Apparatus and Method for Combusting a Fuel at High Pressure and High Temperature, and Associated System and Device

• US 20100300063A1
• Filed: 02/26/2010
• Published: 12/02/2010
• Est. Priority Date: 02/26/2009
• Status: Active Grant

• Current Assignee: 8 Rivers Capital, LLC, Palmer Labs, LLC
• Original Assignee: Palmer Labs, LLC
• Inventors: Allam, Rodney John, Brown, Glenn William JR., Palmer, Miles R.
• Granted Patent: US 9,416,728 B2
• Time in Patent Office: Days
• US Class Current: 60/39.461
• CPC Class Codes: F01K 13/00 General layout or general methods of operation of complete plants
• CPC Class Codes: F01K 23/10 with exhaust fluid of one cycle heating the fluid in another cycle F01K17/025 takes precedence
• CPC Class Codes: F01K 25/103 Carbon dioxide F01K25/065 takes precedence
• CPC Class Codes: F01K 3/185 using waste heat from outside the plant F02G5/00 takes precedence
• CPC Class Codes: F01K 3/186 using electric heat
• CPC Class Codes: F02C 1/005 being recirculated
• CPC Class Codes: F02C 3/04 having a turbine driving a compressor power transmission arrangements F02C7/36; control of working fluid flow F02C9/16
• CPC Class Codes: F02C 3/20 using a special fuel, oxidant, or dilution fluid to generate the combustion products
• CPC Class Codes: F02C 3/22 the fuel or oxidant being gaseous at standard temperature and pressure F02C3/28 takes precedence
• CPC Class Codes: F02C 3/34 with recycling of part of the working fluid, i.e. semi-closed cycles with combustion products in the closed part of the cycle
• CPC Class Codes: F02C 7/00 Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants controlling F02C9/00
• CPC Class Codes: F02G 5/02 Profiting from waste heat of exhaust gases
• CPC Class Codes: F05D 2260/203 by transpiration cooling
• CPC Class Codes: F05D 2260/61 Removal of CO2
• CPC Class Codes: F05D 2260/611 Sequestration of CO2
• CPC Class Codes: F22B 35/12 operating at critical or supercritical pressure
• CPC Class Codes: F23D 1/00 Burners for combustion of pulverulent fuel disposition of burners F23C
• CPC Class Codes: F23J 15/027 using cyclone separators
• CPC Class Codes: F23J 2900/15025 Cyclone walls forming heat exchangers
• CPC Class Codes: F23L 2900/07001 Injecting synthetic air, i.e. a combustion supporting mixture made of pure oxygen and an inert gas, e.g. nitrogen or recycled fumes
• CPC Class Codes: F23L 2900/07002 : Injecting inert gas, other than steam or evaporated water, into the combustion chambers
• CPC Class Codes: F23L 2900/07003 : Controlling the inert gas supply
• CPC Class Codes: F23L 2900/07007 : using specific ranges of oxygen percentage
• CPC Class Codes: F23L 2900/07008 : Injection of water into the combustion chamber
• CPC Class Codes: F23L 7/002 : Supplying water
• CPC Class Codes: F23L 7/007 : Supplying oxygen or oxygen-enriched air
• CPC Class Codes: F23M 2900/05004 : Special materials for walls or lining
• CPC Class Codes: F23M 5/00 : Casings; Linings; Walls
• CPC Class Codes: F23M 5/08 : Cooling thereof; Tube walls
• CPC Class Codes: F23M 5/085 : using air or other gas as the cooling medium
• CPC Class Codes: F23R 2900/00004 : Preventing formation of deposits on surfaces of gas turbine components, e.g. coke deposits
• CPC Class Codes: F23R 3/005 : Combined with pressure or heat exchangers
• CPC Class Codes: F23R 3/06 : Arrangement of apertures along the flame tube
• CPC Class Codes: F25J 2230/06 : Adiabatic compressor, i.e. without interstage cooling
• CPC Class Codes: F25J 2240/70 : Steam turbine, e.g. used in a Rankine cycle
• CPC Class Codes: F25J 2240/82 : with waste heat recovery, e.g. in a combined cycle, i.e. for generating steam used in a Rankine cycle
• CPC Class Codes: F25J 2260/80 : Integration in an installation using carbon dioxide, e.g. for EOR, sequestration, refrigeration etc.
• CPC Class Codes: F25J 3/04018 : of main feed air
• CPC Class Codes: F25J 3/04533 : for the direct combustion of fuels in a power plant, so-called "oxyfuel combustion"
• CPC Class Codes: F25J 3/04545 : for the gasification of solid or heavy liquid fuels, e.g. integrated gasification combined cycle [IGCC]
• CPC Class Codes: F25J 3/04618 : for cooling an air stream fed to the air fractionation unit
• CPC Class Codes: Y02E 20/32 : Direct CO2 mitigation
• CPC Class Codes: Y02E 20/34 : Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Abstract

A combustor apparatus is provided, comprising a mixing arrangement for mixing a carbonaceous fuel with enriched oxygen and a working fluid to form a fuel mixture. A combustion chamber is at least partially defined by a transpiration member. The transpiration member is at least partially surrounded by a pressure containment member. The combustion chamber has opposed inlet and outlet portions. The inlet portion of the combustion chamber is configured to receive the fuel mixture for the fuel mixture to be combusted at a combustion temperature. The combustion chamber is further configured to direct the resulting combustion product toward the outlet portion. The transpiration member directs a transpiration substance therethrough toward the combustion chamber for buffering interaction between the combustion product and the transpiration member. Associated systems, apparatuses, and methods are also provided.

Claims

1. A combustor apparatus, comprising:

a mixing arrangement configured to mix a carbonaceous fuel with enriched oxygen and a working fluid to form a fuel mixture; and

a combustion chamber at least partially defined by a transpiration member, the transpiration member further being at least partially surrounded by a pressure containment member, the combustion chamber having an inlet portion and an opposing outlet portion, the inlet portion of the combustion chamber being configured to receive the fuel mixture for the fuel mixture to be combusted within the combustion chamber at a combustion temperature to form a combustion product, the combustion chamber being further configured to direct the combustion product toward the outlet portion, the transpiration member being configured to direct a transpiration substance therethrough toward the combustion chamber for buffering interaction between the combustion product and the transpiration member.

2. An apparatus according to claim 1, wherein the mixing arrangement is further configured to mix one of a solid carbonaceous fuel, a liquid carbonaceous fuel, and a gaseous carbonaceous fuel with the enriched oxygen and the working fluid.

3. An apparatus according to claim 1, wherein the working fluid comprises one of carbon dioxide and water.

4. An apparatus according to claim 1, wherein the enriched oxygen comprises oxygen having a molar purity of greater than about 85%.

5. An apparatus according to claim 1, wherein the carbonaceous fuel is a particulate solid, and the mixing arrangement is further configured to mix the particulate solid carbonaceous fuel with a fluidizing substance.

6. An apparatus according to claim 5, wherein the particulate solid carbonaceous fuel has an average particle size of between about 50 microns and about 200 microns.

7. An apparatus according to claim 5, wherein the fluidizing substance comprises one of water and liquid CO₂ having a density of between about 450 kg/m³ and about 1100 kg/m³, the fluidizing substance cooperating with the particulate solid carbonaceous fuel to form a slurry having between about 25 weight % and about 55 weight % of the particulate solid carbonaceous fuel.

8. An apparatus according to claim 1, wherein the combustion chamber is further configured to receive the fuel mixture in the inlet portion thereof at a pressure of between about 40 bar and about 500 bar.

9. An apparatus according to claim 1, wherein the transpiration substance is configured to be introduced into the combustion chamber via the transpiration member so as to regulate an exit mixture of the transpiration substance and the combustion product about the outlet portion of the combustion chamber at a temperature of between about 500°

C. and about 2000°

C.

10. An apparatus according to claim 1, wherein the combustion temperature is configured such that any incombustible elements in the carbonaceous fuel are liquefied within the combustion product.

11. An apparatus according to claim 10, wherein the transpiration substance comprises carbon dioxide directed through the transpiration member such that the transpiration substance forms a buffer layer immediately adjacent to the transpiration member within the combustion chamber, the buffer layer being configured to buffer interaction between the transpiration member and the liquefied incombustible elements and heat associated with the combustion product.

12. An apparatus according to claim 1, wherein the combustion temperature is between about 1300°

C. and about 3,500°

C.

13. An apparatus according to claim 1, further comprising a heat removal device associated with the pressure containment member and configured to control a temperature thereof.

14. An apparatus according to claim 13, wherein the heat removal device comprises a heat transfer jacket having a liquid circulated therein.

15. A combustion method, comprising:

mixing a carbonaceous fuel with enriched oxygen and a working fluid using a mixing arrangement to form a fuel mixture;

receiving the fuel mixture in an inlet portion of a combustion chamber defined by a transpiration member, the transpiration member further being at least partially surrounded by a pressure containment member;

combusting the fuel mixture within the combustion chamber at a combustion temperature to form a combustion product;

directing the combustion product toward an outlet portion of the combustion chamber; and

directing a transpiration substance through the transpiration member toward the combustion chamber such that the transpiration substance buffers interaction between the combustion product and the transpiration member.

16. A method according to claim 15, wherein mixing a carbonaceous fuel with enriched oxygen and a working fluid further comprises mixing one of a solid carbonaceous fuel, a liquid carbonaceous fuel, and a gaseous carbonaceous fuel with enriched oxygen and the working fluid.

17. A method according to claim 15, wherein mixing a carbonaceous fuel with enriched oxygen and a working fluid further comprises mixing a carbonaceous fuel with enriched oxygen and a working fluid comprising one of carbon dioxide and water.

18. A method according to claim 15, wherein mixing a carbonaceous fuel with enriched oxygen and a working fluid further comprises mixing a carbonaceous fuel with enriched oxygen having a molar purity of greater than about 85% and the working fluid.

19. A method according to claim 15, wherein the carbonaceous fuel is a particulate solid, and the method further comprises mixing the particulate solid carbonaceous fuel with a fluidizing substance via the mixing arrangement.

20. A method according to claim 19, wherein mixing the particulate solid carbonaceous fuel with a fluidizing substance further comprises mixing the particulate solid carbonaceous fuel having an average particle size of between about 50 microns and about 200 microns with a fluidizing substance.

21. A method according to claim 19, wherein mixing the particulate solid carbonaceous fuel with a fluidizing substance further comprises mixing the particulate solid carbonaceous fuel with a fluidizing substance comprising one of water and liquid CO₂ having a density of between about 450 kg/m³ and about 1100 kg/m³, to form a slurry having between about 25 weight % and about 55 weight % of the particulate solid carbonaceous fuel.

22. A method according to claim 15, wherein receiving the fuel mixture further comprises receiving the fuel mixture in the inlet portion of the combustion chamber at a pressure of between about 40 bar and about 500 bar.

23. A method according to claim 15, wherein directing a transpiration substance further comprises directing a transpiration substance through the transpiration member toward the combustion chamber such that the transpiration introduced into the combustion chamber via the transpiration member regulates an exit mixture of the transpiration substance and the combustion product about the outlet portion of the combustion chamber at a temperature of between about 500°

C. and about 2000°

C.

24. A method according to claim 15, wherein combusting the fuel mixture within the combustion chamber at a combustion temperature further comprises combusting the fuel mixture within the combustion chamber at a combustion temperature configured such that any incombustible elements in the carbonaceous fuel are liquefied within the combustion product.

25. A method according to claim 24, wherein directing a transpiration substance through the transpiration member further comprises directing a transpiration substance comprising carbon dioxide through the transpiration member such that the transpiration substance forms a buffer layer immediately adjacent to the transpiration member within the combustion chamber, the buffer layer being configured to buffer interaction between the transpiration member and the liquefied incombustible elements and heat associated with the combustion product.

26. A method according to claim 15, wherein combusting the fuel mixture within the combustion chamber at a combustion temperature further comprises combusting the fuel mixture within the combustion chamber at a combustion temperature of between about 1300°

C. and about 3,500°

C.

27. A method according to claim 15, further comprising controlling a temperature of the pressure containment member with a heat removal device associated therewith.

28. A method according to claim 27, wherein controlling a temperature of the pressure containment member comprises controlling a temperature of the pressure containment member with a heat removal device comprising a heat transfer jacket associated with the pressure containment member and having a liquid circulated therein.

29. An energy generation system, comprising:

a combustor apparatus, including;

a mixing arrangement configured to mix a carbonaceous fuel with enriched oxygen and a working fluid to form a fuel mixture; and

a combustion chamber at least partially defined by a transpiration member, the transpiration member further being at least partially surrounded by a pressure containment member, the combustion chamber having an inlet portion and an opposing outlet portion, the inlet portion of the combustion chamber being configured to receive the fuel mixture for the fuel mixture to be combusted within the combustion chamber at a combustion temperature to form a combustion product, the combustion chamber being further configured to direct the combustion product toward the outlet portion, the transpiration member being configured to direct a transpiration substance therethrough toward the combustion chamber for buffering interaction between the combustion product and the transpiration member; and

a transformation apparatus configured to receive the combustion product, the transformation apparatus being responsive to the combustion product to transform energy associated therewith into kinetic energy.

30. A system according to claim 29, wherein the mixing arrangement is further configured to mix one of a solid carbonaceous fuel, a liquid carbonaceous fuel, and a gaseous carbonaceous fuel with enriched oxygen and the working fluid.

31. A system according to claim 29, wherein the working fluid comprises one of carbon dioxide and water.

32. A system according to claim 29, wherein the enriched oxygen comprises oxygen having a molar purity of greater than about 85%.

33. A system according to claim 29, wherein the carbonaceous fuel is a particulate solid having an average particle size of between about 50 microns and about 200 microns, and the mixing arrangement is further configured to mix the particulate solid carbonaceous fuel with a fluidizing substance comprising one of water and liquid CO₂ having a density of between about 450 kg/m³ and about 1100 kg/m³, the fluidizing substance cooperating with the particulate solid carbonaceous fuel to form a slurry having between about 25 weight % and about 55 weight % of the particulate solid carbonaceous fuel.

34. A system according to claim 29, wherein the combustion chamber is further configured to receive the fuel mixture in the inlet portion thereof at a pressure of between about 40 bar and about 500 bar.

35. A system according to claim 29, wherein the transpiration substance is configured to be introduced into the combustion chamber via the transpiration member so as to regulate an exit mixture of the transpiration substance and the combustion product about the outlet portion of the combustion chamber at a temperature of between about 500°

C. and about 2000°

C.

36. A system according to claim 29, wherein the combustion temperature is configured such that any incombustible elements in the carbonaceous fuel are liquefied within the combustion product.

37. A system according to claim 29, wherein the combustion temperature is between about 1300°

C. and about 3,500°

C.

38. A system according to claim 29, wherein the carbonaceous fuel is a solid, and the system further comprises a separator apparatus disposed between the combustor apparatus and the transformation apparatus, the separator apparatus being configured to substantially remove liquefied incombustible elements from the combustion product received thereby prior to the combustion product being directed to the transformation apparatus.

39. A system according to claim 38, wherein the transpiration substance is configured to be introduced into the combustion chamber via the transpiration member so as to regulate a mixture of the transpiration substance and the combustion product entering the separator apparatus above a liquification temperature of the incombustible elements.

40. A system according to claim 39, further comprising a transpiration substance delivery device disposed subsequently to the separator apparatus and configured to deliver the transpiration substance to the combustion product having the liquefied incombustible elements substantially removed therefrom so as to regulate a mixture of the transpiration substance and the combustion product entering the transformation apparatus at a temperature of between about 500°

C. and about 2000°

C.

41. A system according to claim 38, wherein the separator apparatus further comprises a plurality of serially arranged centrifugal separator devices, each centrifugal separator device having a plurality of centrifugal separator elements operably arranged in parallel.

42. A system according to claim 38, wherein the liquefied incombustible elements removed from the combustion product by the separator apparatus are removably collected in a sump associated with the separator apparatus.

43. A system according to claim 38, wherein the separator apparatus is configured to be one of housed by the pressure containment member and defined by a pressure-containing housing.

44. A system according to claim 43, wherein the separator apparatus further comprises a heat-dispersion system operably engaged with the one of the pressure containment member and the pressure-containing housing so as to remove heat therefrom.

45. A system according to claim 44, wherein the heat-dispersion system comprises a heat transfer jacket having a liquid circulated therein.

46. A system according to claim 38, wherein surfaces of the separator apparatus exposed to one of the combustion product and the liquefied incombustible elements associated therewith are comprised of a material configured to have at least one of a high temperature resistance, a high corrosion resistance, and a low thermal conductivity.

47. A system according to claim 29, wherein the transpiration substance comprises carbon dioxide directed through the transpiration member such that the transpiration substance forms a buffer layer immediately adjacent to the transpiration member within the combustion chamber, the buffer layer being configured to buffer interaction between the transpiration member and the liquefied incombustible elements and heat associated with the combustion product.

48. A system according to claim 29, wherein the combustor apparatus further comprises a heat removal device associated with the pressure containment member and configured to control a temperature thereof, the heat removal device comprising a heat transfer jacket having a liquid circulated therein.

49. A system according to claim 29, wherein the combustor apparatus is configured such that the combustion product includes greater than about 500 ppm O₂ and less than about 50 ppm CO.

50. A system according to claim 29, wherein the combustor apparatus is configured such that the combustion product includes H₂ and CO at a combined concentration of greater than about 1%, and less than about 10 ppm O₂.

51. A system according to claim 29, wherein the transformation apparatus comprises a turbine device, the turbine device being responsive to the combustion product so as to transform the energy associated therewith into kinetic energy.

52. A system according to claim 29, wherein the transformation apparatus further comprises a generator device configured to transform the kinetic energy into electricity.

53. A separator apparatus adapted to be implemented with a combustor apparatus configured to combust a solid carbonaceous fuel to form a combustion product such that any incombustible elements in the solid carbonaceous fuel are liquefied within the combustion product, said separator apparatus comprising:

a plurality of serially arranged centrifugal separator devices, including an inlet centrifugal separator device configured to receive the combustion product and the liquefied incombustible elements associated therewith and an outlet centrifugal separator device configured to exhaust the combustion product having the liquefied incombustible elements substantially removed therefrom, each centrifugal separator device having a plurality of centrifugal separator elements operably arranged in parallel, each centrifugal separation element being configured to remove at least a portion of the liquefied incombustible elements from the combustion product and to direct the at least a portion of the liquefied incombustible elements to a sump; and

a pressure-containing housing configured to house the centrifugal separator devices and the sump.

54. A separator apparatus according to claim 53, further comprising a heat-dispersion system operably engaged with the pressure-containing housing so as to remove heat therefrom.

55. A separator apparatus according to claim 54, wherein the heat-dispersion system comprises a heat transfer jacket having a liquid circulated therein.

56. A separator apparatus according to claim 55, further comprising a heat recovery device operably engaged with the heat transfer jacket, the heat recovery device being configured to receive the liquid circulated in the heat transfer jacket and to recover thermal energy from the liquid.

57. A separator apparatus according to claim 53, wherein surfaces of the separator apparatus exposed to one of the combustion product and the liquefied incombustible elements associated therewith are comprised of a material configured to have at least one of a high temperature resistance, a high corrosion resistance, and a low thermal conductivity.

58. A separator apparatus according to claim 53, wherein the separator apparatus is configured to substantially remove the liquefied incombustible elements from the combustion product and to maintain the incombustible elements in a low viscosity liquid form at least until removal thereof from the sump.