Uncoupled, thermal-compressor, gas-turbine engine

• US 20050126171A1
• Filed: 09/28/2004
• Published: 06/16/2005
• Est. Priority Date: 11/01/2002
• Status: Abandoned Application

• Current Assignee: George Lasker
• Original Assignee: George Lasker
• Inventors: Lasker, George
• Application Number:
  US10/952,411
• Publication Number:
  US 20050126171A1
• Time in Patent Office: Days
• US Class Current: 60/645
• CPC Class Codes: F02C 1/04 the working fluid being heated indirectly in a fluidised-bed combustor F02C3/205
• CPC Class Codes: F02C 1/05 characterised by the type or source of heat, e.g. using nuclear or solar energy
• CPC Class Codes: F02C 6/00 Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas-turbine plants for special use
• CPC Class Codes: F02G 1/04 of closed-cycle type
• CPC Class Codes: F03G 6/064 having a gas turbine cycle, i.e. compressor and gas turbine combination
• CPC Class Codes: F03G 6/068 having other power cycles, e.g. Stirling or transcritical, supercritical cycles; combined with other power sources, e.g. wind, gas or nuclear
• CPC Class Codes: F24S 20/20 Solar heat collectors for receiving concentrated solar energy, e.g. receivers for solar power plants
• CPC Class Codes: F28F 21/04 of ceramic; of concrete; of natural stone
• CPC Class Codes: F28F 3/086 having one or more openings therein forming tubular heat-exchange passages
• CPC Class Codes: Y02E 10/40 Solar thermal energy, e.g. solar towers
• CPC Class Codes: Y02E 10/46 Conversion of thermal power into mechanical power, e.g. Rankine, Stirling or solar thermal engines
• CPC Class Codes: Y02E 20/14 Combined heat and power generation [CHP]
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

The invention is for a continuous-combustion, closed-cycle, gas turbine engine with a regenerator and a displacer. It has embodiments that remove heater and cooler interior volumes during gas compression, which enable it to scale well to very large sizes. Low combustion temperatures insure very low emissions. The displacer levitated by an integral gas bearing and small clearance seal and given oscillatory translational motion by electromagnetic forces operates without surface wear. The turbine blades, subjected only to warm gases, are durable and inexpensive. Thus, this engine has a very long, continuous, maintenance-free service life. This gas turbine engine also operates without back work allowing high efficiency for both low and rated output. Pressurized encapsulation permits use of low-cost ceramics for high temperature components. The invention includes a unique monolithic ceramic heater, a compact high-capacity regenerator and a constant-power gas turbine.

Claims

1. A heat engine comprising a thermal compressor to power a compressed gas drive.

2. A heat engine according to claim 1, with continuous internal combustion in a hot chamber of the thermal compressor, and further comprising:

(a) a thermal compressor with combustion occurring in the hot chamber or at some point in the gas dynamic circuit between the hot chamber and a regenerator;

(b) means for pumping fuel into the hot chamber of the thermal compressor; and

(c) a pushrod-driven integral compressor, expander and displacer which respectively pressurizes air up to the system operating pressure, extracts energy from the products of combustion before discharging them into the atmosphere and provides system pressurization.

3. A heat engine according to claim 2, with the regenerator integrated into a closed container structure so that none of the closed container structure is subjected to both high temperatures and high tensile stresses.

4. A heat engine according to claim 3, with elements that improve volumetric efficiency by effectively removing a cooler interior volume during compression, and further comprising a thermal compressor valve set configured so that:

(a) during the compression stroke gas follows a path from the cold chamber, then through the regenerator and then into the hot chamber;

(b) during the intake stroke gas follows a path from the hot chamber and regenerator and then discharges from the thermal compressors to an external cooler; and

(c) simultaneously, during the intake stroke, fresh gas directly enters a cold chamber.

5. A heat engine according to claim 4, with elements that significantly reduce noise, friction and wear and further comprising:

(a) a pushrod that interfaces with the crank drive by means of an integral thrust bearing and spin motor, and in so doing an integral pushrod, compressor, expander and displacer assembly can spin continuously;

(b) a noise mitigator to transform the pulsating intake and exhaust gases into a near continuous intake and exhaust flow processes by means of a cylinder divided by a spring loaded piston wherein one side is connected to an intake of the compressor and the other side is connected to an exhaust of the expander;

(c) a heat exchanger that transfers heat of compression in the compressor to expanding gas in the expander;

(d) an integral lubrication and heat exchanger system that pressurizes oil, sprays it in compressor and expander chambers, and separates it from air and products of combustion; and

(e) an integral cooler and exhaust gas scrubber comprising a gas to atmosphere heat exchanger, a chamber with means to form a dense water aerosol and a liquid-gas separator wherein the gas entering the cooler moves first through the heat exchanger, thence to a water aerosol and finally to a liquid-gas separator.

6. A heat engine according to claim 1, further comprising a heat engine with a continuous external combustion thermal compressor and a displacer and closed container that has no contact between them and therefore no wear surfaces and comprising:

(a) a continuous external combustion thermal compressor which receives gas at engine ambient pressure and discharges it at a high pressure, and comprising;

a displacer and closed container, an external combustion heater, a cooler that rejects heat, a regenerator, a region or tank for accumulating low-pressure gas, a region or tank for accumulating high-pressure gas, a pair of pump check valves, a piping set that connects the elements, and a compressed gas drive which transforms compressed gas into mechanical power delivered to a load;

(b) an integral gas bearing that supports the displacer relative to the closed container and small clearance displacer seal comprising two concentric cylinders with one attached to the displacer and one attached to the closed container;

(c) a spin motor that induces axial rotation;

(d) a linear electromagnetic drive that induces reciprocating motion of the displacer; and

(e) means to determine the position of the displacer relative to the closed container.

7. A heat engine according to claim 6, further comprising a valve configured to confine gas near the end of a displacer stroke at both ends of the closed container and in so doing induce a displacer gas dynamic bounce.

8. A heat engine according to claim 7, further comprising:

(a) a set of nested cylinders attached to the cold end of the closed container;

(b) a set of nested cylinders attached to the displacer and interlaced with the set of nested cylinders attached to the cold end of the closed container;

(c) a pair of nested cylinders in, one from (a) and one from (b), forming an exciter that magnetically induces an electric current powering the circuits attached to the displacer and both cylinders forming one or more integral electrical winding and iron core structures;

(d) a pair of nested cylinders, one from (a) and one from (b), forming a displacer spin motor that magnetically induces a displacer torque and both cylinders forming one or more integral electrical winding and iron core structures;

(e) a pair of nested cylinders, one from (a) and one from (b), forming a linear motor that magnetically induces longitudinal force in the displacer and both cylinders forming one or more integral electrical winding and iron core structures;

(f) a pair of nested cylinders, one from (a) and one from (b), forming a transducer system from which the position of the displacer can be determined and both cylinders forming one or more integral electrical winding and iron core structures; and

(g) a pair of nested cylinders, one from (a) and one from (b), forming an integral air bearing and small clearance seal, with one attached to the displacer and one attached to the closed container.

9. A heat engine according to claim 7, further comprising:

(a) a set of nested cylinders attached to the cold end of the closed container;

(b) a set of nested cylinders attached to the displacer and interlaced with the set of nested cylinders attached to the cold end of the closed container;

(c) a pair of nested cylinders, one from (a) and one from (b), forming an exciter that magnetically induces a current powering the displacer circuits and both cylinders forming one or more integral electrical winding and iron core structures;

(d) a pair of nested cylinders, one from (a) and one from (b), forming a displacer spin motor that magnetically induces a displacer torque and both cylinders forming one or more integral electrical winding and iron core structures;

(e) a pair of nested cylinders, one from (a) and one from (b), forming a linear motor that magnetically induces a longitudinal force in the displacer and both cylinders forming one or more integral electrical winding and iron core structures;

(f) a set of three nested cylinders, two from (a) and one from (b), forming a displacer position system and with the cylinders attached to the displacer forming an optical pulse generator and the other two being structures that respectively support a lamp and a light receiver; and

(g) a pair of nested cylinders, one from (a) and one from (b), forming an integral air bearing and small clearance seal.

10. A heat engine according to claim 7, further comprising:

(a) a set of nested cylinders attached to the cold end of the closed container;

(b) a set of nested cylinders attached to the displacer and interlaced with the set of nested cylinders attached to the cold end of the closed container;

(c) a pair of nested cylinders, one from (a) and one from (b), forming a displacer spin motor that magnetically induces a torque, with one containing a permanent magnet and attached to the displacer, and the other one attached to the closed container and forming one or more integral electrical winding and iron core structures;

(d) a pair of nested cylinders, one from (a) and one from (b), forming a linear motor that magnetically induces a longitudinal force in the displacer, with one containing a permanent magnet and attached to the displacer, and the other one attached to the closed container and forming one or more integral electrical windings and iron core structures;

(e) a pair of nested cylinders, one from (a) and one from (b), forming a transducer system from which the position of the displacer can be determined with one being a permanent magnet attached to the displacer and one forming an integral electrical winding and iron core structure attached to the closed container; and

(f) a pair of nested cylinders, one from (a) and one from (b), forming an integral air bearing and small clearance seal with one cylinder attached to the displacer and one attached to the closed container.

11. A heat engine according to claim 7, further comprising:

(a) a set of nested cylinders attached to the cold end of the closed container;

(b) a set of nested cylinders attached to the displacer and interlaced with the set of nested cylinders attached to the cold end of the closed container;

(c) a pair of nested cylinders, one from (a) and one from (b), forming a displacer spin motor that magnetically induces a displacer torque, with one containing a permanent magnet and attached to the displacer, and the other one attached to the closed container and forming one or more integral electrical winding and iron core structures;

(d) a pair of nested cylinders, one from (a) and one from (b), forming a linear motor that magnetically induces a longitudinal force in the displacer, with one containing a permanent magnet and attached to the displacer, and the other one attached to the closed container and forming one or more integral electrical windings and iron core structures;

(e) a set of three nested cylinders, two from (a) and one from (b), forming a displacer position system with one cylinder attached to the displacer and two attached to the closed container, and with the cylinder attached to the displacer forming an optical pulse generator, and the other two being structures that respectively support a lamp and a light receiver; and

(f) a pair of nested cylinders, one from (a) and one from (b), forming an integral air bearing and small clearance seal.

12. A heat engine according to claim 1, further comprising a heat engine with an external combustion thermal compressor that uses a displacer, center-rod support and a linear electromagnetic drive, comprising:

(a) a closed container, an external combustion heater, a cooler, a regenerator, a region or tank for accumulating low-pressure gas, a region or tank for accumulating high-pressure gas, a pair of pump check valves, a piping set that connects the elements, and a compressed gas drive which transforms compressed gas into mechanical power and delivers it to a load;

(b) a displacer supported by a lubricated slender center rod with means of balancing the pressure at the base of the center rod with the closed container cold chamber;

(c) a displacer drive coil attached to the displacer and attached to spring-like leads that serve to bring power to the displacer coil;

(d) a spring set that causes the displacer to bounce at the end of the stroke;

(e) a stationary electromagnetic drive circuit that directs magnetic flux through the displacer drive coil;

(f) a position sensor used by the displacer linear drive controller to control displacer motion;

(g) a power supply that provides regulated power to the displacer drive coil and stationary electromagnetic drive coils; and

(h) a displacer drive controller.

13. A heat engine according to claim 8 having variable output torque comprising:

(a) a second compressor for receiving compressed gas from the compressed gas drive controller operatively connected to an adjustable flow valve

(c) a motor for driving the second compressor operatively connected to the controller; and

(d) a third check valve connected between the second compressor and a storage tank for receiving gas from the second compressor and delivering the gas to the storage tank for subsequent transmission of the gas under the control of the controller to the adjustable flow valve wherein turbine output torque is regulated by controlling the speed of the compressor motor to reduce engine pressure and by opening the adjustable flow valve to increase engine pressure.

14. A heat engine according to claim 13, having improved volumetric efficiency, further comprising a thermal compressor valve set configured so that:

(a) during the compression stroke, the gas follows a path from the cold region through the regenerator to the heater and thereafter into the hot region;

(b) during the intake stroke, the gas follows a path from the hot region, through the heater to the regenerator and thereafter is discharged from the thermal compressors to an external cooler; and

(c) simultaneously, during the intake stroke, fresh gas is directly introduced to the cold region.

15. A heat engine according to claim 13, that effectively removes heat during compression, and further comprising a thermal compressor valve set configured so that:

(a) during the compression stroke, the gas in the cold chamber passes through the cooler through the regenerator and into the hot region;

(b) during the subsequent intake stroke, the gas in the hot region passes from the heater, through the regenerator and cooler and into the cold region; and

(c) simultaneously during the intake stroke, fresh gas is directly introduced to the cold region.

16. A heat engine according to claim 15, having improved volumetric efficiency wherein both hot and cold gas volumes are removed during compression, and further comprising a thermal compressor valve set configured so that:

(a) during the compression stroke, the gas follows a path from the cold region through the regenerator and into the hot region;

(b) during the intake stroke, the gas follows a path from the hot chamber, through the heater, to the regenerator and thereafter is discharged from the thermal compressors to an external cooler; and

(c) simultaneously, during the intake stroke, fresh gas directly enters the cold region.

17. A heat engine according to claim 16, with engine high temperature elements of ceramic manufacture, resistant to thermal fatigue and thermal shock failures, and further comprising:

(a) a pressure chamber that contains a high-pressure gas and encapsulates an engine structural assembly that is protected from thermal fatigue and thermal shock failures;

(b) an engine structural assembly containing high temperature ceramic elements that are protected from thermal fatigue and thermal shock failures and configured so that these elements are primarily subjected to compressive stresses; and

(c) means that thermally insulate the pressure chamber from the high temperature elements.

18. A heat engine according to claim 17 integrated into a cogeneration system and further comprising:

(a) a turbo generator; and

(b) a cooler integrated into a hot water tank

19. A heat engine according to claim 17 integrated into a coal-fired power plant and further comprising:

(a) a coal-fired heater, and

(b) a turbo generator.

20. A heat engine according to claim 17 integrated into an engine that uses a solar receiver as a heater and further comprising a solar receiver.

21. A heat engine according to claim 17, configured to provide a direct drive, low speed and high torque output and further comprising a drive system that incorporates a reaction turbine.

22. A heat engine according to claim 17, which operates in outer space, uses solar energy, can operate continuously for 15 years, and does not require maintenance, and further comprising a solar receiver used as the engine heater.

23. A heat engine according to claim 1, further comprising an integral solar energy and natural gas TC heat engine system comprising:

(a) a thermal compressor integrated with a solar receiver;

(b) a sun-tracking parabolic mirror;

(c) a thermal compressor integrated with a natural gas heater;

(d) a low-pressure tank;

(e) a high-pressure tank;

(f) a hot water tank with a heat exchanger that transfers rejected engine heat to the water; and

(g) a turbo generator.

24. A heat engine according to claim 1, further comprising a seal and integral gas bearing for use with a thermal-compressor displacer, comprising two concentric cylinders having a small clearance, manufactured from a material with a small coefficient of thermal expansion and a high service temperature, and attached so that pressure equalizes on both sides of each cylinder.

25. A heat engine according to claim 1, further comprising A motorized, thermal-compressor, displacer-center-rod bushing that maintains a displacer centering force and comprises:

(a) a lubricated slender center rod that supports a displacer;

(b) an inner bushing that rotates, is motor driven, supports the center rod and provides a fluid dynamic centering force that acts on the center rod;

(c) an outer bushing that interfaces with the inner bushing;

(d) a support structure for the outer bushing;

(e) a motor that rotates the inner bushing; and

(f) means to enable the gas pressure at the base of the center rod to equalize with the pressure of the closed container cold chamber.

26. A heat engine according to claim 1, further comprising an active vibration-mitigation system used with an electromagnetic-drive thermal compressor engine comprising:

(a) a system support plate;

(b) a vibration isolation spring that is attached at one end to the system support plate and at the other end to the engine;

(c) an active damper drive coil and structure that is attached to the system support plate;

(d) an active damper armature housed in the damper drive coil;

(e) a motion sensor that is attached to the system support plate; and

(f) a controller that receives a signal from the motion sensor, commands displacer and damper armature motion and correlates this process so that the system-support-plate vibrations are nullified.

27. A heat engine according to claim 1, further comprising an integrated, thermal-compressor and vibration-mitigation system assembly comprising:

(a) an electromagnetic-drive thermal compressor;

(b) a heater;

(c) a tilted-disk, vibration-mitigation subsystem;

(d) a vessel for pressurizing the high-temperature engine components; and

(e) a controller that correlates tilt disk position and speed with thermal compressor displacer motion to nullify vibrations.

28. A heat engine according to claim 1, further comprising a thermal compressor regenerator with a high gas throughput, low interior volume and a low-pressure drop, and comprising a heat recovery media configured as a folded plate.

29. A thermal compressor regenerator according to claim 28 further comprising an additional function so that it both recovers heat from the previous cycle and receives heat from a heat.

30. A thermal compressor regenerator according to claim 28 modified so that it serves a second function of an oxidation catalytic converter and further comprising an oxidation catalytic material integrated into the heat recovery medium.

31. A heat engine according to claim 1, further comprising a heater for gas-cycle heat engines with a sequence of combustion chambers and heat exchangers configured so that combustion occurs in stages with heat extracted after every stage and fuel rates controlled to limit peak combustion temperatures as a means of controlling the formation of NOx compounds, and comprising:

(a) an intake filter that receives intake air from the atmosphere and discharges it to the air pump;

(b) an air pump that receives air from the air filter and delivers it to an exhaust heat recuperator;

(c) an exhaust recuperator that transfers heat from the exhaust gases to the intake gases and fuel, and which receives air from an air pump and delivers it to a first combustion chamber;

(d) a combustion chamber that receives air from the recuperator and fuel from the fuel-flow control valve, and delivers products of combustion to a heat exchanger;

(e) a heat exchanger that transfers heat from the products of combustion to the thermal compressor working fluid and which receives products of combustion from the combustion chamber and delivers them to a second combustion chamber;

(f) a process that repeats (d) and (e) several times and then delivers the products of combustion to the last combustion chamber;

(g) a recuperator that receives heat from the last combustion chamber, delivers it to the exhaust, and transfers heat from the exhaust gases to the intake air and fuel;

(h) a fuel system comprising;

a fuel tank, a fuel pump, a motor and a fuel filter, and sends fuel to a flow control valve;

(i) a fuel-flow-control valve that receives fuel from the fuel filter and delivers it to a recuperator that heats the fuel and then sends it to a starter fuel heater;

(j) a starter fuel heater that is used to initially heat fuel during engine start-up and comprising an electrical heating element and which receives fuel from the recuperator and delivers it to all the combustion chambers at a high enough temperature so that combustion can occur;

(k) an igniter located in the last combustion chamber to ignite fuel during start up;

(l) a temperature sensor that measures the temperature of the exhaust gases just before entering the recuperator;

(m) an oxygen sensor that measures the exhaust gas oxygen level; and

(n) a controller that regulates the speed of the air pump motor and the fuel pump motor, and receives the output of the temperature and oxygen sensors.

32. A heater for gas-cycle heat engines according to claim 31, further comprising a ceramic heat exchanger configured as a monolithic structure formed by sintering a stack of plates and comprising:

(a) a front structural plate;

(b) a stack of plate sets wherein each set comprises;

a ceramic cloth layer and a ceramic tubing layer; and

(c) an aft structural plate.

33. A heater for gas cycle heat engines according to claim 32, further comprising:

(a) a pressurized containment structure; and

(b) regenerator elements so configured to minimize tensile stresses when pressurized.

34. A heat engine according to claim 1, further comprising a monolithic ceramic heater formed by joining a plate stack comprised of a three-plate repeated sequence, a front plate and an aft plate with the plate sequence comprised of a cloth layer, a working fluid pipe plate layer, and a porous, fuel-pipe plate layer.

35. A heat engine according to claim 1, further comprising a thermal compressor heat engine with a structure pressurized to enhance resistance to thermal fatigue and thermal shock failures of high temperature elements by minimizing tensile stresses, and comprising:

(a) a pressure chamber that contains a high-pressure gas and encapsulates a structural assembly being protected from thermal fatigue and thermal shock failures;

(b) a structural assembly which is protected from thermal fatigue and thermal shock failures; and

(c) means to insulate thermally between a pressure chamber and a structural assembly that is protected from thermal fatigue and thermal shock failures.

36. A thermal compressor heat engine according to claim 35, further comprising a structure that uses ceramic material for all high temperature elements.

37. A heat engine according to claim 1, further comprising a gas-dynamic drive that maintains a near constant power output over a specified speed range and comprising a turbine, a stator, a gas discharge nozzle, and means that enables velocity compounding to occur.

38. A gas-dynamic drive according to claim 37, which eliminates transverse turbine forces, and further comprising a stator-blade arrangement that nullifies gas-dynamic forces not inducing a turbine drive torque.

39. A gas-dynamic drive according to claim 38, further comprising an additional turbine, stator and nozzle that can induce a reverse torque, and thus form a system with a forward and reverse-retard capability.

40. A gas-dynamic drive according to claim 39, further comprising a mask that covers the stator blades associated with the reverse-retard turbine when operating in the forward drive mode.

41. A gas-dynamic drive according to claim 40, further comprising means of magnetically transferring the torque of the turbine contained in a pressurized chamber to a chamber at a different pressure.

42. A gas-dynamic drive according to claim 41, further comprising an electric clutch that transfers torque from one chamber to another without contact.

43. A gas-dynamic drive according to claim 42, with a configuration that simplifies manufacture and further comprising a toroidal shell pressure chamber containing the turbine and fabricated with the shell in contact with rotating elements but which will develop a clearance gap between the toroidal shell pressure chamber and interior rotating elements when this chamber is pressurized.

44. A gas-dynamic drive according to claim 43, with a quasi-uniform turbine torque output and further comprising:

(a) a turbine nozzle that can vary the flow rate;

(b) a pressure gauge that measures the pressure upstream of the nozzle; and

(c) a nozzle controller that modulates the nozzle so that pressure fluctuations do not induce corresponding turbine-torque fluctuations.

45. A gas-dynamic drive according to claim 44, with a lightweight vehicle wheel mountable configuration and further comprising:

(a) a planetary reduction gear which provides a high torque output; and

(b) a disk brake system that stops the vehicle.

46. A gas dynamic drive according to claim 37 with elements that can convert mechanical energy into compressed gas energy and comprising a turbine operating in reverse, a stator, a gas discharge nozzle, a gas intake nozzle, means that enable velocity compounding to occur and means to store the compressed gas.