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WO2018107279A1 - Appareil pour extraire de l'énergie à partir de la chaleur perdue - Google Patents

Appareil pour extraire de l'énergie à partir de la chaleur perdue Download PDF

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Publication number
WO2018107279A1
WO2018107279A1 PCT/CA2017/051498 CA2017051498W WO2018107279A1 WO 2018107279 A1 WO2018107279 A1 WO 2018107279A1 CA 2017051498 W CA2017051498 W CA 2017051498W WO 2018107279 A1 WO2018107279 A1 WO 2018107279A1
Authority
WO
WIPO (PCT)
Prior art keywords
air
common structure
brayton cycle
working fluid
heat
Prior art date
Application number
PCT/CA2017/051498
Other languages
English (en)
Inventor
Paul Merswolke
Francis DI BELLA
Original Assignee
Blue Box Technology Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Blue Box Technology Inc. filed Critical Blue Box Technology Inc.
Priority to CA3045185A priority Critical patent/CA3045185A1/fr
Priority to MX2019006899A priority patent/MX2019006899A/es
Priority to EP17881463.8A priority patent/EP3555432A4/fr
Priority to US16/468,833 priority patent/US20200095899A1/en
Publication of WO2018107279A1 publication Critical patent/WO2018107279A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
    • F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K25/00—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
    • F01K25/08—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K13/00—General layout or general methods of operation of complete plants
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C1/00—Gas-turbine plants characterised by the use of hot gases or unheated pressurised gases, as the working fluid
    • F02C1/04—Gas-turbine plants characterised by the use of hot gases or unheated pressurised gases, as the working fluid the working fluid being heated indirectly
    • F02C1/05—Gas-turbine plants characterised by the use of hot gases or unheated pressurised gases, as the working fluid the working fluid being heated indirectly characterised by the type or source of heat, e.g. using nuclear or solar energy
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16M—FRAMES, CASINGS OR BEDS OF ENGINES, MACHINES OR APPARATUS, NOT SPECIFIC TO ENGINES, MACHINES OR APPARATUS PROVIDED FOR ELSEWHERE; STANDS; SUPPORTS
    • F16M1/00—Frames or casings of engines, machines or apparatus; Frames serving as machinery beds
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16M—FRAMES, CASINGS OR BEDS OF ENGINES, MACHINES OR APPARATUS, NOT SPECIFIC TO ENGINES, MACHINES OR APPARATUS PROVIDED FOR ELSEWHERE; STANDS; SUPPORTS
    • F16M5/00—Engine beds, i.e. means for supporting engines or machines on foundations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00—Methods of steam generation characterised by form of heating method
    • F22B1/02—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/16—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being hot liquid or hot vapour, e.g. waste liquid, waste vapour
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/44—Details; Accessories
    • F23G5/46—Recuperation of heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D15/00—Adaptations of machines or engines for special use; Combinations of engines with devices driven thereby
    • F01D15/10—Adaptations for driving, or combinations with, electric generators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
    • F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
    • F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
    • F01K23/065—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle the combustion taking place in an internal combustion piston engine, e.g. a diesel engine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
    • F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
    • F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
    • F01K23/10—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle with exhaust fluid of one cycle heating the fluid in another cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
    • F02G5/00—Profiting from waste heat of combustion engines, not otherwise provided for
    • F02G5/02—Profiting from waste heat of exhaust gases

Definitions

  • the disclosure relates generally to extracting useful energy from waste heat, and more particularly to extracting useful energy from waste heat using the Brayton thermodynamic cycle.
  • the disclosure describes a Brayton cycle apparatus for extracting energy from waste heat released from an industrial device.
  • the apparatus comprises:
  • an air compressor configured to receive ambient air and compress the ambient air
  • an air turbine configured for fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air
  • a working fluid heater configured to facilitate transfer of the waste heat to the compressed air at a location upstream of the air turbine during operation
  • the working fluid heater may be at least partially disposed into a base of the common structure.
  • the common structure may comprise a support platform.
  • the air turbine and the air compressor may be disposed on an upper side of the support platform and the working fluid heater may be disposed on a lower side of the support platform.
  • the working fluid heater may be disposed vertically below the air compressor and the air turbine.
  • the working fluid heater may be disposed vertically below the generator.
  • the air compressor may comprise a first compressor stage and a second compressor stage.
  • the apparatus may comprise an intercooler mounted to the common structure.
  • the intercooler may be configured to cool the air between the first compressor stage and the second compressor stage of the air compressor during operation.
  • the working fluid heater may comprise a recuperator configured to facilitate heat transfer from exhaust air from the air turbine to the compressed air upstream of the air turbine.
  • the apparatus may comprise a steam generator mounted to the common structure and coupled to receive a first heat-carrying fluid from the recuperator and facilitate heat transfer from the first heat-carrying fluid to water to produce steam during operation.
  • the steam generator may be coupled to receive a second heat-carrying fluid from the working fluid heater and facilitate heat transfer from the second heat- carrying fluid to the water to produce the steam during operation.
  • the apparatus may comprise a steam generator mounted to the common structure and configured to receive a heat-carrying fluid from the working fluid heater and facilitate heat transfer from the heat-carrying fluid to water to produce steam during operation.
  • the common structure may comprise an upper portion and a lower portion. The upper portion may be configured to interface with a lower portion of a common structure of another Brayton cycle apparatus to permit vertical stacking.
  • the working fluid heater may comprise a fuel-burning auxiliary heater configured to heat the compressed air upstream of the air turbine.
  • the common structure may comprise a skid.
  • Embodiments may include combinations of the above features.
  • the disclosure describes a system comprising:
  • an industrial device configured to release waste heat
  • a Brayton cycle apparatus for extracting energy from the waste heat released by the industrial device, the apparatus comprising:
  • an air compressor configured to receive ambient air and compress the ambient air
  • an air turbine in fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air;
  • a working fluid heater configured to facilitate transfer of the waste heat to the compressed air at a location upstream of the air turbine during operation;
  • an electric generator drivingly coupled to the air turbine for converting some of the energy extracted by the air turbine into electrical energy; and a common structure to which the air compressor, the air turbine, the working fluid heater and the electric generator are mounted to define a transportable unit integrated with the industrial device.
  • the working fluid heater may be at least partially disposed in a base of the common structure.
  • the common structure may comprise a support platform.
  • the air turbine and the air compressor may be disposed on an upper side of the support platform and the working fluid heater may be disposed on a lower side of the support platform.
  • the working fluid heater may be disposed vertically below the air compressor and the air turbine.
  • the working fluid heater may be disposed vertically below the generator.
  • the air compressor may comprise a first compressor stage and a second compressor stage.
  • the apparatus may comprise an intercooler mounted to the common structure. The intercooler may be operatively coupled to cool the air between the first compressor stage and the second compressor stage of the air compressor.
  • the working fluid heater may comprise a recuperator configured to facilitate heat transfer from exhaust air from the air turbine to the compressed air upstream of the air turbine.
  • the system may comprise a steam generator mounted to the common structure and coupled to receive a first heat-carrying fluid from the recuperator and facilitate heat transfer from the first heat-carrying fluid to water to produce steam during operation.
  • the steam generator may be coupled to receive a second heat-carrying fluid from the working fluid heater and facilitate heat transfer from the second heat- carrying fluid to the water to produce the steam during operation.
  • the system may comprise a steam generator mounted to the common structure and coupled to receive a heat-carrying fluid from the working fluid heater and facilitate heat transfer from the heat-carrying fluid to water to produce steam during operation.
  • the common structure may comprise a skid.
  • the system may comprise an organic Rankine cycle device operatively coupled to receive a flow of air exhausted by the air turbine.
  • the system may comprise a combustion device operatively coupled to receive a flow of air exhausted by the air turbine.
  • the industrial device may comprise an incinerator.
  • the industrial device may comprise a fired heater.
  • the common structure of the apparatus may comprise an upper portion and a lower portion. The upper portion may be configured to interface with a lower portion of a common structure of another Brayton cycle apparatus to permit vertical stacking.
  • the Brayton cycle apparatus may be a first Brayton cycle apparatus and the system may comprise a second Brayton cycle apparatus. The first Brayton cycle apparatus and the second Brayton cycle apparatus may be stacked vertically.
  • the Brayton cycle apparatus may be a first Brayton cycle apparatus and the system may comprise a second Brayton cycle apparatus.
  • the system may comprise a support structure supporting the first Brayton cycle apparatus above the second Brayton cycle apparatus in a vertically stacked relationship during operation.
  • the working fluid heater may comprise a fuel-burning auxiliary heater configured to heat the compressed air upstream of the air turbine.
  • Embodiments may include combinations of the above features. [0038] In a further aspect, the disclosure describes a method for integrating a
  • Brayton cycle apparatus with an industrial device releasing waste heat.
  • the method comprises:
  • the method may comprise installing the working fluid heater to be at least partially disposed in a base of the common structure.
  • the method may comprise installing the working fluid heater to be disposed vertically below the air compressor and the air turbine. [0041 ] The method may comprise operatively installing an intercooler to cool the air between a first compressor stage and a second compressor stage of the air compressor on the common structure prior to transporting the transportable Brayton cycle unit.
  • the method may comprise operatively installing a steam generator configured to receive a heat-carrying fluid from the working fluid heater on the common structure prior to transporting the transportable Brayton cycle unit.
  • the method may comprise integrating the transportable Brayton cycle unit with an organic Rankine cycle device.
  • the industrial device may comprise an incinerator.
  • the industrial device may comprise a fired heater.
  • Integrating the transportable Brayton cycle unit with the industrial device may comprise vertically stacking the transportable Brayton cycle unit with another transportable Brayton cycle unit.
  • the method may comprise integrating the transportable Brayton cycle unit with a combustion device operatively coupled to receive a flow of air exhausted by the air turbine.
  • Embodiments may include combinations of the above features.
  • the disclosure describes a Brayton cycle apparatus for extracting energy from waste heat released from an industrial device.
  • the apparatus comprises:
  • an air compressor configured to receive ambient air and compress the ambient air
  • an air turbine configured for fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air
  • an electric generator configured to be drivingly coupled to the air turbine for converting some of the energy extracted by the air turbine into electrical energy; and a common structure to which the air compressor, the air turbine and the electric generator are mounted in an in-use configuration to define a transportable unit for integration with the industrial device.
  • the air compressor may comprise a first compressor stage and a second compressor stage and the apparatus may comprise an intercooler mounted to the common structure, the intercooler being configured to cool the air between the first compressor stage and the second compressor stage of the air compressor during operation.
  • the common structure may comprise an upper portion and a lower portion, the upper portion being configured to interface with a lower portion of a common structure of another Brayton cycle apparatus to permit vertical stacking.
  • the common structure may comprise a skid.
  • Embodiments may include combinations of the above features.
  • FIG. 1 is a schematic representation of an exemplary industrial system installation including an exemplary embodiment of an apparatus for extracting useful energy from waste heat;
  • FIG. 2 is a schematic representation of another exemplary industrial system installation including another exemplary embodiment of the apparatus for extracting useful energy from waste heat;
  • FIGS. 3A and 3B are schematic perspective views of another exemplary embodiment of the apparatus respectively showing a side and a front thereof;
  • FIGS. 4A and 4B are schematic perspective views of another exemplary embodiment of the apparatus respectively showing a side and a front thereof;
  • FIG. 5 is a schematic representation of another exemplary industrial system installation comprising a plurality of energy extraction apparatus vertically stacked relative to each other to promote efficient use of space;
  • FIGS. 6A and 6B are isometric views of an exemplary support structure for supporting two energy extraction apparatus in a vertically stacked relationship
  • FIG. 7 illustrates a flowchart of a method for integrating a Brayton cycle apparatus with an industrial device producing waste heat
  • FIG. 8 is a perspective view of the support structure for supporting two energy extraction apparatus in a vertically stacked relationship as shown in FIGS. 6A and 6B where duct work has been omitted from the two energy extraction apparatus.
  • the present disclosure relates to apparatus for extracting useful energy from waste heat streams using the Brayton cycle and associated methods.
  • such apparatus may be packaged to promote efficient use of space and also to facilitate transport and installation.
  • the main components of the apparatus e.g., compressor, turbine, heat exchanger and electric generator
  • the common structure may permit the main components of the apparatus to be pre-assembled on the common structure, transported to a site as a substantially ready-to-use unit and installed in a substantially "plug-and-play" manner.
  • the apparatus disclosed herein may be appropriate for installation in an industrial environment for extracting useful energy from one or more sources of waste heat released by one or more industrial devices.
  • the common structure may be configured to permit two or more apparatus to be stacked vertically.
  • FIG. 1 is a schematic representation of an exemplary industrial system installation 10 including one or more industrial devices 12 (referred hereinafter in the singular) that may be used in an industrial process and which may release waste heat as a by-product of an industrial process, and, an exemplary apparatus 14 for extracting useful energy from the waste heat.
  • industrial device 12 may be of any type suitable for use in industrial process(es) associated with: (i) petroleum and coal products, (ii) chemical manufacturing, (iii) cement, lime, glass, tile, or brick manufacturing, (iv) metal manufacturing (e.g., casting foundry), (v) pulp and paper, (vi) wood products, (vii) food manufacturing, (viii) landfill gas production or (ix) bio-waste energy for example.
  • industrial device 12 may, for example, be an incinerator, furnace or fired heater (e.g., in an oil refinery).
  • industrial device 12 may, for example, be a rotary kiln calciner, a raw material melting furnaces, an annealing oven, a tempering furnace, a coke oven, a blast furnace, an electric arc furnace, a basic oxygen furnace, a melting furnace, a heat treating furnace, or a reverberatory furnace.
  • the source of waste heat may comprise a flow of a relatively hot heat- carrying fluid such as flue gas(es) or steam for example.
  • the source of waste heat may be substantially continuous or intermittent.
  • the amount of waste heat available may be substantially constant or variable depending on the industrial device 12.
  • the heat- carrying fluid may have a temperature that is between about 232°C (450°F) and about 1232°C (2250°F).
  • the heat-carrying fluid may have a temperature that is between about 232°C (450°F) and about 650°C (1200°F).
  • the heat-carrying fluid may have a temperature that is greater than about 538°C (1000°F).
  • the heat-carrying fluid may have a temperature that is about 816°C (1500°F). In some embodiments, the heat-carrying fluid may have a temperature that is between about 538°C (1000°F) and about 816°C (1500°F). In some embodiments, the heat-carrying fluid may have a temperature that is between about 760°C (1400°F) and about 871 °C (1600°F). In some embodiments, the heat- carrying fluid may have a temperature that is between about 704°C (1300°F) and about 927°C (1700°F). In some embodiments, the heat-carrying fluid may have a temperature that is between about 927°C (1700°F) and about 1232°C (2250°F).
  • the heat-carrying fluid may have a temperature that is greater than about 1232°C (2250°F). In some embodiments, the heat-carrying fluid may have a mass flow rate that is between about 4.5 kg/s and about 29.5 kg/s (10-65 lb/sec).
  • energy extraction apparatus 14 may be configured to operate as a suitable Brayton cycle.
  • apparatus 14 may be configured to operate as an open Brayton cycle where ambient air may be used as a working fluid.
  • Apparatus 14 may be configured to be disposed relatively proximal to industrial device 12 to facilitate the transfer of the waste heat released by industrial device 12 to apparatus 14.
  • apparatus 14 may, for example, be disposed in the same facility (e.g., factory, building) as industrial device 12.
  • apparatus 14 may be packaged as a pre-assembled and transportable unit that makes efficient use of space (i.e., efficient packaging) an that may have a relatively small footprint.
  • Apparatus 14 may comprise common structure 16 which may comprise a base to which at least come components of apparatus 14 may be assembled and directly or indirectly mounted thereto.
  • the main components of apparatus 14 may be assembled and operatively coupled together in a configuration that is substantially ready to be used so that apparatus 14 may be pre-assembled and delivered to the site as a pre-assembled unit.
  • the pre-assemble unit i.e., apparatus 14
  • the pre-assemble unit may then be integrated with industrial device 12 in a manner that permits useful energy to be extracted by apparatus 14 from the waste heat released by industrial device 12.
  • Apparatus 14 may comprise (e.g., single or multi-stage) air compressor
  • Air compressor 18 mounted to common structure 16 and configured to receive ambient air and compress the ambient air.
  • Air compressor 18 may, for example, be of the radial or axial type.
  • Apparatus 14 may comprise (e.g., single or multi-stage) air turbine 20 mounted to common structure 16 and configured for fluid communication with air compressor 18 for receiving the compressed air and extracting energy from the compressed air.
  • Air turbine 20 may, for example, be of the radial or axial type.
  • turbine 20 and compressor 18 may be drivingly coupled together via common shaft 21 or other means so that turbine 20 may drive compressor 18 during operation.
  • air turbine 20 and air compressor 18 may be drivingly coupled together via a gearbox depending on respective speed requirements.
  • Apparatus 14 may comprise electric motor/generator 22 mounted to common structure 16 and drivingly coupled to air turbine 20 for converting some of the energy extracted by air turbine 20 into electrical energy.
  • Electric motor/generator 22 may, for example, be of the induction type.
  • Electric motor/generator 22 may be (e.g., selectively) electrically coupled to supply electrical energy to an electrical load during its operation as a generator.
  • Electric motor/generator 22 may be (e.g., selectively) electrically coupled to receive electrical energy from an electrical power source load during its operation as a motor.
  • Apparatus 14 may comprise working fluid heater 24 (e.g., air heater) mounted to common structure 16 and configured to facilitate heat transfer from a source of heat that is disposed externally of apparatus 14 (e.g., waste heat being released from nearby industrial device 12) to the working fluid (e.g., compressed air) at a location upstream of air turbine 20 during operation.
  • working fluid heater 24 or part(s) thereof may be mounted to common structure 16 or may be installed remotely from common structure 16.
  • working fluid heater 24 installed at a location that is close to the source of waste heat but remote from common structure 16 while still being operatively coupled (e.g., via suitable ducting) to one or more components of system 10 that may be mounted to common structure 16.
  • working fluid heater 24 may comprise one or more suitable fluid-to-fluid heat exchangers of the shell-and-tube type or of the plate fin type for example.
  • working fluid heater 24 may comprise one or more relatively compact surface heat exchangers.
  • working fluid heater 24 may be configured to facilitate heat transfer from a flow of fluid (e.g., flue gas, steam) carrying the waste heat to the compressed air at a location downstream of air compressor 18 and upstream of air turbine 20.
  • Electric motor/generator 22 may be configured to operate either as a generator or as a motor depending on the state of operation of apparatus 14. For example, during start-up of apparatus 14, electric motor/generator 22 may operate as a motor to initiate the operation of air compressor 18 so that ambient air may be drawn into air compressor 18, compressed and driven through working fluid heater 24 and through air turbine 20. In the exemplary embodiment shown in FIG.
  • electric motor/generator 22 may be operated as a motor to initiate rotation of air turbine 20, which in turn may initiate rotation of air compressor 18 via shaft 21 .
  • air turbine 20 will begin to extract energy from the flow of heated air therethrough and can then begin to drive electric motor/generator 22 as an electric generator and can also begin to drive air compressor 18 via shaft 21 .
  • electric motor/generator 22 may switch from operating as a motor to operating as a generator.
  • apparatus 14 may comprise a separate motor (not shown) for driving air compressor 18 during start-up or at other times.
  • system 10 may comprise other subsystems or devices (e.g., heat load(s)) configured to receive the air exhausted from turbine 20 and further extract energy from the exhausted air.
  • a suitable organic Rankine cycle device 26 may be operatively coupled to apparatus 14 to receive a flow of air exhausted from turbine 20.
  • FIG. 2 is a schematic representation of another exemplary industrial system installation 10 including another exemplary embodiment of apparatus 14 for extracting useful energy from waste heat.
  • the embodiment shown in FIG. 2 illustrates additional (i.e., optional) components that may be included in apparatus 14 in comparison with the embodiment of FIG. 1 .
  • FIGS. 1 and 2 only illustrate main components of apparatus 14 in schematic form and that apparatus 14 may comprise one or more control devices (e.g., suitable controllers, instruments and control valves) and additional system integration components that are omitted from the figures for the sake of clarity. It is understood that, in light of the present disclosure, one of ordinary skill would understand the integration of such components.
  • apparatus 14 may comprise a multi-stage compressor 28 comprising first compressor stage 18A and second compressor stage 18B.
  • Apparatus 14 may comprise intercooler 28 mounted to common structure 16 where intercooler 28 may be operatively coupled to cool the air between first compressor stage 18A and second compressor stage 18B.
  • intercooler 28 may promote an increased air charge density which may be desirable in some situations.
  • working fluid heater 24 may comprise main heat exchanger (HX) 30 of suitable type to facilitate heat transfer from the source of waste heat (e.g., flue gas, steam) to the compressed air at a location upstream of air turbine 20.
  • main heat exchanger 30 of working fluid heater 24 may be mounted to common structure 16 or may be installed remotely from common structure 16 as explained above. Main heat exchanger 30 may be installed to receive a flow of heat-carrying fluid therethrough.
  • working fluid heater 24 may also comprise recuperator 32, which may also be a heat exchanger of suitable type but configured to facilitate heat transfer from air exhausted from air turbine 20 to the compressed air at a location upstream of turbine 20.
  • recuperator 32 may be integrated into or separate from main heat exchanger 30.
  • recuperator 32 of working fluid heater 24 may be mounted to common structure 16 or may be installed remotely from common structure 16 as explained above.
  • recuperator 32 may serve to recover some thermal energy that may be carried by the air exhausted from air turbine 20 and pre-heat the pressurized air upstream of main heat exchanger 30.
  • all or a portion of the air exhausted from air turbine 20 may be directed to optional organic Rankine cycle device 26. It is understood that the type(s) of available and beneficial uses for heat recuperated from the air exhausted from air turbine 20 will depend on specific operating conditions.
  • working fluid heater 24 may comprise an optional auxiliary heater 33 to add heat to the compressed air at a location upstream of air turbine 20.
  • auxiliary heater 33 may be mounted to common structure 16 or may be installed remotely from common structure 16.
  • Auxiliary heater 33 may be configured and disposed to add heat to the compressed air at a location downstream of main heat exchanger 30 and upstream of air turbine 20.
  • Auxiliary heater 33 may be referred to as a "booster" for supplementing the amount of heat transferred to the compressed air.
  • auxiliary heater 33 may comprise a fuel burner and suitable heat exchange means for transferring heat released from the combustion of the fuel to the compressed air.
  • a suitable fuel such as oil or natural gas may be used as a fuel for auxiliary heater 33.
  • apparatus 14 may comprise steam generator 34 mounted to common structure 16 to further make use of waste heat available on apparatus 14.
  • steam generator 34 may be coupled to receive a heat- carrying fluid from working fluid heater 24 and facilitate heat transfer from the heat- carrying fluid to water to produce (e.g., pressurized) steam during operation of apparatus 14 before discharging the heat-carrying fluid out of apparatus 14.
  • steam generator 34 may be coupled to receive a first heat-carrying fluid from recuperator 32 and facilitate heat transfer from the first heat-carrying fluid to water to produce steam during operation.
  • the first heat-carrying fluid may comprise air exhausted from air turbine 20 that has passed through recuperator 32.
  • steam generator 34 may be coupled to receive a second heat-carrying fluid from main heat exchanger 30 and facilitate heat transfer from the second heat- carrying fluid to the water to produce the steam during operation.
  • the second heat- carrying fluid may comprise flue gas or steam from industrial device 12 that has passed through main heat exchanger 30.
  • the first and second heat- carrying fluids may be mixed prior to entering steam generator 34.
  • the first and second heat-carrying fluids may be combined together downstream of recuperator 32 and of main heat exchanger 30 but upstream of steam generator 34.
  • Residual heat available within system 10 may be used for one or more secondary applications.
  • heat-carrying air in system 10 may be used as combustion air in an incinerator (e.g. of industrial device 12) for example or used to meet a hot air demand in a heating, ventilating and cooling (HVAC) system of a building.
  • HVAC heating, ventilating and cooling
  • air exhausted from air turbine 20 may be selectively directed to one or more users (e.g., recuperator 32, steam generator 34, organic Rankine cycle device 26, combustion air and hot air demand) by the selective opening and closing of valves V1 -V6 shown in FIG. 2.
  • the condition of the combustion air delivered to combustion device 35 can be tailored to match requirements of combustion device 35.
  • the temperature, pressure and flow rate of the combustion air delivered to the associated combustion device 35 via valve V4 may be monitored and controlled to be within ranges that permit the direct injection of the combustion air into combustion 35 device (e.g., directly) without further conditioning.
  • the condition and amount of air being discharged from system 10 via valve V4 may be controlled by way of adjusting the operation of one or more components of system 10.
  • one or more components of system 10 may be controlled to obtain a desired pressure, temperature and flow rate of compressed air at one or more desired locations within system 10 and such control may be used to tailor the condition of the combustion air delivered by system 10 via valve V4.
  • combustion devices 35 can require combustion blowers sometimes call "induction fans" that supply combustion air at a desired condition to their combustion chambers.
  • the ability to tailor the condition of the combustion air supplied by system 10 may eliminate or reduce the need for such combustion blowers since the combustion air supplied may need no further conditioning.
  • a combustion device 35 operatively coupled to receive combustion air from system 10 may not necessarily have a combustion blower.
  • a combustion blower of a combustion device 35 operatively coupled to receive combustion air from system 10 may be turned off or adjusted accordingly based on the condition of the combustion air received from system 10. For example, in some situations, such combustion blower may be turned off completely when combustion air is received from system 10 and turned on when combustion air is not received from system 10.
  • combustion blower may be activated on an as-needed basis and the operation of such combustion blower may be part of a suitable control loop that determines the need for operating the combustion blower and activates the combustion blower accordingly (e.g., based on the presence and/or condition of the combustion air received from system 10).
  • FIGS. 3A and 3B are schematic perspective views of another exemplary embodiment of apparatus 14 respectively showing a side and a front thereof.
  • the embodiment of apparatus 14 shown in FIGS. 3A and 3B may contain components previously described above. Like components are identified using like reference numerals.
  • air compressor 28 i.e., stages 28A and 28B
  • air turbine 20 and electric motor/generator 22 may be drivingly coupled via a suitable gearbox 36.
  • Gearbox 36 may be mounted to common structure 16.
  • Apparatus 14 may also comprise a suitable lubrication system represented schematically at reference numeral 38.
  • common structure 16 may comprise or have a base that resembles a skid so that apparatus 14 may be considered a "skid-mounted" Brayton cycle unit for example. Accordingly, common structure 16 may comprise one or more support platforms 40 and one or more ground-engaging members 42. Ground- engaging members 42 may cause support platform 40 to be elevated from a ground or floor so that apparatus 14 may be transported as a pre-assembled unit using a fork lift truck for example. Various components of apparatus 14 may be mounted directly or indirectly to an upper side of support platform 40. In some embodiments, electric motor/generator 22 may be mounted directly to support platform 40 and air compressor stages 18A, 18B and air turbine 20 may be indirectly mounted to support platform 40 via a housing of gearbox 36.
  • some components of apparatus 14 may be vertically superimposed so as to make efficient use of space and reduce a footprint of apparatus 14.
  • working fluid heater 24 may be disposed vertically above air compressor stages 18A, 18B and vertically above air turbine 20.
  • working fluid heater 24 may be disposed vertically above electric motor/generator 22 and vertically above gearbox 36.
  • the elevated position of working fluid heater 24 may be desirable in some situations depending on the position of the source of waste heat. In some cases as might be suitable for the available waste heat, working fluid heater 24 may have recuperator 32 integrated therewith.
  • working fluid heater 24 may be integrated in the skid-mounted Brayton cycle unit defined by apparatus 14, or, alternatively, working fluid heater 24 may not be integrated in the skid-mounted unit.
  • working fluid heater 24 (or part(s) thereof) may not be mounted to common structure 16 and instead be installed at a location closer to the source of waste heat while still being operatively coupled to (i.e., in fluid communication with) one or more components of apparatus 14.
  • FIGS. 4A and 4B are schematic perspective views of another exemplary embodiment of apparatus 14 respectively showing a side and a front thereof.
  • the embodiment of apparatus 14 shown in FIGS. 4A and 4B may contain components previously described above. Like components are identified using like reference numerals.
  • working fluid heater 24 may be integrated into a base of common structure 16 for packaging efficiency, increased stability of apparatus 14, reduced length of duct work and/or other reasons.
  • the base of common structure 16 may comprise upper platform 40A and lower platform 40B where working fluid heater 24 may be disposed vertically between upper platform 40A and lower platform 40B.
  • Ground engaging members 42 may be disposed on a lower side of lower platform 40B.
  • Upper platform 40A may be considered a support platform to which one or more components of apparatus 14 may be mounted.
  • air turbine 20 and air compressor 18 i.e., first stage 18A and second stage 18B
  • working fluid heater 24 may be disposed on a lower side of upper platform 40A.
  • electric motor/generator 22, gearbox 36 and intercooler 28 may be disposed on an upper side of upper platform 40A and hence above working fluid heater 24.
  • FIG. 5 is a schematic representation of an exemplary system installation 10 comprising a plurality of energy extraction apparatus 14A, 14B vertically stacked relative to each other to promote efficient use of space (i.e., efficient packaging).
  • First apparatus 14A and second apparatus 14B may be operatively coupled to the same or to different respective industrial devices 12.
  • first apparatus 14A and second apparatus 14B may be operatively coupled to the same or to different respective organic Rankine cycle devices 26.
  • common structure 16B of second (i.e., lower) apparatus 14B may comprise upper portion 16B-U and common structure 16A of first (i.e., upper) apparatus 14A may comprise lower portion 16A-L where upper portion 16B- U of second apparatus 14B may be configured to interface with lower portion 16A-L of first apparatus 14A to permit vertical stacking of two or more apparatus 14.
  • common structure 16B may comprise vertical supports 44 supporting first apparatus 14A vertically above second apparatus 14B. It is understood that common structure 16A could similarly comprise vertical supports (not shown) for supporting a third apparatus (not shown) vertically above first apparatus 14A in some embodiments.
  • FIGS. 6A and 6B are isometric views of an exemplary support structure
  • support structure 46 for supporting two energy extraction apparatus 14A, 14B in a vertically stacked relationship.
  • suitable structure for permitting stacking of apparatus 14A, 14B may form part of common structure 16 as explained above in relation to FIG. 5.
  • a separate support structure 46 may be used to permit stacking of apparatus 14A, 14B.
  • support structure 46 may be configured as a shelving unit comprising upper shelf 48A, lower shelf 48B and one or more braces 50 supporting upper shelf 48A in a vertically spaced apart relationship above lower shelf 48B.
  • upper shelf 48A may support upper apparatus 14A above lower apparatus 14B during operation when apparatus 14A, 14B are operatively coupled to industrial device(s) 12 for example.
  • FIG. 7 illustrates a flowchart of a method 100 for integrating one or more Brayton cycle apparatus 14 with one or more industrial devices 12 releasing waste heat.
  • method 100 may comprise: assembling components (e.g., air compressor 18, air turbine 20, working fluid heater 24 and electric motor/generator 22) of apparatus 14 in an in-use configuration on common structure 16 to define a transportable Brayton cycle unit (i.e., apparatus 14) (see block 102); transporting the transportable Brayton cycle unit (i.e., apparatus 14) to a location of industrial device 12 (see block 104); and integrating the transportable Brayton cycle unit (i.e., apparatus 14) with industrial device 12 to permit the transportable Brayton cycle unit (i.e., apparatus 14) to extract energy from the waste heat (see block 106).
  • a transportable Brayton cycle unit i.e., apparatus 14
  • transportable Brayton cycle unit i.e., apparatus 14
  • apparatus 14 transportable Brayton cycle unit with industrial device 12 to permit the transportable Brayton cycle unit
  • the installation of various pieces of equipment of apparatus 14 onto common structure 16 in their in-use configuration may comprise the relative positioning and mounting of the pieces of equipment to common structure 16.
  • some pieces of equipment may be operatively coupled together so that they are in a ready-to use state.
  • some further integration of the pieces of equipment may be required after transporting apparatus 14.
  • some of the duct work and/or other integration device(s) may not necessarily be incorporated into apparatus 14 prior to transport and may need to be incorporated after transport (e.g., during the integration of apparatus 14 with industrial device 12).
  • method 100 may comprise installing working fluid heater 24 to be at least partially disposed in a base (e.g., between upper platform 40A and lower platform 40B) of common structure 16 as shown in FIGS. 4A and 4B for example.
  • method 100 may comprise installing working fluid heater 24 to be disposed vertically below air compressor 18 and air turbine 20.
  • method 100 may comprise operatively installing intercooler 28 for cooling the air between a first stage 18A and a second stage 18B of air compressor 18 prior to transporting transportable Brayton cycle apparatus 14.
  • method 100 may comprise operatively installing steam generator 34 for receiving a heat-carrying fluid from working fluid heater 24 prior to transporting transportable Brayton cycle apparatus 14.
  • method 100 may comprise integrating transportable Brayton cycle apparatus 14 with organic Rankine cycle device 26. [00100] In some embodiments, method 100 may comprise integrating the transportable Brayton cycle apparatus 14 with combustion device 35 so that combustion device 35 may be operatively coupled to receive a flow of air exhausted by air turbine 20.
  • industrial device 12 may comprise an incinerator.
  • industrial device 12 may comprise a fired heater.
  • integrating transportable Brayton cycle apparatus 14 with industrial device 12 may comprise vertically stacking transportable Brayton cycle apparatus 14A with another transportable Brayton cycle apparatus 14B as shown in FIGS. 5, 6A and 6B for example.
  • FIG. 8 is a perspective view of the support structure 46 for supporting two energy extraction apparatus 14A and 14B in a vertically stacked relationship as shown in FIGS. 6A and 6B where some duct work has been omitted from the two apparatus 14A and 14B.
  • Each apparatus 14A, 14B is in an exemplary configuration suitable for transport as a transportable Brayton cycle unit where various pieces of equipment of apparatus 14 are assembled onto common structure 16 in their in-use configurations (e.g., positions and orientations) but some of the duct work and optionally other system integration equipment has not yet been installed.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Engine Equipment That Uses Special Cycles (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un appareil à cycle de brayton permettant d'extraire de l'énergie à partir de la chaleur perdue libérée par des dispositifs industriels. Un appareil donné à titre d'exemple comprend une structure commune à laquelle les composants principaux d'un cycle de Brayton sont montés dans une configuration d'utilisation pour définir une unité transportable pour une intégration avec un dispositif industriel. L'invention concerne également des systèmes et des méthodes associés.
PCT/CA2017/051498 2016-12-13 2017-12-12 Appareil pour extraire de l'énergie à partir de la chaleur perdue WO2018107279A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
CA3045185A CA3045185A1 (fr) 2016-12-13 2017-12-12 Appareil pour extraire de l'energie a partir de la chaleur perdue
MX2019006899A MX2019006899A (es) 2016-12-13 2017-12-12 Aparato para extraer energia de calor residual.
EP17881463.8A EP3555432A4 (fr) 2016-12-13 2017-12-12 Appareil pour extraire de l'énergie à partir de la chaleur perdue
US16/468,833 US20200095899A1 (en) 2016-12-13 2017-12-12 Apparatus for extracting energy from waste heat

Applications Claiming Priority (2)

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US201662433440P 2016-12-13 2016-12-13
US62/433,440 2016-12-13

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WO2018107279A1 true WO2018107279A1 (fr) 2018-06-21

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EP (1) EP3555432A4 (fr)
CA (1) CA3045185A1 (fr)
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WO (1) WO2018107279A1 (fr)

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US20200095899A1 (en) 2020-03-26
CA3045185A1 (fr) 2018-06-21
MX2019006899A (es) 2019-10-15
EP3555432A1 (fr) 2019-10-23
EP3555432A4 (fr) 2020-08-12

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