FLARE SYSTEM

Abstract

A flare system including a flare stack and a modular flare unit connected in parallel with the flare stack. The modular flare unit includes a frame, at least two energy conversion modules detachably supported by the frame, a fuel manifold, an air manifold, an exhaust manifold, and an electric generator. Each energy conversion module includes a combustion chamber configured to receive a flow of residue gas through the fuel inlet for combustion in the chamber at (or close to) atmospheric pressure, and a Stirling engine configured to convert heat from the combustion chamber into mechanical energy. The electric generator is connected to generate electric power from the mechanical energy.

Claims

1. A flare system for recovery of energy in a flow of residual gas generated in an industrial process, the system including: a flare stack, connected to the flow of residue gas and arranged to perform open combustion of said residue gas, and at least one modular flare unit connected to said flow of residue gas in parallel with the flare stack, said modular flare unit being arranged to recover energy in said residue gas, each modular flare unitincluding: a frame ; at least two energy conversion modules detachably supported by the frame; a fuel manifold connected to receive the flow of residue gas; an air manifold connected to receive air from the ambient; an exhaust manifold connected to receive exhaust from the energy conversion modules and an electric generator, each energy conversion module including: a combustion chamber having a fuel inlet selectively connectable to said fuel manifold via a fuel valve (34), an air inlet selectively connectable to said air manifold via an air valve, and an exhaust outlet connected to said exhaust manifold, said combustion chamber configured to receive a flow of residue gas through the fuel inlet for combustion in the chamber at close to atmospheric pressure, and a Stirling engine configured to convert heat from the combustion chamber into mechanical energy, said Stirling engine having a heat engine heat exchanger including a set of tubes conducting a compressible working fluid, a portion of said heat engine heat exchanger extending into the combustion chamber, and one or several cylinders each having a piston connected to an output shaft, wherein said electric generator is connected to the output shaft and is configured to generate electric power from said mechanical energy.

2. The flare system according to claim 1, wherein the flare stack is an elevated flare stack or a ground flare stack.

3. The flare system according to claim 1, wherein each energy conversion module comprises one electrical generator.

4. The flare system according to claim 1, wherein each energy conversion module further comprises an air heat exchanger configured to pre-heat incoming air using exhausts from said exhaust outlet and/or a fuel heat exchanger configured to pre-heat incoming fuel using exhausts from said exhaust outlet.

5. The flare system according to claim 1, further comprising a gas conditioning unit arranged upstream the modular flare unit .

6. The flare system according to claim 1, further comprising a gas storage unit arranged upstream the modular flare unit .

7. The flare system according to claim 1, wherein the modular flare unit further comprises at least one air filter, connected to remove particles from air supplied to each air inlet.

8. The flare system according to claim 1, wherein each Stirling engine has a plurality, preferably four, cylinders.

9. The flare system according to claim 1, wherein each Stirling engine has equal power capacity.

10. The flare system according to claim 1, wherein each energy conversion module has substantially equal physical and functional design.

11. The flare system according to claim 1, further comprising an air fan arranged to force ambient air into the air manifold.

12. The flare system according to claim 1, further comprising an exhaust fan arranged to force exhausts out from said exhaust manifold.

13. The flare system according to claim 1, further comprising a CO.sub.2 capturing unit arranged on said exhaust manifold .

14. The flare system according to claim 1, wherein the modular flare unit is housed in an intermodal container.

15. The flare system according to claim 1, wherein a pressure in each combustion chamber is 0 - 500 mbar greater than atmospheric pressure, .

16. The flare system according to claim 1, wherein a pressure in each combustion chamber is 50 - 100 mbar greater than atmospheric pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The present invention will be described in more detail with reference to the appended drawings, showing currently preferred embodiments of the invention.

[0035] FIG. 1 shows a schematic view of an industrial site such as a smelting plant, including several modular flare units according to the present invention.

[0036] FIGS. 2a and 2b are diagrams showing examples of fluctuating energy content in the flow of residue gas from the smelting plant in FIG. 1.

[0037] FIG. 3 shows in greater detail one of the modular flare units in FIG. 1 according to an embodiment of the invention.

[0038] FIG. 4a is a schematic block diagram of one of the energy conversion modules in FIG. 3.

[0039] FIG. 4b is a schematic perspective view of one of the energy conversion modules in FIG. 3.

[0040] FIG. 5a shows a perspective view of some parts an exemplary energy conversion module as shown in FIG. 4b.

[0041] FIG. 5b shows one working fluid circuit of the Stirling engine in FIG. 5a.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0042] Embodiments of the present invention will now be described with reference to an industrial site 1 where a smelting plant 2 is operated. The smelting plant receives metal ore 3, and outputs different types of metal. As a bi-product of this process is a flow of residue gas, including a mix of gaseous compounds, including H2, CO, and also various particles. As it may contain toxic gases (such as CO), this gas must be handled carefully, and not be emitted into the ambient surroundings.

[0043] As an example, the flare system according to the invention may be useful for residue gasses containing CO, H.sub.2 and various C.sub.xH.sub.y gases. Residue gas of this kind are typically formed during production of Ferro-alloys. In addition to residue gas from ferro-alloy production, the flare system disclosed herein could be useful also for Combined Oxygen Gas (COG), Blast Furnace Gas (BFG) and Basic Oxygen Furnace Gas (BOFG).

[0044] Table 1 below (published in the article “Burners in the steel industry: utilization of by-product combustion gases in reheating furnaces and annealing lines”, by Sebastian Caillat, Energy Procedia, Volume 120, August 2017, Pages 20-27) provides typical gas compositions for three different metal industry processes, Combined Oxygen Gas (COG), Blast Furnace Gas (BFG) and Basic Oxygen Furnace Gas (BOFG).

TABLE-US-00001 Typical gas composition and characteristics in steel mills [2], [5], [6], [8] Element/Parameter Unit COG BFG BOFG H.sub.2 % vol. 36.1 - 61.7 1 - 8 2 - 10 CO % vol. 3.4 - 5.8 19 - 27 55 - 80 CH.sub.4 % vol. 15.7- 27 - - C.sub.xH.sub.y % vol. 1.4 - 2.4 - - CO.sub.2 % vol. 1 - 5.4 16 - 26 10 - 18 N.sub.2 +Ar % vol. 1.5 - 6 44 - 58 8 - 26 Low Heating Value MJ/Nm.sup.3 9 - 19 2.6 - 4.0 7.1 - 10.1 Density kg/Nm.sup.3 0.45 - 0.65 ~1.3 1.32 - 1.38 Specific air demand Nm.sup.3/Nm.sup.3 4.2 - 4.9 0.5 - 0.8 1.34 - 1.90 Adiabatic flame temperature °C ~2000 ~1400 ~2000

[0045] Some residual gasses (e.g. COG) may be reused to a high extent within the industrial process (e.g. smelting). Also BOFG and BFG is reused (drying) within the metal industry process, but there is significant a surplus that typically is burned in a flare stack. The site 1 in FIG. 1 therefore includes a flare stack 7, where the residue gas may be burned, thereby effectively getting rid of toxic gases like CO. The stack is provided with reside gas through pipe 8, channeling all gas which is not reused in the plant or otherwise recovered.

[0046] As discussed above, there are several reasons to flare the surplus gas, including: [0047] Security [0048] Relatively small quantities not profitable to distribute or feed a turbine or other large scale power plant [0049] Fluctuating flow, requiring a dynamic combustion process [0050] High - and fluctuating - hydrogen content and impurities that prevent usage of internal combustion engines for power production

[0051] Returning to the example in FIG. 1, there is a relatively large flow of residue gas with fluctuating energy content, as illustrated in FIG. 2.

[0052] In order to avoid flaring the rather large amounts of energy in the residue gas, an additional flare system 10 is connected in parallel with the flare stack 7, to a branch 9 of pipe 8.

[0053] The additional flare system 10 is modular, and includes several standard built units 30 optimized to local gas supply (see FIG. 3), each unit including a several, preferably more than 10, energy conversion modules 40 with a Stirling engine (see FIG. 4). The number of modules 40 in each unit 30 may vary depending on design choice, but typically two rows of modules (an upper and a lower row) is suitable, leading to an even number of modules. A gas conditioning unit 11 is arranged along the pipe 9, and is configured to pre-condition the residue gas. The pre-conditioning may involve pre-heating the residue gas to a temperature suitable for combustion in the flare system 10. Further, the pre-conditioning unit 11 may include a filter, e.g. a “scrubber”, to remove particles present in the residue gas. As an example, residue gas from the smelting plant may contain 50 mg/Nm.sup.3, which is preferably reduced to around 2.5 mg/Nm.sup.3 by the scrubber. It may also be appropriate to dehumidify the residue gas, i.e. remove water vapor present in the gas. As an example, the humidity may be brought down to 80% or less, Finally, the conditioning unit may pressurize the gas to an extent that it is forced to the flare system 10. Alternatively, the flare system 10 may comprise one or several fans to create an under-pressure sucking the residue to the flare system 10.

[0054] FIG. 3 shows one of the units 30 in more detail. In the illustrated case each unit 11 includes fourteen energy conversion modules 40, each being releasably arranged in a frame 31, e.g. formed by a standard size intermodal cargo container. In the illustrated case, the frame 31 has a predefined number of bays 32, each which is configured to receive an energy conversion module 40. The bay is provided with a suitable mechanical fixation device, for securing the module 40 in the bay 32. Although not illustrated in FIG. 3, each bay 32 may also be closed by a lid or hatch, to prevent access to the modules 40.

[0055] Each energy conversion module 40 includes a Stirling engine 41 and one combustion chamber 42, as will be shown more clearly in FIGS. 4a and 4b. As an example, each Stirling engine may have an output power of 30 kW, in which case the unit 30 (which here has 14 modules) has an output power of around 400 kW. In FIG. 1 there are six flare units 30, thus a total energy converting output power of around 2.4 MW.

[0056] This is indicated in FIG. 2a as six 400 kW “slices” 21. The modular flare system 10 has been adapted to the expected average flow of residual gas from this particular plant. As is clear from FIG. 2, the first three flare units (the lower three slices 21) will operate 24/7, as the energy content always exceeds 1.2 MW. The next two units will operate almost always, only briefly interrupted during periods 22 when the energy content of the residue gas is lower than average. And the final unit (uppermost slice 21a) will operate at least 80% of the time (i.e. 80% utilization ratio), providing a maximum energy conversion capacity of 2.4 MW. The threshold for when an additional flare unit should be added to the system, i.e. at what expected utilization ratio, will be determined by factors such as: local energy prices, available output power from the electrical grid, energy content of the residue gas, maintenance scheduling, efficiency of the Stirling engine (due to e.g. height above sea level), requirements on local environment, Capex and cost of capital, etc. During periods 23 when the flow exceeds this level, the conventional flare stack will be used to burn the excess residue gas. During periods 22 when the flow is low, a specific unit could be shut down for maintenance and/or replacing of flare modules.

[0057] It is noted that it may be beneficial to also include an intermediate gas storage 12 connected to the pipe 9, in order to allow for storage of surplus residue gas during periods when the gas energy content exceeds the capacity of the flare system 10. Such intermediate storage of gas may be an important factor when planning the energy conversion system. The intermediate storage 12 could be present within the industrial facility (as shown in FIG. 1) or could be built together with the flare system according to the local prerequisites. Intermediate storage may be specifically useful for quickly varying energy content, as illustrated in FIG. 2b. Here, the gas flow has periodic energy peaks corresponding to the capacity of two flare units. Under such circumstances, it may not be possible to economically motivate an additional flare unit. However, by introducing an intermediate gas storage 12, it may be possible to operate an additional flare unit almost continuously (slice 21b in FIG. 2b). Quickly variating gas flow requires smaller intermediate storage capacity compared to slow variations.

[0058] The unit 30 is connected to the pipe 9 (see FIG. 1) and includes a manifold 33 which connects the flow of residue gas to each combustion chamber 42, where it can be combusted at near atmospheric pressure. Typically, the pressure in the combustion chamber 42 is slightly greater than atmospheric pressure, e.g. 0 - 500 mbar greater, preferably 50 - 100 mbar greater. Each branch of the manifold 33 is provided with an ON/OFF valve 34, to enable disconnection of each module 40 from the flow of residue gas.

[0059] A second manifold 35 is connected to provide air from the ambient to the modules 40. A fan 36 forces ambient air into the manifold 35. Each branch of this manifold 35 is also provided with some means to interrupt the flow, for example a valve 37. Alternatively, each module 40 may be provided with an individual fan for incoming air, in which case the flow of incoming air may be interrupted by turning off the fan.

[0060] A third manifold 38 is connected to receive exhaust from the modules 40. A fan 39 is arranged to force the exhaust through the manifold 38. Optionally a filtering unit 50 may be arranged at the end of the exhaust manifold 38 to provide additional particle filtering and/or CO.sub.2 capture of the exhaust gases. This may be especially advantageous if additional recovery of heat energy from the exhaust gases is intended. It is noted that the exhaust gases (even after cooling in the heat exchangers 44 and 45, see below) may contain significant amounts of heat energy, which may be recovered.

[0061] Although all three manifolds 33, 35 and 38 are illustrated as arranged external to the frame 31, one or several of the manifolds may alternatively be arranged inside the frame. For example, the fuel and air manifolds 33, 35 may be arranged inside the frame 31, while the exhaust manifold 38 is arranged outside the frame 31.

[0062] With reference to FIGS. 4a and 4b, the module 40 includes a Stirling engine 41, a low pressure combustion chamber 42, and a heat engine heat exchanger 43 extending into the chamber 42. The module further comprises an air heat exchanger 44 connected to the air supply valve 36. A fuel inlet 46 of the combustion chamber is connected to receive residual gas, while an air inlet 47 is connected to receive air from the air heat exchanger 44. An exhaust outlet 48 of the combustion chamber is connected to the air heat exchanger 44, where it pre-heats the incoming air. The residual gas may be conditioned and preheated in the conditioning unit 11. However, each module 40 may also include a fuel heat exchanger 45 configured to heat the incoming fuel (residual gas) using the exhausts. As shown in FIG. 4b, it may be connected downstream the air heat exchanger. As a result of the heat exchanger(s), the temperature of the combusted exhaust gases can be significantly reduced, and the energy conversion can be made even more efficient.

[0063] It is noted that the air heat exchanger 44 and fuel heat exchanger 45 alternatively be shared by several (or all) energy conversion modules 40 in the unit 30. Each module 40 should, however, be provided with separate valves 34 and 36 in order to allow disconnection of the module 40.

[0064] Also shown in FIG. 4b is an air filter 36a arranged before the valve 35 to remove particles from the incoming air. This filter 36a may be integrated in the fan 36, or may be individual for each module 40.

[0065] The Stirling engine 41 is further connected to an output shaft (not shown in FIGS. 4a and 4b), and the module 40 is thus configured to convert chemical energy in the residue gas to mechanical (rotational) energy. The output shaft is in turn connected to an electrical generator 49 for generation of electrical energy. The generator may be connected to a local energy storage, to the local industry power grid, or be connected to supply power to the mains power grid.

[0066] In the illustrated example, each module 40 includes a separate generator 49. However, it is also possible that two or more modules 40 are connected to a common generator. Indeed, all modules 40 of a flare unit 30 may share one single generator.

[0067] FIG. 5a shows some of the elements of the energy conversion module 40 in more detail. In the upper part of the figure is the combustion chamber 42 with the fuel inlet 46, and the heat engine heat exchanger 43 extending into the chamber 42. In the lower part of the figure is the Stirling engine 41 having one or several cylinders 51 each having a piston 52 connected to an output shaft 53 by means of a rod 54.

[0068] The components and working principles of the Stirling engine are known in the art, and will not be described in detail here. However, in brief, a Stirling engine moves a working fluid (e.g. hydrogen gas) back and forth between a cold side and a warm side of a cylinder. On the warm side, the working fluid expands, thus operating the piston in the cylinder. On its path between the cold side and the warm side, the working fluid is heated. During operation of the Stirling engine, the working fluid pressure thus alternates between a high pressure (during the compression stage) and a low pressure (during the expansion stage). As an example, the pressure ratio may be 1 to 1.6.

[0069] In the present example, the heating of working fluid is accomplished by the heat engine heat exchanger 43, which comprises a set of tubes 43a extending into the combustion chamber. As fuel is burned in the combustion chamber, the working fluid in the heat exchanger is heated before reaching the warm side of the cylinder.

[0070] The illustrated Stirling engine 41 comprises four cylinders 51, each associated with one section of the heat exchanger 43, as shown in FIG. 5b. In principle, each cylinder 51 and associated part of the heat exchanger 43 form a separate working fluid circuit 55. Typically, however, these fluid circuits are connected, such that each four-cylinder Stirling engine has only one single working fluid circuit 55.

[0071] In order to disconnect and remove an energy conversion module 40 form the unit 30, the valves 34 and 37 are closed, and the module is disconnected from all three manifolds 33, 35 and 38. Further, the generator 49 is disconnected from the power system to which it delivers electrical power. After that, the module 40 may be removed from the frame 31.

[0072] In principle, such disconnection and removal of a module 40 may be performed while other Stirling engines in the unit 30 are still operating. For security reasons, however, the disconnection and removal of a module is typically performed during a (short) interruption of the industrial process.

[0073] As mentioned above, the unit 30 may then be operated with one less module 40, or alternatively the module 40 is replaced by another module 40 before operation is resumed.

[0074] The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. For example, the number of cylinders in each Stirling engine may be other than four. Also, the number of energy conversion modules in each unit (container) may be smaller than or greater than 14 (although it is preferably an even number for symmetry reasons). Most likely a unit (container) contains at least ten modules.