HYBRID THERMAL CYCLE WITH ENHANCED EFFICIENCY

- HARRIS CORPORATION

A flow of first working fluid (F1) is provided to a boiler (203) to produce (104) a flow of first working fluid vapor. A second working fluid (F2) in vaporous form is compressed (106), after which a third working fluid is formed by mixing (108) the first working fluid vapor and the second working fluid. Thermal energy is transferred (110) directly between the first and second working fluids in a mixing chamber (206) exclusive of any intervening structure. The third working fluid is expanded (112) to perform work, after which the first working fluid is extracted (114) as condensate, leaving a residual portion of the third working fluid. The cycle is repeated (116, 118, 120) using the condensate as the first working fluid and the residual portion as a constituent of the second working fluid.

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Description
BACKGROUND OF THE INVENTION

1. Statement of the Technical Field

The invention concerns thermal energy cycles, and more particularly systems and methods for merging thermal energy cycles including multi-pass energy recirculation techniques which enable normally rejected thermal energy to be re-used in the cycle, repeatedly.

2. Description of the Related Art

Heat engines use energy provided in the form of heat to perform mechanical work, and exhaust a portion of the applied heat which cannot be used to perform work. This conversion of heat energy to mechanical work is performed by taking advantage of a temperature differential that exists between a hot “source” and a cold “sink.” Heat engines can be modeled on various different well known thermodynamic processes or cycles. Examples of typical thermal cycles are the Brayton Cycle, the Rankine Cycle and Refrigeration Cycles.

A combined cycle is an assembly of two or more of these processes that convert heat into mechanical energy, by combining the thermodynamic cycles. The exhaust of one heat engine associated with a first cycle is used to provide the heat source that is used in a second cycle. For example, an open Brayton cycle is commonly combined with a Rankine cycle to form a combined cycle for power plant applications. The open Brayton cycle is typically implemented as a turbine burning a fuel, and the exhaust from this combustion process is used as the heat source in the Rankine cycle. In such a scenario, the Rankine cycle is referred to as a bottoming cycle because it uses some waste heat from the Brayton cycle to perform useful work. When using high temperature sources of heat (e.g. 2000° F.), a combined open Brayton cycle with a Rankine bottoming cycle can ideally be expected to provide an energy conversion efficiency as high as 60%. In the case of low temperature heat sources (e.g. 700° F.) conversion efficiencies are much lower, traditionally below about 35%.

SUMMARY OF THE INVENTION

Embodiments of the invention concern a method for producing work from heat in a continuous cycle. The method involves heating a pressurized flow of a first working fluid F1 to form an F1 vapor, and compressing an F2 vapor comprised of a second working fluid F2. The F1 vapor and the F2 vapor are mixed to form a third working fluid F3. Within the third working fluid, thermal energy is transferred directly between the F1 vapor and the F2 vapor, exclusive of any intervening structure. During or after this transfer of thermal energy, the third working fluid is expanded to perform useful work. The third working fluid is then cooled to extract a condensate comprised of F1 and a residual portion of the third working fluid from which the condensate has been extracted. The continuous cycle is repeated using the first working fluid F1 obtained as the condensate, and using the residual portion as a constituent of the second working fluid F2.

The invention also includes a system for producing work from heat in a continuous cycle. The system includes at least one boiler configured to heat a pressurized flow of a first working fluid F1 to form an F1 vapor. The system also includes a compressor configured to compress an F2 vapor comprised of a second working fluid F2. A mixing chamber is configured to mix the F1 vapor and the F2 vapor which has been compressed to form a third working fluid F3. The mixing chamber is further configured to facilitate a transfer of thermal energy directly between the F1 vapor and the F2 vapor, exclusive of any intervening structure. An expander is provided to expand the third working fluid to perform work after or during the transferring of thermal energy. A condenser assembly is configured to extract from the third working fluid F3 a condensate comprised of F1 and a residual portion of the third working fluid from which the condensate has been extracted.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be described with reference to the following drawing figures, in which like numerals represent like items throughout the figures, and in which:

FIG. 1 is a flow chart that is useful for understanding a hybrid thermal cycle, with imbedded low pressure boiler.

FIG. 2 is a drawing that is useful for understanding a heat engine configured for implementing the hybrid thermal cycle in FIG. 1.

FIGS. 3A-3C show alternative embodiments of the heat engine in FIG. 2.

FIG. 4 is an exemplary embodiment of a heat engine incorporating certain optional features, and which is useful for understanding the invention.

 DETAILED DESCRIPTION

The invention is described with reference to the attached figures. The figures are not drawn to scale and they are provided merely to illustrate the instant invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the invention. One having ordinary skill in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the invention. The invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the invention.

The invention concerns a Hybrid Thermal Cycle (HTC) comprising fluids F1, F2, and F3 where F3 is comprised of a mixture of fluids F1 and F2. The F1 fluid is a fluid construct that is advantageously selected so that it is capable of transitioning from a liquid to a vapor in some parts of the cycle, and from a vapor to a liquid during other portions of the cycle. Fluid F2 is preferably selected so that it remains vaporous throughout the cycle. The F1 fluid is mixed with the F2 fluid in parts of the cycle to form the F3 fluid. Later in the cycle the F1 fluid is separated from the F3 fluid. Following a compression portion of the cycle during which F2 is compressed, there is an expansion part of the cycle during which F3, comprised of a mixture of F1 and F2, is expanded. During this expansion, the F1 fluid functions to support or maintain the temperature of the F2 fluid, preventing it from cooling more rapidly than without the latent heat that available from the F1 fluid. If the F2 fluid were expanded without the portion of the F1 fluid it would cool more rapidly, having less capacity to perform work. This characteristic or effect in the cycle is desirable as it enables the fluid mixture F3 to perform work for a longer period of time during expansion. This ability of F1 to effectively delay the cooling of F2 essentially ends when the F1 fluid reaches a point where it transitions from a vapor back into a liquid. At the end of the expansion process, at least a portion of the F1 fluid condenses out of the F3, leaving a residual portion, which is F2.

One aspect of the invention concerns the basic idea that it is possible to get more power out of a thermal source if energy is extracted at two (or more) thermal energy extraction points. The thermal extraction points are defined by thermal and pressure points that are on the working fluid saturation line. These are unique temperatures and pressures where the working fluid can have a phase transition from a liquid to a vapor. By arranging for the system to extract energy across a working fluid phase transition, it is possible to enable a larger quantity of thermal energy extraction from the thermal source. Most thermal extraction or exchange systems use a single boiler at a set output temperature (this temperature is controlled by the thermal input to the boiler.)

The foregoing basic idea can be improved using several enhancements to this base concept. For example, in some embodiments of the invention, it is possible to split the thermal extraction points—and by doing so it is possible to acquire a larger quantity of useful energy from the heat (thermal) source. It is therefore possible to generate a larger quantity of power from that source of heat, (with the heat of vaporization being extracted from the source at separate & unique temperature & pressure points along the working fluid saturation line. Because of the use of latent heats to extract power from a thermal source, the quantity of power derived from the source can be considerably larger relative to the power extraction capability using only one vapor transition point (i.e., the working fluid boiling point). This process enables extracting much larger quantities of useful thermal energy and therefore enabling the production of larger quantities of useful work from a thermal source, as when compared to using only one boil off point. Notably, traditional calculations for overall cycle thermal efficiency may show little or no improvement, but when measuring the efficiency of extracting power from the same source as is the benchmark standard today—there is a considerable improvement in the extraction efficiency. The inventive cycle construct enables the thermal energy extracted at the two or more unique extraction points to be valuable in the production of power.

Other enhancements to the basic concept involve one or more refrigeration loops which are advantageously utilized to transfer heat to and/or from various parts of the cycle. These refrigeration loops can comprise internal refrigeration loops which transfer thermal energy between different parts of the cycle using the working fluids F1, F2 and/or F3. These refrigeration loops can also comprise external refrigeration loops which transfer thermal energy to and/or from various parts of the cycle. These external refrigeration loops use working fluids other than F1, F2 and F3. The external refrigeration loop or loops can be configured to move thermal energy into the cycle from external sources and/or out of the cycle to external sinks. The external refrigeration loops can also move thermal energy within the cycle.

Referring now to FIG. 1, there is provided a flowchart that is useful for understanding a basic first embodiment of the invention. The process 100 begins in step 101 and continues with steps 102, 104, and 106. In step 102, a first flow F1(1) of a first working fluid F1 (in liquid form) is communicated to a low pressure boiler which is heated by a low temperature thermal source. An internal pressure of the low pressure boiler is chosen so that it is approximately equal to a vaporization pressure of the first working fluid at the temperature of the low temperature thermal source. The relatively low pressure within the low pressure boiler facilitates vaporization of F1(1) to form a first flow of first working fluid vapor (F1(1) vapor). More particularly, the lower pressure within the low pressure boiler facilitates vapor formation at a relatively low temperature which corresponds to the temperature of the thermal source at a lower temperature. In this way, the F1(1) fluid can effectively scavenge heat available from the low temperature thermal source which is not generally useful in other parts of the cycle. The thermal energy absorbed by the F1(1) vapor is used in various ways within the cycle as will be described below.

In step 104, a second flow F1(2) of the first working fluid F1 is provided in liquid form to a high pressure boiler. In some embodiments, this step can be preceded by a pre-heating step that is not shown in FIG. 1. In step 104, the high pressure boiler produces a second flow of first working fluid vapor (F1(2) vapor) using a high temperature thermal source having a temperature higher than the low temperature thermal source. In step 105, this second flow of the first working fluid vapor can be expanded to perform useful work. The expansion of the F1(2) vapor is facilitated by providing a pressure drop across an expansion device, capable of extracting useful work (power). This expansion step is optional and in some embodiments it may be omitted. However, the expanding performed in step 105 offers certain advantages. For example, this expanding step can facilitate extraction of a portion of the useful energy in the F1(2) vapor as it exits the high pressure boiler, which energy exceeds that which is available in the F1(1) vapor as it exits the low pressure boiler. The expanding step has a further advantage insofar as it can transition the F1(2) vapor to the lower pressure of the F1(1) vapor prior to the two vapors being mixed in a subsequent step. When conditions suggest that these advantages can be realized by the inclusion of the expanding step, then expanding step 105 is preferably included. Concurrently with steps 102, 104 (and optionally step 105), a second working fluid F2 having a vaporous form is compressed in step 106.

The process continues in step 108 with the formation of a third working fluid F3. The F3 working fluid is formed as a mixture of working fluids F1(1), F1(2) and the compressed F2. Within the F3 mixture, thermal energy is transferred in step 110 directly between F1(1), F1(2) and the second working fluid F2, exclusive of any intervening structure. In other words, the fluids are able to directly exchange or share the thermal energy they contain. Subsequently, the third working fluid is expanded in step 112 to perform useful work concurrently with or after the transference of heat described in step 110. The expansion of the vapor mixture is facilitated by providing a pressure drop across an expansion device, capable of extracting useful work (power).

The process in FIG. 1 continues by cooling the third working fluid in step 114 to extract at least a portion of the first working fluid, in the form of a condensate, from the third working fluid F3. The condensing process can be comprised of traditional methods in which the excess heat within F3 is displaced to the ambient surroundings. This heat displacement can be performed using cooling coils and fans and/or cooling water that is obtained either directly from ground resources or cooled using commercially available and well recognized processes.

For purposes of describing process 100, it has been assumed that separate high and low pressure boilers are used. However, the invention is not limited in this regard and the use of more than one boiler as described is optional. For example, in some embodiments, only a high pressure boiler can be used as described in step 104. If only a high pressure boiler is used, then step 102 can be omitted and the process is simply performed without F1(1) vapor. In such embodiments, F3 vapor is formed exclusively of F2 vapor and F1(1) vapor. In other respects, the method generally performed as described above with respect to process 100.

As an alternative to these conventional condensing methods, the liquid F1 can be used directly as part of the condensing process, or an internally powered condensate method can be used. An example of such an internally powered condensate method is shown in FIG. 3 and will be described in greater detail below in relation to a system for implementing the methods described herein.

As a result of the condensing process in step 114, the F1 working fluid (F1 condensate) will be separated from the F3 working fluid, thereby leaving a residual portion of F3 from which the condensate has been extracted. This residual portion of F3 is F2. Thereafter, the continuous cycle is repeated using the first working fluid (F1 condensate) recovered in the condensing step and the second working fluid F2. More particularly, in step 116 a first flow of the first working fluid F1 recovered as condensate in step 114 is once again provided to the low pressure boiler as F1(1). If the process does not include the use of the low pressure boiler, step 116 can be omitted. A second flow of the first working fluid F1 recovered as condensate is provided in step 118 to the high pressure boiler as F1(2). Finally, in step 120, F2 working fluid (which is comprised of the residual portion of F3 produced in step 114) is provided to be compressed again in step 106. Optionally, in step 117 a portion of the residual portion of F3 obtained in the condensing process can also be communicated to the low pressure boiler, after which it can be thought of as a component of F1(1). If step 102 is omitted (i.e., the process does not include the use of the low pressure boiler), step 116 can also be omitted.

The process 100 can include several other optional steps. These optional steps will be briefly described here, and will be described in further detail in reference to the FIGS. 2 and 3. One optional step (not shown in FIG. 1) that can be included in the process involves an internal refrigeration cycle which facilitates a transfer of thermal energy from the low temperature thermal source to the F1(1) vapor. The F1(1) working fluid, prior to entering the low pressure boiler in step 102, can be drawn through an expansion valve or pressure regulator which is upstream of a low pressure zone. In some embodiments, the low pressure zone can be facilitated by the use of a compressor or vacuum pump. The expansion valve or pressure regulator helps facilitate a lower pressure environment within the low pressure boiler. In such embodiments, the pressure of the F1(1) flow is reduced as compared to a pump pressure established by a pump used to supply a flow of F1(1) to both the high pressure boiler and low pressure boiler. The lower pressure environment thus established in the low pressure boiler is advantageous because it facilitates a lower vaporization temperature for the F1(1) working fluid. Lowering the pressure of the F1(1) in this way allows it to more effectively acquire heat from the low temperature source. More particularly, the F1(1) working fluid communicated to the expansion valve is dominantly in a liquid form. The decrease in pressure which occurs at the expansion valve causes the F1(1) liquid to transition to a vapor. This process involves a latent transfer of heat from the surrounding environment to the F1(1) working fluid as the fluid transitions from liquid to vapor in this manner, and provides a very large potential for the fluid to absorb heat, such potential being hundreds of times greater than processes which transfer thermal energy to a liquid or vapor in the absence of a state change. The acquired heat can be used later in the process, after the F1(1) is mixed with the F2 working fluid.

Another optional step can involve spray cooling of the F2 working fluid as it is compressed in step 106. In such embodiments, a spray of liquid (e.g. F1 liquid) is added to the residual portion of F3 working fluid to comprise the F2 working fluid. The spray of F1 liquid can be added just before or during the compression process in step 106. The liquid spray can reduce the compressor work required by maintaining a lower compression temperature. The spray (being liquid) experiences a latent heat transformation (liquid to vapor), such that small quantities of spray will have substantial cooling capacity. This process therefore creates a given volume of F2 working fluid containing a partial volume of F1 at a lower temperature for a specified pressure. Also, the F2 working fluid can be heated prior to compression or can possess a higher initial temperature than normally would be desirable. The heat for this operation can come from an external source, but preferably is derived from another portion of the cycle. For example, an external refrigeration loop with a fourth working fluid can be used to transfer thermal energy from the condensing process to heat the F2 working fluid where F2 is in fact acting in the capacity of the refrigerant, since it absorbs heat while in the form of a saturated vapor, and prior to being compressed.

The method 100 will now be described in further detail in relation to components that form an effective heat engine 200 which is shown in FIG. 2. The configuration of FIG. 2 is capable of implementing the method 100. However, it should be appreciated that the heat engine shown is merely provided by way of example and is not intended to limit the invention. Many variations of heat engines incorporating the inventive methods are possible. Accordingly, heat engines incorporating the inventive methods can include more or fewer components or steps and still remain within the scope of the invention. Several of the optional features described with respect to the process 100 are likewise shown in FIG. 2. Still, it will become apparent as the discussion progresses that some or all of these optional features can be omitted, and such features are not necessary to practice the invention.

The heat engine 200 makes use of a high temperature thermal source 225 and optionally a low temperature thermal source 227. The “high temperature” nomenclature which is used to describe thermal source 225 is intended to emphasize that such thermal source is at a higher temperature as compared to the temperature of low temperature thermal source 227. Although thermal source 225 will have a higher temperature compared to low temperature thermal source 227, it should be appreciated that high temperature thermal source 225 can actually have a relatively low temperature as compared to those temperatures which are normally used to provide efficient operation of a conventional heat engine. For example, in some embodiments, the high temperature thermal source 225 may actually only have a temperature of about 800° F. or less. In other embodiments, the high temperature thermal source 225 can have a temperature of about 400° F. or less. The ability to efficiently utilize such sources of heat is a significant advantage of the present invention.

Suitable choices for working fluids F1 and F2 will be described below in further detail. Still, given the anticipated temperatures for thermal source 225, 227, it can be advantageous to select the working fluid F1 to be a low vapor state formulation to facilitate vaporization of such working fluid at relatively low temperatures. Examples of such low vapor state formulations can include fluids such as methanol or pentane.

A high pressure boiler 203 can use as its primary heat source a supply of steam from the high temperature thermal source 225. For example, the high temperature thermal source can be a geothermal well or waste heat from some high temperature process or other power generation system. The low temperature thermal source can be a thermal source that is entirely independent of the high temperature thermal source 225. However, it can be advantageous to select the optional low temperature thermal source 227 to be a down-line flow from the high temperature thermal source 225, after such flow has provided a portion of its thermal energy to the high pressure boiler 203. This concept is illustrated in FIG. 2 by optional flow path 250. For example, if the high temperature thermal source is a geothermal well, then the low temperature thermal source 227 can optionally be a flow of residual hot water from high pressure boiler 203, prior to returning same to the geothermal well, and after it has provided a portion of its thermal energy to the boiler 203. Another example of the potential utility of this inventive approach might incorporate the use of an exit steam line of a commercial power generation system. This could be a coal, natural gas, or nuclear power plant, as these plants commonly reject a steam and condensate mixture at energy states commensurate with geothermal wells. Still, the invention is not limited in this regard and any other suitable heat sources can be used for this purpose.

The invention can optionally include a low pressure boiler 207. The advantage obtained by using the low pressure boiler may depend on the particular operating conditions and system requirements. When computer modeling suggests that such advantages can be realized by the using a combination of the high pressure boiler and the low pressure boiler, then such low pressure boiler is preferably included within the system.

The high pressure boiler 203 will generally have a higher internal operating pressure as compared to the optional low pressure boiler 207. However, it should be appreciated that high pressure boiler 203 can actually have a relatively low pressure as compared to those operating pressures which are normally used to provide efficient operation of a conventional heat engine. For example, in conventional heat engines, high pressure boilers typically are understood as boilers that operate in the range of 1000 to 3000 psi. In contrast, the high pressure boiler 203 can operate at a pressure in the range of 300 psi or less. Still, the invention is not limited in this regard and the actual operating pressure in the high pressure boiler 203 and optional low pressure boiler 207 can vary in accordance with the available heat source and other design conditions. Conventional heat exchanger 252 can be used to transfer thermal energy to the high pressure boiler 203 from the supply of steam provided by the high temperature thermal source. Similarly, heat exchangers 254, 256 can be used to transfer thermal energy to the pre-heater 202 and low pressure boiler 207 from the hot water or steam associated with the low temperature thermal source 227.

Referring again to FIG. 2, a first working fluid F1 (in liquid form) is pressurized using a pump 201. If a low pressure boiler 207 is included, then a first flow F1(1) of the working fluid F1 fluid is communicated to the interior of the low pressure boiler. The system 200 is shown in FIG. 2 as including a low pressure compressor/vacuum pump 257 and an expansion valve 217. The low pressure compressor/vacuum pump is an optional component associated with the low pressure boiler 207. Initially, the operation of the low pressure boiler shall be described without this optional component, after which the operation of the system shall be described with the inclusion of this component.

In the absence of low pressure compressor/vacuum pump 257, the low pressure boiler 207 can have a relatively low internal pressure as compared to the high pressure boiler 203. The relatively low pressure can be maintained by a suitable pressure regulator or expansion valve 217 at the input side of the low pressure boiler. In some embodiments, the relatively low pressure within the low pressure boiler 207 can be facilitated by diverting the F1(1) vapor to the inlet of compressor 204. For example, an optional flow path 262 can be used for this purpose. Still, the invention is not limited in this regard and in some embodiments, the pressure within the mixing chamber 206 can maintained sufficiently without the use of low pressure compressor/vacuum pump 257 and without compressor 204. In a preferred embodiment of the invention, the pressure within the low pressure boiler 207 is maintained such that it is approximately equal to a vaporization pressure of F1 at a temperature corresponding to the low temperature thermal source 227. The temperature in the low pressure boiler 207 is determined by the low temperature thermal source 227. The relatively low pressure and relatively low temperature within the low pressure boiler 207 facilitates vapor formation (sometimes referred to herein as F1(1) vapor). In this way, the F1(1) working fluid can effectively scavenge heat available from the thermal source at a relatively low temperature (e.g., the temperature associated with the low temperature thermal source 227). Using the foregoing technique, the F1(1) working fluid effectively scavenges heat from low temperature thermal source 227, which thermal energy would not otherwise be considered useful for purposes of performing work. The F1(1) vapor from the low pressure boiler 207 is communicated to a mixing chamber 206 (sometimes referred to herein as a mixer), which will be discussed below in further detail. The F1(1) vapor will contain a certain amount of thermal potential energy (heat energy) when it enters into the mixing chamber 206.

Alternatively, if the low pressure compressor/vacuum pump 257 is included in the design of system 200, then low pressure compressor/vacuum pump 257 can be used to create a low pressure environment within the low pressure boiler that draws the F1(1) working fluid through expansion valve 217. The low pressure environment is selected to create a pressure differential at the outlet of the expansion valve that enables the F1(1) working fluid to vaporize as it is drawn into the environment within the low pressure boiler. The F1(1) working fluid has significant capacity to absorb thermal energy from the heat exchanger 256 because of it has a temperature and vaporization point that is commensurate with the thermal energy that is available from the low temperature thermal source 227. The advantage obtained by using low pressure compressor 257 and expansion valve 217 may depend on the particular operating conditions and system requirements. When computer modeling suggests that such advantages can be realized by the use of the multiple boilers then these components are preferably included within the system. The expansion valve 217 is also sometimes referred to as a flow restrictor or throttle. Expansion valves, flow restrictors and other types of throttling means are well known in the art and therefore will not be described here in detail. However, it should be appreciated that the expansion valve (or other type of flow control means) would be sized and configured to accomplish the desired cooling described herein, within the fluid capabilities of the flow provided.

A second flow F1(2) of a first liquid working fluid F1 is also pressurized using the pump 201. The pressurized fluid is communicated to the high pressure boiler 203 which is maintained at a relatively high temperature as determined by high temperature thermal source 225. The high pressure boiler 203 will add a predetermined amount of thermal energy to the F1(2) working fluid. As a result of these operations, the F1(2) working fluid is converted to a vapor (sometimes referred to herein as F1(2) vapor). The system 200 can optionally include a pre-heater 202. The pre-heater can use a heat exchanger 254 and a flow of hot water from a low temperature thermal source 227 to pre-heat the flow of F1(2) liquid prior to the heating such fluid in the high-pressure boiler 203. The advantage obtained by using pre-heater 202 may depend on the particular operating conditions and system requirements. When computer modeling suggests that such advantages can be realized by the use of the pre-heater then it is preferably included within the system.

The use of separate high and low pressure boilers can potentially offer several advantages. Most notably, the two separate boilers 203, 207 operating at different pressures can facilitate the establishment of different boiling point temperatures for F1 working fluid. Accordingly, the F1 working fluid can effectively acquire latent energy associated with a liquid to vapor transition at each of a temperature associated with the high temperature thermal source, and at a temperature associated with the low temperature thermal source. Still, it should be appreciated that the use of a low pressure boiler is not necessary in the present invention, and in some embodiments of the invention, the flow path comprising the low pressure boiler 207 can be entirely omitted from system 200. In such embodiments, the expansion valve 217 and the low pressure compressor/vacuum pump 257 would also be omitted from system 200.

Moreover, the invention has been described herein with respect to a high pressure boiler 203 and a low pressure boiler 207, i.e., two boilers. As such, two boil-off points are established and used to more efficiently perform work utilizing the available thermal energy from the heat source. Although only two boilers are included in the embodiments shown herein, it should be understood that the invention is not limited in this regard. It is contemplated that additional boilers can be used to provide additional boil off points, where each boiler operates at a predetermined temperature and pressure to transport heat to a corresponding flow of the first working fluid. For example, a system could utilize a low pressure boiler, medium pressure boiler, and high pressure boiler. More generally, at least a third flow of the first working fluid can be communicated to a third pressure boiler to produce a third flow of first working fluid vapor at a pressure different from the low pressure boiler and the high pressure boiler. The third pressure boiler will use a thermal source having a temperature different as compared to the low temperature thermal source and the high temperature thermal source. Systems with four or more boilers are possible and may be desirable under certain operating conditions as will be apparent to those skilled in the art. The resulting vapor from each boiler can be subsequently transported to the mixing chamber where a transfer of thermal energy can occur as previously described. The relative advantage of including three or more boilers in the system 200 will depend on the particular operating conditions and system requirements. When computer modeling suggests that such advantages can be realized by the use of the three or more boilers then they are preferably included within the system.

The F1(2) vapor formed in high pressure boiler 203 is optionally communicated to an expander 209 where the thermal energy contained in the F1(2) vapor is used to perform work. As explained above in relation to FIG. 1, the use of an expander at this stage in the cycle can potentially offer advantages under certain operating conditions. When modeling suggests that such advantages can be realized by the use of the expander 209, then its use is preferably included within the system. Still, a designer may choose to omit the expander 209 in some embodiments. The F1(2) vapor, which will still contain high quantities of thermal energy, is subsequently communicated to the mixing chamber 206.

The F1(2) flow of F1 working fluid vapor is communicated to the mixing chamber 206. If a low pressure boiler 207 is included in the system design, then the flow of F1(1) working fluid vapor is also communicated to the mixing chamber. Within the mixing chamber 206, F1(2) vapor (and the F1(1) vapor if included) are mixed with a vaporous flow of working fluid F2 which has been compressed in compressor 204. These three separate vaporous fluid flows comprised of F1(1), F1(2) and F2 are combined or mixed to form a vaporous mixture which is referred to herein as third working fluid F3 (or F3 vapor). Due to this mixing of the working fluids, the transfer of thermal energy between the fluids is facilitated. In some embodiments, additional thermal energy can optionally be provided from an independent source to the F3 vapor contained in the mixing chamber 206. For example, the additional thermal energy can be provided to the mixer from a source that is external to the system shown in FIG. 2. It should be understood that the construct of the mixing chamber may comprise a broad array of physical embodiments. These features may include lower and higher pressure zones, artifacts to induce or reduce turbulence, one or more venturi's to increase or decrease specific flow velocities and expansion or restrictions that are intended to enhance, tune and optimize the condition of the overall fluid mixture F3 entering the expander 208.

It is not necessary for all thermal energy transfer between the F1(1), F1(2) and F2 vapor to occur within the mixing chamber 206. In some embodiments of the invention, a portion of such transfer can occur after the F3 vapor exits the mixing chamber. For example, in an embodiment of the invention, at least a portion of such transfer can continue occurring as the F3 vapor continues through an expansion cycle discussed below. Also, it is possible for the F1(1), F1(2) vapor, and the F2 vapor fluids to enter the mixer at approximately the same temperatures and pressures. However, as a result of the different chemical compositions of such fluids, transfer or exchange of thermal energy as between them, can still potentially take place in a subsequent expansion cycle. Details of the expansion cycle are discussed below with regard to expander 208.

Significantly, the thermal transfer described herein occurs directly between the mixed working fluids F1(1), F1(2), F2 and not across physical boundaries such as a thermally conductive wall of a heat exchanger (as would be the case if a conventional heat exchanger was used for this purpose). Consequently, the transfer of thermal energy between the F1(1), F1(2), and F2 vapor can occur in a way that is substantially instantaneous, and highly efficient. In effect, this process provides a heat exchanger without the presence of physical walls separating the fluids that are exchanging heat (i.e. a wall-less heat exchanger).

The mixing chamber 206 receive a vaporous fluid volumetric flow of F1(1) at pressure p1(1), a vaporous fluid volumetric flow of fluid F1(2) at pressure p1(2), and a vaporous fluid volumetric flow of fluid F2 at pressure p2. In some embodiments, the pressures p1(1), p1(2) and p2 are substantially the same pressure. In an embodiment of the invention, the volume of the mixing chamber is not restrictive with respect to the flow of fluids F1(1), F1(2) and F2. Accordingly, the volume of the mixing chamber can be selected to be VF1(1)+VF1(2)+VF2=VF3 where VF1(1) is the volumetric flow rate of fluid F1(1); VF1(2) is the volumetric flow rate of fluid F1(2); VF2 is the volumetric flow rate of fluid F2, and VF3 is the volumetric flow rate of VF1(1)+VF1(2)+VF2 at a near constant pressure. Still, the invention is not limited in this regard and the volume of the mixing chamber 206 could be increased or decreased, thereby providing the potential to change the flow velocity and having an affect on the pressure of the third working fluid F3.

The vaporous third working fluid F3 is communicated under pressure from the mixing chamber 206 to expander 208 for performing useful work. A rotating output shaft 205c of expander 208 can be connected directly or indirectly to the rotating output shaft 205a of expander 209 as shown in FIG. 2. A portion of the output power from expanders 208, 209 can be used to directly or indirectly drive input drive shaft 205b of compressor 204. The output power from expanders 208, 209 can also be used to directly or indirectly drive input drive shaft 205d of low pressure compressor/vacuum pump 257. It is additionally feasible that none of the shafts 205a-205d are connected, meaning it possible to use motors, generators or other appropriate transmission devices to provide similar functionality Well known conventional expander technology can be used for purposes of implementing expander 208, provided that it is capable of using a pressurized vapor to perform useful work. For example, the expander 208 can be an axial flow turbine, custom turbo-expander, vane expander or reciprocating expander. Advantageously the expander 208 will be selected by those skilled in the art to provide high conversion efficiency based on the specific thermodynamic and fluid properties of F3 delivered to the expander for a particular embodiment of the cycle. Still, the invention is not limited in this regard. After such work is performed by the expander 208, the F3 working fluid is communicated from the expander to a condenser assembly 210 as hereinafter described.

The condenser assembly 210 includes a condenser 212. The condenser assembly 210 includes at least three ports. Port 221 is used to receive the F3 working fluid provided to the condenser. Port 222 is used to communicate F1 working fluid condensate (F1 liquid) out of the condenser, and thereafter to pump 201 for re-use within the system. Port 223 is used to communicate a flow of the residual portion of F3 to the compressor 204 where it is re-used as a primary constituent of the F2 working fluid. The condenser 212 can be any device capable of condensing at least a portion of the F1 a working fluid from its vapor state to its liquid state.

As is well known in the art, condensing is commonly performed by cooling the working fluid under designated states of pressure. This cooling process will generally involve a release of heat contained in the third working fluid F3. The condenser cools the F3 fluid and thereby facilitates the condensing of the F1 fluid contained within the F3 fluid mixture. The F1 portion therefore drops out as a liquid in the form of condensate 219, and is collected in the condenser as F1 fluid (liquid), and is available for reuse. This process leaves a residual portion of the F3 working fluid. The residual portion of F3 is a remaining portion of the one or more fluids previously comprising F3 that exist after the F1 condensate has been extracted from F3. With the F1 (liquid) condensate and the residual portion of F3 available separate, the process has essentially returned to its starting point. Thereafter, the entire process described above can be repeated in a continuous cycle.

The performance of the condenser 212 is reliant on many factors, including the properties of the constituent fluids, the flow rates of the fluids, the ratios of the fluids, the condenser pressure and temperature, and hardware or apparatus physical configuration. These are all common variables that are well understood by those skilled in the art of condenser designs. The temperature and pressure conditions inside the condenser 212 are chosen so that the F1 constituent part of F3 is converted to a condensate within the condenser, while the second working fluid F2 is not condensed. In other words, a residual portion of F3 will remain in a vaporous state. This residual portion of F3 is later used as a constituent of the second working fluid F2. Those skilled in the art will appreciate that this condensing process applied for purposes of separating F1 from the residual portion of F3 can be accomplished by choosing the first and second working fluid to have different thermal properties. Under some operational parameters it is possible to have the F1, F2 and therefore the F3 fluids all be the same fluid. In this case, simply a portion of the overall flow is converted back and forth between liquid and vapor states.

In conventional Rankine cycle heat engines, the condensers can often be the most constraining part of the system. This is because it is necessary to completely condense 100% of the vapor that comprises the working fluid. Because of the difficulty in accomplishing 100% condensate, many systems will bleed a portion of the working fluid outside of the main system. This bleed process may include directly releasing working fluid to the atmosphere or to an independent reservoir that is outside of the primary condenser of the system. A key advantage of the current invention is the ability to not require a full condensate process. Accordingly, condenser 212 may not actually condense 100% of F1 from the vaporous F3 mixture. Advantageously, this condition is acceptable for purposes of the present invention, and a portion of F1 can be permitted to remain mixed within a residual portion of F3. For purposes of the present description, any portion of the residual F1, either in the vapor or liquid form (carried in the fluid stream), after the condensing process, therefore remaining in F2), can be considered a constituent of F2 by design.

The present invention can include several possible configurations with respect to the condenser assembly 210. In a first alternative embodiment shown in FIG. 3A, a condenser assembly 210 includes condenser 212 and a conventional heat exchanger 232. The condensing process is facilitated by cooling the heat exchanger using a flow of fluid from a cold reservoir 260. In such embodiments, the cold reservoir can be a natural source of coolant fluid supplied by pumping or any other source of coolant (e.g. a cold side of a refrigerant loop). A flow of the F3 working fluid is cooled as it passes over an exterior of tubular cooling members 234. The tubular cooling members define internal flow channels containing the coolant. The cooling members 234 can include fins and can be formed as coils to facilitate heat transfer.

In a second alternative embodiment shown in FIG. 3B, the F1 working fluid within the condenser is used as a refrigerant in an internal refrigeration cycle. As used herein, the phrase “internal refrigeration cycle” refers to a refrigeration cycle in which the F1 or a residual portion of F3 is used as a refrigerant. The internal refrigeration cycle in FIG. 3B facilitates transfer of thermal energy from the F3 working fluid in the condenser to the F1 working fluid, thereby making such thermal energy available for use later in the cycle. As shown in FIG. 3B, condenser 212 can include an heat exchanger 236 and an expansion valve 214. The expansion valve (or other type of throttling means) would be sized and configured to accomplish the desired cooling described herein, within the fluid capabilities of the flow provided. The heat exchanger 236 includes tubular cooling members 238. Interior flow channels defined within cooling members 238 are in fluid communication with the expansion valve 214 and the port 222. A low pressure compressor or pump 201 is provided at port 222 and creates an environment within the interior flow paths of the cooling members that is at a lower pressure as compared to the environment within the condenser 212. As a result of this difference in pressure, F1 working fluid accumulated in the condenser 212 is drawn through the expansion valve 214 and into the interior flow channels of the cooling members.

The F1 working fluid is cooled as it is drawn through the expansion valve 214 and transitions to the lower pressure environment within the cooling members. As such, the F1 working fluid is effectively used as a refrigerant. The F3 working fluid is provided to the heat exchanger assembly as previously described with respect to FIG. 2. The F3 working fluid flows over the exterior of the cooling members, which facilitate a transfer of thermal energy from the F3 working fluid outside the cooling members to the F1 working fluid inside the cooling members. Cooling of F3 facilitates the separation of F1 condensate from the F3 working fluid, and leaves a residual portion of F3 at port 223. The F1 working fluid within the cooling members (which has absorbed thermal energy from the F3 working fluid) exits the condenser assembly at port 222 and is communicated to the low pressure boiler 207 or high pressure boiler 203. Accordingly, available thermal energy within the condenser is effectively transferred to the F1 working fluid, where it is available for use in the cycle.

In a third alternative embodiment shown in FIG. 3C, the F3 working fluid within the condenser is used as a refrigerant in an internal refrigeration cycle. The internal refrigeration cycle facilitates the production of F1 condensate by cooling the F3 working fluid entering the condenser. Concurrently, the internal refrigeration cycle transfers thermal energy from the F3 working fluid to the residual portion of F3 which then exits the condenser at port 223. In this way, the internal refrigeration cycle scavenges thermal energy in the F3 working fluid and makes such thermal energy available for use later in the cycle. Another way to understand FIG. 3C is that the configuration is effectively dehumidifying (removing the liquid portion from) the F3 flow.

As shown in FIG. 3C, the condenser 212 can include a heat exchanger 336 and an expansion valve 314. The heat exchanger includes tubular cooling members 338. Interior flow channels defined within the tubular cooling members are in fluid communication with the expansion valve 314 and an output plenum 318. A low pressure compressor or vacuum pump 330 is in fluid communication with the plenum 318. The low pressure compressor 330 provides a reduced pressure within the plenum 318 as compared to an environment within a condenser chamber 319.

The operation of the condenser assembly in FIG. 3C shall now be described in further detail. A flow of F3 working fluid is provided to the condenser assembly at port 221. The F3 working fluid is communicated to input plenum 317 where it proceeds to flow over the exterior surfaces of the tubular cooling members 338. The cooling members 338 operate to cool the F3 working fluid, thereby facilitating the extraction of F1 working fluid as condensate 219. This process separates the F1 working fluid from the F3 working fluid and leaves a residual portion of F3 within the condenser chamber 319. As a result of the difference in pressure between the environment in output plenum 318 and the condenser chamber 319, the residual portion of F3 accumulated in the condenser chamber is drawn through the expansion valve 214. The residual portion of F3 is cooled as it is drawn through one or more expansion valves 314 and transitions to the lower pressure environment within the tubular cooling members. The cooling of the residual portion of F3 facilitates a transfer of thermal energy from the F3 working fluid (flowing around the exterior of the cooling members) to the residual portion of F3 inside the cooling members. After absorbing thermal energy from the F3 working fluid, the residual portion of F3 flows into the output plenum 318 and is provided to low pressure compressor 330. The low pressure compressor 330 communicates the residual portion of F3 to output port 223. Thereafter, the residual portion of F3 is communicated to the compressor 204 as previously described with respect to FIG. 2. Accordingly, available thermal energy within the condenser is effectively transferred to the F2 working fluid by the internal refrigeration cycle, where it is available for use in the cycle. The process described with respect to FIG. 3C has the potential to move a portion of thermal energy (heat) from F3 to F2. This heat is further combined with the compression heat of F2 in compressor 204. The result of such compression process in compressor 204 is an increase the temperature of the overall mixture in mixing chamber 206. This is of value because the F1(1) and F1(2) fluids can arrive at the mixing chamber 206 at or near saturation, and it is beneficial to start the expansion process at a temperature and pressure condition that is above the saturation line.

In FIG. 3C, the low pressure compressor 330 is disposed at an output side of expansion valve 314 to provide the required pressure differential. However, compressor 330 could instead be provided between condenser input port 221 and plenum 317 to increase the pressure in condenser chamber 319 and in the flow channels of cooling members 338. The resulting pressure increase in these zones could then be used to provide the required pressure differential across the expansion valve 314. In the limit of the design it is possible to comprise a configuration where the compressor 330 is not incorporated at all. In that case, the high pressure side of the heat exchanger is simply the exit of the expander 208 and the low pressure side of the heat exchanger is afforded by the compressor 204; this being the simplest configuration that is possible.

Based on the foregoing disclosure it will be understood that the condenser assembly 210 used for the present invention can be effected using the conventional condenser arrangement shown in FIG. 2, the condenser arrangements shown in FIGS. 3A-3C, or any other suitable condensing arrangement. The specifics of a particular design are reliant on many factors, including the properties of the constituent fluids, the flow rates of the fluids, the ratios of the fluids, the condenser pressure and temperature, and hardware or apparatus physical configuration. These are all common variables that are well understood by those skilled in the art of condenser designs.

The residual portion of F3 working fluid can be communicated directly to the compressor 204, where it comprises the exclusive constituent of F2 working fluid. However, in some embodiments of the invention, the system can advantageously include an optional spray cooling system. The spray cooling system includes a spray inlet 244 as shown. The spray cooling system is arranged such that a spray of a liquid can be added to the residual portion of F3 working fluid prior to or during compressing same in the compressor 204. For example, the liquid spray can be mixed with the residual portion of F3 in an input plenum 240 where the liquid spray becomes a constituent part of the F2 working fluid. The liquid spray (vaporizing from a liquid to a vapor) advantageously functions to cool the F2 working fluid during the compression process in compressor 204. In a preferred embodiment, the spray cooling system utilizes F1 working fluid liquid as the liquid spray. In such embodiments, a flow of F1 working fluid can be provided from pump 201 as shown.

A heater element 242 is optionally included in system 200. The heater element is configured to transfer thermal energy to the F2 working fluid as it begins the compression process in compressor 204. The thermal energy imparted to the F2 working fluid can be provided from any suitable source of thermal energy. For example, in some embodiments, a conventional refrigeration loop (not shown) can be configured to transfer thermal energy from condenser 212 to the heater element 242. In such embodiments, the refrigeration loop extracts thermal energy from within the condenser 212 and transfers such thermal energy to the F2 working fluid at heater element 242. An external refrigeration loop can be used for this purpose, meaning that the refrigeration loop can utilize as a refrigerant a working fluid other than the F1, F2 or F3 used in the remaining processes in system 200. Of course, any suitable type of refrigerant can be used in the external refrigeration loop. The refrigeration loop can have the added benefit of aiding in the production of condensate by performing a cooling function within the condenser 212.

Certain optional flow paths can also be provided in the system 200. These optional flow paths can enhance the operation of the system under certain operating conditions. For example, in some embodiments, a flow path 258 can be added at the output of port 223 to communicate to the low pressure boiler 207 some part of the residual portion of F3. Flow path 258 is provided in addition to the flow path 260 and the volumetric flow of working fluid through each of these two paths can be regulated by means of suitable valve (not shown). The flow of the residual portion of F3 to the low pressure boiler can be heated in the low pressure boiler, where the residual portion of F3 becomes a component of the F1(1) working fluid vapor.

Another optional flow path is flow path 262, which can communicate a portion of the F1(1) working fluid vapor to the inlet of compressor 204. In such embodiments, the portion of the F1(1) working fluid communicated to the compressor 204 becomes a constituent component of the F2 working fluid. The use of one or more of the optional flow paths described herein can potentially offer efficiency advantages under certain operating conditions. When computer modeling suggests that such advantages can be realized by the use of the optional flow paths 258, 262 then their use is preferably included within the system. Still, a designer may choose to omit these optional flow paths in some embodiments.

An example of the operation of exemplary heat engine 400 will now be provided with reference to FIG. 4. The operation of heat engine 400 as described herein is based on computer modeling. The heat engine 400 includes certain optional features described above. For example, the heat engine includes separate high and low pressure boilers 207, 203 and expander 209. The heat engine also includes the optional condenser assembly shown in FIG. 3C which uses F3 working fluid as a refrigerant. This particular example does not include optional pre-heater 202 and does not include a liquid spray system or heat exchanger 242. It also does not include optional flow paths 258 or 262. It should be appreciated that the invention is not limited to the particular configuration shown and any one or more of these elements could have been included. Accordingly, heat engine 400 merely represents one possible combination of the various optional features described herein that could be incorporated into an operational system incorporating the inventive arrangements.

For purposes of this computer model it is assumed that the first working fluid F1 is methanol and the second working fluid F2 is a mixture of helium, nitrogen and methanol. More particularly, the mixture is chosen to contain 1 part helium, 7 parts nitrogen, and 2 parts methanol by weight. Also, the invention is not limited to the working fluids and/or to the temperatures, pressures and/or mass flow rates that are stated herein. The following flow rates are assumed:

F1(1)=2 lbs/s
F1(2)=2 lbs/s
F2=10 lbs/s (7 lbs/s nitrogen, 1 lb/s helium, 2 lb/s methanol)
F3=14 lbs/s

For this example we assume that the high temperature heat source temperature is 310° F. and that the heat added to working fluid F1(2) in the high pressure boiler 203 is 1072 kW. This produces high pressure F1(1) vapor at the output of the high pressure boiler 203 at a temperature of 280° F. and a pressure of 130 psia. This high pressure vapor is used to perform 34 kW of work in expander 209. The vapor exits the expander 209 at relatively low pressure and temperature (T=226° F., p=65 psia).

An outflow of the heating process at high pressure boiler 203 provides the low temperature thermal source 227 at a temperature of about 250° F. The low temperature thermal source is used to provide thermal energy to the low pressure boiler 207 where 1,042 kW is added to the F1(1) working fluid. This produces low pressure F1(1) vapor at the output of the low pressure boiler (T=226° F., p=65 psia). An outflow of the heating process at low pressure boiler 207 is returned to the source, such as a geothermal well, at a temperature of about 170° F.

Concurrent with the foregoing vaporization steps, the F2 working fluid is compressed in compressor 204. The F2 working fluid is also heated as a result of being compressed. In the exemplary model, the F2 working fluid enters the compressor 204 at a temperature of 165° F. and a pressure of 17 psia. The compressor uses 978 kW of power to perform the compressing operation, which results in the F2 working fluid exiting the compressor at a temperature of 390° F., and a pressure of 65 psia. The process continues as described with F1(1), F1(2), and F2 being mixed in the mixing chamber 206 to form F3 working fluid. The F3 working fluid is subsequently delivered to the expander 208, where it can perform 1,418 kW of work. As noted above, an output shaft of expander 208 can be connected directly or indirectly to compressor 204, so that a portion of this work output can be used to drive compressor 204. After the F3 working fluid has been used to perform useful work, it exits the expander 208 at relatively low pressure and temperature (T=149° F., p=14 psia) and is communicated to port 221 of the condenser assembly 210. At condenser assembly 210, the F3 working fluid is compressed in compressor 430. Compressor 430 uses 103 kW of power to pressurize the F3 working fluid as it enters the condenser 212.

The condensing process effectively results in the separation of the F1 working fluid from the residual portion of F3 as previously described. Note that in this example, the residual portion of F3 is the only component of F2. The residual portion of F3 produced by the condenser 212 has a relatively low temperature and pressure (T=165° F., p=17 psia). The F1 working fluid is pressurized by liquid pump 201 for transport to the low pressure boiler 207 and the high pressure boiler 203. Approximately 41 kW of power is consumed by pumping (e.g. pump 201) and by other mechanical systems losses. These losses are simplistically represented in FIG. 3 as losses associated with the condenser 212.

Given the foregoing assumptions, a tabular representation of the model in FIG. 4 is presented below in Table 1:

TABLE 1 Heat Added in High Pressure Boiler Qin HP = 1,072 kW Heat added in Low Pressure boiler Qin LP = 1,042 kW Work of Compression Win = 1,081 kW Work Extracted Wout = 1,452 kW Pumping & Mechanical Loss Wpump =   41 kW Net Work WNet =   330 kW Cycle Efficiency ηth = 15.6%

Notably, computer modeling shows that a total of 330 kW of power can be extracted from the relatively poor quality thermal source in this example. In contrast, a conventional Rankine cycle utilizing the same heat source geothermal vapor at the same temperature (310° F.), and using only a single boiler, could only extract about 136 kW. In this regard it may be noted that the efficiency for such a conventional Rankine Cycle under these conditions would be 12.7%. Accordingly, the present invention has the potential to produce a substantially larger amount of power by extracting larger quantities of thermal energy from same, relatively poor quality thermal source (i.e., relatively low temperature) as compared to more conventional commercial power systems.

The heat engine 200, 400 and its associated cycle described in FIGS. 1-4 can be optimized based on the choice of working fluids internal to the cycle, in concert with selection of the most appropriate chemical configurations of the fluids. For example, F1 and F2 are advantageously comprised of chemical compositions such that during the course of the cycle, F1 transitions between a liquid and vapor and F2 remains dominantly vapor (it being understood that a portion of liquid may reside in a vapor stream when the vapor stream is saturated). However, the invention is not limited in this regard, and it is also possible to operate the cycle with many chemically unique constructs comprising different mixing ratios thereof.

The heat cycle described with respect to FIGS. 1-4 has many advantages over conventional systems. For example, the cycle provides higher thermal transfer rates which are made possible by having the working fluids function as the heat exchanger (or act in the capacity of a heat exchanger). This technique is utilized in all of the various embodiments to facilitate transfer thermal energy between F1 and F2. A further advantage is gained in the present invention by selecting the fluid chemical properties, physical properties, and fluid temperatures/pressure within the cycle such that the latent heat of vaporization is used for thermal exchange purposes. In particular, the high pressure boiler 203 can at least provide the first working fluid (F1) with thermal energy equal to the latent heat of vaporization for such working fluid. Those skilled in the art will appreciate that liquid to vapor transformations provide very high thermal capacity. A similar advantage can be gained in low pressure boiler 207 where relatively low pressure conditions are maintained to facilitate vaporization of the respective working fluid at relatively low temperature. The latent heat of vaporization thus acquired by the respective working fluids in each case can provide both higher motive capacity and higher thermal capacity to improve power production efficiencies.

The cycle and associated apparatus described with respect to FIGS. 1-4 has the potential to increase the conversion efficiency of certain heat resources (e.g., heat resources of less than 800° F.). More particularly, the cycle has the potential to increase conversion efficiency for heat resources having temperatures less than 400° F. Significantly, the present invention can facilitate power generation from such relatively low temperature sources at efficiency levels that have the potential to compete with heat sources based on hydrocarbon energy resources (which typically are at a much higher temperature). One aspect of the invention that permits this important result involves mixing the volumes of the fluids F1 and F2 (in vapor state). The process of combining the two vapors facilitates providing relatively large quantities of available energy to the expander 208. Note that the Rankine portion of the cycle (pump 201, high pressure boiler 203, optional expander 209 and expander 208) alone creates a lesser amount of available vapor volume (relative to the substantial amounts of heat energy added) but, this fluid transports very large quantities of thermal capacity. Conversely, the Brayton portion (compressor 204, mixing chamber 206, second expander 208, condenser assembly 210) alone has large volumetric capacity but less effective or less efficient thermal exchange capacity, relative to the source of heat. The resulting combination of thermal capacity and volumetric capacity enable a larger potential to extract work for each unit of thermal energy added.

In the present invention, a large quantity of heat energy is extracted from the high temperature thermal source 225 by means of vaporization. The latent heat of vaporization provides a useful method for converting very large quantities of heat in the F1 liquid into kinetic energy residing in the vapor. Still, the ability of the vaporous fluid to perform work and therefore create power is constrained by the overall volume that is created (relative to the heat that is consumed in creating that volume). In order to overcome this limitation, it is advantageous to have a large volume second working fluid (F2) that facilitates the process of producing the actual power.

Providing a large volume second working fluid in vaporous form presents another challenge. In particular, vaporous fluids tend to be difficult to heat by heat exchanger means, as such devices are governed by principles of convection. The invention overcomes the limitations of the prior art, and facilitates improved efficiency by moving large quantities of thermal potential energy to the first working fluid F1 (in the Rankine portion of the cycle), and then transferring this thermal energy directly to the second working fluid F2 (in the Brayton portion of the cycle) by mixing the first and second working fluids. Notably, a Brayton cycle and a Rankine cycle each has the capability to convert thermal energy to power at a relatively low efficiency (typically less than 15% assuming 400° F. is the heat source temperature). However, by combining the methods of these independent cycles, where the best features of each is utilized, it is possible that the resulting cycle efficiency can be increased.

In the embodiments shown in FIGS. 1-4, efficiency of the cycle is enhanced by making maximum use of available heat from a thermal source. In certain scenarios, the high pressure boiler 203 can use as its primary heat source a supply of steam (e.g. from a geothermal well) which, after use becomes a down-line flow of residual hot water. The residual hot water is conventionally understood as being not useful for purposes of performing work. But in the present invention this residual hot water is optionally used to vaporize a flow of working fluid by means of low pressure boiler 207. In such embodiments, the heat is extracted from the low temperature thermal source 227 by maintaining a relatively low pressure environment within the low pressure boiler 207 (thereby lowering the temperature at which the F1(1) working fluid will vaporize) and by lowering the temperature of F1(1) as it transitions into such low pressure environment (thereby enabling the F1(1) working fluid a greater capacity to absorb available thermal energy. This enables a portion of the normally rejected or unused thermal energy from the source to be introduced within the cycle, at a location where it is capable of being used to perform work.

In general, the cycle described in FIGS. 1-4 will be configured based on the nature or type of thermal source available for providing thermal energy. From there, appropriate fluid mixtures are selected and modeled using computer simulation tools. The operation and control of the cycle is then fine tuned around desired control points of temperature and pressure within the apparatus of the system configuration chosen. These temperatures and pressures are dominantly controlled by altering the fluid flow rates of the individual working fluids of certain fluid combinations at select points within the cycle.

In the embodiments shown in FIGS. 1-4, the temperature of F1(1) and F1(2) are generally controlled by selecting the source temperature used for boilers 203, 207 and/or controlling the flow rate of the working fluid. The pressure of the working fluids F1(1) and F1(2) supplied to the boilers 203, 207 is controlled by pump 201. Accordingly, the initial pressure levels of F1(1) and F1(2) can be controlled by the pump 201, and valve operable means that are common in the art of power systems. Conventional pressure regulators can be used to manage (control) the pressure in high pressure boiler 203 and low pressure boiler 207.

In FIGS. 2-4, the temperature and pressure of working fluid F2 is generally controlled by the operation of compressor 204, optional heat exchanger 242, and the optional liquid spray system described herein. These elements are coordinated by the designer or system operator to raise the temperature and pressure of F2 to a suitable level so that it enters the mixing chamber 206 at approximately the same pressure as F1(1) and F1(2). Specific designs of the mixing chamber would allow for or enable deviations in pressures between these fluids, and are intended to be included within the scope of the present invention.

The pressure, temperature and construct of the heated working fluid mixture F3 entering the expander is key for establishing the performance capability of the cycle. These factors include the constituent mass flow rates and therefore establish the parameters for the expansion rate and the design requirements of the expander 208. It is further understood that the expander performance is highly dependent on the energy content and expansion profile of the F3 flow. It would be understood by those skilled in the art that the volumetric flow rate, density, pressure, and temperature can be used to establish the performance characteristics and therefore provide the basis for the best expander design. These parameters can be established and controlled within the cycle construct for a broad range of applications where the cycle is designed around the available thermal source temperature and heat rate.

The mixing ratio of F1 and F2 contained within the F3 flow can be either static or dynamic. Static fluid mixing involves mixing the F1 working fluid (i.e., F1(1), F1(2)) with the F2 working fluid at a fixed rate. In other words, a fixed mass flow rate is used for each working fluid under set conditions of temperature and pressure. In such an embodiment, the dynamics of each working fluid remains at a near steady state, with the input thermal energy set at a near constant rate, and a constant or substantially constant output (shaft mechanical energy). The ability to dynamically alter the flows and mixtures facilitates control of the cycle relative to deviations in heat addition and/or power extraction. Dynamic fluid mixing involves mixing the working fluids at variable rates. For example, such dynamic mixing might be implemented for purposes of controlling the operational dynamics of such an engine system. In such a dynamic fluid mixing implementation, the state conditions of temperature, pressure, and mass flow for each working fluid may be fluctuating dynamically as a function of fluctuations or changes within the operating cycle. In those instances where the input (thermal) energy is being changed in conjunction with load levels (i.e. power output levels), it can be more appropriate in some embodiments to change the relative mass flow rates of F1 and F2 rather than changing the gross overall flow rate as a set mixture (or fixed mixture ratio). If the mass flow rate of F1 is changed, this change can be implemented by varying the flow rate of F1(1), F1(2) or both. Still, the invention is not limited in this regard, and the gross overall flow rate of F3 can be changed with a fixed mixture ratio. In yet a further alternative embodiment, the mixing ratio of F1 and F2, and the overall flow rate of F3, can be changed.

In very general terms, the ratio of first working fluid F1 to second working fluid F2 contained in F3 would be about ⅓ (one-third) to ⅔ (two-thirds) in an embodiment of the invention. The ratios may in various embodiments also extend over a range. The range can extend from a first arrangement having ⅕ first working fluid to ⅘ second working fluid, to a second arrangement having ⅔ first working fluid and ⅓ second working fluid. Still, the invention is not limited in this regard.

Fluid selection for operating the configuration of thermodynamic cycles described herein is based on many inter-related factors. The conditions of operating temperature and pressure are important in selection of the chemical makeup of the fluid. It is also desirable to choose a boiling point of the first working fluid which is appropriate relative to the source temperature of available heat. For example, if the source of heat is geothermal with a temperature of 350° F., it is desirable to have a first working fluid F1 that has the capability to absorb heat from the source thru vaporization of the selected working fluid at a rate that is commensurate with both the heat rate of the source and the size of the desired system. It is further desirable to select F1 so that it can re-condense to liquid in the condenser efficiently relative to the condensate cooling that is available. For example, F1 can be chosen to be propane in some embodiments since it changes from a liquid to a vapor at lower temperatures than other working fluids, such as pentane (assuming the same operating pressure). This configuration would be appropriate where there is a large supply of a cooling medium (such as cold water) that is readily available. Fluid choices are also governed by the latent heat value and heating capacity of the constituent working fluids.

Use of some fluids as the first working fluid can also be a disadvantage in the present invention. For example, working fluids with extremely low volumetric expansion potential may not be the best choice for use in the present invention. Also, certain fluids that have higher boiling points and good volumetric expansion capabilities may only operate at temperatures that are above the source temperature. Accordingly, such fluids would be ruled out for a lower temperature source, but may perform well for another configuration with a higher temperature thermal source. There may be fluids that that perform well in some parts of the cycle, but may not perform well in the other parts of the cycle. Accordingly, it is important to select and match the fluid capability with the characteristics of the thermal energy source.

The first and second working fluids, and ratios thereof, should also be selected such that they work in concert with one another. In particular, the more rapid cooling of the second fluid (as compared to the first fluid) during the expansion process can facilitate the exchange of energy from the first fluid to the second fluid. This leaves the first fluid very close to the vapor to liquid transition point as it approaches the end of the expansion cycle. As the first working fluid condenses, it is therefore separated from the second working fluid and can be collected in the condenser. This unique fluid capability provides the means to tune the thermal take-up rates (heat addition/vaporization) and additionally the drop-out rates (condensate rates) of the fluids in operation.

In one example of the invention, F1 can be water, and F2 can be a mixture comprised of nitrogen, helium and water vapor. Since F1 is water in this example, mixing of F1 and F2 will result in a fluid F3 which is also a mixture of nitrogen, helium, and water. The difference between the two fluids F2 and F3 is that F3 will have a higher percentage of water vapor as compared to F2. Still, the foregoing is merely one example of fluids that could be selected for use as F1, F2 and F3. Similar effects can be achieved using alternative fluid combinations. In one embodiment, the water in the example could be replaced with methanol, pentane, or ammonia to achieve the same phenomena at lower temperatures. In such a scenario, helium could still be used as a constituent of F2, or as an alternative, argon, hydrogen or neon could be used instead. Still, the invention is not limited to these particular fluids.

The various cycles described herein are an improvement over other cycles because they posses the inherent capacity to use larger quantities of the available source energy (i.e., heat energy) effectively over a broad range of temperatures. There is no compromise to the integrity of basic thermodynamic principles or processes in the overall cycle configuration. In fact, each of the separate process steps described in the cycle herein represents a well understood thermodynamic process. The dynamics of each cycle portion can be traced to similar processes occurring independently in conventional systems. Still, this invention goes beyond such conventional methods and systems because they do not combine process steps in the manner described herein, and therefore do not achieve the same results.

Computer models have been developed to evaluate the details of each of the cycle processes, the relationships across the individual cycle boundaries, and the hardware that supports each specific process. These models facilitate evaluation of the cycle as a whole. The cycle advantageously involves improving thermal to power conversion efficiencies at lower source energy temperatures. This approach is afforded by having the capability to use a larger quantity of the source energy over a given temperature range and in addition is capable of re-using a portion of normally rejected thermal energy by means of re-circulation. Accordingly, the computer models involve an evaluation process that incorporates iterative calculations within the performance simulations to account for the recycled energy. Such modeling and simulation has validated this unique method of using latent heat energy through appropriate placement of vapor state transitions. The resulting method and apparatus is capable of converting a greater portion of available thermal source energy to work than is currently understood to be possible using conventional means known today.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

All of the apparatus, methods and algorithms disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the invention has been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the apparatus, methods and sequence of steps of the method without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain components may be added to, combined with, or substituted for the components described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined.

Claims

1. A method for producing work from heat in a continuous cycle comprising:

heating a pressurized flow of a first working fluid F1 to form an F1 vapor;
compressing an F2 vapor comprised of a second working fluid F2;
mixing said F1 vapor and said F2 vapor to form a third working fluid F3;
within said third working fluid, transferring thermal energy directly between said F1 vapor and said F2 vapor, exclusive of any intervening structure;
expanding said third working fluid to perform useful work after or during said transferring;
cooling said third working fluid to extract a condensate comprised of F1 and a residual portion of said third working fluid from which said condensate has been extracted; and
repeating said continuous cycle using said first working fluid F1 obtained as said condensate, and using said residual portion as a constituent of the second working fluid F2.

2. The method according to claim 1, further comprising pre-heating said pressurized flow of first working fluid F1, prior to said heating step.

3. The method according to claim 2, further comprising using a high temperature flow of fluid from a high temperature thermal source to provide thermal energy for said heating step, and using a low temperature flow of fluid to provide thermal energy for said pre-heating step, wherein said low temperature flow is a downstream flow of said high temperature flow obtained after said high temperature flow has been used in said heating step.

4. The method according to claim 1, wherein said heating step comprises:

separating said first working fluid F1 into at least an F1(1) flow and a F1(2) flow;
performing said heating step with respect to said F1(1) flow at a first temperature and first pressure to form a flow of F1(1) vapor;
performing said heating step with respect to said F1(2) flow at a second temperature and second pressure, different from said first temperature and first pressure, to form a flow of F1(2) vapor.

5. The method according to claim 4, wherein said mixing step comprises mixing said F2 vapor with said F1(1) vapor and said F1(2) vapor.

6. The method according to claim 4, further comprising using a high temperature flow of fluid from a high temperature thermal source to provide thermal energy for heating said F1(2) flow, and using a low temperature flow of fluid to provide thermal energy for heating said F1(1) flow, wherein said low temperature flow is a downstream flow of said high temperature flow obtained after said high temperature flow has been used for heating said F1(2) flow.

7. The method according to claim 4, further comprising heating a flow of said residual portion of F3 together with said F1(1) flow at said first temperature and said first pressure.

8. The method according to claim 4, further comprising transitioning said F1(1) flow from a higher pressure environment to a lower pressure environment, through an expansion valve, prior to said heating step.

9. The method according to claim 1, further comprising expanding said F1 vapor prior to said mixing step.

10. The method according to claim 1, further comprising adding thermal energy to said third working fluid concurrent with said mixing.

11. The method according to claim 1, further comprising adding a spray of liquid to said residual portion of F3 before or during said compressing.

12. The method according to claim 11, wherein said liquid is said first working fluid F1.

13. The method according to claim 11, further comprising heating said residual portion of F3 and said liquid spray, prior to said compressing.

14. The method according to claim 1, further comprising combining at least a portion of said F1(1) vapor with said residual portion of F3 prior to said compressing.

15. The method according to claim 1, further comprising using a refrigeration cycle to cool said third working fluid F3 to facilitate said extraction of said condensate.

16. The method according to claim 15, wherein said refrigeration cycle is an internal refrigeration cycle which transports available thermal energy from the third working fluid F3 to at least one of the first working fluid F1 or the second working fluid F2.

17. The method according to claim 16, further comprising implementing said internal refrigeration cycle using said condensate comprised of F1 as a refrigerant to extract said available thermal energy from said third working fluid F3.

18. The method according to claim 16, further comprising implementing said internal refrigeration cycle using said residual portion of said third working fluid as a refrigerant to extract said available thermal energy from said third working fluid F3.

19. A system for producing work from heat in a continuous cycle comprising:

at least one boiler configured to heat a pressurized flow of a first working fluid F1 to form an F1 vapor;
a compressor configured to compress an F2 vapor comprised of a second working fluid F2;
a mixing chamber configured to mix said F1 vapor and said F2 vapor which has been compressed to form a third working fluid F3 and to facilitate a transfer of thermal energy directly between said F1 vapor and said F2 vapor, exclusive of any intervening structure;
an expander configured to expand said third working fluid to perform work after or during said transferring;
a condenser assembly configured to extract from said third working fluid F3 a condensate comprised of F1 and a residual portion of said third working fluid from which said condensate has been extracted.

20. The system according to claim 19, further comprising a fluid communication system configured to facilitate repetition of said continuous cycle using said first working fluid F1 obtained as said condensate, and using said residual portion as a constituent of the second working fluid F2.

21. The system according to claim 19, further comprising a pre-heater configured to pre-heat said pressurized flow of first working fluid F1, prior to said heating step.

22. The system according to claim 21, wherein said boiler is heated by a high temperature flow of fluid from a high temperature thermal source, said pre-heater is heated by a low temperature flow of fluid, and wherein said low temperature flow is a downstream flow of said high temperature flow obtained after said high temperature flow has been used in said heating step.

23. The system according to claim 19, wherein said at least one boiler includes:

a low pressure boiler configured to heat an F1(1) flow of said first working fluid at a first temperature and first pressure to form a flow of F1(1) vapor;
a high pressure boiler configured to heat an F1(2) flow of said first working fluid at a second temperature and second pressure, different from said first temperature and first pressure, to form a flow of F1(2) vapor.

24. The system according to claim 23, wherein said mixing chamber is configured to mix said F2 vapor with said F1(1) vapor and said F1(2) vapor.

25. The system according to claim 23, wherein said high pressure boiler is configured to be heated using a high temperature flow of fluid from a high temperature thermal source for heating said F1(2) flow, said low pressure boiler is configured to be heated by a low temperature flow of fluid to provide thermal energy for heating said F1(1) flow, and wherein said low temperature flow is a downstream flow of said high temperature flow obtained after said high temperature flow has been used for heating said F1(2) flow.

26. The system according to claim 19, further comprising an F1 expander configured to expand said F1 vapor before said F1 vapor is communicated to said mixing chamber.

27. The system according to claim 23, wherein said low pressure boiler is configured to heat a flow of said residual portion of F3 together with said F1(1) flow at said first temperature and said first pressure.

28. The system according to claim 23, further comprising a compressor or vacuum pump configured to maintain said first a pressure within said low pressure boiler, and an expansion valve configured to restrict said F1(1) flow entering said low pressure boiler.

29. The system according to claim 19, wherein said mixing chamber is configured to receive a supply of thermal energy and to communicate said supply of thermal energy to said third working fluid.

30. The system according to claim 19, further comprising a spray cooling system configured to add a spray of a liquid to said residual portion of F3 before or during compressing operations performed by said compressor.

31. The system according to claim 30, wherein said liquid is said first working fluid F1.

32. The system according to claim 30, further comprising a heat exchanger configured to heat said residual portion of F3 and said liquid spray, prior to said compressing operations performed by said compressor.

33. The system according to claim 19, wherein a fluid flow path is configured to combine at least a portion of said F1(1) vapor with said residual portion of F3 prior to performing compressing operations by said compressor.

34. The system according to claim 19, further comprising a refrigeration apparatus configured to cool said third working fluid F3 to facilitate said extraction of said condensate.

35. The system according to claim 34, wherein said refrigeration apparatus comprises an internal refrigeration cycle which transports available thermal energy from the third working fluid F3 to at least one of the first working fluid F1 or the second working fluid F2.

36. The system according to claim 35, wherein said refrigeration apparatus is configured to use said condensate comprised of F1 as a refrigerant to extract available thermal energy from said third working fluid F3.

37. The system according to claim 35, wherein said refrigeration apparatus is configured to use said residual portion of said third working fluid as a refrigerant to extract said available thermal energy from said third working fluid F3.

Patent History
Publication number: 20140026573
Type: Application
Filed: Jul 24, 2012
Publication Date: Jan 30, 2014
Applicant: HARRIS CORPORATION (Melbourne, FL)
Inventor: William R. Palmer (Melbourne, FL)
Application Number: 13/556,387