U.S. patent application number 14/774209 was filed with the patent office on 2016-03-03 for control system for a heat engine system utilizing supercritical working fluid.
This patent application is currently assigned to ECHOGEN POWER SYSTEMS, L.L.C.. The applicant listed for this patent is Brett A. BOWAN, ECHOGEN POWER SYSTEMS, L.L.C.. Invention is credited to Brett A. Bowan.
Application Number | 20160061055 14/774209 |
Document ID | / |
Family ID | 51659078 |
Filed Date | 2016-03-03 |
United States Patent
Application |
20160061055 |
Kind Code |
A1 |
Bowan; Brett A. |
March 3, 2016 |
CONTROL SYSTEM FOR A HEAT ENGINE SYSTEM UTILIZING SUPERCRITICAL
WORKING FLUID
Abstract
A heat engine system and a method for generating electrical
energy from the heat engine system are provided. The method
includes circulating via a turbo pump a working fluid within a
working fluid circuit of the heat engine system. The method also
includes transferring thermal energy from a heat source stream to
the working fluid by at least a primary heat exchanger, feeding the
working fluid into a power turbine and converting the thermal
energy from the working fluid to mechanical energy, and converting
the mechanical energy into electrical energy by a generator coupled
to the power turbine. At least one valve operatively coupled to a
control system is modulated in order to synchronize the generator
with an electrical grid. A generator breaker is closed such that
the generator and electrical grid are electrically coupled and the
electrical energy is supplied to the electrical grid.
Inventors: |
Bowan; Brett A.; (Copley,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BOWAN; Brett A.
ECHOGEN POWER SYSTEMS, L.L.C. |
Copley
Akron |
OH
OH |
US
US |
|
|
Assignee: |
ECHOGEN POWER SYSTEMS,
L.L.C.
Akron
OH
|
Family ID: |
51659078 |
Appl. No.: |
14/774209 |
Filed: |
March 12, 2014 |
PCT Filed: |
March 12, 2014 |
PCT NO: |
PCT/US14/24548 |
371 Date: |
September 10, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61779275 |
Mar 13, 2013 |
|
|
|
Current U.S.
Class: |
290/40B |
Current CPC
Class: |
F01D 15/10 20130101;
F01D 17/20 20130101; F01K 25/103 20130101; F01K 7/06 20130101; F01K
13/02 20130101; F01K 7/32 20130101 |
International
Class: |
F01D 17/20 20060101
F01D017/20; F01D 15/10 20060101 F01D015/10 |
Claims
1. A method for synchronizing a generator of a heat engine system
with an electrical grid, comprising: circulating, via a turbo pump,
a working fluid within a working fluid circuit of the heat engine
system, wherein the working fluid circuit has a high pressure side
and a low pressure side and at least a portion of the working fluid
is in a supercritical state; transferring thermal energy from a
heat source stream to the working fluid by at least a primary heat
exchanger fluidly coupled to and in thermal communication with the
high pressure side of the working fluid circuit; feeding the
working fluid into a power turbine and converting the thermal
energy from the working fluid to mechanical energy of the power
turbine; converting the mechanical energy into electrical energy by
the generator coupled to the power turbine; comparing at least one
electrical energy parameter of the electrical energy converted by
the generator with at least one grid parameter of the electrical
grid configured to be electrically coupled to the generator; and
modulating at least one valve of a plurality of valves operatively
coupled to a process control system to change a flow rate of the
working fluid fed into the power turbine, such that the at least
one electrical energy parameter of the electrical energy converted
by the generator is substantially similar to the at least one grid
parameter of the electrical grid, thereby synchronizing the
generator with the electrical grid.
2. The method of claim 1, wherein the plurality of valves comprises
at least one valve selected from a power turbine trim valve, a
power turbine throttle valve, a power turbine bypass valve, a drive
turbine throttle valve, a turbo pump bypass valve, or combinations
of valves thereof.
3. The method of claim 1, wherein the at least one electrical
energy parameter is selected from the group consisting of voltage,
phase sequence, phase angle, waveform, and frequency.
4. The method of claim 1, wherein the at least one grid parameter
is selected from the group consisting of voltage, phase sequence,
phase angle, waveform, and frequency.
5. The method of claim 1, wherein the heat engine system comprises
a plurality of sensors, at least one sensor of the plurality of
sensors being disposed adjacent each of the plurality of valves and
further being operatively coupled to the process control system and
configured to detect at least one system parameter.
6. The method of claim 5, further comprising transmitting from the
at least one sensor a sensor signal based on the at least one
system parameter to the process control system.
7. The method of claim 6, wherein the process control system
includes at least one controller including a ramp profile
algorithm, such that the at least one controller is configured to
manipulate the at least one valve to a predetermined valve position
over a predetermined time period based on at least one of the
sensor signals.
8. The method of claim 1, wherein the at least one valve is a power
turbine trim valve, a power turbine bypass valve, a drive turbine
throttle valve, and a turbo pump bypass valve.
9. The method of claim 1, wherein the working fluid comprises
carbon dioxide.
10. A method for generating electrical energy for an electrical
grid with a heat engine system comprising a power generator,
comprising: synchronizing the power generator with the electrical
grid in accordance with the method of claim 1; closing a generator
breaker, thereby electrically coupling the power generator and the
electrical grid; and feeding the electrical energy generated by the
power generator to the electrical grid.
11. The method of claim 10, wherein the at least one valve is a
power turbine trim valve, a power turbine throttle valve, a power
turbine bypass valve, a drive turbine throttle valve, a turbo pump
bypass valve, or combinations of valves thereof.
12. The method of claim 11, wherein the at least one electrical
energy parameter is selected from the group consisting of voltage,
phase sequence, phase angle, waveform, and frequency.
13. The method of claim 12, wherein the at least one grid parameter
is selected from the group consisting of voltage, phase sequence,
phase angle, waveform, and frequency.
14. A method for supplying electrical energy to an electrical grid
from a heat engine system, comprising: circulating via a turbo pump
a working fluid within a working fluid circuit of the heat engine
system, wherein the working fluid circuit has a high pressure side
and a low pressure side and at least a portion of the working fluid
is in a supercritical state; transferring thermal energy from a
heat source stream to the working fluid by at least a primary heat
exchanger fluidly coupled to and in thermal communication with the
high pressure side of the working fluid circuit; feeding the
working fluid into a power turbine and converting the thermal
energy from the working fluid to mechanical energy of the power
turbine; converting the mechanical energy into electrical energy by
a power generator coupled to the power turbine; comparing a
plurality of electrical energy parameters of the electrical energy
converted by the power generator with a plurality of grid
parameters of the electrical grid configured to be electrically
coupled to the power generator; modulating at least one valve
selected from a power turbine trim valve, a power turbine throttle
valve, a power turbine bypass valve, a drive turbine throttle
valve, a turbo pump bypass valve, or combinations of valves
thereof, each operatively coupled to a process control system to
change a flow rate of the working fluid fed into the power turbine,
such that the a plurality of electrical energy parameters of the
electrical energy converted by the power generator is substantially
similar to the plurality of grid parameters of the electrical grid,
thereby synchronizing the power generator with the electrical grid;
and closing the generator breaker, such that the power generator
and electrical grid are electrically coupled and the electrical
energy is supplied to the electrical grid.
15. The method of claim 14, wherein the plurality of electrical
energy parameters includes voltage, phase sequence, phase angle,
waveform, and frequency.
16. The method of claim 14, wherein the plurality of grid
parameters includes voltage, phase sequence, phase angle, waveform,
and frequency.
17. The method of claim 14, wherein the heat engine system
comprises a plurality of sensors, at least one sensor of the
plurality of sensors being disposed adjacent each of the power
turbine trim valve, the power turbine throttle valve, the power
turbine bypass valve, the turbo pump bypass valve, and the drive
turbine throttle valve, and further being operatively coupled to
the process control system and configured to detect at least one
system parameter, and the method further comprises transmitting
from the at least one sensor a sensor signal based on the at least
one system parameter to the process control system.
18. The method of claim 17, wherein the process control system
includes at least one controller including a ramp profile
algorithm, such that the at least one controller is configured to
manipulate one or more of the power turbine trim valve, the power
turbine throttle valve, the power turbine bypass valve, the turbo
pump bypass valve, and the drive turbine throttle valve to a
predetermined valve position over a predetermined time period based
on at least one of the sensor signals.
19. The method of claim 14, wherein the working fluid comprises
carbon dioxide.
20. A method for supplying electrical energy to an electrical grid
from a heat engine system, comprising: starting a drive turbine
from a working fluid including carbon dioxide being circulated via
a start pump within a working fluid circuit of the heat engine
system; circulating via a turbo pump coupled to the drive turbine
the working fluid within the working fluid circuit of the heat
engine system, wherein the working fluid circuit has a high
pressure side and a low pressure side and at least a portion of the
working fluid is in a supercritical state; transferring thermal
energy from a heat source stream to the working fluid by at least a
primary heat exchanger fluidly coupled to and in thermal
communication with the high pressure side of the working fluid
circuit; feeding the working fluid into a power turbine and
converting the thermal energy from the working fluid to mechanical
energy of the power turbine; converting the mechanical energy into
electrical energy by a power generator coupled to the power
turbine; comparing a plurality of electrical energy parameters of
the electrical energy converted by the power generator with a
plurality of grid parameters of the electrical grid configured to
be electrically coupled to the power generator, wherein the
plurality of electrical energy parameters includes voltage, phase
sequence, phase angle, waveform, and frequency; and the plurality
of grid parameters includes voltage, phase sequence, phase angle,
waveform, and frequency; modulating a power turbine trim valve, a
power turbine throttle valve, a power turbine bypass valve, a turbo
pump bypass valve, a drive turbine throttle valve, or combinations
of valves thereof, each operatively coupled to a process control
system to change a flow rate of the working fluid fed into the
power turbine, such that the plurality of electrical energy
parameters of the electrical energy converted by the power
generator is substantially similar to the plurality of grid
parameters of the electrical grid, thereby synchronizing the power
generator with the electrical grid; and closing the generator
breaker, such that the power generator and electrical grid are
electrically coupled and the electrical energy is supplied to the
electrical grid.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Prov. Appl. No.
61/779,275, filed on Mar. 13, 2013, the contents of which are
hereby incorporated by reference to the extent not inconsistent
with the present disclosure.
BACKGROUND
[0002] Waste heat is often created as a byproduct of industrial
processes where flowing streams of high-temperature liquids, gases,
or fluids must be exhausted into the environment or removed in some
way in an effort to maintain the operating temperatures of the
industrial process equipment. Some industrial processes utilize
heat exchanger devices to capture and recycle waste heat back into
the process via other process streams. However, the capturing and
recycling of waste heat is generally infeasible by industrial
processes that utilize high temperatures or have insufficient mass
flow or other unfavorable conditions.
[0003] Waste heat can be converted into useful energy by a variety
of turbine generator or heat engine systems that employ
thermodynamic methods, such as Rankine cycles. Rankine cycles and
similar thermodynamic methods are typically steam-based processes
that recover and utilize waste heat to generate steam for driving a
turbine, turbo, or other expander connected to an electric
generator.
[0004] An organic Rankine cycle utilizes an organic solvent as the
working fluid instead of water, as used during a traditional
Rankine cycle. The organic solvent has a lower boiling-point than
water. Exemplary lower boiling-point working fluids include
hydrocarbons, such as light hydrocarbons (e.g., propane or butane)
and halogenated hydrocarbons, such as hydrochlorofluorocarbons
(HCFCs) or hydrofluorocarbons (HFCs) (e.g., R245fa). More recently,
in view of issues such as thermal instability, toxicity,
flammability, and production cost of the lower boiling-point
working fluids, some thermodynamic cycles have been modified to
circulate non-hydrocarbon working fluids, such as ammonia.
[0005] The control of a power turbine coupled to an
energy-producing component, such as a generator, is quite relevant
to the operation and efficiency of the Rankine cycle process and to
the generation of electrical energy. Generally, control of the
power turbine is provided to synchronize the generator with a
corresponding electrical grid and to provide electrical energy to
the grid after the synchronization of the generator with the
electrical grid. In many Rankine cycle processes, a pump or
compressor may be used to initiate the cycle and build high system
pressure before feeding the working fluid to a waste heat exchanger
in fluid communication with the power turbine. In certain
scenarios, the power turbine may experience thermal shock from the
working fluid being heated in the waste heat exchanger and fed to
the power turbine. Thus, the working fluid must typically be
attemperated to reduce the likelihood of thermal shock to the power
turbine. Generally, conventional methods are time-consuming and
inefficient in stabilizing the system and reducing the likelihood
of thermal shock of the power turbine in order to synchronize the
generator to the grid and provide power to the grid.
[0006] Therefore, there is a need for a heat engine system and a
method for generating electrical energy, whereby flow rates,
temperatures, and pressures within a working fluid system are
precisely and accurately controlled within acceptable limits in
order to maximize the efficiency of the heat engine system to
generate electricity.
SUMMARY
[0007] Embodiments of the disclosure may provide a method for
synchronizing a generator of a heat engine system with an
electrical grid. The method may include circulating, via a turbo
pump, a working fluid within a working fluid circuit of the heat
engine system. The working fluid circuit may have a high pressure
side and a low pressure side, and at least a portion of the working
fluid may be in a supercritical state. The method may also include
transferring thermal energy from a heat source stream to the
working fluid by at least a primary heat exchanger fluidly coupled
to and in thermal communication with the high pressure side of the
working fluid circuit. The method may further include feeding the
working fluid into a power turbine and converting the thermal
energy from the working fluid to mechanical energy of the power
turbine, and converting the mechanical energy into electrical
energy by a power generator coupled to the power turbine. The
method may also include comparing at least one electrical energy
parameter of the electrical energy converted by the power generator
with at least one grid parameter of the electrical grid configured
to be electrically coupled to the power generator. The method may
further include modulating at least one valve of a plurality of
valves operatively coupled to a process control system to change a
flow rate of the working fluid fed into the power turbine, such
that the at least one electrical energy parameter of the electrical
energy converted by the power generator is substantially similar to
the at least one grid parameter of the electrical grid, thereby
synchronizing the power generator with the electrical grid.
[0008] Embodiments of the disclosure may further provide a method
for synchronizing a generator of a heat engine system with an
electrical grid. The method may include circulating, via a turbo
pump, a working fluid within a working fluid circuit of the heat
engine system. The working fluid circuit may have a high pressure
side and a low pressure side, and at least a portion of the working
fluid may be in a supercritical state. The method may also include
transferring thermal energy from a heat source stream to the
working fluid by at least a primary heat exchanger fluidly coupled
to and in thermal communication with the high pressure side of the
working fluid circuit. The method may further include feeding the
working fluid into a power turbine and converting the thermal
energy from the working fluid to mechanical energy of the power
turbine, and converting the mechanical energy into electrical
energy by a power generator coupled to the power turbine. The
method may also include comparing a plurality of electrical energy
parameters of the electrical energy converted by the power
generator with a plurality of grid parameters of the electrical
grid configured to be electrically coupled to the generator. The
method may further include modulating at least one valve of a power
turbine trim valve, a power turbine throttle valve, a power turbine
bypass valve, a turbo pump bypass valve, and a drive turbine
throttle valve, each operatively coupled to a process control
system to change a flow rate of the working fluid fed into the
power turbine, such that the plurality of electrical energy
parameters of the electrical energy converted by the power
generator is substantially similar to the plurality of grid
parameters of the electrical grid, thereby synchronizing the power
generator with the electrical grid. The method may also include
closing the generator breaker, such that the power generator and
electrical grid are electrically coupled, and the electrical energy
is supplied to the electrical grid.
[0009] Embodiments of the disclosure may further provide a method
for supplying electrical energy to an electrical grid from a heat
engine system. The method may include starting a drive turbine from
a working fluid including carbon dioxide being circulated via a
start pump within a working fluid circuit of the heat engine
system. The method may also include circulating, via a turbo pump
coupled to the drive turbine, the working fluid within the working
fluid circuit of the heat engine system. The working fluid circuit
may have a high pressure side and a low pressure side, and at least
a portion of the working fluid may be in a supercritical state. The
method may also include transferring thermal energy from a heat
source stream to the working fluid by at least a primary heat
exchanger fluidly coupled to and in thermal communication with the
high pressure side of the working fluid circuit. The method may
further include feeding the working fluid into a power turbine and
converting the thermal energy from the working fluid to mechanical
energy of the power turbine, and converting the mechanical energy
into electrical energy by a power generator coupled to the power
turbine.
[0010] The method may also include comparing a plurality of
electrical energy parameters of the electrical energy converted by
the power generator with a plurality of grid parameters of the
electrical grid configured to be electrically coupled to the
generator. The plurality of electrical energy parameters may
include voltage, phase sequence, phase angle, waveform, and
frequency, and the plurality of grid parameters may include
voltage, phase sequence, phase angle, waveform, and frequency. The
method may further include modulating a power turbine trim valve, a
power turbine throttle valve, a power turbine bypass valve, a turbo
pump bypass valve, and a drive turbine throttle valve, each
operatively coupled to a process control system to change a flow
rate of the working fluid fed into the power turbine, such that the
plurality of electrical energy parameters of the electrical energy
converted by the power generator is substantially similar to the
plurality of grid parameters of the electrical grid, thereby
synchronizing the power generator with the electrical grid. The
method may also include closing the generator breaker, such that
the power generator and electrical grid are electrically coupled,
and the electrical energy is supplied to the electrical grid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present disclosure is best understood from the following
detailed description when read with the accompanying Figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale. In fact, the
dimensions of the various features may be arbitrarily increased or
reduced for clarity of discussion.
[0012] FIG. 1 illustrates an exemplary heat engine system,
according to one or more embodiments disclosed herein.
[0013] FIG. 2 depicts a schematic diagram of a control system
configured to operate a power turbine throttle valve, according to
one or more embodiments disclosed herein.
[0014] FIG. 3 depicts a schematic diagram of a control system
configured to operate a power turbine trim valve, according to one
or more embodiments disclosed herein.
[0015] FIG. 4 depicts a schematic diagram of a control system
configured to operate a power turbine bypass valve, according to
one or more embodiments disclosed herein.
[0016] FIG. 5 depicts a schematic diagram of a control system
configured to operate a drive turbine throttle valve, according to
one or more embodiments disclosed herein.
[0017] FIG. 6 depicts a schematic diagram of a control system
configured to operate a turbo pump bypass valve, according to one
or more embodiments disclosed herein.
[0018] FIG. 7 is a flow chart depicting a method for synchronizing
a generator of a heat engine system with an electrical grid,
according to one or more embodiments disclosed herein.
[0019] Like numerals shown in the Figures and discussed herein
represent like components throughout the multiple embodiments
disclosed herein.
DETAILED DESCRIPTION
[0020] It is to be understood that the present disclosure describes
several exemplary embodiments for implementing different features,
structures, or functions of the invention. Exemplary embodiments of
components, arrangements, and configurations are described herein
to simplify the present disclosure; however, these exemplary
embodiments are provided merely as examples and are not intended to
limit the scope of the invention. Additionally, the present
disclosure may repeat reference numerals and/or letters in the
various exemplary embodiments and across the Figures provided
herein. This repetition is for the purpose of simplicity and
clarity and does not in itself dictate a relationship between the
various exemplary embodiments and/or configurations discussed in
the various Figures. Moreover, the formation of a first feature
over or on a second feature in the present disclosure may include
embodiments in which the first and second features are formed in
direct contact, and may also include embodiments in which
additional features may be formed interposing the first and second
features, such that the first and second features may not be in
direct contact. Finally, the exemplary embodiments described herein
may be combined in any combination of ways, i.e., any element from
one exemplary embodiment may be used in any other exemplary
embodiment without departing from the scope of the disclosure.
[0021] Additionally, certain terms are used throughout the
following description and claims to refer to particular components.
As one skilled in the art will appreciate, various entities may
refer to the same component by different names, and as such, the
naming convention for the elements described herein is not intended
to limit the scope of the invention, unless otherwise specifically
defined herein. Further, the naming convention used herein is not
intended to distinguish between components that differ in name but
not function. Further, in the following discussion and in the
claims, the terms "including", "containing", and "comprising" are
used in an open-ended fashion, and thus should be interpreted to
mean "including, but not limited to". All numerical values in this
disclosure may be exact or approximate values unless otherwise
specifically stated. Accordingly, various embodiments of the
disclosure may deviate from the numbers, values, and ranges
disclosed herein without departing from the intended scope.
Furthermore, as it is used in the claims or specification, the term
"or" is intended to encompass both exclusive and inclusive cases,
i.e., "A or B" is intended to be synonymous with "at least one of A
and B", unless otherwise expressly specified herein.
[0022] FIG. 1 depicts an exemplary heat engine system 200 that
contains a process system 210 and a power generation system 220
fluidly coupled to and in thermal communication with a waste heat
system 100 via a working fluid circuit 202, as described in one or
more embodiments herein. The heat engine system 200 may be referred
to as a thermal engine system, an electrical generation system, a
waste heat or other heat recovery system, and/or a thermal to
electrical energy system, as described in one or more embodiments
herein. The heat engine system 200 may be generally configured to
encompass one or more elements of a Rankine cycle, a derivative of
a Rankine cycle, or another thermodynamic cycle for generating
electrical energy from a wide range of thermal sources.
[0023] In one or more embodiments described herein, FIG. 1 depicts
the working fluid circuit 202 containing the working fluid and
having a high pressure side and a low pressure side, wherein at
least a portion of the working fluid contains carbon dioxide in a
supercritical state. In many examples, the working fluid contains
carbon dioxide, and at least a portion of the carbon dioxide is in
a supercritical state. FIG. 1 depicts the high and low pressure
sides of the working fluid circuit 202 of the heat engine system
200 by representing the high pressure side with "______" and the
low pressure side with "-.-.-."--as described in one or more
embodiments. The heat engine system 200 also may have a heat
exchanger 120 fluidly coupled to and in thermal communication with
the high pressure side of the working fluid circuit 202, configured
to be fluidly coupled to and in thermal communication with the heat
source stream 110, and configured to transfer thermal energy from
the heat source stream 110 to the working fluid within the working
fluid circuit 202. The heat exchanger 120 may be fluidly coupled to
the working fluid circuit 202 upstream of a power turbine 228 and
downstream of a recuperator 216.
[0024] The heat engine system 200 may further contain the power
turbine 228 disposed between the high pressure side and the low
pressure side of the working fluid circuit 202, fluidly coupled to
and in thermal communication with the working fluid circuit, and
configured to convert thermal energy to mechanical energy by a
pressure drop in the working fluid flowing between the high and the
low pressure sides of the working fluid circuit 202. The heat
engine system 200 may also contain a power generator 240 coupled to
the power turbine 228 and configured to convert the mechanical
energy into electrical energy. A power outlet 242 may be
electrically coupled to the power generator 240 and configured to
transfer the electrical energy from the power generator 240 to an
electrical grid 244. The electrical grid 244 may be electrically
coupled to the power generator 240 via a generator breaker 243. The
generator breaker 243 may be configured to be in an open position
or a closed position, such that in the open position, the heat
engine system 200 may be electrically decoupled from the electrical
grid 244, and in a closed position, the heat engine system 200 may
be electrically coupled to the electrical grid 244, thereby
allowing for electrical energy to be transmitted to the electrical
grid 244 from the heat engine system 200.
[0025] The heat engine system 200 may further contain a turbo pump
260, which may have a drive turbine 264 and a pump portion 262. The
pump portion 262 of the turbo pump 260 may be fluidly coupled to
the low pressure side of the working fluid circuit 202 by an inlet
configured to receive the working fluid from the low pressure side
of the working fluid circuit 202, fluidly coupled to the high
pressure side of the working fluid circuit 202 by an outlet
configured to release the working fluid into the high pressure side
of the working fluid circuit 202, and configured to circulate the
working fluid within the working fluid circuit 202. The drive
turbine 264 of the turbo pump 260 may be fluidly coupled to the
high pressure side of the working fluid circuit 202 by an inlet
configured to receive the working fluid from the high pressure side
of the working fluid circuit 202, fluidly coupled to the low
pressure side of the working fluid circuit 202 by an outlet
configured to release the working fluid into the low pressure side
of the working fluid circuit 202, and configured to rotate the pump
portion 262 of the turbo pump 260.
[0026] In some embodiments, the heat engine system 200 may further
contain a heat exchanger 150 which may be generally fluidly coupled
to and in thermal communication with the heat source stream 110 and
independently fluidly coupled to and in thermal communication with
the high pressure side of the working fluid circuit 202, such that
thermal energy may be transferred from the heat source stream 110
to the working fluid. The heat exchanger 150 may be fluidly coupled
to the working fluid circuit 202 downstream to the outlet of the
pump portion 262 of the turbo pump 260 and upstream from the inlet
of the drive turbine 264 of the turbo pump 260. A drive turbine
throttle valve 263 may be fluidly coupled to the working fluid
circuit 202 downstream of the heat exchanger 150 and upstream of
the inlet of the drive turbine 264 of the turbo pump 260. The
working fluid containing the absorbed thermal energy may flow from
the heat exchanger 150 to the drive turbine 264 of the turbo pump
260 via the drive turbine throttle valve 263. Therefore, in some
embodiments, the drive turbine throttle valve 263 may be utilized
to control the flow rate of the heated working fluid flowing from
the heat exchanger 150 to the drive turbine 264 of the turbo pump
260.
[0027] In some embodiments, a recuperator 216 may be fluidly
coupled to the working fluid circuit 202 and configured to transfer
thermal energy from the working fluid within the low pressure side
to the working fluid within the high pressure side of the working
fluid circuit 202. In other embodiments, a recuperator 218 may be
fluidly coupled to the working fluid circuit 202 downstream of the
outlet of the pump portion 262 of the turbo pump 260 and upstream
of the heat exchanger 150 and configured to transfer thermal energy
from the working fluid within the low pressure side to the working
fluid within the high pressure side of the working fluid circuit
202.
[0028] FIG. 1 further depicts the waste heat system 100 of the heat
engine system 200 having three heat exchangers (e.g., the heat
exchangers 120, 130, and 150) fluidly coupled to the high pressure
side of the working fluid circuit 202 and in thermal communication
with the heat source stream 110. Such thermal communication
provides the transfer of thermal energy from the heat source stream
110 to the working fluid flowing throughout the working fluid
circuit 202. In one or more embodiments disclosed herein, two,
three, or, optionally, four or more heat exchangers may be fluidly
coupled to and in thermal communication with the working fluid
circuit 202, such as a primary heat exchanger, a secondary heat
exchanger, a tertiary heat exchanger, respectively the heat
exchangers 120, 150, and 130, and/or an optional quaternary heat
exchanger (not shown). For example, the heat exchanger 120 may be
the primary heat exchanger fluidly coupled to the working fluid
circuit 202 upstream of an inlet of the power turbine 228, the heat
exchanger 150 may be the secondary heat exchanger fluidly coupled
to the working fluid circuit 202 upstream of an inlet of the drive
turbine 264 of the turbine pump 260, and the heat exchanger 130 may
be the tertiary heat exchanger fluidly coupled to the working fluid
circuit 202 upstream of an inlet of the heat exchanger 120.
[0029] The waste heat system 100 may also contain an inlet 104 for
receiving the heat source stream 110 and an outlet 106 for passing
the heat source stream 110 out of the waste heat system 100. The
heat source stream 110 may flow through and from the inlet 104,
through the heat exchanger 120, through one or more additional heat
exchangers, if fluidly coupled to the heat source stream 110, and
to and through the outlet 106. In some examples, the heat source
stream 110 may flow through and from the inlet 104, through the
heat exchangers 120, 150, and 130, respectively, and to and through
the outlet 106. The heat source stream 110 may be routed to flow
through the heat exchangers 120, 130, 150, and/or additional heat
exchangers in other desired orders.
[0030] The heat source stream 110 may be a waste heat stream such
as, but not limited to, gas turbine exhaust stream, industrial
process exhaust stream, or other combustion product exhaust
streams, such as furnace or boiler exhaust streams. The heat source
stream 110 may be at a temperature within a range from about
100.degree. C. to about 1,000.degree. C., or greater than
1,000.degree. C., and in some examples, within a range from about
200.degree. C. to about 800.degree. C., more narrowly within a
range from about 300.degree. C. to about 600.degree. C. The heat
source stream 110 may contain air, carbon dioxide, carbon monoxide,
water or steam, nitrogen, oxygen, argon, derivatives thereof, or
mixtures thereof. In some embodiments, the heat source stream 110
may derive thermal energy from renewable sources of thermal energy,
such as solar or geothermal sources.
[0031] In some embodiments, the types of working fluid that may be
circulated, flowed, or otherwise utilized in the working fluid
circuit 202 of the heat engine system 200 include carbon oxides,
hydrocarbons, alcohols, ketones, halogenated hydrocarbons, ammonia,
amines, aqueous, or combinations thereof. Exemplary working fluids
that may be utilized in the heat engine system 200 include carbon
dioxide, ammonia, methane, ethane, propane, butane, ethylene,
propylene, butylene, acetylene, methanol, ethanol, acetone, methyl
ethyl ketone, water, derivatives thereof, or mixtures thereof.
Halogenated hydrocarbons may include hydrochlorofluorocarbons
(HCFCs), hydrofluorocarbons (HFCs) (e.g.,
1,1,1,3,3-pentafluoropropane (R245fa)), fluorocarbons, derivatives
thereof, or mixtures thereof.
[0032] In many embodiments described herein, the working fluid the
working fluid circulated, flowed, or otherwise utilized in the
working fluid circuit 202 of the heat engine system 200, and the
other exemplary circuits disclosed herein, may be or may contain
carbon dioxide (CO.sub.2) and mixtures containing carbon dioxide.
Generally, at least a portion of the working fluid circuit 202
contains the working fluid in a supercritical state (e.g.,
sc-CO.sub.2). Carbon dioxide utilized as the working fluid or
contained in the working fluid for power generation cycles has many
advantages over other compounds typically used as working fluids,
since carbon dioxide has the properties of being non-toxic and
non-flammable and is also easily available and relatively
inexpensive. Due in part to a relatively high working pressure of
carbon dioxide, a carbon dioxide system may be much more compact
than systems using other working fluids. The high density and
volumetric heat capacity of carbon dioxide with respect to other
working fluids makes carbon dioxide more "energy dense" meaning
that the size of all system components can be considerably reduced
without losing performance. It should be noted that use of the
terms carbon dioxide (CO.sub.2), supercritical carbon dioxide
(sc-CO.sub.2), or subcritical carbon dioxide (sub-CO.sub.2) is not
intended to be limited to carbon dioxide of any particular type,
source, purity, or grade. For example, industrial grade carbon
dioxide may be contained in and/or used as the working fluid
without departing from the scope of the disclosure.
[0033] In other exemplary embodiments, the working fluid in the
working fluid circuit 202 may be a binary, ternary, or other
working fluid blend. The working fluid blend or combination can be
selected for the unique attributes possessed by the fluid
combination within a heat recovery system, as described herein. For
example, one such fluid combination includes a liquid absorbent and
carbon dioxide mixture enabling the combined fluid to be pumped in
a liquid state to high pressure with less energy input than
required to compress carbon dioxide. In another exemplary
embodiment, the working fluid may be a combination of carbon
dioxide (e.g., sub-CO.sub.2 or sc-CO.sub.2) and one or more other
miscible fluids or chemical compounds. In yet other exemplary
embodiments, the working fluid may be a combination of carbon
dioxide and propane, or carbon dioxide and ammonia, without
departing from the scope of the disclosure.
[0034] The working fluid circuit 202 generally has a high pressure
side and a low pressure side and contains a working fluid
circulated within the working fluid circuit 202. The use of the
term "working fluid" is not intended to limit the state or phase of
matter of the working fluid. For instance, the working fluid or
portions of the working fluid may be in a liquid phase, a gas
phase, a fluid phase, a subcritical state, a supercritical state,
or any other phase or state at any one or more points within the
working fluid circuit 202, the heat engine system 200, or
thermodynamic cycle. In one or more embodiments, the working fluid
is in a supercritical state over certain portions of the working
fluid circuit 202 of the heat engine system 200 (e.g., a high
pressure side) and in a subcritical state over other portions of
the working fluid circuit 202 of the heat engine system 200 (e.g.,
a low pressure side). FIG. 1 depicts the high and low pressure
sides of the working fluid circuit 202 of the heat engine system
200 by representing the high pressure side with "______" and the
low pressure side with "-.-.-."--as described in one or more
embodiments. In other embodiments, the entire thermodynamic cycle
may be operated such that the working fluid is maintained in either
a supercritical or subcritical state throughout the entire working
fluid circuit 202 of the heat engine system 200.
[0035] Generally, the high pressure side of the working fluid
circuit 202 contains the working fluid (e.g., sc-CO.sub.2) at a
pressure of about 15 MPa or greater, such as about 17 MPa or
greater, or about 20 MPa or greater. In some examples, the high
pressure side of the working fluid circuit 202 may have a pressure
within a range from about 15 MPa to about 30 MPa, more narrowly
within a range from about 16 MPa to about 26 MPa, more narrowly
within a range from about 17 MPa to about 25 MPa, and more narrowly
within a range from about 17 MPa to about 24 MPa, such as about
23.3 MPa. In other examples, the high pressure side of the working
fluid circuit 202 may have a pressure within a range from about 20
MPa to about 30 MPa, more narrowly within a range from about 21 MPa
to about 25 MPa, and more narrowly within a range from about 22 MPa
to about 24 MPa, such as about 23 MPa.
[0036] The low pressure side of the working fluid circuit 202
contains the working fluid (e.g., CO.sub.2 or sub-CO.sub.2) at a
pressure of less than 15 MPa, such as about 12 MPa or less, or
about 10 MPa or less. In some examples, the low pressure side of
the working fluid circuit 202 may have a pressure within a range
from about 4 MPa to about 14 MPa, more narrowly within a range from
about 6 MPa to about 13 MPa, more narrowly within a range from
about 8 MPa to about 12 MPa, and more narrowly within a range from
about 10 MPa to about 11 MPa, such as about 10.3 MPa. In other
examples, the low pressure side of the working fluid circuit 202
may have a pressure within a range from about 2 MPa to about 10
MPa, more narrowly within a range from about 4 MPa to about 8 MPa,
more narrowly within a range from about 5.2 MPa to about 8 MPa, and
more narrowly within a range from about 5.2 MPa to about 7 MPa,
such as about 6 MPa.
[0037] As stated above, the heat engine system 200 may further
contain the power turbine 228 disposed between the high pressure
side and the low pressure side of the working fluid circuit 202,
disposed downstream of the heat exchanger 120, and fluidly coupled
to and in thermal communication with the working fluid circuit. The
power turbine 228 may be an expansion device capable of
transforming a pressurized fluid into mechanical energy, generally,
transforming high temperature and pressure fluid into mechanical
energy, thereby rotating a shaft in an exemplary embodiment. The
power turbine 228 may contain or be a turbine, a turbo, an
expander, or another device for receiving and expanding the working
fluid discharged from the heat exchanger 120. The power turbine 228
may have an axial construction or radial construction and may be a
single-staged device or a multi-staged device. Exemplary devices
that may be utilized in the power turbine 228 include an expansion
device, a geroler, a gerotor, a valve, other types of positive
displacement devices such as a pressure swing, a turbine, a turbo,
or any other device capable of transforming a pressure or
pressure/enthalpy drop in a working fluid into mechanical energy. A
variety of expanding devices are capable of working within the
inventive system and achieving different performance properties
that may be utilized as the power turbine 228.
[0038] The power turbine 228 may be generally coupled to the power
generator 240 by the driveshaft 230. A gearbox 232 may be generally
disposed between the power turbine 228 and the power generator 240
and adjacent or encompassing the driveshaft 230. The driveshaft 230
may be a single piece or contain two or more pieces coupled
together. In one example, a first segment of the driveshaft 230
extends from the power turbine 228 to the gearbox 232, a second
segment of the driveshaft 230 extends from the gearbox 232 to the
power generator 240, and multiple gears are disposed between and
coupled to the two segments of the driveshaft 230 within the
gearbox 232.
[0039] In some configurations, the heat engine system 200 may also
provide for the delivery of a portion of the working fluid, seal
gas, bearing gas, air, or other gas into a chamber or housing, such
as a housing 238 within the power generation system 220 for
purposes of cooling one or more parts of the power turbine 228. In
other configurations, the driveshaft 230 may include a seal
assembly (not shown) designed to prevent or capture any working
fluid leakage from the power turbine 228. Additionally, a working
fluid recycle system may be implemented along with the seal
assembly to recycle seal gas back into the working fluid circuit
202 of the heat engine system 200.
[0040] The power generator 240 may be a generator, an alternator
(e.g., permanent magnet alternator), or other device for generating
electrical energy, such as transforming mechanical energy from the
driveshaft 230 and the power turbine 228 to electrical energy. The
power outlet 242 may be electrically coupled to the power generator
240 and configured to transfer the generated electrical energy from
the power generator 240 to the electrical grid 244 via the
generator breaker 243. The electrical grid 244 may be or include an
electrical grid, an electrical bus (e.g., plant bus), power
electronics, other electric circuits, or combinations thereof. The
electrical grid 244 generally contains at least one alternating
current bus, alternating current grid, alternating current circuit,
or combinations thereof. In one example, the power generator 240 is
a generator and is electrically and operably connected to the
electrical grid 244 via the power outlet 242 and the generator
breaker 243. In another example, the power generator 240 is an
alternator and is electrically and operably connected to power
electronics (not shown) via the power outlet 242. In another
example, the power generator 240 is electrically connected to power
electronics which are electrically connected to the power outlet
242.
[0041] The power electronics may be configured to convert the
electrical power into desirable forms of electricity by modifying
electrical properties, such as voltage, current, phase, or
frequency. The power electronics may include converters or
rectifiers, inverters, transformers, regulators, controllers,
switches, resistors, storage devices, and other power electronic
components and devices. In other embodiments, the power generator
240 may contain, be coupled with, or be other types of load
receiving equipment, such as other types of electrical generation
equipment, rotating equipment, a gearbox (e.g., gearbox 232), or
other device configured to modify or convert the shaft work created
by the power turbine 228. In one embodiment, the power generator
240 is in fluid communication with a cooling loop having a radiator
and a pump for circulating a cooling fluid, such as water, thermal
oils, and/or other suitable refrigerants. The cooling loop may be
configured to regulate the temperature of the power generator 240
and power electronics by circulating the cooling fluid to draw away
generated heat.
[0042] The heat engine system 200 may also provide for the delivery
of a portion of the working fluid into a chamber or housing of the
power turbine 228 for purposes of cooling one or more parts of the
power turbine 228. In one embodiment, due to the potential need for
dynamic pressure balancing within the power generator 240, the
selection of the site within the heat engine system 200 from which
to obtain a portion of the working fluid is critical because
introduction of this portion of the working fluid into the power
generator 240 should respect or not disturb the pressure balance
and stability of the power generator 240 during operation.
Therefore, the pressure of the working fluid delivered into the
power generator 240 for purposes of cooling is the same or
substantially the same as the pressure of the working fluid at an
inlet of the power turbine 228. The working fluid is conditioned to
be at a desired temperature and pressure prior to being introduced
into the power turbine 228. A portion of the working fluid, such as
the spent working fluid, exits the power turbine 228 at an outlet
of the power turbine 228 and is directed to one or more heat
exchangers or recuperators, such as recuperators 216 and 218. The
recuperators 216 and 218 may be fluidly coupled to the working
fluid circuit 202 in series with each other. The recuperators 216
and 218 are operative to transfer thermal energy between the high
pressure side and the low pressure side of the working fluid
circuit 202.
[0043] In one embodiment, the recuperator 216 may be fluidly
coupled to the low pressure side of the working fluid circuit 202,
disposed downstream of a working fluid outlet on the power turbine
228, and disposed upstream of the recuperator 218 and/or the
condenser 274. The recuperator 216 may be configured to remove at
least a portion of thermal energy from the working fluid discharged
from the power turbine 228. In addition, the recuperator 216 may
also be fluidly coupled to the high pressure side of the working
fluid circuit 202, disposed upstream of the heat exchanger 120
and/or a working fluid inlet on the power turbine 228, and disposed
downstream of the heat exchanger 130. The recuperator 216 may be
configured to increase the amount of thermal energy in the working
fluid prior to flowing into the heat exchanger 120 and/or the power
turbine 228. Therefore, the recuperator 216 may be operative to
transfer thermal energy between the high pressure side and the low
pressure side of the working fluid circuit 202. In some examples,
the recuperator 216 may be a heat exchanger configured to cool the
low pressurized working fluid discharged or downstream of the power
turbine 228 while heating the high pressurized working fluid
entering into or upstream of the heat exchanger 120 and/or the
power turbine 228.
[0044] Similarly, in another embodiment, the recuperator 218 may be
fluidly coupled to the low pressure side of the working fluid
circuit 202, disposed downstream of a working fluid outlet on the
power turbine 228 and/or the recuperator 216, and disposed upstream
of the condenser 274. The recuperator 218 may be configured to
remove at least a portion of thermal energy from the working fluid
discharged from the power turbine 228 and/or the recuperator 216.
In addition, the recuperator 218 may also be fluidly coupled to the
high pressure side of the working fluid circuit 202, disposed
upstream of the heat exchanger 150 and/or a working fluid inlet on
a drive turbine 264 of turbo pump 260, and disposed downstream of a
working fluid outlet on a pump portion 262 of turbo pump 260. The
recuperator 218 may be configured to increase the amount of thermal
energy in the working fluid prior to flowing into the heat
exchanger 150 and/or the drive turbine 264. Therefore, the
recuperator 218 may be operative to transfer thermal energy between
the high pressure side and the low pressure side of the working
fluid circuit 202. In some examples, the recuperator 218 may be a
heat exchanger configured to cool the low pressurized working fluid
discharged or downstream of the power turbine 228 and/or the
recuperator 216 while heating the high pressurized working fluid
entering into or upstream of the heat exchanger 150 and/or the
drive turbine 264.
[0045] A cooler or a condenser 274 may be fluidly coupled to and in
thermal communication with the low pressure side of the working
fluid circuit 202 and may be configured or operative to control a
temperature of the working fluid in the low pressure side of the
working fluid circuit 202. The condenser 274 may be disposed
downstream of the recuperators 216 and 218 and upstream of the
start pump 280 and the turbopump 260. The condenser 274 receives
the cooled working fluid from the recuperator 218 and further cools
and/or condenses the working fluid which may be recirculated
throughout the working fluid circuit 202. In many examples, the
condenser 274 is a cooler and may be configured to control a
temperature of the working fluid in the low pressure side of the
working fluid circuit 202 by transferring thermal energy from the
working fluid in the low pressure side to a cooling loop or system
outside of the working fluid circuit 202.
[0046] A cooling media or fluid is generally utilized in the
cooling loop or system by the condenser 274 for cooling the working
fluid and removing thermal energy outside of the working fluid
circuit 202. The cooling media or fluid flows through, over, or
around while in thermal communication with the condenser 274.
Thermal energy in the working fluid is transferred to the cooling
fluid via the condenser 274. Therefore, the cooling fluid is in
thermal communication with the working fluid circuit 202, but not
fluidly coupled to the working fluid circuit 202. The condenser 274
may be fluidly coupled to the working fluid circuit 202 and
independently fluidly coupled to the cooling fluid. The cooling
fluid may contain one or multiple compounds and may be in one or
multiple states of matter. The cooling fluid may be a media or
fluid in a gaseous state, a liquid state, a subcritical state, a
supercritical state, a suspension, a solution, derivatives thereof,
or combinations thereof.
[0047] In many examples, the condenser 274 is generally fluidly
coupled to a cooling loop or system (not shown) that receives the
cooling fluid from a cooling fluid return 278a and returns the
warmed cooling fluid to the cooling loop or system via a cooling
fluid supply 278b. The cooling fluid may be water, carbon dioxide,
or other aqueous and/or organic fluids (e.g., alcohols and/or
glycols), air or other gases, or various mixtures thereof that is
maintained at a lower temperature than the temperature of the
working fluid. In other examples, the cooling media or fluid
contains air or another gas exposed to the condenser 274, such as
an air steam blown by a motorized fan or blower. A filter 276 may
be disposed along and in fluid communication with the cooling fluid
line at a point downstream of the cooling fluid supply 278b and
upstream of the condenser 274. In some examples, the filter 276 may
be fluidly coupled to the cooling fluid line within the process
system 210.
[0048] The heat engine system 200 may further contain several
pumps, such as a turbo pump 260 and a start pump 280, disposed
within the working fluid circuit 202 and fluidly coupled between
the low pressure side and the high pressure side of the working
fluid circuit 202. The turbo pump 260 and the start pump 280 may be
operative to circulate the working fluid throughout the working
fluid circuit 202. The start pump 280 may be generally a motorized
pump and may be utilized to initially pressurize and circulate the
working fluid in the working fluid circuit 202. Once a
predetermined pressure, temperature, and/or flow rate of the
working fluid is obtained within the working fluid circuit 202, the
start pump 280 may be taken off line, idled, or turned off and the
turbo pump 260 is utilized to circulate the working fluid during
the electricity generation process. The working fluid enters each
of the turbo pump 260 and the start pump 280 from the low pressure
side of the working fluid circuit 202 and exits each of the turbo
pump 260 and the start pump 280 from the high pressure side of the
working fluid circuit 202.
[0049] The start pump 280 may be a motorized pump, such as an
electric motorized pump, a mechanical motorized pump, or other type
of pump. Generally, the start pump 280 may be a variable frequency
motorized drive pump and may contain a pump portion 282 and a
motor-drive portion 284. The motor-drive portion 284 of the start
pump 280 contains a motor and a drive including a driveshaft and
gears (not shown). In some examples, the motor-drive portion 284
has a variable frequency drive, such that the speed of the motor
may be regulated by the drive. The pump portion 282 of the start
pump 280 is driven by the motor-drive portion 284 coupled thereto.
The pump portion 282 has an inlet for receiving the working fluid
from the low pressure side of the working fluid circuit 202, such
as from the condenser 274 and/or the working fluid storage system
290. The pump portion 282 has an outlet for releasing the working
fluid into the high pressure side of the working fluid circuit
202.
[0050] Start pump inlet valve 283 and start pump outlet valve 285
may be utilized to control the flow of the working fluid passing
through the start pump 280. Start pump inlet valve 283 may be
fluidly coupled to the low pressure side of the working fluid
circuit 202 upstream of the pump portion 282 of the start pump 280
and may be utilized to control the flow rate of the working fluid
entering the inlet of the pump portion 282. Start pump outlet valve
285 may be fluidly coupled to the high pressure side of the working
fluid circuit 202 downstream of the pump portion 282 of the start
pump 280 and may be utilized to control the flow rate of the
working fluid exiting the outlet of the pump portion 282.
[0051] The turbo pump 260 may be generally a turbo-drive pump or a
turbine-drive pump and utilized to pressurize and circulate the
working fluid throughout the working fluid circuit 202. The turbo
pump 260 may contain a pump portion 262 and a drive turbine 264
coupled together by a driveshaft 267 and an optional gearbox (not
shown). The drive turbine 264 may be configured to rotate the pump
portion 262 and the pump portion 262 may be configured to circulate
the working fluid within the working fluid circuit 202.
[0052] The driveshaft 267 may be a single piece, as shown in FIG.
1, or may contain two or more pieces coupled together. In one
example, a first segment of the driveshaft 267 extends from the
drive turbine 264 to the gearbox, a second segment of the
driveshaft 267 extends from the gearbox to the pump portion 262,
and multiple gears are disposed between and coupled to the two
segments of the driveshaft 267 within the gearbox.
[0053] The drive turbine 264 of the turbo pump 260 may be driven by
heated working fluid, such as the working fluid flowing from the
heat exchanger 150. The drive turbine 264 may be fluidly coupled to
the high pressure side of the working fluid circuit 202 by an inlet
configured to receive the working fluid from the high pressure side
of the working fluid circuit 202, such as flowing from the heat
exchanger 150. The drive turbine 264 may be fluidly coupled to the
low pressure side of the working fluid circuit 202 by an outlet
configured to release the working fluid into the low pressure side
of the working fluid circuit 202.
[0054] The pump portion 262 of the turbo pump 260 may be driven by
the driveshaft 267 coupled to the drive turbine 264. The pump
portion 262 of the turbo pump 260 may be fluidly coupled to the low
pressure side of the working fluid circuit 202 by an inlet
configured to receive the working fluid from the low pressure side
of the working fluid circuit 202. The inlet of the pump portion 262
is configured to receive the working fluid from the low pressure
side of the working fluid circuit 202, such as from the condenser
274 and/or the working fluid storage system 290. Also, the pump
portion 262 may be fluidly coupled to the high pressure side of the
working fluid circuit 202 by an outlet configured to release the
working fluid into the high pressure side of the working fluid
circuit 202 and circulate the working fluid within the working
fluid circuit 202.
[0055] In one configuration, the working fluid released from the
outlet on the drive turbine 264 is returned into the working fluid
circuit 202 downstream of the recuperator 216 and upstream of the
recuperator 218. In one or more embodiments, the turbo pump 260,
including piping and valves, is optionally disposed on a turbo pump
skid 266, as depicted in FIG. 1. The turbo pump skid 266 may be
disposed on or adjacent to the main process skid 212.
[0056] A drive turbine bypass valve 265 is generally coupled
between and in fluid communication with a fluid line extending from
the inlet on the drive turbine 264 with a fluid line extending from
the outlet on the drive turbine 264. The drive turbine bypass valve
265 is generally opened to bypass the turbo pump 260 while using
the start pump 280 during the initial stages of generating
electricity with the heat engine system 200. Once a predetermined
pressure and temperature of the working fluid is obtained within
the working fluid circuit 202, the drive turbine bypass valve 265
is closed, and the heated working fluid is flowed through the drive
turbine 264 to start the turbo pump 260.
[0057] The drive turbine throttle valve 263 may be coupled between
and in fluid communication with a fluid line extending from the
heat exchanger 150 to the inlet on the drive turbine 264 of the
turbo pump 260. The drive turbine throttle valve 263 is configured
to modulate the flow of the heated working fluid into the drive
turbine 264, which in turn may be utilized to adjust the flow of
the working fluid throughout the working fluid circuit 202.
Additionally, valve 293 may be utilized to provide back pressure
for the drive turbine 264 of the turbo pump 260.
[0058] A turbo pump attemperator valve 295 may be fluidly coupled
to the working fluid circuit 202 via a bypass line 291 disposed
between the outlet on the pump portion 262 of the turbo pump 260
and the inlet on the drive turbine 264 and/or disposed between the
outlet on the pump portion 282 of the start pump 280 and the inlet
on the drive turbine 264. The bypass line 291 and the turbo pump
attemperator valve 295 may be configured to flow the working fluid
from the pump portion 262 or 282, around and avoid the recuperator
218 and the heat exchanger 150, and to the drive turbine 264, such
as during a warm-up or cool-down step of the turbo pump 260. The
bypass line 291 and the turbo pump attemperator valve 295 may be
utilized to warm the working fluid with the drive turbine 264 while
avoiding the thermal heat from the heat source stream 110 via the
heat exchangers, such as the heat exchanger 150.
[0059] A check valve 261 is disposed downstream of the outlet of
the pump portion 262 of the turbo pump 260, and the check valve 281
is disposed downstream of the outlet of the pump portion 282 of the
start pump 280. Check valves 261 and 281 are flow control safety
valves and generally utilized to regulate the directional flow or
to prohibit backflow of the working fluid within the working fluid
circuit 202. Check valve 261 is configured to prevent the working
fluid from flowing upstream towards or into the outlet of the pump
portion 262 of the turbo pump 260. Similarly, check valve 281 is
configured to prevent the working fluid from flowing upstream
towards or into the outlet of the pump portion 282 of the start
pump 280.
[0060] A power turbine bypass line 208 may be fluidly coupled to
the working fluid circuit 202 at a point upstream of an inlet of
the power turbine 228 and at a point downstream of an outlet of the
power turbine 228. The power turbine bypass line 208 is configured
to flow the working fluid around and avoid the power turbine 228
when a power turbine bypass valve 219 is in an opened position. The
flow rate and the pressure of the working fluid flowing into the
power turbine 228 may be reduced or stopped by adjusting the power
turbine bypass valve 219 to the opened position. Alternatively, the
flow rate and the pressure of the working fluid flowing into the
power turbine 228 may be increased or started by adjusting the
power turbine bypass valve 219 to the closed position due to the
backpressure formed through the power turbine bypass line 208.
[0061] In one or more embodiments, the working fluid circuit 202
provides a bypass flowpath for the start pump 280 via the start
pump bypass line 224 and a start pump bypass valve 254, as well as
a bypass flowpath for the turbo pump 260 via the turbo pump bypass
line 226 and a turbo pump bypass valve 256. One end of the start
pump bypass line 224 may be fluidly coupled to an outlet of the
pump portion 282 of the start pump 280, and the other end of the
start pump bypass line 224 may be fluidly coupled to a fluid line
226. Similarly, one end of a turbo pump bypass line 226 may be
fluidly coupled to an outlet of the pump portion 262 of the turbo
pump 260, and the other end of the turbo pump bypass line 226 is
coupled to the start pump bypass line 229. In some configurations,
the start pump bypass line 224 and the turbo pump bypass line 226
merge together as a single line upstream of coupling to a fluid
line 229. The fluid line 229 extends between and may be fluidly
coupled to the recuperator 218 and the condenser 274. The start
pump bypass valve 254 is disposed along the start pump bypass line
224 and fluidly coupled between the low pressure side and the high
pressure side of the working fluid circuit 202 when in a closed
position. Similarly, the turbo pump bypass valve 256 is disposed
along the turbo pump bypass line 226 and fluidly coupled between
the low pressure side and the high pressure side of the working
fluid circuit 202 when in a closed position.
[0062] FIG. 1 further depicts a power turbine throttle valve 250
fluidly coupled to a bypass line 246 on the high pressure side of
the working fluid circuit 202 and upstream of the heat exchanger
120, as disclosed by at least one embodiment described herein. The
power turbine throttle valve 250 may be fluidly coupled to the
bypass line 246 and configured to modulate, adjust, or otherwise
control the working fluid flowing through the bypass line 246 for
controlling a general coarse flow rate of the working fluid within
the working fluid circuit 202. The bypass line 246 may be fluidly
coupled to the working fluid circuit 202 at a point upstream of the
valve 293 and at a point downstream of the pump portion 282 of the
start pump 280 and/or the pump portion 262 of the turbo pump 260.
Additionally, a power turbine trim valve 252 may be fluidly coupled
to a bypass line 248 on the high pressure side of the working fluid
circuit 202 and upstream of the heat exchanger 150, as disclosed by
another embodiment described herein. The power turbine trim valve
252 may be fluidly coupled to the bypass line 248 and configured to
modulate, adjust, or otherwise control the working fluid flowing
through the bypass line 248 for controlling a fine flow rate of the
working fluid within the working fluid circuit 202. In an exemplary
embodiment, the power turbine trim valve 252 may be used for
controlling a fine flow rate of the working fluid to synchronize
the power generator 240 with the electrical grid 244. The bypass
line 248 may be fluidly coupled to the bypass line 246 at a point
upstream of the power turbine throttle valve 250 and at a point
downstream of the power turbine throttle valve 250.
[0063] The power turbine bypass valve 219, the drive turbine
throttle valve 263, the power turbine throttle valve 250, the power
turbine trim valve 252, and the turbo pump bypass valve 256 may be
independently, and in combination, controlled by the process
control system 204. The heat engine system 200 includes the process
control system 204 communicably connected, wired and/or wirelessly,
with numerous sets of sensors, valves, and pumps, in order to
process the measured and reported temperatures, pressures, and mass
flow rates of the working fluid at the designated points within the
working fluid circuit 202. In response to these measured and/or
reported parameters, the process control system 204 may be operable
to selectively adjust the valves in accordance with a control
program or algorithm, thereby maximizing operation of the heat
engine system 200.
[0064] The process control system 204 may be communicably and
operatively connected, wired and/or wirelessly, with the power
turbine bypass valve 219, the drive turbine throttle valve 263, the
power turbine throttle valve 250, the power turbine trim valve 252,
the turbo pump bypass valve 256, and other parts of the heat engine
system 200. The process control system 204 may be operatively
connected to the working fluid circuit 202 and a mass management
system 270 and may be enabled to monitor and control multiple
process operation parameters of the heat engine system 200. Such
operation parameters may include, for example, the pressure,
temperature, and flow rate of the working fluid in various
locations in the heat engine system 200.
[0065] The process control system 204 includes at least one
controller 206, and in at least one embodiment, includes a
plurality of controllers 206. In an exemplary embodiment, at least
one controller 206 contains one or more algorithms utilized to
control the drive turbine throttle valve 263, the power turbine
bypass valve 219, the power turbine throttle valve 250, the power
turbine trim valve 252, and the turbo pump bypass valve 256, as
well as other valves, pumps, and sensors within the heat engine
system 200. In an exemplary embodiment, the controller 206 includes
one or more ramp profile algorithms. In one embodiment, the process
control system 204, via the ramp profile algorithms embedded in one
or more controllers 206, is enabled to move, adjust, manipulate, or
otherwise control, the drive turbine throttle valve 263, the power
turbine bypass valve 219, the power turbine throttle valve 250, the
power turbine trim valve 252, and/or the turbo pump bypass valve
256 for adjusting or controlling the flow rate of the working fluid
throughout the working fluid circuit 202. By controlling the flow
rate of the working fluid, the process control system 204 is also
operable to regulate the temperatures and pressures throughout the
working fluid circuit 202, thereby maximizing operation of the heat
engine system 200.
[0066] Further, in certain embodiments, the process control system
204, as well as any other controllers or processors disclosed
herein, may include one or more non-transitory, tangible,
machine-readable media, such as read-only memory (ROM), random
access memory (RAM), solid state memory (e.g., flash memory),
floppy diskettes, CD-ROMs, hard drives, universal serial bus (USB)
drives, any other computer readable storage medium, or any
combination thereof. The storage media may store encoded
instructions, such as firmware, that may be executed by the process
control system 204 or any of the other controllers disclosed herein
(e.g., the one or more controllers 206) to operate the logic or
portions of the logic presented in the methods disclosed herein.
For example, in certain embodiments, the heat engine system 200 may
include computer code disposed on a computer-readable storage
medium or a process controller that includes such a
computer-readable storage medium. The computer code may include
instructions for initiating a control function to alternate the
position of one or more of the drive turbine throttle valve 263,
the power turbine bypass valve 219, the power turbine throttle
valve 250, the power turbine trim valve 252, and/or the turbo pump
bypass valve 256.
[0067] Additionally, the process control system 204 may operate
with the heat engine system 200 semi-passively with the aid of
several sets of sensors. The first set of sensors is arranged at or
adjacent the suction inlet of the turbo pump 260 and the start pump
280 and the second set of sensors is arranged at or adjacent the
outlet of the turbo pump 260 and the start pump 280. The first and
second sets of sensors monitor and report the pressure,
temperature, mass flow rate, or other properties of the working
fluid within the low and high pressure sides of the working fluid
circuit 202 adjacent the turbo pump 260 and the start pump 280. As
shown in FIG. 1, the pressures adjacent the turbo pump 260 and the
start pump 280, upstream and downstream, may be referred to as
pressure P1 and pressure P2, respectively. The third set of sensors
is arranged either inside or adjacent the working fluid storage
vessel 292 of the working fluid storage system 290 to measure and
report the pressure, temperature, mass flow rate, or other
properties of the working fluid within the working fluid storage
vessel 292. Additionally, an instrument air supply (not shown) may
be coupled to sensors, devices, or other instruments within the
heat engine system 200 including the mass management system 270
and/or other system components that may utilize a gaseous supply,
such as nitrogen or air.
[0068] During operation of the heat engine system 200 in accordance
with one embodiment, as shown in FIG. 7, a method 10 provides for
synchronizing a generator of a heat engine system with an
electrical grid. The method 10 may include circulating, via a turbo
pump, a working fluid within a working fluid circuit of the heat
engine system (block 12). The working fluid circuit may have a high
pressure side and a low pressure side, and at least a portion of
the working fluid may be in a supercritical state. The method 10
may also include transferring thermal energy from a heat source
stream to the working fluid by at least a primary heat exchanger
fluidly coupled to and in thermal communication with the high
pressure side of the working fluid circuit (block 14). The method
10 may further include feeding the working fluid into a power
turbine and converting the thermal energy from the working fluid to
mechanical energy of the power turbine (block 16), and converting
the mechanical energy into electrical energy by a power generator
coupled to the power turbine (block 18). The method 10 may also
include comparing at least one electrical energy parameter of the
electrical energy converted by the power generator with at least
one grid parameter of the electrical grid configured to be
electrically coupled to the power generator (block 20). The method
10 may further include modulating at least one valve of a plurality
of valves operatively coupled to a process control system to change
a flow rate of the working fluid fed into the power turbine (block
22), such that the at least one electrical energy parameter of the
electrical energy converted by the power generator is substantially
similar to the at least one grid parameter of the electrical grid,
thereby synchronizing the power generator with the electrical grid.
Further, in certain embodiments, the method 10 may optionally also
include closing the generator breaker such that the power generator
and the electrical grid are electrically coupled, and the
electrical energy is supplied to the electrical grid (block
24).
[0069] In an exemplary operation of the heat engine system 200, the
start pump 280 may be utilized to initially pressurize and
circulate the working fluid in the working fluid circuit 202. Once
a predetermined pressure, temperature, and/or flow rate of the
working fluid is obtained within the working fluid circuit 202, the
start pump 280 may be taken off line, idled, or turned off, and the
turbo pump 260 is utilized to circulate the working fluid during
the electricity generation process. The working fluid may enter one
of or both the turbo pump 260 and the start pump 280 from the low
pressure side of the working fluid circuit 202 and exit the
corresponding turbo pump 260 and/or the start pump 280 from the
high pressure side of the working fluid circuit 202.
[0070] In one or more exemplary embodiments disclosed herein,
during or subsequent to the turbo pump 260 being activated and
thereby pumping the working fluid from the low pressure side to the
high pressure side, the process control system 204 may transmit one
or more control signals to the power turbine throttle valve 250
and/or the power turbine trim valve 252. Such control signals
generally cause the power turbine throttle valve 250 and/or the
power turbine trim valve 252 to gradually and independently open,
via the ramp profile algorithm embedded in at least one controller
in a portion of the process control system 204, as depicted in FIG.
2 for the power turbine throttle valve 250 and in FIG. 3 for the
power turbine trim valve 252. Therefore, the working fluid flow
rate passing through the power turbine throttle valve 250 and/or
the power turbine trim valve 252 may be closely controlled and
regulated, thereby controlling at least one electrical energy
parameter generated by the power generator 240. The at least one
electrical energy parameter may be voltage, phase sequence, phase
angle, waveform, and/or frequency. In an exemplary embodiment, the
electrical energy parameter includes frequency. The power turbine
throttle valve 250 and/or the power turbine trim valve 252 may be
independently manipulated, such that the flow rate through the
power turbine throttle valve 250 and/or the power turbine trim
valve 252 provides the power turbine 228 with a sufficient speed to
synchronize the coupled power generator 240 with the corresponding
electrical grid 244. Synchronization of the power generator 240 and
electrical grid 244 may occur when the electrical energy parameters
are substantially similar. The electrical grid parameters may
include voltage, phase sequence, phase angle, waveform, and
frequency. In an exemplary embodiment, the electrical energy
parameters and electrical grid parameters may be compared. The
generator breaker 243 may be manipulated into a closed position
when the compared electrical grid parameters and the electrical
energy parameters are substantially similar, thereby electrically
coupling the heat engine system 200 and the electrical grid 244 and
allowing for the electrical communication of energy from the heat
engine system 200 to the electrical grid 244.
[0071] In some instances, the power turbine bypass valve 219 may be
manipulated by a control signal generated by the process control
system 204. Such instances may occur when the flow rate through the
power turbine throttle valve 250 and/or the power turbine trim
valve 252 provides the power turbine with a speed generating a
frequency and/or other electrical energy parameter in the power
generator 240, such that synchronization of the power generator 240
with the electrical grid 244 is unachievable. Thus, the power
turbine bypass valve 219 may be gradually opened, via the ramp
profile algorithm embedded in at least one controller in a portion
of the process control system 204 shown in FIG. 4, to reduce the
flow rate through the power turbine 228, thereby providing for an
adjustment to the speed of the power turbine 228, thereby allowing
for the proper frequency and/or other electrical energy parameters
for the synchronization of the power generator 240 with the
electrical grid 244. As shown in FIG. 1, the opening of the power
turbine bypass valve 219 permits at least a portion of the working
fluid fed from the heat exchanger 120 to be bypassed via power
turbine bypass line 208 from flowing through the power turbine
228.
[0072] As stated above, the drive turbine throttle valve 263 and/or
the turbo pump bypass valve 256 may be configured to modulate the
flow of the heated working fluid into the drive turbine 264, which
in turn may be utilized to adjust the flow of the working fluid
throughout the working fluid circuit 202. Further, by modulating
the flow of the heated working fluid into the drive turbine 264 via
the drive turbine throttle valve 263 and/or the turbo pump bypass
valve 256, the pressure P2 at the power turbine trim valve 252 is
modulated accordingly. Thus, the drive turbine throttle valve 263
and/or the turbo pump bypass valve 256 may be used to modulate the
pressure P2 at the power turbine trim valve 252 and the power
turbine throttle valve 250. To provide relief in instances in which
the pressure P2, downstream of the turbo pump 260 and upstream of
each of the power turbine throttle valve 250 and power turbine trim
valve 252, exceeds desired parameters associated with the
corresponding pressure P1 upstream of the turbo pump 260, the turbo
pump bypass valve 256 may be modulated to reduce pressure P2 in the
heat engine system 200 in order to reduce risk of damage to the
turbo pump 260.
[0073] In an exemplary embodiment, the process control system 204
may be operatively connected to the drive turbine throttle valve
263 and/or the turbo pump bypass valve 256 and configured to
transmit a control signal to the drive turbine throttle valve 263
and/or the turbo pump bypass valve 256, thereby gradually opening,
via the ramp profile algorithm embedded in at least one controller
in a portion of the process control system 204 shown in FIG. 5, to
maintain sufficient pressure P2 at the power turbine trim valve
252, such that the flow rate through the power turbine trim valve
252 is sufficient to synchronize the power generator 240 with the
electrical grid 244. Further, the process control system may be
operatively connected to the turbo pump bypass valve 256 and
configured to transmit a control signal to the turbo pump bypass
valve 256 to gradually open, via the ramp profile algorithm
embedded in at least one controller in a portion of the process
control system 204 shown in FIG. 6, to reduce the pressure at the
power turbine trim valve 252 in instances in which the pressure P2
may be outside of a desired parameter in relation to the pressure
P1 (turbo pump bearing differential P2-P1).
[0074] In addition to the foregoing, in an exemplary embodiment,
upon synchronization of the power generator 240 with the electrical
grid 244, the process control system 204 may be configured to
transmit a command signal to the power turbine trim valve 252, such
that the power turbine trim valve 252 is completely opened to allow
working fluid to flow therethrough. In order to create a sufficient
flow rate into the power turbine 228 to produce the necessary
electrical energy in the power generator 240 required by the
electrical grid 244, the process control system 204 may be further
configured to transmit a control signal to the drive turbine
throttle valve 263, thereby modulating the drive turbine throttle
valve 263 to provide more flow through the drive turbine 264,
thereby increasing the pressure P2 at the power turbine trim valve
252 and allowing for a higher flow rate into the power turbine 228
via the power turbine trim valve 252 and the power turbine throttle
valve 250. In an exemplary embodiment, the process control system
204 may be further configured to transmit a command signal to the
turbo pump bypass valve 256 when the pressure P2 at the power
turbine trim valve 252 and the power turbine throttle valve 250
exceeds the desired parameters in relation to the pressure P1 as
required to reduce the risk of damage to the turbo pump 260.
[0075] As stated above, the process control system 204 may be
configured to operate the power turbine bypass valve 219, the drive
turbine throttle valve 263, the power turbine trim valve 252, and
the turbo pump bypass valve 256 independently or in combination, to
provide electrical energy to the electrical grid 244 from the heat
engine system 200. Accordingly, the modulation of any of the valves
in the heat engine system 200 by the process control system 204 may
require a correction or modulation of at least one other valve in
the heat engine system 200. Thus, the modulation and operation of
the power turbine bypass valve 219, the drive turbine throttle
valve 263, the power turbine trim valve 252, and the turbo pump
bypass valve 256 by the process control system may be a dynamic
process including open-loop and/or closed-loop feedback systems,
wherein the modulation of a valve may require a corresponding
modulation of at least one other valve.
[0076] A bypass line 160 may be fluidly coupled to a fluid line 131
of the working fluid circuit 202 upstream of the heat exchangers
120, 130, and/or 150 by a bypass valve 162, as illustrated in FIG.
1. The bypass valve 162 may be a solenoid valve, a hydraulic valve,
an electric valve, a manual valve, or derivatives thereof. In many
examples, the bypass valve 162 is a solenoid valve and configured
to be controlled by the process control system 204.
[0077] In one or more embodiments, the working fluid circuit 202
provides release valves 213a, 213b, 213c, and 213d, as well as
release outlets 214a, 214b, 214c, and 214d, respectively, in fluid
communication with each other. Generally, the release valves 213a,
213b, 213c, and 213d remain closed during the electricity
generation process, but may be configured to automatically open to
release an over-pressure at a predetermined value within the
working fluid. Once the working fluid flows through the valve 213a,
213b, 213c, or 213d, the working fluid is vented through the
respective release outlet 214a, 214b, 214c, or 214d. The release
outlets 214a, 214b, 214c, and 214d may provide passage of the
working fluid into the ambient surrounding atmosphere.
Alternatively, the release outlets 214a, 214b, 214c, and 214d may
provide passage of the working fluid into a recycling or
reclamation step that generally includes capturing, condensing, and
storing the working fluid.
[0078] The release valve 213a and the release outlet 214a may be
fluidly coupled to the working fluid circuit 202 at a point
disposed between the heat exchanger 120 and the power turbine 228.
The release valve 213b and the release outlet 214b may be fluidly
coupled to the working fluid circuit 202 at a point disposed
between the heat exchanger 150 and the drive turbine 264 of the
turbo pump 260. The release valve 213c and the release outlet 214c
may be fluidly coupled to the working fluid circuit 202 via a
bypass line that extends from a point between the valve 293 and the
pump portion 262 of the turbo pump 260 to a point on the turbo pump
bypass line 226 between the turbo pump bypass valve 256 and the
fluid line 229. The release valve 213d and the release outlet 214d
may be fluidly coupled to the working fluid circuit 202 at a point
disposed between the recuperator 218 and the condenser 274.
[0079] In some embodiments, the overall efficiency of the heat
engine system 200 and the amount of power ultimately generated can
be influenced by the inlet or suction pressure at the pump when the
working fluid contains supercritical carbon dioxide. In order to
minimize or otherwise regulate the suction pressure of the pump,
the heat engine system 200 may incorporate the use of a mass
management system ("MMS") 270. The mass management system 270
controls the inlet pressure of the start pump 280 by regulating the
amount of working fluid entering and/or exiting the heat engine
system 200 at strategic locations in the working fluid circuit 202,
such as at tie-in points, inlets/outlets, valves, or conduits
throughout the heat engine system 200. Consequently, the heat
engine system 200 becomes more efficient by increasing the pressure
ratio for the start pump 280 to a maximum possible extent.
[0080] The mass management system 270 may contain at least one
vessel or tank, such as a storage vessel (e.g., working fluid
storage vessel 292), a fill vessel, and/or a mass control tank
(e.g., mass control tank 286), fluidly coupled to the low pressure
side of the working fluid circuit 202 via one or more valves, such
as the valve 287. In one exemplary configuration, the valve 287 is
a fluid (e.g., CO.sub.2) transfer pump inlet valve. The valves are
moveable--as being partially opened, fully opened, and/or
closed--to either remove working fluid from the working fluid
circuit 202 or add working fluid to the working fluid circuit 202.
Exemplary embodiments of the mass management system 270, and a
range of variations thereof, are found in U.S. application Ser. No.
13/278,705, filed Oct. 21, 2011, published as U.S. Pub. No.
2012-0047892, and issued as U.S. Pat. No. 8,613,195, the contents
of which are incorporated herein by reference to the extent
consistent with the present disclosure. Briefly, however, the mass
management system 270 may include a plurality of valves and/or
connection points, each in fluid communication with the mass
control tank 286. The valves may be characterized as termination
points where the mass management system 270 is operatively
connected to the heat engine system 200. The connection points and
valves may be configured to provide the mass management system 270
with an outlet for flaring excess working fluid or pressure, or to
provide the mass management system 270 with additional/supplemental
working fluid from an external source, such as a fluid fill
system.
[0081] In some embodiments, the mass control tank 286 may be
configured as a localized storage tank for additional/supplemental
working fluid that may be added to the heat engine system 200 when
needed in order to regulate the pressure or temperature of the
working fluid within the working fluid circuit 202 or otherwise
supplement escaped working fluid. By controlling the valves, the
mass management system 270 adds and/or removes working fluid mass
to/from the heat engine system 200 with or without the need of a
pump, thereby reducing system cost, complexity, and
maintenance.
[0082] In some examples, a working fluid storage vessel 292 is part
of a working fluid storage system 290 and may be fluidly coupled to
the working fluid circuit 202. At least one connection point, such
as a working fluid feed 288, may be a fluid fill port for the
working fluid storage vessel 292 of the working fluid storage
system 290 and/or the mass management system 270. Additional or
supplemental working fluid may be added to the mass management
system 270 from an external source, such as a fluid fill system via
the working fluid feed 288. Exemplary fluid fill systems are
described and illustrated in U.S. Pat. No. 8,281,593, the contents
of which are incorporated herein by reference to the extent
consistent with the present disclosure.
[0083] In another embodiment described herein, bearing gas and seal
gas may be supplied to the turbo pump 260 or other devices
contained within and/or utilized along with the heat engine system
200. One or multiple streams of bearing gas and/or seal gas may be
derived from the working fluid within the working fluid circuit 202
and contain carbon dioxide in a gaseous, subcritical, or
supercritical state. In some examples, the bearing gas or fluid is
flowed by the start pump 280, from a bearing gas supply 296a and/or
a bearing gas supply 296b, into the working fluid circuit 202,
through a bearing gas supply line (not shown), and to the bearings
within the power generation system 220. In other examples, the
bearing gas or fluid is flowed by the start pump 280, from the
working fluid circuit 202, through a bearing gas supply line (not
shown), and to the bearings within the turbo pump 260. In some
examples, the seal gas supply 298 is a connection point or valve
that feeds into a seal gas system. A gas return 294 is generally
coupled to a discharge, recapture, or return of bearing gas, seal
gas, and other gases. The gas return 294 provides a feed stream
into the working fluid circuit 202 of recycled, recaptured, or
otherwise returned gases--generally derived from the working fluid.
The gas return is generally fluidly coupled to the working fluid
circuit 202 upstream of the condenser 274 and downstream of the
recuperator 218.
[0084] In some embodiments described herein, the waste heat system
100 is disposed on or in a waste heat skid 102 fluidly coupled to
the working fluid circuit 202, as well as other portions,
sub-systems, or devices of the heat engine system 200. The waste
heat skid 102 may be fluidly coupled to a source of and an exhaust
for the heat source stream 110, a main process skid 212, a power
generation skid 222, and/or other portions, sub-systems, or devices
of the heat engine system 200.
[0085] In one or more configurations, the waste heat system 100
disposed on or in the waste heat skid 102 generally contains inlets
122, 132, and 152 and outlets 124, 134, and 154 fluidly coupled to
and in thermal communication with the working fluid within the
working fluid circuit 202. The inlet 122 is disposed upstream of
the heat exchanger 120, and the outlet 124 is disposed downstream
of the heat exchanger 120. The working fluid circuit 202 is
configured to flow the working fluid from the inlet 122, through
the heat exchanger 120, and to the outlet 124 while transferring
thermal energy from the heat source stream 110 to the working fluid
by the heat exchanger 120. The inlet 152 is disposed upstream of
the heat exchanger 150, and the outlet 154 is disposed downstream
of the heat exchanger 150. The working fluid circuit 202 is
configured to flow the working fluid from the inlet 152, through
the heat exchanger 150, and to the outlet 154 while transferring
thermal energy from the heat source stream 110 to the working fluid
by the heat exchanger 150. The inlet 132 is disposed upstream of
the heat exchanger 130 and the outlet 134 is disposed downstream of
the heat exchanger 130. The working fluid circuit 202 is configured
to flow the working fluid from the inlet 132, through the heat
exchanger 130, and to the outlet 134 while transferring thermal
energy from the heat source stream 110 to the working fluid by the
heat exchanger 130.
[0086] In one or more configurations, the power generation system
220 is disposed on or in the power generation skid 222 generally
contains inlets 225a, 225b and an outlet 227 fluidly coupled to and
in thermal communication with the working fluid within the working
fluid circuit 202. The inlets 225a, 225b are upstream of the power
turbine 228 within the high pressure side of the working fluid
circuit 202 and are configured to receive the heated and high
pressure working fluid. In some examples, the inlet 225a may be
fluidly coupled to the outlet 124 of the waste heat system 100 and
configured to receive the working fluid flowing from the heat
exchanger 120 and the inlet 225b may be fluidly coupled to the
outlet 241 of the process system 210 and configured to receive the
working fluid flowing from the turbo pump 260 and/or the start pump
280. The outlet 227 is disposed downstream of the power turbine 228
within the low pressure side of the working fluid circuit 202 and
is configured to provide the low pressure working fluid. In some
examples, the outlet 227 may be fluidly coupled to the inlet 239 of
the process system 210 and configured to flow the working fluid to
the recuperator 216.
[0087] A filter 215a may be disposed along and in fluid
communication with the fluid line at a point downstream of the heat
exchanger 120 and upstream of the power turbine 228. In some
examples, the filter 215a may be fluidly coupled to the working
fluid circuit 202 between the outlet 124 of the waste heat system
100 and the inlet 225a of the process system 210.
[0088] The portion of the working fluid circuit 202 within the
power generation system 220 is fed the working fluid by the inlets
225a and 225b. A power turbine stop valve 217 may be fluidly
coupled to the working fluid circuit 202 between the inlet 225a and
the power turbine 228. The power turbine stop valve 217 is
configured to control the working fluid flowing from the heat
exchanger 120, through the inlet 225a, and into the power turbine
228 while in an opened position. Alternatively, the power turbine
stop valve 217 may be configured to cease the flow of working fluid
from entering into the power turbine 228 while in a closed
position.
[0089] A power turbine attemperator valve 223 may be fluidly
coupled to the working fluid circuit 202 via a bypass line 211
disposed between the outlet on the pump portion 262 of the turbo
pump 260 and the inlet on the power turbine 228 and/or disposed
between the outlet on the pump portion 282 of the start pump 280
and the inlet on the power turbine 228. The bypass line 211 and the
power turbine attemperator valve 223 may be configured to flow the
working fluid from the pump portion 262 or 282, around and avoid
the recuperator 216 and the heat exchangers 120 and 130, and to the
power turbine 228, such as during a warm-up or cool-down step. The
bypass line 211 and the power turbine attemperator valve 223 may be
utilized to warm the working fluid with heat coming from the power
turbine 228 while avoiding the thermal heat from the heat source
stream 110 flowing through the heat exchangers, such as the heat
exchangers 120 and 130. In some examples, the power turbine
attemperator valve 223 may be fluidly coupled to the working fluid
circuit 202 between the inlet 225b and the power turbine stop valve
217 upstream of a point on the fluid line that intersects the
incoming stream from the inlet 225a. The power turbine attemperator
valve 223 may be configured to control the working fluid flowing
from the start pump 280 and/or the turbo pump 260, through the
inlet 225b, and to a power turbine stop valve 217, the power
turbine bypass valve 219, and/or the power turbine 228.
[0090] The power turbine bypass valve 219 may be fluidly coupled to
a turbine bypass line that extends from a point of the working
fluid circuit 202 upstream of the power turbine stop valve 217 and
downstream of the power turbine 228. Therefore, the bypass line and
the power turbine bypass valve 219 are configured to direct the
working fluid around and avoid the power turbine 228. If the power
turbine stop valve 217 is in a closed position, the power turbine
bypass valve 219 may be configured to flow the working fluid around
and avoid the power turbine 228 while in an opened position. In one
embodiment, the power turbine bypass valve 219 may be utilized
while warming up the working fluid during a start-up operation of
the electricity generating process. An outlet valve 221 may be
fluidly coupled to the working fluid circuit 202 between the outlet
on the power turbine 228 and the outlet 227 of the power generation
system 220.
[0091] In one or more configurations, the process system 210 is
disposed on or in the main process skid 212 generally contains
inlets 235, 239, and 255 and outlets 231, 237, 241, 251, and 253
fluidly coupled to and in thermal communication with the working
fluid within the working fluid circuit 202. The inlet 235 is
upstream of the recuperator 216, and the outlet 154 is downstream
of the recuperator 216. The working fluid circuit 202 is configured
to flow the working fluid from the inlet 235, through the
recuperator 216, and to the outlet 237 while transferring thermal
energy from the working fluid in the low pressure side of the
working fluid circuit 202 to the working fluid in the high pressure
side of the working fluid circuit 202 by the recuperator 216. The
outlet 241 of the process system 210 is downstream of the turbo
pump 260 and/or the start pump 280, upstream of the power turbine
228, and configured to provide a flow of the high pressure working
fluid to the power generation system 220, such as to the power
turbine 228. The inlet 239 is upstream of the recuperator 216,
downstream of the power turbine 228, and configured to receive the
low pressure working fluid flowing from the power generation system
220, such as to the power turbine 228. The outlet 251 of the
process system 210 is downstream of the recuperator 218, upstream
of the heat exchanger 150, and configured to provide a flow of
working fluid to the heat exchanger 150. The inlet 255 is
downstream of the heat exchanger 150, upstream of the drive turbine
264 of the turbo pump 260, and configured to provide the heated
high pressure working fluid flowing from the heat exchanger 150 to
the drive turbine 264 of the turbo pump 260. The outlet 253 of the
process system 210 is downstream of the pump portion 262 of the
turbo pump 260 and/or the pump portion 282 of the start pump 280,
couples a bypass line disposed downstream of the heat exchanger 150
and upstream of the drive turbine 264 of the turbo pump 260, and
configured to provide a flow of working fluid to the drive turbine
264 of the turbo pump 260.
[0092] Additionally, a filter 215c may be disposed along and in
fluid communication with the fluid line at a point downstream of
the heat exchanger 150 and upstream of the drive turbine 264 of the
turbo pump 260. In some examples, the filter 215c may be fluidly
coupled to the working fluid circuit 202 between the outlet 154 of
the waste heat system 100 and the inlet 255 of the process system
210.
[0093] In another embodiment described herein, as illustrated in
FIG. 1, the heat engine system 200 contains the process system 210
disposed on or in a main process skid 212, the power generation
system 220 disposed on or in a power generation skid 222, the waste
heat system 100 disposed on or in a waste heat skid 102. The
working fluid circuit 202 extends throughout the inside, the
outside, and between the main process skid 212, the power
generation skid 222, the waste heat skid 102, as well as other
systems and portions of the heat engine system 200. In some
embodiments, the heat engine system 200 contains the bypass line
160 and the bypass valve 162 disposed between the waste heat skid
102 and the main process skid 212. A filter 215b may be disposed
along and in fluid communication with the fluid line 135 at a point
downstream of the heat exchanger 130 and upstream of the
recuperator 216. In some examples, the filter 215b may be fluidly
coupled to the working fluid circuit 202 between the outlet 134 of
the waste heat system 100 and the inlet 235 of the process system
210.
[0094] The foregoing has outlined features of several embodiments
so that those skilled in the art may better understand the present
disclosure. Those skilled in the art should appreciate that they
may readily use the present disclosure as a basis for designing or
modifying other processes and structures for carrying out the same
purposes and/or achieving the same advantages of the embodiments
introduced herein. Those skilled in the art should also realize
that such equivalent constructions do not depart from the spirit
and scope of the present disclosure, and that they may make various
changes, substitutions and alterations herein without departing
from the spirit and scope of the present disclosure.
* * * * *