[특허]System and method for converting heat energy into electrical energy through and organic rankine cycle (ORC) system

TMEIC Corporation

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System and method for converting heat energy into electrical energy through and organic rankine cycle (ORC) system

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	F01K-013/02 F01K-023/10 F01K-025/08 F23J-015/06
출원번호	US-0512066 (2010-01-26)
등록번호	US-9347339 (2016-05-24)
국제출원번호	PCT/US2010/022026 (2010-01-26)
§371/§102 date	20120525 (20120525)
국제공개번호	WO2011/093850 (2011-08-04)
발명자 / 주소	Durmaz, Ahmet Lara, Marcelo Andres
출원인 / 주소	TMEIC Corporation
대리인 / 주소	New River Valley IP Law, P.C.
인용정보	피인용 횟수 : 0 인용 특허 : 16

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A system and method for converting otherwise wasted energy produced in the form of heated gases as a byproduct of an industrial process into electrical energy. At least some waste gases are diverted from a typical exhaust structure through a heat exchanger and back into the exhaust structure. The amount of gases flowing through the heat exchanger is monitored and regulated by a controller. A heat source liquid is simultaneously circulated under pressure through the heat exchanger and through an organic Rankine cycle system. The amount of heat source liqu...

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1. A system for converting excess energy generated as a byproduct of a fuel-powered industrial process in the form of heated exhaust gases directed to an exhaust structure into electrical energy comprising: a heat exchanger having a gas input and a gas output, each connected to an exhaust structure, and having further a heat source liquid input and a heat source liquid output;a tap connected with the exhaust structure and the heat exchanger and comprising a tap input and a tap output such that during use:(i) a first stream of gas in the exhaust structure flows from a location upstream of the tap input to a location that is both downstream of the tap input and upstream of the tap output, and then flows from the location upstream of the tap output to a location downstream of the tap output;(ii) a second stream of gas flows through the tap input and into the tap, then through the gas input and into the heat exchanger, then through the gas output and the tap output and back into the exhaust structure and the first stream of gas; an organic Rankine cycle (ORC) system having a first input connected to the heat source liquid output of said heat exchanger and a first output connected to the heat source liquid input of said heat exchanger, said ORC system further having a generator delivering electric power to a second output of said ORC system;a fan for regulating the temperature of the liquid heat source by changing the amount of gases circulated between the exhaust structure and the gas input and the gas output of said heat exchanger, wherein speed of the fan is based in part on a heat source liquid target temperature, which is calculated by software in a first controller and is calculated based on a function having as input variables: (a) monitored fuel consumption data of the fuel-powered industrial process, (b) a temperature feedback of heated gases entering the gas input of the heat exchanger, and (c) an initial liquid heat source target temperature; andheat source liquid circulator for regulating the heat transfer to said ORC by changing the amount of liquid circulated between said ORC and said heat exchanger. 2. The system of claim 1 wherein the fan comprises: an exhaust gases fan connected to a vent;a first electric motor connected to said exhaust gases fan; anda first variable frequency drive connected to said first electric motor;wherein the first controller is connected to said first variable frequency drive for monitoring and regulating said first variable frequency drive. 3. The system of claim 2 wherein the fan further comprises: second controller connected to said first controller for monitoring fuel consumption data of the industrial process and transmitting that data to said first controller;first sensor connected to the gas input of said heat exchanger for measuring the temperature of the exhaust gases at that point and for transmitting that data to said first controller;second sensor connected to the heat source liquid output of said heat exchanger for measuring the temperature of the liquid at that point and for transmitting that data to said first controller;third sensor connected to the heat source liquid output of said heat exchanger for measuring the pressure of the heat source liquid at that point and for transmitting that data to said first controller; anda protective power transducer connected between the second output of said ORC system and said first controller. 4. The system of claim 3 wherein said heat source liquid circulator comprises: a pressurized heat source liquid expansion tank;a pressure relief valve connected to said expansion tank and to said first controller;a variable speed circulating pump connected at its input to said expansion tank and at its output to the heat source liquid input of said heat exchanger;a second electric motor connected to said pump;a second variable frequency drive connected to said second electric motor; andfourth sensor connected to said ORC for measuring the temperature of the cooling medium used by said ORC, and wherein further said second variable frequency drive is further connected to said first controller. 5. The system of claim 3 wherein said heat source liquid circulator comprises: a pressurized heat source liquid expansion tank;a pressure relief valve connected to said expansion tank and to said first controller;a fixed speed circulating pump connected at its input to said expansion tank and at its output to the heat source liquid input of said heat exchanger; anda second electric motor connected to said pump. 6. A method for regulating the generation of electrical power from heated waste gases emitted from a fuel-powered industrial device into an exhaust structure using a heat exchanger having a gas input connected to the exhaust structure and a gas output connected to a variable speed exhaust fan which is itself connected to the exhaust structure and having further an organic Rankine cycle device (ORC) with an evaporator having a heat source liquid input connected to a liquid output of the heat exchanger and a heat source liquid output connected to a pressurized source of liquid further connected to a pump and thereafter to a liquid input of the heat exchanger wherein the ORC incorporates an expander coupled to a generator having an electrical output connected to a transducer comprising: diverting a portion of the waste gases away from the exhaust structure into the gas input of the heat exchanger through a tap in communication with the exhaust structure and the heat exchanger such that during use:(i) a first stream of gas in the exhaust structure flows from a location upstream of an input to the tap to a location that is both downstream of the input to the tap and upstream of an output to the tap, then flows to a location downstream of the output to the tap, and(ii) a second stream of gas flows through the tap input and into the tap, then through the gas input and into the heat exchanger, then through the tap output and back into the exhaust structure and the first stream of gas;regulating through a first controller the heat source liquid temperature by changing the amount of the waste gases so diverted by varying the speed of the exhaust fan, wherein the speed of the fan is based in part on a heat source liquid target temperature, which is calculated by software in the first controller and is calculated based on a function having as input variables: (a) monitored fuel consumption data of the fuel-powered industrial process, (b) a temperature feedback of heated gases entering the gas input of the heat exchanger, and (c) an initial liquid heat source target temperature;controlling through the first controller the amount of heat transferred from the heat source liquid to the ORC by changing the flow of the liquid circulated between the ORC and the heat exchanger by managing the operation of the pump; andmonitoring at the transducer the amount of electricity generated by the generator at the electrical output. 7. A method for regulating the production of electrical power from heated waste gases generated as a byproduct of a fuel-powered industrial device comprising: providing waste gases as a first stream of gas and diverting a part of the first stream of gas at a temperature measured by a first sensor as a second stream of gas through a tap input and into a tap connected with an exhaust structure, then through a gas input and into a heat exchanger before being expelled from a gas output of the heat exchanger through a tap output and back into the exhaust structure, such that the first stream of gas flows from a location upstream of the tap input to a location that is both downstream of the tap input and upstream of the tap output, and then flows from the location upstream of the tap output to a location downstream of the tap output;regulating the circulation of the waste gases through the heat exchanger by an exhaust gases fan driven by a first electric motor the speed of which is controlled by a first variable frequency drive (VFD) itself further controlled by a first controller incorporating a Proportional-Integral regulator, said first controller being connected to a second controller further connected to the fuel-powered device for monitoring fuel consumption and to the first sensor and wherein further a heat source liquid is delivered to a liquid input of the heat exchanger before being expelled from a liquid output of the heat exchanger into a heat source liquid circuit at a temperature measured by a second sensor and a pressure measured by a third sensor both of which sensors being connected to the first controller;regulating the circulation of the heat source liquid through the heat exchanger by a pump driven by a second electric motor the speed of which is controlled by a second variable frequency drive (VFD) itself further controlled by the first controller, while the heat source liquid pump inlet is also connected to a liquid expansion tank subject to pressurization with inert gas, the pressure of which is monitored by the third sensor, the expansion tank also including a pressure relief valve monitored by the first controller, the heat source liquid expelled from the liquid output being then directed through an evaporator located in an organic Rankine cycle (ORC) system incorporating a heat sink circuit having a fourth sensor connected to the first controller for measuring the temperature of the ORC cooling medium, an expander connected to a generator and a power transducer connected between the generator and the first controller;calculating an optimum target temperature for the heat source liquid based on a function having as input variables: (a) monitored fuel consumption data of the fuel-powered industrial process, (b) a temperature feedback of heated gases entering the gas input of the heat exchanger, and (c) an initial liquid heat source target temperature;further calculating a desired speed feed forward command for the first variable frequency drive;yet further calculating a speed adjustment;setting the target speed of the first variable frequency drive;further setting the maximum allowable speed of the first variable frequency drive;limiting the exhaust fan speed or calculating the target speed for the second variable frequency drive;further determining the maximum allowable speed for the second VFD and when appropriate limiting the pump speed. 8. The system of claim 1, further comprising: a first variable frequency drive operably connected to the fan, wherein the first variable frequency drive is configured for regulating speed of the fan; anda second variable frequency drive operably connected to the heat source liquid circulator, wherein the second variable frequency drive is configured for regulating speed of the heat source liquid circulator. 9. The system of claim 8, further comprising: a first sensor for measuring temperature of gases in the tap;a second sensor for measuring temperature of the heat source liquid;wherein the first controller is configured for receiving an input from the first sensor and an input from the second sensor and for sending a first command to the first variable frequency drive and a second command to the second variable frequency drive based on the input from the first sensor and the input from the second sensor; wherein the first command is for changing speed of the first variable frequency drive, thereby regulating the speed of the fan and an amount of gas moving through the tap during use; andwherein the second command is for changing speed of the second variable frequency drive, thereby regulating the speed of the heat source liquid circulator during use. 10. The system of claim 9, further comprising: a third sensor, which is a pressure sensor, for measuring pressure of the heat source liquid, wherein during use the first controller is capable of receiving input from the pressure sensor, such that if the input from the pressure sensor exceeds a threshold, the speed of the first variable speed drive is reduced thereby slowing the amount of gases moving through the tap. 11. The system of claim 10 further comprising a heat sink circuit for circulating a cooling medium and a fourth sensor for measuring temperature of the cooling medium. 12. The system of claim 11, wherein during use the first controller is capable of receiving an input from the fourth sensor for calculating a reference for the second variable frequency drive to regulate the speed of the heat source liquid circulator. 13. The system of claim 12, further comprising a second controller which during use is capable of providing data to the first controller on fuel-consumption rate of a fuel-powered device to which the exhaust structure is part of. 14. The system of claim 2, further comprising an electric power transducer for monitoring an electric power output of the ORC system and for transmitting the electric power output to the first controller. 15. The system of claim 14, wherein the first controller is configured to send a command to the first variable frequency drive to reduce the speed or stop operation of the fan in response to excess electric power output of the ORC system.

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System and method for converting heat energy into electrical energy through and organic rankine cycle (ORC) system

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