METHOD AND APPARATUS FOR THE UTILIZATION OF WASTE HEAT FROM GASEOUS HEAT SOURCES CARRYING SUBSTANTIAL QUANTITIES OF DUST

• US 20100083662A1
• Filed: 10/06/2008
• Published: 04/08/2010
• Est. Priority Date: 10/06/2008
• Status: Active Grant

• Current Assignee: Kalina Power Limited
• Original Assignee: Kalex, LLC
• Inventors: Kalina, Alexander I.
• Granted Patent: US 8,087,248 B2
• Time in Patent Office: Days
• US Class Current: 60/730
• CPC Class Codes: C04B 7/36 Manufacture of hydraulic cements in general
• CPC Class Codes: C04B 7/475 using the waste heat, e.g. of the cooled clinker, in an other way than by simple heat exchange in the cement production line, e.g. for generating steam
• CPC Class Codes: F01K 13/00 General layout or general methods of operation of complete plants
• CPC Class Codes: F05B 2230/31 Layer deposition
• CPC Class Codes: F05C 2253/12 Coating
• CPC Class Codes: F28D 21/001 for thermal power plants or industrial processes
• CPC Class Codes: F28D 21/0014 the heat being recuperated from waste air or from vapors for air conditioning F24F12/001
• CPC Class Codes: F28D 9/04 the conduits being formed by spirally-wound plates or laminae
• CPC Class Codes: Y02P 40/121 Energy efficiency measures, e.g. improving or optimising the production methods

Abstract

An apparatus, system and method for transferring heat from a hot flue gas stream from a cement plant including large particles and dust to a working fluid of a power plant via a high temperature heat transfer fluid without exposing all or most of the equipment to the erosive force of the particles and dust is disclosed where the apparatus includes a cement plant, a particle separation and heat transfer system and a power plant

Claims

1. An apparatus comprising:

a cement plant CP,

a particulate separation and heat transfer system PSHTS, and

a power plant PP,

where the cement plant CP producing a hot gas stream including large particles and dust, the PSHTS removes the large particles and the dust to produce a heated high temperature transfer fluid stream and transfer its heat to a working fluid stream of the power plant PP where a portion of its heat is converted to a usable form of energy.

2. The apparatus of claim 1, wherein the PSHTS comprises:

a separator C adapted to remove substantially all large particles from the hot gas stream from the cement plant CP,

a scrubber S adapted to bring the substantially large particle-free hot gas stream into heat exchange with a cooled high temperature heat transfer fluid stream to from a cooled gas stream and a heated high temperature heat transfer fluid stream including a portion of the dust from the gas stream,

a pump P adapted to raise a pressure of the heated high temperature heat transfer fluid stream to a desired high pressure,

a fan F adapted to remove substantially all of the dust from the pressurized heated high temperature heat transfer fluid stream, and

a heat exchanger HE transferring heat from the substantially dust-free high temperature heat transfer fluid stream to the working fluid stream of the power plant PP to form the vaporized working fluid stream.

3. The apparatus of claim 2, wherein the scrubber S includes a packing structure.

4. The apparatus of claim 3, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.

5. The apparatus of claim 1, wherein the PSHTS comprises:

a separator C adapted to remove substantially all large particles from the hot gas stream from the cement plant CP,

a pump P adapted to raise a pressure of the substantially large particle-free hot gas stream to a desired high pressure,

a fan F adapted to remove substantially all of the dust from the pressurized substantially large particle-free hot gas stream to a desired high pressure to form a substantially large particle and dust free hot gas stream,

a scrubber S adapted to bring the substantially large particle and dust free hot gas stream into heat exchange with a cooled high temperature heat transfer fluid stream to from a cooled substantially large particle and dust free gas stream and a heated high temperature heat transfer fluid stream including a portion of the dust from the gas stream, and

a heat exchanger HE transferring heat from the substantially dust-free high temperature heat transfer fluid to the working fluid stream of the power plant PP to form the vaporized working fluid stream.

6. The apparatus of claim 5, wherein the scrubber S includes a packing structure.

7. The apparatus of claim 6, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.

8. An apparatus comprising:

a cement plant CP,

a particulate separation and heat transfer system PSHTS comprising;

a separator C adapted to remove substantially all large particles from the hot gas stream from the cement plant CP,

a scrubber S adapted to bring the substantially large particle-free hot gas stream into heat exchange with a cooled high temperature heat transfer fluid stream to from a cooled gas stream and a heated high temperature heat transfer fluid stream including a portion of the dust from the gas stream,

a pump P adapted to raise a pressure of the heated high temperature heat transfer fluid stream to a desired high pressure,

a fan F adapted to remove substantially all of the dust from the pressurized heated high temperature heat transfer fluid stream, and

a heat exchanger HE transferring heat from the substantially dust-free high temperature heat transfer fluid stream to the working fluid stream of the power plant PP to form the vaporized working fluid stream, and

a power plant PP,

where the cement plant CP producing a hot gas stream including large particles and dust, the PSHTS removes the large particles and the dust to produce a heated high temperature transfer fluid stream and transfer its heat to a working fluid stream of the power plant PP where a portion of its heat is converted to a usable form of energy.

9. The apparatus of claim 8, wherein the scrubber S includes a packing structure.

10. The apparatus of claim 9, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.

11. An apparatus comprising:

a cement plant CP,

a particulate separation and heat transfer system PSHTS comprising;

a separator C adapted to remove substantially all large particles from the hot gas stream from the cement plant CP,

a pump P adapted to raise a pressure of the substantially large particle-free hot gas stream to a desired high pressure,

a fan F adapted to remove substantially all of the dust from the pressurized substantially large particle-free hot gas stream to a desired high pressure to form a substantially large particle and dust free hot gas stream,

a scrubber S adapted to bring the substantially large particle and dust free hot gas stream into heat exchange with a cooled high temperature heat transfer fluid stream to from a cooled substantially large particle and dust free gas stream and a heated high temperature heat transfer fluid stream including a portion of the dust from the gas stream, and

a heat exchanger HE transferring heat from the substantially dust-free high temperature heat transfer fluid to the working fluid stream of the power plant PP to form the vaporized working fluid stream, and

a power plant PP,

where the cement plant CP producing a hot gas stream including large particles and dust, the PSHTS removes the large particles and the dust to produce a heated high temperature transfer fluid stream and transfer its heat to a working fluid stream of the power plant PP where a portion of its heat is converted to a usable form of energy.

12. The apparatus of claim 11, wherein the scrubber S includes a packing structure.

13. The apparatus of claim 12, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.

14. A method for extracting heat from a cement plant hot gas stream comprising:

forwarding a hot gas stream including large particles and dust from a cement plant CP to a particulate separation and heat transfer system PSHTS,

forming a heated high temperature heat transfer fluid stream substantially free of large particles and dust in the PSHTS,

transferring heat from the substantially large particle and dust free heated high temperature heat transfer fluid stream to a working fluid stream of a power plant PP to from a vaporized working fluid stream, and

converting a portion of heat in the vaporized working fluid stream to a usable form of energy.

15. A method comprising:

forwarding a hot gas stream including large particles and dust from a cement plant CP to a large particle separator C to from a substantially large particle free hot gas stream,

simultaneously forwarding the substantially large particle free hot gas stream via a bottom port into a scrubber S, and a cooled high temperature heat transfer fluid stream via an upper side port into the scrubber S to form a cooled substantially dust free gas stream exiting the scrubber S via a top port and a heated high temperature heat transfer fluid stream including substantially all of the dust from the of the substantially large particle free hot gas stream exiting the scrubber S via a lower side port,

pressurizing the dust containing, heated high temperature heat transfer fluid stream in a pump P to a desired higher pressure to form a pressurized dust containing, heated high temperature heat transfer fluid stream,

filtering the pressurized dust containing, heated high temperature heat transfer fluid stream in a filter or a plurality of filters to form a substantially dust free heated high temperature heat transfer fluid stream, and

heating a working fluid stream from a power plant PP in a heat exchanger HE to form a heated working fluid stream and the cooled high temperature heat transfer fluid stream.

16. The method of claim 15, further comprising:

converting a portion of the heated working fluid stream in the power plant PP to a usable form of energy.

17. The method of claim 15, wherein the scrubber S includes a packing structure.

18. The method of claim 17, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.

19. A method comprising:

forwarding a hot gas stream including large particles and dust from a cement plant CP to a large particle separator C to from a substantially large particle free hot gas stream,

pressurizing the substantially large particle free, hot gas stream in a pump P to a desired higher pressure to form a pressurized substantially large particle free, hot gas stream,

filtering the pressurized substantially large particle free, hot gas stream in a filter or a plurality of filters to form a substantially large particle and dust free, hot gas stream,

simultaneously forwarding the substantially large particle and dust free hot gas stream via a bottom port into a scrubber S, and a cooled high temperature heat transfer fluid stream via an upper side port into the scrubber S to form a cooled substantially dust free gas stream exiting the scrubber S via a top port and a heated high temperature heat transfer fluid stream including substantially all of the dust from the of the substantially large particle free hot gas stream exiting the scrubber S via a lower side port, and

heating a working fluid stream from a power plant PP in a heat exchanger HE to form a heated working fluid stream and the cooled high temperature heat transfer fluid stream.

20. The method of claim 19, further comprising:

converting a portion of the heated working fluid stream in the power plant PP to a usable form of energy.

21. The apparatus of claim 19, wherein the scrubber S includes a packing structure.

22. The apparatus of claim 21, wherein the packing structure comprises a corrugated material and a non-corrugated material formed into a roll.