to either
the environment or to a fourth cylinder; and so on.
[0040] The principle may be extended to more than two cylinders to
suit particular applications. For example, a narrower output force
range for a given range of reservoir pressures is achieved by
having a first, high-pressure cylinder operating between, for
example, approximately 3,000 psig and approximately 300 psig and a
second, larger-volume, lower-pressure cylinder operating between,
for example, approximately 300 psig and approximately 30 psig. When
two expansion cylinders are used, the range of pressure within
either cylinder (and thus the range of force produced by either
cylinder) is reduced as the square root relative to the range of
pressure (or force) experienced with a single expansion cylinder,
e.g., from approximately 100:1 to approximately 10:1 (as set forth
in the '853 application). Furthermore, as set forth in the '595
application, N appropriately sized cylinders can reduce an original
operating pressure range R to R.sup.1/N. Any group of N cylinders
staged in this manner, where N.gtoreq.2, is herein termed a
cylinder group.
[0041] All of the approaches described above for converting
potential energy in compressed gas into mechanical and electrical
energy may, if appropriately designed, be operated in reverse to
store electrical energy as potential energy in a compressed gas.
Since the accuracy of this statement will be apparent to any person
reasonably familiar with the principles of electrical machines,
power electronics, pneumatics, and the principles of
thermodynamics, the operation of these mechanisms to both store
energy and recover it from storage will not be described for each
embodiment. Such operation is, however, contemplated and within the
scope of the invention and may be straightforwardly realized
without undue experimentation.
[0042] Embodiments of the invention may be implemented using any of
the integrated heat-transfer systems and methods described in the
'703 application and/or with the external heat-transfer systems and
methods described in the '426 patent. In addition, the systems
described herein, and/or other embodiments employing liquid-spray
heat exchange or external gas heat exchange, may draw or deliver
thermal energy via their heat-exchange mechanisms to external
systems (not shown) for purposes of cogeneration, as described in
U.S. patent application Ser. No. 12/690,513, filed Jan. 20, 2010
(the '513 application), the entire disclosure of which is
incorporated by reference herein.
[0043] The compressed-air energy storage and recovery systems
described herein are preferably "open-air" systems, i.e., systems
that take in air from the ambient atmosphere for compression and
vent air back to the ambient atmosphere after expansion, rather
than systems that compress and expand a captured volume of gas in a
sealed container (i.e., "closed-air" systems). Thus, the systems
described herein generally feature one or more cylinder assemblies
for the storage and recovery of energy via compression and
expansion of gas. Selectively fluidly connected to the cylinder
assembly are (i) a reservoir for storage of compressed gas after
compression and supply of compressed gas for expansion thereof, and
(ii) a vent for exhausting expanded gas to atmosphere after
expansion and supply of gas for compression. The reservoir for
storage of compressed gas may include or consist essentially of,
e.g., one or more one or more pressure vessels (i.e., containers
for compressed gas that may have rigid exteriors or may be
inflatable, and that may be formed of various suitable materials
such as metal or plastic) or caverns (i.e., naturally occurring or
artificially created cavities that are typically located
underground). Open-air systems typically provide superior energy
density relative to closed-air systems.
[0044] Furthermore, the systems described herein may be
advantageously utilized to harness and recover sources of renewable
energy, e.g., wind and solar energy. For example, energy stored
during compression of the gas may originate from an intermittent
renewable energy source of, e.g., wind or solar energy, and energy
may be recovered via expansion of the gas when the intermittent
renewable energy source is nonfunctional (i.e., either not
producing harnessable energy or producing energy at
lower-than-nominal levels). As such, the systems described herein
may be connected to, e.g., solar panels or wind turbines, in order
to store the renewable energy generated by such systems.
[0045] In one aspect, embodiments of the invention feature a
compressed-gas energy storage and recovery system including or
consisting essentially of a cylinder assembly for compressing gas
to store energy and/or expanding gas to recover energy, and a spray
mechanism for introducing heat-transfer fluid within a chamber of
the cylinder assembly to exchange heat with gas in the chamber,
thereby increasing efficiency of the energy storage and recovery.
The spray mechanism includes or consists essentially of a plurality
of nozzles for collectively producing an aggregate spray filling
substantially an entire volume of the chamber. The aggregate spray
includes or consists essentially of a plurality of overlapping
individual sprays each produced by one of the plurality of
nozzles.
[0046] Embodiments of the invention may include one or more of the
following, in any of a variety of combinations. Each individual
spray may be an atomized spray of individual droplets. The
individual droplets may have an average diameter ranging from
approximately 0.2 mm to approximately 1 mm. The plurality of
nozzles may maintain a Weber value of gas within the chamber of at
least 40. Each nozzle may maintain a pressure drop across the
nozzle of less than approximately 50 psi. At least one nozzle may
have a divergent cross-sectional profile. At least one nozzle may
include or consist essentially of a mechanism (e.g., a plurality of
vanes and/or a corkscrew) for breaking of the flow of heat-transfer
fluid through the nozzle. The system may include a control system
for controlling the introduction of heat-transfer fluid into the
chamber such that the compression and/or expansion of gas is
substantially isothermal. The spray mechanism may occupy
approximately the entire top surface of the chamber. The plurality
of nozzles may be arranged in a triangular grid such that each
nozzle having six nearest-neighbor nozzles is approximately
equidistant from each of the six nearest-neighbor nozzles. The
plurality of nozzles may be arranged in a plurality of concentric
rings.
[0047] The system may include a movable boundary mechanism
separating the cylinder assembly into two chambers and a rod
coupled to the boundary mechanism and extending through at least
one of the chambers. The spray mechanism may define a hole
therethrough to snugly accommodate the rod. A crankshaft for
converting reciprocal motion of the boundary mechanism into rotary
motion may be mechanically coupled to the rod. A motor/generator
may be coupled to the crankshaft. The spray mechanism may include a
threaded connector for engaging a complementary threaded connector
disposed within the cylinder assembly. The spray mechanism may
include an interior channel (which may be toroidal) for
transmitting heat-transfer fluid from a source external to the
cylinder assembly to the plurality of nozzles. The system may
include at least one o-ring groove configured to accommodate an
o-ring for forming a liquid-impermeable seal between the spray
mechanism and the interior surface of the chamber.
[0048] A compressed-gas reservoir for storage of gas after
compression and supply of compressed gas for expansion thereof may
be selectively fluidly connected to the cylinder assembly. A vent
for exhausting expanded gas to atmosphere and supply of gas for
compression thereof may be selectively fluidly connected to the
cylinder assembly. An intermittent renewable energy source (e.g.,
of wind or solar energy) may be connected to the cylinder assembly.
Energy stored during compression of gas may originate from the
intermittent renewable energy source, and energy may be recovered
via expansion of gas when the intermittent renewable energy source
is nonfunctional.
[0049] The spray mechanism may include or consist essentially of a
spray head or a spray rod. The system may include a circulation
apparatus for circulating heat-transfer fluid to the spray
mechanism and/or a heat exchanger for maintaining the heat-transfer
fluid at a substantially constant temperature. The circulation
apparatus may circulate heat-transfer fluid from the cylinder
assembly through the heat exchanger and back to the cylinder
assembly. The cylinder assembly may include or consist essentially
of two separated chambers (e.g., a pneumatic chamber and a
hydraulic chamber, or two pneumatic chambers). The system may
include a heat-transfer fluid for introduction within the chamber.
The heat-transfer fluid may include or consist essentially of
water. The plurality of nozzles may be organized into at least two
nozzle groups, at least one nozzle group not being active during a
portion of a single cycle or compression or expansion.
[0050] In another aspect, embodiments of the invention feature a
method for improving efficiency of compressed-gas energy storage
and recovery. Gas is compressed to store energy and/or expanded to
recover energy within a chamber of a cylinder assembly. During the
compression and/or expansion, an entire volume of the chamber is
substantially filled with an atomized spray of heat-transfer fluid
to exchange heat between the gas and the atomized spray, thereby
increasing efficiency of the energy storage and recovery. The
atomized spray includes or consists essentially of a plurality of
overlapping individual sprays each produced within the chamber.
[0051] Embodiments of the invention may include one or more of the
following, in any of a variety of combinations. The heat exchange
between the gas and the atomized spray may render the compression
and/or expansion substantially isothermal. Expanded gas may be
vented to atmosphere and/or compressed gas may be stored in a
compressed-gas reservoir. Energy stored during compression of gas
may originate from an intermittent renewable energy source (e.g.,
of wind or solar energy). Energy may be recovered via expansion of
gas when the intermittent renewable energy source is nonfunctional.
The individual sprays may be each produced by one of a plurality of
nozzles organized into at least two nozzle groups. At least one
nozzle group may not be active during a portion of a single cycle
of compression or expansion.
[0052] In yet another aspect, embodiments of the invention feature
a compressed-gas energy storage and recovery system including or
consisting essentially of a cylinder assembly for compressing gas
to store energy and/or expanding gas to recover energy, an
actuating mechanism, and a heat-transfer mechanism for introducing
heat-transfer fluid within a chamber of the cylinder assembly to
exchange heat with gas in the chamber, thereby increasing
efficiency of the energy storage and recovery. The heat-transfer
mechanism includes or consists essentially of a plurality of
nozzles. The actuating mechanism controls the number of active
nozzles introducing heat-transfer fluid within the chamber during a
single cycle of compression or expansion of gas.
[0053] Embodiments of the invention may include one or more of the
following, in any of a variety of combinations. The actuating
mechanism may include or consist essentially of at least one
cracking-pressure valve. The actuating mechanism may include or
consist essentially of a plurality of valves (e.g., each valve
being associated with a nozzle) and a control system for
controlling the valves based at least on a pressure within the
cylinder assembly. The system may include a sensor for measuring
the pressure within the cylinder assembly, and the control system
may be responsive to the sensor. The control system may control the
cylinder assembly and/or the heat-transfer mechanism to render the
compression and/or expansion substantially isothermal. The
plurality of nozzles may be substantially identical to each other.
At least two nozzles may differ in at least one characteristic,
e.g., type, size, and/or throughput. The heat-transfer mechanism
may include or consist essentially of a spray head and/or a spray
rod. The system may include a heat exchanger and a circulation
apparatus for circulating heat-transfer fluid between the heat
exchanger and the cylinder assembly. The plurality of nozzles may
be organized into at least two nozzle groups, and at least one
nozzle group may not be active during a portion of the single cycle
of compression or expansion.
[0054] A compressed-gas reservoir for storage of gas after
compression and supply of compressed gas for expansion thereof may
be selectively fluidly connected to the cylinder assembly. A vent
for exhausting expanded gas to atmosphere and supply of gas for
compression thereof may be selectively fluidly connected to the
cylinder assembly. An intermittent renewable energy source (e.g.,
of wind or solar energy) may be connected to the cylinder assembly.
Energy stored during compression of gas may originate from the
intermittent renewable energy source, and energy may be recovered
via expansion of gas when the intermittent renewable energy source
is nonfunctional.
[0055] The cylinder assembly may include or consist essentially of
two separated chambers (e.g., a pneumatic chamber and a hydraulic
chamber, or two pneumatic chambers). The system may include a
movable boundary mechanism separating the cylinder assembly into
two chambers. A crankshaft for converting reciprocal motion of the
boundary mechanism into rotary motion may be mechanically coupled
to the boundary mechanism. A motor/generator may be coupled to the
crankshaft. The heat-transfer fluid may be introduced within the
chamber in the form of an atomized spray filling substantially an
entire volume of the chamber.
[0056] In another aspect, embodiments of the invention feature a
method for improving efficiency of compressed-gas energy storage
and recovery. Gas is compressed to store energy and/or expanded to
recover energy within a chamber of a cylinder assembly. During the
compression and/or expansion, heat-transfer fluid is introduced
into the chamber through at least one of a plurality of nozzles to
exchange heat with the gas, thereby increasing efficiency of the
energy storage and recovery. The number of active nozzles
introducing the heat-transfer fluid is based at least in part on a
pressure of the gas in the chamber.
[0057] Embodiments of the invention may include one or more of the
following, in any of a variety of combinations. The heat exchange
between the heat-transfer fluid and the gas may render the
compression and/or expansion substantially isothermal. Expanded gas
may be vented to atmosphere, and/or compressed gas may be stored in
a compressed-gas reservoir. Energy stored during compression of gas
may originate from an intermittent renewable energy source (e.g.,
of wind or solar energy). Energy may be recovered via expansion of
gas when the intermittent renewable energy source is nonfunctional.
The heat-transfer fluid may be recirculated between the chamber and
an external heat exchanger to maintain the heat-transfer fluid at a
substantially constant temperature. During a first portion of a
single cycle of expansion or compression at least one nozzle may
not be active. During a second portion of the single cycle of
expansion or compression different from the first portion, each of
the nozzles may be active. The heat-transfer fluid may be
introduced within the chamber in the form of an atomized spray
filling substantially the entire volume of the chamber.
[0058] In yet another aspect, embodiments of the invention feature
a method for energy storage and recovery. Gas is compressed within
a chamber of a cylinder assembly to store energy. During the
compression, heat-transfer fluid is introduced into the chamber at
a rate that increases as the pressure of the gas increases. The
heat-transfer fluid exchanges heat with the gas, thereby increasing
efficiency of the energy storage.
[0059] Embodiments of the invention may include one or more of the
following, in any of a variety of combinations. Introducing the
heat-transfer fluid may include or consist essentially of
increasing the spraying power of heat-transfer fluid at a
less-than-geometric rate relative to the rate of introduction. The
rate of introduction may be increased by increasing the number of
active nozzles introducing the heat-transfer fluid into the
chamber. The heat-transfer fluid may be recirculated between the
chamber and a heat exchanger to maintain the heat-transfer fluid at
a substantially constant temperature. The heat-exchange between the
gas and the hear-transfer fluid renders the compression
substantially isothermal.
[0060] These and other objects, along with advantages and features
of the invention, will become more apparent through reference to
the following description, the accompanying drawings, and the
claims. Furthermore, it is to be understood that the features of
the various embodiments described herein are not mutually exclusive
and can exist in various combinations and permutations. Note that
as used herein, the terms "pipe," "piping" and the like shall refer
to one or more conduits that are rated to carry gas or liquid
between two points. Thus, the singular term should be taken to
include a plurality of parallel conduits where appropriate. Herein,
the terms "liquid" and "water" interchangeably connote any mostly
or substantially incompressible liquid, the terms "gas" and "air"
are used interchangeably, and the term "fluid" may refer to a
liquid or a gas unless otherwise indicated. As used herein unless
otherwise indicated, the term "substantially" means .+-.10%, and,
in some embodiments, .+-.5%. A "valve" is any mechanism or
component for controlling fluid communication between fluid paths
or reservoirs, or for selectively permitting control or venting.
The term "cylinder" refers to a chamber, of uniform but not
necessarily circular cross-section, which may contain a slidably
disposed piston or other mechanism that separates the fluid on one
side of the chamber from that on the other, preventing fluid
movement from one side of the chamber to the other while allowing
the transfer of force/pressure from one side of the chamber to the
next or to a mechanism outside the chamber. In the absence of a
mechanical separation mechanism, a "chamber" or "compartment" of a
cylinder may correspond to substantially the entire volume of the
cylinder. A "cylinder assembly" may be a simple cylinder or include
multiple cylinders, and may or may not have additional associated
components (such as mechanical linkages among the cylinders). The
shaft of a cylinder may be coupled hydraulically or mechanically to
a mechanical load (e.g., a hydraulic motor/pump or a crankshaft)
that is in turn coupled to an electrical load (e.g., rotary or
linear electric motor/generator attached to power electronics
and/or directly to the grid or other loads), as described in the
'595 and '853 applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] In the drawings, like reference characters generally refer
to the same parts throughout the different views. Cylinders, rods,
and other components are depicted in cross section in a manner that
will be intelligible to all persons familiar with the art of
pneumatic and hydraulic cylinders. Also, the drawings are not
necessarily to scale, emphasis instead generally being placed upon
illustrating the principles of the invention. In the following
description, various embodiments of the present invention are
described with reference to the following drawings, in which:
[0062] FIG. 1 is a schematic diagram of portions of a
compressed-air energy storage and recovery system that may be
utilized in conjunction with various embodiments of the
invention;
[0063] FIG. 2 is an illustration of three types of liquid-flow
breakup;
[0064] FIG. 3 is a chart showing the relationship of liquid-flow
breakup to two dimensionless constants;
[0065] FIG. 4 is a chart showing the relationship of liquid-flow
breakup to two dimensionless constants, with the effect of high air
pressure indicated;
[0066] FIG. 5 is a table showing variables associated with spray
production for various orifice diameters and constant Weber number
for air;
[0067] FIG. 6 is a plot of water-spray heat-transfer limits
estimated mathematically;
[0068] FIG. 7 is a plot of droplet trajectory lengths;
[0069] FIG. 8 shows three types of orifice cross-section in
accordance with various embodiments of the invention;
[0070] FIG. 9 is an isometric view of a spray head in accordance
with various embodiments of the invention;
[0071] FIG. 10 is a plan view of the spray head of FIG. 9;
[0072] FIG. 11 is a schematic view of spray coverage from a spray
head in accordance with various embodiments of the invention;
[0073] FIG. 12 is a side view of the spray head of FIG. 9;
[0074] FIG. 13 is an axial cross-section of the spray head of FIG.
9;
[0075] FIG. 14 is top-down view of the spray head of FIG. 9;
[0076] FIG. 15 is an axial cross section of a double-acting
pneumatic cylinder incorporating two of the spray heads shown in
FIG. 9;
[0077] FIG. 16 is an isometric view of a spray head in accordance
with various other embodiments of the invention;
[0078] FIG. 17 is a plan view of the spray head of FIG. 16;
[0079] FIG. 18 is an assembly view of the spray head of FIG.
16;
[0080] FIG. 19 is an axial cross section of the spray head of FIG.
16;
[0081] FIG. 20 is bottom view of the spray head of FIG. 16;
[0082] FIG. 21 is an axial cross section of a double-acting
pneumatic cylinder incorporating two of the spray heads shown in
FIG. 16;
[0083] FIG. 22A is a schematic drawing of a pneumatic
expander-compressor cylinder into which a heat-exchange liquid is
injected in accordance with various embodiments of the
invention;
[0084] FIG. 22B is the system of FIG. 22A in a different state of
operation; and
[0085] FIG. 23 is a schematic diagram of portions of a
compressed-air energy storage and recovery system in accordance
with various embodiments of the invention.
DETAILED DESCRIPTION
[0086] FIG. 1 illustrates portions of a compressed air energy
storage and recovery system 100 that may be utilized with
embodiments of the present invention. The system 100 includes a
cylinder assembly 102, a heat-transfer subsystem 104, and a control
system 105 for controlling operation of the various components of
system 100. During system operation, compressed air is either
directed into vessel 106 (e.g., one or more pressure vessels or
caverns) during storage of energy or released from vessel 106
during recovery of stored energy. Air is admitted to the system 100
through vent 108 during storage of energy, or exhausted from the
system 100 through vent 108 during release of energy.
[0087] The control system 105 may be any acceptable control device
with a human-machine interface. For example, the control system 105
may include a computer (for example a PC-type) that executes a
stored control application in the form of a computer-readable
software medium. More generally, control system 105 may be realized
as software, hardware, or some combination thereof. For example,
control system 105 may be implemented on one or more computers,
such as a PC having a CPU board containing one or more processors
such as the Pentium, Core, Atom, or Celeron family of processors
manufactured by Intel Corporation of Santa Clara, Calif., the
680.times.0 and POWER PC family of processors manufactured by
Motorola Corporation of Schaumburg, Ill., and/or the ATHLON line of
processors manufactured by Advanced Micro Devices, Inc., of
Sunnyvale, Calif. The processor may also include a main memory unit
for storing programs and/or data relating to the methods described
above. The memory may include random access memory (RAM), read only
memory (ROM), and/or FLASH memory residing on commonly available
hardware such as one or more application specific integrated
circuits (ASIC), field programmable gate arrays (FPGA),
electrically erasable programmable read-only memories (EEPROM),
programmable read-only memories (PROM), programmable logic devices
(PLD), or read-only memory devices (ROM). In some embodiments, the
programs may be provided using external RAM and/or ROM such as
optical disks, magnetic disks, or other storage devices.
[0088] For embodiments in which the functions of controller 105 are
provided by software, the program may be written in any one of a
number of high-level languages such as FORTRAN, PASCAL, JAVA, C,
C++, C#, LISP, PERL, BASIC or any suitable programming language.
Additionally, the software can be implemented in an assembly
language and/or machine language directed to the microprocessor
resident on a target device.
[0089] The control system 105 may receive telemetry from sensors
monitoring various aspects of the operation of system 100 (as
described below), and may provide signals to control valve
actuators, valves, motors, and other electromechanical/electronic
devices. Control system 105 may communicate with such sensors
and/or other components of system 100 via wired or wireless
communication. An appropriate interface may be used to convert data
from sensors into a form readable by the control system 105 (such
as RS-232 or network-based interconnects). Likewise, the interface
converts the computer's control signals into a form usable by
valves and other actuators to perform an operation. The provision
of such interfaces, as well as suitable control programming, is
clear to those of ordinary skill in the art and may be provided
without undue experimentation.
[0090] The cylinder assembly 102 includes a piston 110 (or other
suitable boundary mechanism) slidably disposed therein with a
center-drilled rod 112 extending from piston 110 and preferably
defining a fluid passageway. The piston 110 divides the cylinder
assembly 102 into a first chamber (or "compartment") 114 and a
second chamber 116. The rod 112 may be attached to a mechanical
load, for example, a crankshaft or hydraulic system. Alternatively
or in addition, the second chamber 116 may contain hydraulic fluid
that is coupled through other pipes 118 and valves to a hydraulic
system 120 (which may include, e.g., a hydraulic motor/pump and an
electrical motor/generator). The heat-transfer subsystem 104
includes or consists essentially of a heat exchanger 122 and a
booster-pump assembly 124.
[0091] At any time during an expansion or compression phase of gas
within the first or upper chamber 114 of the cylinder assembly 102,
the chamber 114 will typically contain a gas 126 (e.g., previously
admitted from storage vessel 106 during the expansion phase or from
vent 108 during the compression phase) and (e.g., an accumulation
of) heat-transfer fluid 128 at substantially equal pressure
P.sub.s, (e.g., up to approximately 3,000 psig). The heat-transfer
fluid 128 may be drawn through the center-drilled rod 112 and
through a pipe 130 by the pump 124. The pump 124 raises the
pressure of the heat-transfer fluid 128 to a pressure P.sub.i'
(e.g., up to approximately 3,015 psig) somewhat higher than
P.sub.s, as described in U.S. patent application Ser. No.
13/009,409, filed on Jan. 19, 2011 (the '409 application), the
entire disclosure of which is incorporated by reference herein. The
heat-transfer fluid 128 is then sent through the heat exchanger
122, where its temperature is altered, and then through a pipe 132
to a spray mechanism 134 disposed within the cylinder assembly 102.
In various embodiments, when the cylinder assembly 102 is operated
as an expander, a spray 136 of the heat-transfer fluid 128 is
introduced into the cylinder assembly 102 at a higher temperature
than the gas 126 and, therefore, transfers thermal energy to the
gas 126 and increases the amount of work done by the gas 126 on the
piston 110 as the gas 126 expands. In an alternative mode of
operation, when the cylinder assembly 102 is operated as a
compressor, the heat-transfer fluid 128 is introduced at a lower
temperature than the gas 126. Control system 105 may enforce
substantially isothermal operation, i.e., expansion and/or
compression of gas in cylinder assembly 102, via control over,
e.g., the introduction of gas into and the exhausting of gas out of
cylinder assembly 102, the rates of compression and/or expansion,
and/or the operation of heat-transfer subsystem 104 in response to
sensed conditions. For example, control system 105 may be
responsive to one or more sensors disposed in or on cylinder
assembly 102 for measuring the temperature of the gas and/or the
heat-transfer fluid within cylinder assembly 102, responding to
deviations in temperature by issuing control signals that operate
one or more of the system components noted above to compensate, in
real time, for the sensed temperature deviations. For example, in
response to a temperature increase within cylinder assembly 102,
control system 105 may issue commands to increase the flow rate of
spray 136 of heat-transfer fluid 128.
[0092] The circulating system 124 described above will typically
have higher efficiency than a system which pumps liquid from a low
intake pressure (e.g., approximately 0 psig) to P.sub.i', as
detailed in the '409 application.
[0093] Furthermore, embodiments of the invention may be applied to
systems in which chamber 114 is in fluid communication with a
pneumatic chamber of a second cylinder (rather than with vessel
106). That second cylinder, in turn, may communicate similarly with
a third cylinder, and so forth. Any number of cylinders may be
linked in this way. These cylinders may be connected in parallel or
in a series configuration, where the compression and expansion is
done in multiple stages.
[0094] The fluid circuit of heat exchanger 122 may be filled with
water, a coolant mixture, and/or any acceptable heat-transfer
medium. In alternative embodiments, a gas, such as air or
refrigerant, is used as the heat-transfer medium. In general, the
fluid is routed by conduits to a large reservoir of such fluid in a
closed or open loop. One example of an open loop is a well or body
of water from which ambient water is drawn and the exhaust water is
delivered to a different location, for example, downstream in a
river. In a closed-loop embodiment, a cooling tower may cycle the
water through the air for return to the heat exchanger. Likewise,
water may pass through a submerged or buried coil of continuous
piping where a counter heat-exchange occurs to return the fluid
flow to ambient temperature before it returns to the heat exchanger
for another cycle.
[0095] In various embodiments, the heat-exchange fluid is
conditioned (i.e., pre-heated and/or pre-chilled) or used for
heating or cooling needs by connecting the fluid inlet 138 and
fluid outlet 140 of the external heat exchange side of the heat
exchanger 122 to an installation (not shown) such as a heat-engine
power plant, an industrial process with waste heat, a heat pump,
and/or a building needing space heating or cooling, as described in
the '513 application. The installation may be a large water
reservoir that acts as a constant-temperature thermal fluid source
for use with the system. Alternatively, the water reservoir may be
thermally linked to waste heat from an industrial process or the
like, as described above, via another heat exchanger contained
within the installation. This allows the heat-transfer fluid to
acquire or expel heat from/to the linked process, depending on
configuration, for later use as a heating/cooling medium in the
compressed air energy storage/conversion system.
[0096] For the system 100 in FIG. 1, isothermal efficiency during
gas expansion may be defined as the ratio of the actual work done
on the piston to the theoretical work that could have been done on
the piston if the gas expansion occurred perfectly isothermally.
Total expansion efficiency may be defined as the ratio of the
actual work done on the piston (less the expenditure of energy to
produce the liquid spray) to the theoretical work that could have
been done on the piston if the gas expansion occurred perfectly
isothermally.
[0097] The efficiency of spray mechanisms such as spray mechanism
134 is increased in accordance with various embodiments of the
present invention. Total expansion efficiency depends partly on (a)
the behavior of the liquid injected into the gas and (b) the energy
required to inject the liquid into the gas. Regarding the behavior
of the liquid injected into the gas, the rate at which heat may be
transferred to or from a given quantity of liquid to a given
quantity of gas is generally proportional to the area of contact
between the two (i.e., liquid surface area). When a given volume of
liquid is reduced to N spherical droplets, the total surface area
of the droplets is proportional to N.sup.2/3. Atomization of the
liquid during injection (i.e., large N, creation of a fine spray)
is therefore generally conducive to more rapid heat transfer. For a
given droplet residence time in the gas, more-rapid heat transfer
also typically entails larger total heat transfer.
[0098] The energy required to inject the liquid into the gas is the
energy required to force water through the spray mechanism 134. In
general, for a given liquid flow rate (e.g., gallons per minute)
through each orifice, larger orifices in the spray mechanism 134
will entail a smaller liquid pressure drop (.DELTA.P) from the
interior of the spray mechanism 134 to the interior of chamber 114
and therefore less expenditure of energy (E.sub.i) to inject a
given volume (V.sub.T) of heat-transfer liquid:
E.sub.i=V.sub.T.times..DELTA.P.
[0099] However, in attempting to increase efficiency, the above
considerations may be at odds. Higher injection velocity through an
orifice of given size tends to result in a finer spray and more
surface area (which pertains to consideration (a)) but also
requires a larger .DELTA.P and therefore a greater expenditure of
energy (which pertains to consideration (b)). On the other hand,
for a given rate of liquid flow per orifice, a larger orifice will
entail a lower pressure drop .DELTA.P and therefore lower injection
energy E.sub.i per unit of heat-transfer liquid, but above a
certain diameter a larger orifice will tend to produce a narrow jet
rather than a fine spray. E.sub.i will thus be lower for a larger
orifice (for a fixed flow rate), but so will droplet count N per
unit of liquid volume, with a correspondingly lower rate of heat
transfer. Therefore, to inject heat-exchange liquid in a manner
that increases or maximizes total efficiency, it is necessary to
consider in detail the behavior of a liquid injected into a gas,
that is, liquid-phase dispersion (liquid breakup) in a liquid-gas
system.
[0100] FIG. 2 is an illustration of three types or regimes of
liquid phase breakup. After exiting an orifice, a stream of liquid
entering a volume of gas will eventually break up, forming drops.
The location, form, number, and motions of the drops depend
complexly on the character of the liquid flow through the orifice
(e.g., velocity) and the physical properties (e.g., viscosity,
density, surface tension) of both the liquid and the gas. For
brevity, this discussion ignores the dripping regime, in which
large droplets of approximately uniform size form at the orifice
outlet.
[0101] Under conditions where a jet is produced at the orifice
outlet, three basic types or regimes of liquid phase breakup and
their relationship to liquid properties have been defined in W.
Ohnesorge, "Formation of drops by nozzles and the breakup of liquid
jets," Zeitschrift fur Angewandte Mathematik and Mechanik [Applied
Mathematics and Mechanics], vol. 16, pp. 355-358 (1936) (the
"Ohnesorge reference"), the entire disclosure of which is
incorporated by reference herein. In a first regime 200 shown in
FIG. 2, a liquid jet eventually breaks up into large droplets. In a
second regime 210, a jet breaks up into droplets and rapidly
changing vermiform bodies termed ligaments. In a third regime 220,
the liquid atomizes quickly after exiting the orifice, i.e., forms
a spray consisting of a large number of small droplets.
[0102] FIG. 3 is a chart adapted from the Ohnesorge reference. In
this chart, the three breakup regimes (labeled Droplet, Wave &
Droplet, and Spray) are shown as functions of two dimensionless
numbers, namely the Reynolds number (horizontal axis) and the
Ohnesorge number (vertical axis). The Reynolds numbers (Re) is a
function of the liquid velocity at exit from the hole (.nu.), hole
diameter (D), liquid density (.rho.), and liquid dynamic viscosity
(.mu.): Re=.rho.vD/.mu.. The Ohnesorge number (Oh) is a function of
hole diameter (D), liquid density (.rho.), liquid dynamic viscosity
(.mu.), and liquid surface tension (.sigma.):
Oh=.mu./(.sigma..rho.D).sup.1/2. For a particular case of liquid
flow from an orifice, the ratio of Re to Oh generally determines
the type of breakup that will occur. For a liquid (e.g., water)
having a fixed dynamic viscosity, density, and surface tension, a
flow's Ohnesorge number (vertical coordinate on the chart) is
determined by orifice diameter and its Reynolds number (horizontal
coordinate) is determined by jet velocity. In FIG. 3, a line 300
denotes the transition from the Spray regime to the Wave &
Droplet regime; another line 302 denotes the transition from the
Wave & Droplet regime to the Droplet regime.
[0103] An operating point further to the right of line 300 in FIG.
3 will create a finer spray and therefore a greater total droplet
surface area, which increases heat transfer, and tends to increase
total expansion efficiency. However, because an operating point
further to the right of line 300 requires a greater liquid
velocity, it also requires a greater spray energy (energy required
to generate the spray), which tends to decrease total system
efficiency.
[0104] The chart shown in FIG. 3 is generally valid for liquid
injection into gas at atmospheric pressure. At higher gas
pressures, the aerodynamic forces acting on a jet of a given size
are greater and atomization therefore occurs at lower velocities
(lower Reynolds number, Re). FIG. 4 is a variation of the chart
shown in FIG. 3 modified to reflect higher gas pressure. Five
atomization operating points are denoted by dots 400 placed on the
line 300 that in FIG. 3 corresponds to the boundary between spray
(atomization) breakup and wave-and-droplet breakup at atmospheric
pressure. For an air pressure of approximately 3,000 psig,
atomization tends to occur at lower jet velocities than at
atmospheric pressure. Since Reynolds number Re is proportional to
velocity, the boundary line between wave-and-droplet breakup and
spray breakup is effectively shifted to the left (i.e., to lower
Reynolds numbers) by increased air pressure. This shifted boundary
is indicated by a dashed line 404. In this illustrative example,
raising the air pressure to approximately 3,000 psig has the effect
of shifting the five operating points 400 leftward to new locations
402 on the dashed boundary line 404. That is, all other parameters
being held equal, a jet will typically atomize at lower velocity in
approximately-3,000-psig air. Lower jet velocity corresponds to
lower pressure drop .DELTA.P through each spray-head orifice and,
therefore, to lower injection energy E.sub.i. Dashed boundary line
404 corresponds to Weber number for air (herein denoted
We.sub.air).gtoreq.40. The Weber number of air We.sub.air is a
function of hole diameter (D), air density (.rho..sub.air), liquid
injection velocity (.nu.), and liquid surface tension (.sigma.):
We.sub.air=.rho..sub.air.nu..sup.2D/.sigma..
[0105] FIG. 5 is a table of projections of the energy required to
produce an atomized spray by forcing fluid through a spray head
assuming five different orifice diameters (100 .mu.m, 300 .mu.m,
500 .mu.m, 700 .mu.m, and 900 .mu.m) calculated from the chart of
FIG. 3 and taking into account the higher density of air at
approximately 20 bar (an exemplary pressure into which an atomized
spray may be injected in accordance with various embodiments of the
invention). Given hole diameters of various sizes and the Weber
number for air We.sub.air.gtoreq.40 selected for atomized spray
formation, the required liquid orifice-exit velocity may be
calculated and is provided in the third column of FIG. 5. Knowing
the liquid orifice-exit velocity, the pressure drop across the
orifice (i.e., from the first side of the spray head to the second
side of the spray head) may be calculated and is provided in the
fourth column of FIG. 5.
[0106] Furthermore, having specified the hole diameter and flow
velocity in the first and third columns, and having knowledge of
the specific heat of water, one may use the total flow per kW of
per degree Celsius (heat-transfer coefficient) and an assumed
temperature change of the injected fluid (here 5.degree. C.) to
calculate the number of orifices needed: this number is provided
here in the fifth column of FIG. 5.
[0107] Finally, the energy consumed in forcing the heat-exchange
liquid through the orifices may then be calculated from the
pressure drop and flow rate (flow rate coming from the number of
holes, velocity and area of the holes), and is provided in the
sixth column. This figure is typically a minimum, as forcing the
liquid through the orifices at still higher velocities will also
produce atomized flows, albeit at higher energy cost.
[0108] FIG. 6 is a graph of calculated water spray heat-transfer
rate limits for a range of water droplet sizes (25 .mu.m-900 .mu.m)
for two extremes of water breakup behavior, namely solid jet and
atomized spray, in air at 3,000 psig and at 300 psig. The
horizontal axis is jet or droplet size. The vertical axis is
kilowatts per GPM per degree C. change in the temperature of the
injected water (kW/GPM/.degree. C.). The upper curves 600, 610
denote kW/GPM/.degree. C. for fully atomized injection (i.e., all
injected water forms droplets falling at their terminal velocity)
at 300 psig and 3,000 psig respectively, and correspond to highly
efficient heat transfer. The lower curves 620, 630 denote
kW/GPM/.degree. C. for jet-only injection (i.e., no droplet
breakup, and the jets propagating at 9.1 m/s injection velocity) at
300 psig and 3,000 psig respectively, and correspond to minimally
efficient heat transfer. Due to non-idealities, real-world heat
transfer will typically occur along some curve between these two
sets of extremes.
[0109] From the values in the sixth column of FIG. 5, increasing
orifice size tends to require less injection energy; however, from
the drop-off of the upper curves 600, 610 in FIG. 6, maximal heat
transfer (kW/GPM/.degree. C.) tends to decline with increasing
orifice size. Total efficiency therefore generally may not be
increased simply by using very large orifice sizes. On the other
hand, small orifices are more likely to be clogged by particles
entrained in the liquid flow.
[0110] FIG. 7 is a plot of droplet trajectories for a horizontal
injection velocity of 35.2 m/s and droplet diameter of 100 .mu.m
for injection into a range of gas pressures. Curves 700, 710, 720,
730, and 740 respectively correspond to pressures of 294 psig, 735
psig, 1470 psig, 2205 psig, and 2940 psig. FIG. 7 relates to
another aspect of efficient heat-transfer using injected liquid
sprays, namely volume coverage by individual sprays. At the point
of spray formation outside an orifice, droplets of various sizes
appear with velocity vectors scattered randomly over a certain
solid angle (.ltoreq.2.pi. steradians) centered on the vertical. As
a droplet travels through the gas its horizontal momentum is
dissipated by interaction with the gas and it is accelerated
vertically by gravity. After the horizontal component of a
droplet's momentum has been dissipated, the droplet tends to fall
vertically at a constant terminal velocity determined primarily by
droplet size and gas density. FIG. 7 shows trajectories of droplets
that receive a purely horizontal initial velocity of 35.2 m/s from
an orifice. The horizontal momentum of a droplet is more quickly
dissipated in a higher-pressure gas, which is relatively denser.
This loss of horizontal droplet momentum in denser gas manifests in
FIG. 7 as shorter horizontal distance traveled. Smaller droplets
are generally superior for rapid heat transfer, both because a more
finely atomized volume of heat-transfer liquid presents a larger
liquid-gas surface area and because while falling they attain lower
terminal velocities and thus dwell longer in the gas column.
However, FIG. 7 illustrates the fact that smaller droplets (e.g.,
100 .mu.m) travel shorter horizontal distances in high-pressure
gas. This constrains the width of the falling-droplet column that
tends to form under each spray orifice and therefore increases the
number of orifices required to fill a gas column of given
horizontal cross-section with falling droplets.
[0111] In accordance with various embodiments of the invention, the
geometry of each nozzle is selected to produce droplets having a
diameter of about 0.2 mm to about 1.0 mm. Additionally, the nozzles
may be configured to maintain a pressure drop of the heat-transfer
fluid at less than approximately 50 psi during introduction
thereof.
[0112] Droplets with smaller diameters will generally have lower
terminal velocities than larger droplets. In higher-pressure air,
droplet terminal velocities further decrease, so that drops having
small diameters (e.g., less than 0.2 mm) may not reach all areas of
a cylinder volume during a compression or expansion process.
Additionally, nozzles configured to achieve even smaller average
drop sizes than 0.2 mm (e.g., 0.05 mm) tend to require either
substantially higher pressure drops or much smaller orifice sizes.
Higher pressure drops require more pumping power, and larger
quantities of smaller orifices may be more expensive and more prone
to failure and clogging. Therefore, practicalities of droplet
generation and distribution tend not to favor the generation of
very small droplets, and optimal droplet size for a given cylinder
assembly will be determined by a combination of factors. Among
these factors, air pressures and piston speeds will tend to be more
significant than cylinder diameter. For a liquid spray for
isothermal-type compressed air systems as described herein,
droplets having diameters of about 0.2 mm to about 1.0 mm both (a)
effectively cover the volume of the cylinder chamber and (b)
require relatively low pumping powers. For an exemplary system with
two compression stages (e.g., the first stage compressing from 0
psig to 250 psig and the second stage compressing from 250 psig to
3000 psig), low-pressure cylinder diameters may be approximately 20
inches to approximately 50 inches (e.g., approximately 24 inches to
approximately 42 inches) and high-pressure cylinder diameters may
be approximately 6 inches to approximately 15 inches (e.g.,
approximately 8 inches to approximately 12 inches). Stroke lengths
may be approximately 20 inches to approximately 80 inches (e.g.,
approximately 30 inches to approximately 60 inches). Peak piston
speeds may be between 3 and 15 feet per second. In various
embodiments, any of the above-described cylinders are utilized
singly or in systems featuring two or more cylinders (that are
identical to or different from each other).
[0113] FIG. 8 pertains to another aspect of efficient heat-transfer
using liquid sprays injected into gas, namely the effect of
spray-head channel geometry on spray generation. FIG. 8 shows three
possible types of spray-channel cross-sections, namely convergent
profile 800, parallel profile 802, and divergent profile 804. The
material of the plate through which the channels pass may be metal,
ceramic, or any other rigid substance of sufficient strength.
Liquid flow through each channel is indicated by arrows 806. The
space above the plate through which the channels pass is presumed
to be filled with liquid and the space below the plate is presumed
to be filled primarily with gas. All three channel types shown in
FIG. 8 may be readily manufactured using known techniques, such as
mechanical drilling and laser drilling. Channel cross-section
affects the mode of liquid flow through the channel and,
consequently, the mode of jet or spray formation at the outlet of
the channel (i.e., at the spray orifice). Our experimental work
shows that for simple nozzles the divergent channel type 804
produces an atomized, well-dispersed spray with the least energy
expenditure at a given gas pressure. Spray energy may also be
reduced by use of more complex nozzle designs such as axial
full-cone spray nozzles with internal vanes, large free-passage
helical nozzles, and angled vaneless spray nozzles, all of which
are available commercially from companies such as Spraying Systems
Corporation in Wheaton, Ill.
[0114] FIG. 9 is an isometric view of an illustrative embodiment of
the invention in the form of a spray head 900 configured for
mounting within, e.g., a vertically-oriented pneumatic cylinder
having a cylindrical interior cross section. As shown, the spray
head 900 has the form of a round, straight-sided torus
approximately 18 cm in exterior diameter, although other shapes
(e.g., disc, square) and dimensions are within the scope of the
invention. The faceplate 910 of the spray head 900 is perforated by
a number of orifices 920 that are each approximately 900 .mu.m in
diameter. The orifices 920 are arranged in a triangular grid so
that, in the ideal or infinitely extended grid, each orifice 920 is
approximately 1 cm from each of its six nearest neighbors (where
each orifice and its six nearest neighbors collectively define a
hexagon centered on the orifice and having approximately equal
sides). Other arrangements of orifices 920 may be employed in
accordance with embodiments of the invention. For example,
concentric rings of orifices 920 may be centered on a central
opening 930 of the spray head 900.
[0115] The spray head 900 may be mounted horizontally within a
vertically-oriented cylinder with its faceplate 910 facing downward
at the top of a gas-filled chamber within the cylinder (for
example, in cylinder assembly 102). A piston shaft typically passes
snugly through the circular central opening 930 of the spray head
900 and the lateral surface 940 of the spray head 900 is typically
in snug contact with the cylindrical inner wall of the cylinder.
The open horizontal area at the top of the cylinder chamber may be
wholly occupied by the faceplate 910 of the spray head 900. Each
orifice 920 communicates with the upper side of the faceplate 910
through a channel that may be convergent, straight-sided, or
divergent, as shown in FIG. 8, or which may have some other
configuration (and/or may incorporate mechanisms such as vanes
inside, as described above).
[0116] The spray head 900 is primarily affixed to the cylinder by
means of a threaded protruding collar (1200 in FIGS. 12 and 13) on
its upper side. To prevent the threaded collar from backing out
during operation, two set-screws (or some other suitable number of
set-screws) may be inserted through the spray head 900 through
openings 950. Since the spray head 900 preferably fits snugly into
the cylinder and around a central piston rod, provision is
generally made for applying torque to the spray head 900 in order
to screw its threaded collar (1200 in FIGS. 12, 13) into a matching
thread in the upper end of the cylinder. Four notches 960 (or some
other suitable number of notches 960) may be provided to enable a
tool to apply torque to the spray head 900 during installation;
[0117] however, other methods of securing the spray head within the
cylinder are contemplated and considered within the scope of the
invention.
[0118] Heat-exchange liquid is conveyed to the channels of the
orifices 920 through an arrangement of channels or hollows in the
body of the spray head (see FIGS. 13 and 14) from a source exterior
to the cylinder. Heat-exchange liquid issues from the orifices 920
into the gas-filled chamber of the cylinder. If injection pressure
is sufficient, the liquid will form an atomized spray upon exiting
each orifice. In an illustrative embodiment of the invention,
injection pressure drop from the interior of the spray head 900 to
the exterior is in the range of approximately 30 psi to
approximately 70 psi, for example approximately 50 psi. This
illustrative embodiment will efficiently produce a spray effective
for purposes of heat transfer during injection into gas over the
approximate pressure range of 3,000 psi to 300 psi (e.g., during
expansion to 300 psi of a quantity of gas starting at 3,000 psi or
during compression to 3,000 psi of a quantity of gas starting at
300 psi).
[0119] FIG. 10 is a plan view of the lower surface of spray head
900. When the spray head 900 is installed, the hole 930 is
typically filled with the cylinder piston rod and the lateral
surface 940 of the spray head 900 is in contact with the interior
wall of the cylinder. In this view, in one state of operation,
liquid spray is directed out of the page.
[0120] FIG. 11 is a schematic view of spray coverage from a spray
head 1100 resembling spray head 900 but having a smaller central
hole 1110 and fewer orifices (not explicitly shown). Due to air
resistance, the spray droplets from each spray-head orifice travel
a limited horizontal distance before beginning to fall
approximately vertically (i.e., out of the page) at their terminal
velocity. Each orifice therefore tends to produce a column of
vertically falling droplets centered under it. The approximate
cross-sectional widths and locations of a number of such columns
are shown in FIG. 11 by circles 1120. In various preferred
embodiments of the invention, the orifices are spaced so that when
liquid is being injected into high-pressure gas at an appropriate
injection pressure, the columns of falling spray overlap or
interact with each other, entirely or almost entirely filling the
column of gas contained within the chamber of the cylinder and
maximizing the rate of liquid-gas heat transfer. In a preferred
embodiment, droplets of liquid fill or rain through substantially
the entire gas volume of the chamber of the cylinder, e.g., with
only a few (for example, 1 to 5) droplet diameters of gas-filled
space between any two falling drops. In this preferred embodiment,
a minimal amount of fluid runs down the sides of the cylinder body
(e.g., after droplets impact the sides of the cylinder body), and
the majority of the fluid is raining through the gas.
[0121] FIG. 12 is a side view of the spray head 900. The lower
surface of the faceplate 910 of the spray head 900 is shown
edge-on. One notch 960 for the torque-applying insertion tool
described above is visible. As previously described, the spray head
900 includes a protruding threaded collar 1200. The outer lateral
face of the collar 1200 is preferably threaded (threads not shown)
and screws into a complementary threaded opening disposed in the
top of the cylinder.
[0122] FIG. 13 is an axial cross section of the spray head 900, in
which the faceplate 910 of the spray head 900 is shown edge-on. A
toroidal or ring-shaped channel 1300 (visible in cross-section in
FIG. 13) is disposed in the upper surface of the spray head 900
and, during operation of the spray head 900, is partially or
substantially filled with a pressurized liquid from an exterior
source admitted through inlets in the upper end of the cylinder
(not shown). When the spray head 900 is screwed into position,
o-rings within o-ring grooves 1310, 1320 seal the spray head 900
against the inside of the cylinder and prevent fluid within channel
1300 from exiting around the o-ring grooves 1310, 1320 into the
cylinder.
[0123] Six holes 1330 (two of which are visible in cross-section in
FIG. 13 and all of which are visible end-on in FIG. 14) pass
through the floor of channel 1300 to a second ring-shaped channel
1340 within the spray head 900. This interior channel 1340 conducts
liquid to the faceplate 910 and spray orifices 920. When the spray
head 900 is screwed into position, there may be no precise control
over its final angular orientation, but the upper-surface channel
1300, holes 1330, and interior channel 1340 ensure that, regardless
of the orientation of the fully installed spray head 900 with
respect to the liquid inlets in the upper end of the cylinder,
liquid may flow unimpeded to the spray orifices 920.
[0124] FIG. 14 is a top-down view of the spray head 900, in which
the upper ring-shaped channel 1300 is fully visible, as are the six
holes 1330 that communicate with the inner ring-shaped channel 1340
(FIG. 13). As shown, six holes 1330 are arranged at equal distances
apart about the inner ring-shaped channel; however, any number and
arrangement of holes 1330 may be used to suit a particular
application. The two set-screw clearance holes 950 are also
visible.
[0125] FIG. 15 is a cross-sectional side view of one illustrative
embodiment of the invention utilizing a spray head as described
herein. A high-pressure cylinder 1500 contains a piston 1510 that
is attached to two shafts 1520, 1530 that pass through opposite
ends of the cylinder 1500. One spray head 1540 of the design
described with respect to FIG. 9 is mounted in the upper end of the
cylinder 1500. A second spray head 1550 of the design described
with respect to FIG. 9 is mounted on the lower surface of the
piston 1510. Liquid is conveyed to the upper spray head 1540
directly through the upper end of the cylinder. A center-drilled
channel 1560 within shaft 1520 enables water (or another suitable
heat-exchange fluid) to be conveyed to the spray head 1550 mounted
on the piston 1510 so as to introduce a liquid spray into the lower
chamber 1590. A center-drilled channel 1570 within shaft 1530
enables water to be conveyed out of the upper chamber 1580 of the
cylinder 1500. A system of channels for introduction of liquid to
and removal of liquid from the chambers of a pneumatic cylinder as
described in the '513 application may be utilized with various
embodiments of the invention.
[0126] In the illustrative embodiment shown in FIG. 15, the
cylinder 1500 may compress or expand gas in either chamber and is,
therefore, double-acting. For example, if the cylinder 1500 is
being used to extract mechanical work from the expansion of a gas
in the upper chamber 1580, the upper spray head 1540 may be used to
perform liquid-gas heat exchange during the expansion, during which
the piston 1510 moves downward. Similarly, the lower spray head
1550 may be used during the expansion of a gas in the lower chamber
1590, during which the piston 1510 moves upward. Whatever mode of
operation is chosen, atomized sprays from the orifices of the
active spray head 1540, 1550 form vertical, interacting (and/or
overlapping) cylinders of falling droplets that exchange heat with
substantially all of the interior of the chamber 1580, 1590 being
injected with liquid. In other applications, both spray heads 1540,
1550 are employed simultaneously.
[0127] FIG. 16 is an isometric view of another illustrative
embodiment of the invention in the form of a spray head 1600
configured for mounting within a vertically-oriented pneumatic
cylinder having a cylindrical interior cross section. As shown in
FIG. 16, the spray head 1600 has the form of a round,
straight-sided torus approximately 58 cm in exterior diameter. In
other embodiments it has other shapes (e.g., disc, square) and
dimensions. The faceplate 1610 of the spray head 1600 contains a
number of countersinks 1620 each of which houses a nozzle 1630. The
nozzles 1630 are arranged in concentric rings centered on the
central hole 1640 of spray head 200 such that each nozzle 1630 is
approximately 7 cm from each of its six nearest neighbors. Other
arrangements of nozzles 1630 may be employed, e.g., a triangular
grid as depicted in FIG. 9.
[0128] The spray head 1600 may be mounted horizontally within a
vertically-oriented cylinder with its faceplate 1610 facing
downward at the top of a gas-filled chamber within the cylinder
(such as in, e.g., cylinder assembly 102). A piston shaft typically
passes snugly through the circular central opening 1640, and the
lateral surface 1650 of the spray head 1600 is typically in snug
contact with the cylindrical inner wall of the cylinder. The open
horizontal area at the top of the cylinder chamber is preferably
wholly occupied by the faceplate 1610. The spray head 1600 is
primarily affixed to a cylinder by means of through-holes 1660 that
enable the spray head 1600 to be bolted to the inside of the
cylinder.
[0129] FIG. 17 is a plan view of the lower surface of the spray
head 1600. When the spray head 1600 is installed, the hole 1640 is
typically at least substantially filled with the cylinder piston
rod and the lateral surface 1650 of the spray head 1600 is in
contact with the interior wall of the cylinder. In this view, in
one state of operation, liquid spray (not shown) is directed out of
the page. As described above with reference to FIG. 11, due to air
resistance, the spray droplets in the spray cone from each
spray-head nozzle will travel a limited horizontal distance before
beginning to fall approximately vertically (i.e., out of the page)
at their terminal velocity. Each orifice therefore tends to produce
a column of vertically falling droplets centered under it. In
various embodiments of the invention, the nozzles 1630 are spaced
so that when liquid is being injected into gas at an appropriate
injection pressure, the columns of falling spray overlap or
interact with each other, entirely or almost entirely filling the
column of gas contained within the chamber of the cylinder and
maximizing the rate of liquid-gas heat transfer.
[0130] FIG. 18 is an assembly view of spray head 1600, which as
shown includes a faceplate 1610 and a base plate 1800, sealed
together via inner o-ring 1810, outer o-ring 1820, and bolt o-rings
1830, and connected via a number of connecting bolts 1840. Nozzles
1630 may be threaded into tapered, countersunk holes in faceplate
1610. Water (and/or another suitable heat-transfer fluid) is
directed from an external source into the spray head 1600 via two
inlet ports 1850.
[0131] FIG. 19 is an axial cross section of spray head 1600 in
which the faceplate 1610 is shown edge-on. Three interconnected
toroidal or ring-shaped channels 1900 (visible in cross-section)
are disposed in the inner surface of the base plate 1800 and direct
heat-transfer fluid from the inlet ports 1850 to the nozzles 1630.
During operation of the spray head 1600, channels 1900 are
typically partially or substantially filled with a pressurized
liquid from an exterior source admitted through inlets in the upper
end of the cylinder (not shown). When the spray head 1600 is bolted
into position, o-rings within o-ring grooves 1910 seal the spray
head 1600 against the inside of a cylinder.
[0132] FIG. 20 is a rear or bottom view of the spray head 1600, in
which the inlet ports 1850 through base plate 1800 are clearly
visible, as are the connecting bolts 1840 and the mounting
through-holes 1660. Annular area 2000 is preferably smoothly
polished so that o-rings in o-ring grooves 1910 seal well when
spray head 1600 is mounted to the inside of a cylinder.
[0133] FIG. 21 is a cross-sectional side view of one embodiment
incorporating a spray mechanism as described herein. A cylinder
2100 contains a piston 2110 that is attached to two shafts 2120,
2130 that pass through opposite ends of the cylinder 2100. One
spray head 1600-1 may be mounted in the upper end of the cylinder
2100. A second spray head 1600-2 may be mounted on the lower
surface of the piston 2110. Liquid may be conveyed to the upper
spray head 1600-1 directly through the upper end of the cylinder. A
center-drilled channel 2140 within shaft 2120 enables water to be
conveyed to the spray head 1600-2 mounted on the piston 2110, thus
enabling introduction of a liquid spray into the lower chamber
2150. A center-drilled channel 2160 within shaft 2130 enables water
to be conveyed out of the upper chamber 2170 of the cylinder 2100.
A system of channels for the introduction of liquid to and the
removal of liquid from the chambers of a pneumatic cylinder as
described in the '513 application may be utilized with various
embodiments of the invention.
[0134] In the illustrative application shown in FIG. 21, the
cylinder 2100 may compress or expand gas in either chamber and is,
therefore, double-acting. For example, if the cylinder is being
used to extract mechanical work from the expansion of a gas in the
upper chamber 2170, the upper spray head 1600-1 may be used to
perform liquid-gas heat exchange during the expansion, during which
the piston 2110 moves downward. Similarly, the lower spray head
1600-2 may be used during the expansion of a gas in the lower
chamber 2150, during which the piston 2110 moves upward. Whatever
mode of operation is chosen, atomized sprays from the orifices of
the active spray head 1600-1 and/or 1600-2 preferably form
vertical, interacting (and/or overlapping) cylinders of falling
droplets that exchange heat with all or nearly all of the interior
of the chamber 2150 and/or 2170 being injected with liquid. In
various applications, both spray heads 1600-1, 1600-2 are employed
simultaneously.
[0135] Spray mechanisms (e.g., spray heads) in accordance with
various embodiments of the invention may incorporate multiple
individually controllable groups of nozzles (each of which may
include, e.g., one or more nozzles) utilized to introduce
heat-transfer fluid into a gas in order to thermally condition the
gas during, e.g., expansion and/or compression of the gas. FIG. 22A
depicts portions of an illustrative system 2200 that compresses
and/or expands gas. System 2200 includes a cylinder 2205 (that may
be vertically oriented, as shown) containing a mobile piston 2210
that divides the interior of the cylinder 2205 into a gas-filled
(pneumatic) chamber 2215 and a liquid-filled (hydraulic) chamber
2220. Alternatively, both chambers 2215 and 2220 may be
gas-filled.
[0136] A spray head 2225 (that may share any number of
characteristics with spray heads 900 and 1600 described above)
holds in place a number of spray nozzles 2230, 2235 (eight nozzles
are shown; only two are labeled explicitly). Two independent sets
of spray nozzles are shown, namely (1) the four nozzles 2230 fed by
pipe 2240 and manifold 2245, herein termed Nozzle Set 1 and
depicted with cross-hatching, and (2) the four nozzles 2235 fed by
pipe 2250 and manifold 2255, herein termed Nozzle Set 2 and
depicted without cross-hatching. A valve 2260 controls flow of
heat-exchange liquid to Nozzle Set 1 and a valve 2265 controls flow
of heat-exchange liquid to Nozzle Set 2. Other embodiments are
equipped with three or more independently valved nozzle sets and
with any number of nozzles in each set; also, different nozzle sets
may contain different nozzle types (for example, any of the nozzle
types described above and/or depicted in FIG. 8) or mixtures of
nozzle types. The valves 2260, 2265 may be controlled by control
system 105 or may be a cracking-pressure type that allows liquid to
flow into the spray head 2225 whenever the liquid input pressure
exceeds a certain threshold. The valves 2260, 2265 may be
identical, or of different types.
[0137] In the state of operation shown in FIG. 22A, chamber 2215
contains a quantity of gas undergoing compression. Valve 2265 is
closed and valve 2260 is open. Heat-exchange liquid flows through
pipe 2240, into manifold 2245, and then into the four spray nozzles
2230 of Nozzle Set 1. The heat-exchange liquid issues from Nozzle
Set 1 as a spray 2270 that thermally conditions (i.e., exchanges
heat with) the gas in chamber 2215. Little or no spray issues from
the four spray nozzles 2235 of Nozzle Set 2. Thus, Nozzle Set 1 is
"active" and Nozzle Set 2 is not.
[0138] FIG. 22B depicts the system 2200 in a state of operation
different from that shown in FIG. 22A. In the state of operation
depicted in FIG. 22B, the piston 2210 and rod 2275 have moved
closer to the spray head 2225 than in FIG. 22A and the gas in
chamber 2215 is more compressed. In this or some other state(s) of
operation it may be intended that the rate of heat exchange between
the gas in chamber 2215 and the heat-exchange spray 2270 be
increased. As depicted in FIG. 22B, the amount of spray falling
into chamber 2215 may be increased by allowing heat-exchange liquid
to pass through Nozzle Set 2. In FIG. 22B, valve 2260 is open.
Heat-exchange liquid flows through pipe 2240, into manifold 2245,
and then into the four spray nozzles 2230 of Nozzle Set 1. Valve
2265 is also open, so that heat-exchange liquid flows through pipe
2250, into manifold 2255, and then into the four spray nozzles 2235
of Nozzle Set 2. Thus, in this state of operation, spray issues
from both Nozzle Set 1 and Nozzle Set 2. In this illustrative
embodiment, Nozzle Set 2 contains nozzles of a different design
(e.g., being of a different type and/or having a different size
and/or throughput) from those in Nozzle Set 1 and produces a spray
2280 of, e.g., heavier droplets that fall more rapidly through the
gas in chamber 2215 than does the spray 2270 from Nozzle Set 1
(and/or a greater volume of droplets than is produced by Nozzle Set
1). It will be clear to any person familiar with the art of
pneumatic and hydraulic cylinders that system 2200 may be operated
in reverse, that is, to expand gas rather than compress it.
[0139] The use of two or more independently operable nozzle sets,
as in, e.g., FIG. 22A and FIG. 22B, allows an operator to control
spray quality and quantity as gas pressure in the pneumatic
cylinder (e.g., 2205) varies over a single stroke or over the
course of multiple piston strokes. For example, a given flow rate
of liquid sprayed into a cylinder chamber for heat transfer
produces a certain rate of heat transfer (i.e., heat-transfer
power) for a given spray character and initial temperature
difference between the gas in the chamber and the liquid entering
the chamber. If the power of a compression or expansion--that is,
the rate at which the gas in the cylinder performs work on the
piston, or at which the piston performs work on the gas--increases
during a piston stroke, a higher flow rate of liquid may be
utilized to maintain substantially isothermal compression or
expansion. Under such conditions, by activating a second (or third,
or fourth, etc.) set of nozzles, the higher flow rate may be
achieved with the same through-nozzle pressure drop as with the
lower flow rate for a single nozzle set, or at least without
increasing the through-nozzle pressure drop as much as would be
required by a similar increase of flow rate through a single nozzle
set. Likewise, if compression or expansion power decreases, a lower
flow rate of liquid may be utilized, and this may be achieved by
de-activating one or more nozzle sets. Moreover, different nozzle
sets may provide different spray qualities and average drop sizes
for similar flow rates and pressure drops. In some instances,
larger droplets may be advantageous for rapid coverage of a
cylinder volume (due to their higher terminal velocity), whereas
smaller droplets may be advantageous for heat transfer (due to
their larger surface area). In some such instances, two or more
sets of nozzles may be activated to produce a bi-modal (or
multi-modal) distribution of droplet sizes, achieving both full
volume coverage and rapid heat transfer in an efficient (i.e.,
low-pumping-power) manner.
[0140] In FIGS. 22A and 22B, Nozzle Set 1 and Nozzle Set 2 (and/or
any other nozzle sets) may be individually and/or collectively
controlled by control system 105 based at least in part upon the
pressure within chamber 2215 and/or chamber 2220. For example,
control system 105 may be responsive to a pressure sensor that
measures the pressure within chamber 2215 and/or chamber 2220. The
number of individually controllable nozzle sets spraying
heat-transfer fluid into a chamber may be increased with increasing
pressure within the chamber(s) (and vice versa) in order to more
efficiently exchange heat with the gas within the chamber(s).
[0141] The system 2300 in FIG. 23 generally resembles the system
100 in FIG. 1 except for the means by which heat-exchange spray
2305 (136 in FIG. 1) is produced in an upper chamber 2310 of a
cylinder 2315. System 2300 operates in accordance with embodiments
of the invention described above with relation to FIGS. 22A and
22B. The operation of the cylinder 2315 in FIG. 23 may be identical
to that of cylinder 2205 depicted in FIGS. 22A and 22B. In FIG. 23,
valve 2320 is open and valve 2325 is closed. Valves 2320, 2325
enable heat-exchange liquid to pass through pipes 2330 and/or 2335
into at least one of the two sets of spray nozzles incorporated
into spray head 2340 (which may also share any number of features
with spray heads 900 and/or 1600 described above). In other
embodiments, a spray rod or other contrivance for mounting the
spray nozzles is employed. Heat-exchange liquid 2345 issues from
Nozzle Set 1 in spray head 2340 as spray 2305 that may accumulate
on the upper surface of a piston 2350. A center-drilled channel
2355 in a rod 2360 enables the heat-exchange liquid 2345 to be
withdrawn through a flexible hose 2365 and through a pipe 2370 to a
pump 2375 (which may be similar or identical to pump 124 described
above with reference to FIG. 1). In other embodiments, alternate
techniques of conducting the heat-exchange liquid 2345 to pump 2370
are employed, such as internal piping as described in U.S.
Provisional Patent Application No. 61/384,814, filed Sep. 21, 2010,
the entire disclosure of which is incorporated by reference herein.
Exiting the pump 2375, the heat-exchange liquid is preferably
conveyed by a pipe 2380 to a heat exchanger 2385 where its
temperature may be altered (e.g., to maintain the heat-exchange
liquid at a substantially constant desired temperature as it enters
cylinder 2315). Exiting the heat exchanger 2385, the heat-exchange
liquid enters pipes 2330 and 2335. In the state of operation
depicted in FIG. 23, liquid is prevented from flowing through pipe
2335 because valve 2325 is closed. In another state of operation
(not shown), valves 2320 and 2325 are both open and spray head 2340
produces spray from multiple sets of nozzles, e.g., in the manner
depicted for spray head 2225 in FIG. 22B. It will be clear to any
person familiar with the art of pneumatic and hydraulic cylinders
that system 2300 may be operated in reverse, that is, to expand gas
rather than compress it.
[0142] The pneumatic cylinders shown herein may be outfitted with
an external gas heat exchanger instead of or in addition to liquid
sprays. An external gas heat exchanger may also allow expedited
heat transfer to or from the high-pressure gas being expanded (or
compressed) in the cylinders. Such methods and systems for
isothermal gas expansion (or compression) using an external heat
exchanger are shown and described in the '426 patent.
[0143] Generally, the systems described herein may be operated in
both an expansion mode and in the reverse compression mode as part
of a full-cycle energy storage system with high efficiency. For
example, the systems may be operated as both compressor and
expander, storing electricity in the form of the potential energy
of compressed gas and producing electricity from the potential
energy of compressed gas. Alternatively, the systems may be
operated independently as compressors or expanders.
[0144] The terms and expressions employed herein are used as terms
of description and not of limitation, and there is no intention, in
the use of such terms and expressions, of excluding any equivalents
of the features shown and described or portions thereof, but it is
recognized that various modifications are possible within the scope
of the invention claimed.
* * * * *