Gas turbine blower/pump

Abstract

A low emission, high efficiency Gas Turbine engine operating on a combination of Natural Gas and Bio Gas as fuel, driving either a high efficiency turbo-blower or a high efficiency Turbo Pump system combined with heat recovery systems and in other embodiments is provided a generator of electricity or providing evaporate cooling from using the remaining waste heat in the exhaust gas.

Claims

1. A unit having: (a) a working fluid inlet and a working fluid outlet; (b) an air inlet and an exhaust outlet; (c) an impeller disposed between said working fluid inlet and said working fluid outlet; (d) first and second compressor stages for elevating the pressure of air; wherein the first compressor stage is driven by a low pressure turbine through a first common shaft, and the second compressor stage is driven by a high pressure turbine through a second common shaft; (e) a recuperator for increasing the temperature of said air at said elevated pressure; (f) a gas turbine disposed between said air inlet and said exhaust outlet, where the gas turbine comprises the low pressure turbine, the high pressure turbine and a free power turbine; (g) a combustor for receiving a combustion mixture comprising said air at said elevated temperature and said elevated pressure, and fuel to drive said gas turbine and exhaust through said exhaust outlet; (h) said free power turbine driven by exhaust gases from said low pressure turbine; (i) said recuperator recovering heat from exhaust gases from said free power turbine to preheat said combustion mixture; (j) said gas free power turbine and said impeller connected to a third common shaft so as to drive said impeller and move said working fluid from said fluid inlet to said fluid outlet.

2. The unit as claimed in claim 1 wherein said impeller is an air blower when said working fluid is air.

3. The unit as claimed in claim 1 wherein said impeller is a pump when said working fluid is water.

4. The unit as claimed in claim 1 including an intercooler disposed between said first and second compressor stages to cool said air between said first and second compressor stages.

5. The unit as claimed in claim 4 wherein said fuel is selected from a group of natural gas and biogas.

6. The unit as claimed in claim 5 including a gearbox disposed between said impeller and said free power turbine.

7. The unit as claimed in claim 6 including a heat exchanger.

8. The unit as claimed in claim 7 including an electric generator or refrigerator.

9. An integrated gas turbine unit comprising: (a) a working fluid inlet and working fluid outlet; (b) an air inlet and an exhaust outlet; (c) an impeller disposed between said working fluid inlet and said working fluid outlet; (d) a first and second compressor for elevating the pressure of air; wherein the first compressor is driven by a first pressure turbine through a first common shaft, and the second compressor driven by a second pressure turbine through a second common shaft; (e) an intercooler disposed between said first and second compressor for reducing the temperature of said air before second compressor; (f) a recuperator for increasing the temperature of said air at said elevated pressure; (g) a gas turbine disposed between said air inlet and said exhaust outlet, where the gas turbine comprises the first pressure turbine, the second pressure turbine and a free power turbine; (h) a combustor for receiving a combustion mixture of the air at said elevated pressure and elevated temperature and fuel to drive said gas turbine and exhaust through said exhaust outlet; (i) said first pressure turbine communicating with said second pressure turbine; (j) said recuperator recovering heat from said exhaust gases from said free power turbine to preheat said mixture of the air at said elevated pressure and temperature; and (k) said free powered turbine and said impeller connected to a third common shaft so as to drive said impeller and move said working fluid from said working fluid inlet to said working fluid outlet.

10. The integrated gas turbine unit as claimed in claim 9 wherein said first compressor comprises a low pressure compressor and said second compressor comprises a high pressure compressor.

11. The integrated gas turbine unit as claimed in claim 10 including a heat exchanger communicating with said recuperator and intercooler.

12. The integrated gas turbine as claimed in claim 11 further including a refrigerator disposed between said intercooler and heat exchanger.

13. The integrated gas turbine as claimed in claim 12 further including a gearbox disposed between said free power turbine and said impellor.

14. A method of driving an impeller with a free power turbine comprising: coaxially connecting said impeller and said free power turbine along a shaft; elevating the pressure of air in a first compressor connected to a first pressure turbine through a first common shaft and then elevating the pressure of said air through a second compressor driven by a second pressure turbine connected through a second common shaft; rotatably driving said free power turbine by combusting a mixture of air and fuel so as to rotationally drive the first pressure turbine and said second pressure turbine and directing the exhaust from said first pressure turbine and said second pressure turbine to said free power turbine so as to rotationally drive said free power turbine and impeller along said shaft; capturing waste heat from said free power turbine with a recuperator to preheat said air and positioning said impellor between a working fluid inlet and working fluid outlet.

15. The method of claim 14 comprising: (a) cooling the air with an intercooler heat exchanger disposed between the first compressor and the second compressor.

16. The method of claim 15 wherein said impeller is a blower when said fluid is air.

17. The method of claim 15 wherein the impellor is a pump when said fluid is water.

18. The method of claim 15 wherein said fuel is selected from the group of natural gas and bio fuel.

19. The method as claimed in claim 15 wherein the first pressure turbine is a low pressure turbine and the second pressure turbine is a high pressure turbine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following detailed description will be better understood with reference to the accompany figures, wherein:

(2) FIG. 1 is a perspective view taken from the right front side view of the Gas Turbine unit 10.

(3) FIG. 2 is a perspective view taken from the rear right side view of the Gas Turbine unit 10.

(4) FIG. 3 is a front elevational view of the Gas Turbine unit 10.

(5) FIG. 4. is a left side elevational view of the Gas Turbine Blower unit 10.

(6) FIG. 5 is a right side elevational view of the Gas Turbine Blower unit 10.

(7) FIG. 6 is a rear elevational view of the Gas Turbine unit 10.

(8) FIG. 7 is a top plan view of the Gas Turbine unit 10.

(9) FIG. 8 is a bottom plan view of the Gas Turbine unit 10.

(10) FIG. 9 is a cross sectional view of one embodiment of the invention relating to a Gas Turbine Blower unit 12 taken along lines 9-9 of FIG. 4 showing the rotors mounted in an arrangement with the main components.

(11) FIG. 10 is a schematic diagram of one embodiment of the Gas Turbine Blower unit, blower system shown in FIG. 9 with a gas turbine compressor driven by high-pressure gas turbine, a combustor of natural gas or biogas, a single blower impeller driven by a free power turbine and a recuperator recovering the heat from the exhaust gas that will be used to increase the gas turbine inlet temperature.

(12) FIG. 11 is a cross sectional view of another embodiment of the invention relating to a Gas Turbine Pump unit 16 taken along lines 11-11 of FIG. 7.

(13) FIG. 12 is a schematic diagram of another embodiment of the Gas Turbine Pump unit, device, system shown in FIG. 11 with a gas turbine compressor driven by high pressure gas turbine, a combustor of natural gas or biogas, a single pump impeller driven by free power turbine and a recuperator recovering heat from the exhaust gas to be used to increase the gas turbine inlet temperature.

(14) FIG. 13 is a chart illustrating one example of the efficiency and cost savings of this invention.

(15) FIG. 14 is a schematic diagram of yet another embodiment of the Gas Turbine Blower unit, with a high gas turbine compressor driven by high-pressure gas turbine, a combustor of natural gas or biogas, a single blower impeller driven by a free power turbine a recuperator recovering the heat from the exhaust gas that will be used to increase the gas turbine inlet temperature and an intercooler before the high pressure gas turbine compressor.

(16) FIG. 15 is a cross sectional view of the embodiment shown in schematic diagram FIG. 14.

(17) FIG. 16 is a perspective cross sectional view of FIG. 15.

(18) FIG. 17 is a front elevation view of FIG. 15

(19) FIG. 18 is a perspective view of the yet another embodiment shown in FIGS. 14-17 taken from above and from one side of the unit.

(20) FIG. 19 is a perspective view of the yet another embodiment shown in FIGS. 14-17 taken from above and from one side of the unit.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

(21) The same parts are marked throughout the figures with like numbers.

(22) Two specific embodiments of the present invention will be described below. These embodiments are only exemplary of the present invention. It should be appreciated that in the development of any such actual implementation, as in engineering or design project, numerous detail decisions must be made to achieve the developer's specific goals which may vary from one embodiment to another.

(23) The embodiments discussed below may include an optional gearbox 13 to reduce or increase rotor speed driven by free power turbine, an optional heat exchanger 27 and an optional electrical generator or cooling refrigerator 29 to recovery the wasted heat from the exhaust gas down stream from recuperator 60.

(24) FIGS. 1 through 8 generally illustrate one embodiment of the invention renting to Gas Turbine unit or device 10 having a gas turbine module 12 combustion air inlet 14 blower or pump module 16, exhaust plenum 18, exhaust outlet 20 and inset 22. In one embodiment the inlet 22 is an air inlet or first inlet, or working fluid inlet 24 to a blower 26. In a second embodiment to be described herein the inlet 22 is a water inlet 28 to a pump 40 to be described herein.

(25) The Gas Turbine device 10 also includes an outlet or first outlet or working fluid outlet 32.

(26) In one embodiment the outlet first outlet or working fluid outlet 32 is an air outlet 34. More particularly air through the blower inlet 24 is compressed by a blower impeller 37 and then is discharged through the blower scroll or volute channel 36.

(27) In another embodiment shown for example in FIG. 7 the Gas Turbine unit 10 includes a water inlet 28 a pump impeller 40 and water outlet 42.

(28) The integration of the assembly as described herein not only produces an energy efficient blower/pump system 10 but also presents a unit 10 which is compact in size and design. In one embodiment the width of the unit as shown for example in FIG. 9 can be 39 inches and the height 37 inches. However such dimensions are given by way of example only as other compact sizes may be experienced depending on the size requirement to accomplish the rated flow ranging from 1,000 to 50,000 SCFM and discharge pressures from 0.5 to 1.2 atmospheres.

(29) FIGS. 1, 2, 3, 4, 5, 6, 8, 9 and 10 illustrates one embodiment of a Gas Turbine Blower system 12 which generally includes a centrifugal blower impeller 37, a gas turbine axial and/or centrifugal compressor 50, a natural gas or biogas combustor 70, a high pressure axial and/or radial gas turbine 80, an axial and/or radial free power turbine 90 and a recuperator or heat exchanger 60.

(30) On the blower side, the air through the blower inlet 24 is compressed by the blower impeller 37, and then ii is discharged after leaving the blower scroll 36 to outlet 34. The blower impeller 37 is driven by the free power turbine 90 through a common shaft or axis 17.

(31) On the gas turbine side, the air passes through the inlet 14; is compressed by the compressor 50 to an elevated pressure over ambient pressure of for example 4-5 pressure ratio at which point it enters into the recuperator 80 which increases the air temperature. The heated air is burned with the fuel of natural gas/biogas in the combustor 70, and the high pressure and temperature gas is expanded in the high pressure gas turbine 80, and then the gas is expanded again in the free power turbine 90. Finally the gas is exhausted from the recuperator 60 which recovers heat to the air before combustor 70. The compressor 50 is driven by the high pressure gas turbine 80 through a common shaft or axis 2.

(32) FIG. 10 illustrates the one embodiment of a Gas Turbine Blower system 12 shown in FIGS. 1, 2, 3, 4, 5, 6, 8 and 9. The air flow inlet 24 of the blower 37 is in one example approximately 3000 to 15000 cubic feet per minute (CFM). The discharge air through outlet 34 in one example is 1.2-1.5 pressure ratio to a wastewater treatment system.

(33) A free power turbine 90 provides the power to meet the requirement of working fluid. As shown in the drawing, the free turbine 90 is a single stage axial turbine, but it may be a single radial turbine or may have multiple stages of expansion.

(34) A controller 21 such as a computer or the like is used to adjust the fuel of natural gas/biogas 25 and the air flow inlet 14 of the compressor 50 depending on the requirement of discharge air 34. In order to reduce or increase the speed of the blower impeller 37, an optional gearbox 13 can be installed on the shaft or the axis of rotation 17 between the blower 37 and free power turbine 90. In order to further increase energy efficiency, art optional heat exchanger 27 and an optional electrical generator or refrigerator system 29 can be installed at the exhaust of the recuperator 60.

(35) FIGS. 1, 2, 3, 4, 6, 7, 8, 11 and 12 illustrates another embodiment of the invention in relation to a Gas Turbine Pump unit, device and system 16 which generally includes a pump impeller 40 a gas turbine axial and/or centrifugal compressor 50, a natural gas or biogas combustor 70, a high pressure axial and/for radial turbine 80, a axial and/or radial free power turbine 90 and a recuperator 60.

(36) On the pump side, the water through the pump inlet 28 is compressed by the pump impeller 40, and then it is discharged alter leaving the pump scroll or volute passage 36 to outlet 42. The pump impeller 40 is driven by the free power turbine 90 through a common shaft or axis 17.

(37) FIG. 12 illustrates the embodiment of the invention described in FIGS. 1, 2, 3, 4, 6, 7, 8, 11 relating to the Gas Turbine Pump unit, device and system 16 with other options on a block diagram. The water flow inlet 28 of the pump impeller 40, for example can be approximately 15,000 to 50,000 gallon per minute (GPM), the discharge water through outlet 42 is provided with varying pressure ratio to meet the requirements of a wastewater treatment system. The controller 21 is used to adjust the fuel of natural gas/biogas 25 and the air flow inlet 14 of the compressor 50 depending on the requirement of discharge water through outlet 42. In order to reduce or increase the speed of pump impeller 40, an optional gearbox 13 can be installed on the shaft or axis 17 between the pump 40 and free power turbine 90. In order to further increase energy efficiency, an optional heat exchanger 27 and an optional electrical generator or refrigerator system 29 can be installed at the exhaust of the recuperator 60.

(38) Furthermore FIG. 13 is a chart which illustrates the efficiency and cost savings by utilizing the gas turbine system 10 as described herein versus a traditional electric motor option of traditional methods used before.

(39) In particular FIG. 13 illustrates one example of the operating costs of the electric motor option in several states namely Florida, Texas and California versus the operating costs of the Gas Turbine system 10 as described herein for the same locations in Florida, Texas and California which showed a savings of 31% in costs in Florida, 40% savings in costs in Texas and 33% savings in costs in California, to run the systems with natural gas; based on the current cost of electricity and the historically high level cost of natural gas prices. The savings will be significantly higher when biogas is added to natural gas and more so if the system is operated with only biogas.

(40) FIGS. 14-19 illustrate another embodiment of the invention where like parts are numbered with the same numbers as above.

(41) FIG. 14 in addition to the components described above, shows a high pressure gas turbine compressor 51, which is connected on a common shaft 2 with a high pressure turbine 80. The embodiment shown in FIG. 14 also includes a low pressure gas turbine compressor 53, which is connected on a common shaft 3 to low pressure turbine 81. The free power turbine 90 is connected to low blower impeller 37 by shaft 17. Furthermore, the embodiment shown in FIG. 14 includes an intercooler 31 disposed between the low pressure gas turbine compressor 53 and high pressure gas turbine compressor 51.

(42) Cooling of the inlet air 14 occurs between the two compressor stages 51 and 53 by intercooler 31. This improves the efficiency of the unit since cooled air 14 at the high pressure turbine compressor 51 will be easier to compress than heated air. After the high pressured gas turbine compressor 51 the air is then heated by recuperator or heat exchanger 60 prior to the air entering the combustor 70, thus again improving efficiently as less heat input will be required to combust the air and natural gas (biogas) mixture, if the air is at a higher temperature.

(43) Furthermore, the embodiment shown in FIGS. 14-19 illustrate the optimization of the power turbine with the double inlet design as shown. The design as shown also illustrates flow partitioning optimization as well as cooling flow first past optimization.

(44) Moreover, the turbines as shown are suitable candidates for additive manufacturing (3D printing) for efficient manufacturing.

(45) The embodiment shewn in FIGS. 14-19 illustrate a high efficiency inter-cooled and recuperated gas turbine driven turbo blower delivering air at high volume with intercooler, recuperator and CMHP (for example for ranges of 230 KW 1.2 MW).

(46) The unit is operable by biogas (which is byproduct WWTP) and/natural gas instead of electricity or fossil fuels, which has lower emissions, reducing operating costs of up to 80% with biogas and 40% with natural gas. The unit shown can also be used to retrofit old and existing technologies.

(47) Other advantages of the invention include: The system cars replace conventional electrical blowers; as the units are powered by a gas-turbine engine instead an electric motor, reducing dependence on an electrical grid. Reducing energy consumption. The use of a fuel-flexible clean combustor allowing the burning of biogas with low-pollutant emissions, providing clean power and preventing flaring on WWTP's. Reducing operating costs.

By Way of Example

(48) In one embodiment the low pressure compressor 53 has a pressure ratio of around 3 compared to atmosphere, and a temperature rise of around 125K (235 F) with respect to inlet temperature (293K).

(49) The intercooler 31 reduces the temperature of ˜418 K (125+293) back to inlet temperature (293K). The high pressure compressor 51 can have a pressure ratio of around 3, and a temperature rise of around 125K (235 F) with respect to inlet temperature. The total pressure ratio (PR) of the gas turbine unit described (PR=9), is equal to the PR of the low pressure compressor 53 times PR of high pressure compressor 51; namely PR=3×3=9. The pressure rise is distributed almost evenly between the 2 compressor stages.

(50) For the 3 turbines described in FIGS. 14-19, a similar logic applies. The Pressure ratios are distributed close to evenly between the turbine stages. PR single stage=2.08, and PR machine=2.08×2.08×2.08.

(51) The low pressure gas turbine compressor 53 draws air from atmosphere and delivers air at for example 3 times atmosphere. The high pressure gas turbine compressor 51 delivers air at for example from 3 times atmosphere to 9 times atmosphere.

(52) The term free power turbine 90 is a term well known to those persons skilled in the art and generally refers to providing power to the blower impeller.