Compressor flow extraction apparatus and methods for supercritical CO.SUB.2 .oxy-combustion power generation system
10787963 ยท 2020-09-29
Assignee
Inventors
- David Amos (Orlando, FL, US)
- Jayanta Kapat (Oviedo, FL, US)
- Narasimha Nagaiah (Orlando, FL, US)
- Akshay Khadse (Orlando, FL, US)
Cpc classification
F02C3/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/05
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E20/32
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F05D2260/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/522
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/103
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02C3/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C9/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/52
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/05
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A power generation system burns a fuel in a gas in a combustion chamber, producing one or more combustion products and heating a working fluid, preferably supercritical CO.sub.2, that is chemically the same as a combustion product. The working fluid is mixed with the combustion products to form a combustion output mixture which is used in a turbine to drive a shaft of the turbine connected with a generator, producing electricity. The turbine outputs an exhaust that goes to a working fluid recycling system that connects the turbine outlet with the combustion chamber. The fluid recycling system has a radial compressor that receives and pressurizes the exhaust mixture and sends it to a chamber that has a bleed outlet and a recycling outlet. The recycling outlet transmits a recycled portion of the exhaust mixture to the combustion chamber, and the bleed outlet carries an excess portion of the exhaust mixture that is not to be recycled to an extraction system that removes it from the power generation system for use in other applications.
Claims
1. A power generation system comprising: a fuel source supplying a fuel; a gas source supplying a gas; a combustion apparatus having inlets receiving the fuel and the gas, wherein combustion of the fuel with the gas takes place in the combustion apparatus and produces one or more combustion products; said combustion apparatus also receiving a working fluid that is chemically the same as one or more of said combustion products, and mixing the working fluid with the combustion products so as to produce a combustion output mixture that has been heated by the combustion of the fuel; a turbine receiving the combustion output mixture and using said combustion output mixture to rotate a shaft of the turbine, said turbine outputting at a turbine outlet a turbine output mixture derived from the combustion output mixture; a generator operatively connected with the shaft and driven thereby, said generator converting rotation of the shaft into electrical energy and outputting the electrical energy; a working fluid recycling system connecting the turbine outlet with the combustion apparatus, said fluid recycling system comprising a compressor receiving the turbine output mixture via one or more heat exchangers and increasing the pressure thereof so as to yield a pressurized mixture; said compressor transmitting the pressurized mixture to a dividing structure having a bleed outlet and a recycling outlet; said recycling outlet connecting with the combustion apparatus via said one or more heat exchangers and transmitting thereto a recycled portion of the pressurized mixture; and the bleed outlet carrying a second portion of the pressurized mixture that is not in the recycled portion to an extraction system that removes the second portion of the pressurized mixture from the power generation system; and wherein the bleed outlet has a slot, a series of a plurality of intermittent slots or an annular space extending generally circumferentially of the compressor.
2. The power generation system of claim 1, wherein the fuel is a carbon-containing fuel.
3. The power generation system of claim 2, wherein the gas is an oxygen-containing gas.
4. The power generation system of claim 3, wherein the working fluid contains CO.sub.2.
5. The power generation system of claim 4, wherein the extraction system stores the CO.sub.2 extracted from the system under pressure in one or more containers or supplies CO.sub.2 extracted to an external application.
6. The power generation system of claim 3, wherein the combustion output mixture is a mixture of water and CO.sub.2.
7. The power generation system of claim 6, wherein the turbine extracts energy from the combustion output mixture to rotate the shaft, and the turbine output mixture is a mixture of water and CO.sub.2 at a lower temperature or pressure than the combustion output mixture.
8. The power generation system of claim 6, wherein the water in the turbine output mixture is removed before transmission of the turbine output mixture to the compressor.
9. The power generation system of claim 1, wherein the combustion apparatus includes a structure that supplies the fuel and the gas to a combustion flame zone where the combustion takes place, and a liner surrounding the combustion flame zone, said working fluid being heated by contact with an outer surface of the liner and mixing with the combustion products as the combustion products leave the liner.
10. The power generation system of claim 1, wherein the one or more heat exchangers transfer heat from the turbine output mixture to the recycled portion of the pressurized mixture before transmission thereof to the combustion apparatus.
11. The power generation system of claim 1, wherein the compressor comprises a mixed-flow compressor stage having an impeller fixedly supported on the shaft so as to rotate therewith; said impeller having a radially outwardly-sloping outwardly-disposed concave surface of rotation about a rotational axis about which the shaft rotates, and a plurality of blades extending outwardly from said concave surface; said blades having an outer edge extending adjacent and spaced from an inside surface of a stationary housing surrounding the impeller.
12. The power generation system of claim 11, wherein said blades each have an intake end angled forward in a direction of rotation of the impeller and an outward end that is perpendicular to the direction of rotation.
13. The power generation system of claim 11, wherein said blades each have an intake end angled forward in a direction of rotation of the impeller and an outward end that is angled rearward relative to the direction of rotation of the impeller.
14. The power generation system of claim 1, and said compressor further comprising axial compressor stages receiving the recycled portion of the pressurized mixture and comprising a set of blades extending outwardly from a rotating portion of the compressor and a set of vanes extending inward from a stationary outer structure that are cooperative with the set of blades so as to increase pressure of said recycled portion of the pressurized mixture.
15. The power generation system of claim 1, wherein a counter-flow recuperative heat exchanger receives said recycled portion of the pressurized mixture and a second compressor imparts thereto an increase in pressure.
16. The power generation system of claim 1, wherein the fuel is a hydrocarbon fuel.
17. The power generation system of claim 16, wherein the gas is 100% O.sub.2.
18. The power generation system of claim 1, wherein the fuel is CH.sub.4.
19. The power generation system of claim 1, wherein the gas is an oxygen-containing gas.
20. The power generation system of claim 1, wherein the working fluid is 100% CO.sub.2.
21. The power generation system of claim 1, wherein the working fluid is supercritical CO.sub.2.
22. A turbine-based system employing a Brayton cycle employing supercritical CO.sub.2 as a working fluid, said system comprising: a compressor assembly having a structure defining an annular inlet space to which a first portion of a CO.sub.2 mixture is supplied from a heat exchanger that cools said first portion of the CO.sub.2 mixture, said compressor assembly further including a first compressor driven by a turbine and receiving said first portion of the CO.sub.2 mixture from the annular inlet space, applying an increased pressure thereto, and transmitting a resulting pressurized CO.sub.2 mixture to a generally annular separation space communicating with a recycling structure having a recycling passage configured such that a recycled portion of the pressurized CO.sub.2 mixture proceeds therethrough, and with a bleed structure having a bleed passage through which a bled portion of the pressurized CO.sub.2 mixture proceeds to a CO.sub.2 extraction system that removes the bled portion of the pressurized CO.sub.2 mixture from the turbine-based system and Brayton cycle; a second compressor driven by the turbine and receiving a second portion of the CO.sub.2 mixture from a counter flow recuperative heat exchanger and applying an increased pressure thereto and transmitting the second portion of the CO.sub.2 portion with the recycled portion of the pressurized CO.sub.2 mixture as the working fluid for the turbine via a series of recuperative heat exchangers and a combustor; the turbine driving a shaft having an axis of rotation; and the bleed structure being a first housing portion supported stationary relative to the shaft, and defining the bleed passage as a continuous or intermittent annular-portion slot or series of slots therein extending circumferentially partially or completely around the first housing portion; said continuous or intermittent annular-portion slot or series of slots having a length and width selected such that the bled portion of the CO.sub.2 mixture in the annular separation space enters said bleed passage by proceeding generally radially outward of the annular separation space, and the recycled portion of the CO.sub.2 mixture proceeds past the bleed passage inward thereof and forward to the second compressor, and such that the recycled and bled portions of the CO.sub.2 mixture are in amounts such that development of an excess amount of CO.sub.2 in the system is prevented by removal of the bled portion from the turbine system.
23. The turbine-based system of claim 22, and the first compressor having a first stage and subsequent stages; the first stage of the first compressor being a mixed-flow stage having an impeller fixedly connected with the shaft, said impeller having a concave conical outward surface extending concavely forward and outward from the annular inlet space and toward the annular separation space, and a plurality of blades supported on and extending radially away from said concave conical surface, said blades having intake ends angled so as slope in the direction of rotation of the impeller; the impeller being followed by a diffuser fixedly connected to the stationary outer casing, said diffuser having multitude of flow paths created by vanes of equal circumferential spacing; the subsequent stages of the first compressor being axial compressor stages including a number of angled blades supported in one or more circumferential sets on a body portion rotating with the shaft and extending outwardly therefrom, the recycling passage being a generally cylindrical space defined between the body portion and a second housing portion supported stationary relative to the shaft, and the pressurized recycled portion of the CO.sub.2 mixture being delivered to an annular output space defined in said second housing portion; the first and second stationary housing portions each supporting thereon respective groups of vanes extending radially inward and lengthwise axially of the shaft so as to cooperate with the plurality of blades of the impeller and the axial compressor, respectively; the CO.sub.2 mixture in the annular inlet space having a pressure of 750 to 3,000 psi, and the CO.sub.2 mixture in the annular output space having a pressure of at least 1,500 psi.
24. The turbine-based system of claim 23, wherein the pressure of the CO.sub.2 mixture in the annular inlet space is about 1,100 psi, and the pressure of the CO.sub.2 mixture in the annular output space is at least 5,000 psi.
25. A method of producing energy, said method comprising: reacting fuel with a gas in a combustion chamber so as to form combustion products and heat; heating a working fluid that contains at least one chemical that is the same as one of the combustion products with the heat and mixing the working fluid with the combustion products so as to produce a heated mixture; conducting the heated mixture to a turbine that uses the heated mixture to produce rotation of a shaft and produces an exhaust mixture derived from the heated mixture; driving a generator with rotational energy derived from said rotation of the shaft; compressing the exhaust mixture with a first compressor so as to yield a first pressurized mixture; separating the first pressurized mixture into a bled fraction and a recycled fraction; conducting the recycled fraction to the combustion chamber so as to be recycled as the working fluid in said heating and mixing; and removing the bled fraction from the system; and wherein the first compressor has a first stage that is a mixed-flow stage comprising a rotating impeller that is supported on the shaft so as to be rotated thereby, and the separating being accomplished by causing the first pressurized mixture to flow to a chamber having a circumferentially extending slot that forms a radially outward extending bleed passage through which the bled portion passes.
26. A method according to claim 25, wherein the fuel is a hydrocarbon fuel, and the working fluid is supercritical CO.sub.2; wherein the method further comprises: extracting water from the exhaust mixture before compressing the exhaust gas; transferring heat from the exhaust mixture to the recycled fraction with one or more heat exchangers before said recycled fraction is conducted to the combustion chamber and before the exhaust mixture is compressed by the first compressor; pressurizing the recycled fraction to a pressure of at least 1500 psi before the recycled fraction is directed to the combustion chamber; the pressurizing of the recycled fraction comprising pressurization thereof with a number of axial compressor stages that are rotated with the shaft from the turbine, and that are parts of the said first compressor.
27. The method of claim 26, wherein the recycled fraction is pressurized to a pressure of at least 5,000 psi before the recycled fraction is directed to the combustion chamber.
28. The method of claim 25, wherein the working fluid is heated before being heated by the combustion using an external heat source.
29. The method of claim 28, wherein the working fluid external heat source is a solar heater.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
DETAILED DESCRIPTION
(7)
(8) The thermodynamic arrangement illustrated in
(9) In the heating portion of the subject Brayton cycle, represented in the Combustor 13 in
(10) which extracts substantially 100% O.sub.2 from ambient air. The combustion of the CH.sub.4 in the O.sub.2 releases heat and forms water and carbon dioxide as combustion products. This process of combusting a fossil fuel in an oxygen environment is often referred to as an Oxy-Combustion process.
(11) The main working fluid flow (CO.sub.2) is supplied to the Combustor 13 and an associated Mixer 19 via pipe, connection or Cycle Point 4. The Mixer element 19 is usually structurally combined with the combustor 13, and in it, the H.sub.2O and CO.sub.2 combustion products and the main working fluid (CO.sub.2) are mixed so as to achieve a mixture at the desired turbine inlet temperature supplied by conduit or pipe 5 into the Turbine element 21 connected between conduit or cycle point 5 and conduit, communicating passage or Cycle Point 6. The passage of the mixture through the turbine causes the turbine to rotate shaft 25. Shaft 25 extends through compressor 1 (indicated at 26) and compressor 2 (indicated at 28), driving them, and also leading to and driving generator 27, which generates electrical power.
(12) After passing through the turbine 21 causing rotation of shaft 25, the mixture then proceeds via connection 6 to a series of heat exchangers HTR1, HTR2, and LTR where appropriate recuperative heat energy is exchanged between hot side and cold side working fluids. The mixture loses heat as it passes from conduit 6 through the exchangers HTR1, HTR2 and LTR to conduit or passage 8.
(13) Excess fluids H.sub.2O, and CO.sub.2 generated in the Oxy-Combustion process are extracted from the cycle at appropriate thermodynamic points. The removal of CO.sub.2 prevents the development of excess CO.sub.2 in the system and helps to maintain constant fluid mass in the system.
(14) In conduit 8, the H.sub.2O combustion product from the oxy-combustion is removed from the mixture via outlet 23 by condensation or some other fluid separation method with proper attention paid to the efficient thermodynamic recovery of the sensible heat or heat of vaporization in the water capture and removal. This water is potentially very pure and may have significant commercial value as a by-product of the process.
(15) The remaining fluid after H.sub.2O removal is essentially pure CO.sub.2, which is present in a surplus because it comprises the CO.sub.2 of the combustion products plus CO.sub.2 of the working fluid that is cycling through the system. Passage 8 splits into two conduits or passages.
(16) One of the passages carries some of the CO.sub.2 to compressor 2 (28), which pumps the CO.sub.2 back into the working fluid portion of the system via connection 22 so that it passes through heat exchangers HTR2 and HTR1, receiving heat therefrom and then, after being heated, entering the supercritical CO.sub.2 conduit 4, which carries this CO.sub.2 back to the combustor 13, to complete the cycle and be re-used further in the cycle.
(17) The other passage carries part of the CO.sub.2 to pre-cooler 20, which cools the CO.sub.2 further and transmits it to compressor 1 (26), which optionally transmits a portion of the CO.sub.2 through conduit or passage 24 to the cold side of LTR, where it is heated and flows through HTR2 and HTR1 to be heated further and be returned to supercritical CO.sub.2 conduit 4, and back to the combustor 13 to be used in the system cycle. The rest of the CO.sub.2 received at compressor 1 (26) is sent out via outlet 29 under pressure to be extracted as CO.sub.2 to be stored or transmitted for use by another user for commercial applications such as chemical process use or enhanced oil recovery applications.
(18) This semi-closed thermodynamic cycle is amenable to a solar augmentation hybrid arrangement (not shown). In such a system, a supplementary heat addition from another external source 30, such as a solar collector tower, is transferred to the working fluid flowing in conduit 4 between the heat exchanger HTR1 and the inlet to the combustor 13/mixer 19, thereby reducing the contribution of heat required from the combustor 13 from fossil fuel combustion. This is accomplished by, e.g., a heat exchanger or other heating transfer component in an intermediate part of conduit 4.
(19)
(20) Downstream of the combustion flame zone is a region 39 in which mixing takes place of the hot products of combustion with the main stream working fluid (CO.sub.2) supplied through inlet 41 to act, according to thermodynamic heat-balance relationships, to raise the temperature of the overall mixed-out main working fluid flow and combustion products flows to the desired turbine inlet temperature at the inlet to the turbine element 21 (
(21) It should be noted that the introduction of the main stream working fluid (CO.sub.2) supplied through inlet 41, which circulates around the main combustion liner assembly (33), serves to provide supplementary cooling of the complete liner assembly to help ensure satisfactory temperature and mechanical integrity of the liner assembly which is subjected to very high radiative and convective heat loading.
(22) It should also be noted that, in systems with a combustion/mixer chamber as seen in
(23) Compressor Extraction Point Configuration
(24) According to the invention, there is an extraction point 29 for the excess CO.sub.2 working fluid produced by the Oxy-Combustion process. This extraction point 29 is from compressor 1, indicated at 26 in
(25) Referring to
(26) The intake duct 43 narrows radially/axially inward and forward of the intake shrouds 44 and 45 to meet a multiplicity of airfoil-shaped vanes (Inlet Guide Vanes or IGV's), 46, which serve to properly orient the flow direction upstream of the rotating impeller. The IGV's are supported on the non-rotating outer structure of the compressor, which includes the shrouds 44 and 45, and the IGV's do not rotate with the internal parts of the compressor about the longitudinal axis of the shaft 25. The IGV's may also be so supported as to be capable of rotating about their radial axes in unison, forming a uniform guide angle for the incoming CO.sub.2 flow relative to a longitudinal direction of the compressor that is selected by the operator so as to achieve proper flow orientation relative to the impeller regardless of upstream thermodynamic condition variations.
(27) Forward of the passage in IGV's 46, the passage communicates with an annular chamber defined radially inward of an outer housing 50 that is a surface of rotation that extends around the apparatus 47 and houses an impeller 53 fixedly mounted on body 51, which turns with the shaft 25 of the turbine 21, turning the impeller 53 with it as well. The turning of the impeller 53 draws in the mixture from the duct 43 and expels the fluid into diffuser 54 extending forward from the impeller 53 and also radially inward of housing 50. The diffuser 54 is circumferentially distributed parts of an annular space that is divided by mixed radially/longitudinally extending vanes 54a spaced circumferentially from each other so as to direct the flow of the CO.sub.2 coming from the impeller 53. The vanes 54a are supported on the inward surface of outer wall 50, and are stationary relative to the moving vanes of impeller 53, as are the vanes 46. The vanes 46 have edge portions with edges that extend generally parallel to and axially spaced slightly from the edge portions of the intake ends or inducer 67 of impeller blades 65, and the vanes 54a have edge portions with edges at an angle relative to the radial direction roughly parallel to the angle of the edge of the outlet end 71 of the blades 65. This mixed-flow configuration (that is neither fully radial, nor fully axial) makes for effective compression of the CO.sub.2 passing through the compressor.
(28) In addition, the outer wall 50 is connected through or around the vanes 54a to a conical supporting structure 60 supporting a seal 60a that engages the rotating inner structure 51 of the compressor.
(29) Diffuser 54 lead to an annular space that splits into a narrow, radially-outwardly disposed generally annular aperture 58 between a portion 50a of housing 50 and a portion 50b of an annular channel structure 54b, and a radially inwardly, forwardly-extending cylindrical space generally indicated at 55 around body 51. The aperture 58 may be interrupted in places for support structures between the wall portions 50a and 50b that maintain the shape of the aperture 58. The CO.sub.2 passing through the diffuser 54 to aperture 58 is at a pressure in a range of 750 psi to 3000 psi.
(30) The outwardly disposed aperture 58 (best seen in
(31) In addition to extracting gaseous phase CO.sub.2 by this mechanism, it is important to note that by the nature of the thermodynamic conditions of the CO.sub.2 working fluid at the inlet to the compressor, there may be, by the nature of the supercritical thermodynamics cycle, in an off-design or upset condition, some liquid phase CO.sub.2 present in the working fluid mixture at this point in the cycle. The extraction system described herein provides an effective means for separation and removal of any liquid phase CO.sub.2 working fluid which may be present to avoid liquid impact damage to some of the downstream compressor blading.
(32) As shown in
(33) Referring to
(34) The blades 65 are spaced equally around in a circular arrangement, wherein the blades are farther apart at the circumference of the impeller than in the interior. In the preferred embodiment there are nominally fifteen blades 65 on the impeller fan structure 53. Final selection of the number of impeller blades and particular configuration is a function of specific thermodynamic requirements.
(35) In an alternative embodiment, the blades 65 may be angled at their end portions 71 so as to lie, not in a radial plane that in which the axis of the shaft 25 lies, but to have a circumferentially forward or backward leaning outflow. The choice of outflow angle is related to desired compressor fluid dynamic performance behavior and may be of differing orientation from the radial as determined by specific application.
(36) The terms herein should be read as terms of description not limitation, as those of skill in the art with this disclosure before them will be able to make changes and modifications therein without departing from the spirit of the invention.