Cascade power system
First Claim
Patent Images
1. A cascade power system comprising:
- an energy extraction subsystem,a separation subsystem,a heat exchange subsystem,a heat recovery vapor generator (HRVG) subsystem anda condensation thermal compression (CTCSS) subsystem,where the system is adapted to establish two interacting working fluid cycles, one cycle utilizes a rich multi-component working fluid stream having a higher concentration of a lower boiling component and the other cycle utilizes a lean working multi-component working fluid stream having a lower concentration of the lower boiling component,where each stream is derived from a fully condensed incoming multi-component stream,where the separation subsystem is adapted to produce the lean working fluid stream and a rich make-up working fluid streams, which is combined with the fully condensed incoming multi-component stream to form the rich multi-component working fluid stream,where the heat exchange subsystem and the heat recovery vapor generator (HRVG) subsystem are adapted to heat and vaporize the lean working fluid stream and the rich working fluid stream from heat derived directly and/or indirectly from an external flue gas stream,where the energy extraction subsystem is adapted to extract energy from the lean working fluid stream and the rich working fluid stream in separate turbine or turbine stages,where the CTCSS subsystem is adapted to condense a spent rich stream to form the fully condensed incoming multi-component stream,where a flue gas flow rate is the same throughout the entire HRVG subsystem or is different in different portions of the HRVG subsystem andwhere an initial hot flue gas stream is cooled by a re-circulated portion of a spent flue gas stream exiting the HRVG subsystem prior to the flue gas stream entering the HRVG subsystem.
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Abstract
A cascade power system and a method are disclosed for using a high temperature flue gas stream to directly or indirectly vaporize a lean and rich stream derived from an incoming, multi-component, working fluid stream, extract energy from these streams, condensing a spent stream and repeating the vaporization, extraction and condensation cycle.
58 Citations
38 Claims
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1. A cascade power system comprising:
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an energy extraction subsystem, a separation subsystem, a heat exchange subsystem, a heat recovery vapor generator (HRVG) subsystem and a condensation thermal compression (CTCSS) subsystem, where the system is adapted to establish two interacting working fluid cycles, one cycle utilizes a rich multi-component working fluid stream having a higher concentration of a lower boiling component and the other cycle utilizes a lean working multi-component working fluid stream having a lower concentration of the lower boiling component, where each stream is derived from a fully condensed incoming multi-component stream, where the separation subsystem is adapted to produce the lean working fluid stream and a rich make-up working fluid streams, which is combined with the fully condensed incoming multi-component stream to form the rich multi-component working fluid stream, where the heat exchange subsystem and the heat recovery vapor generator (HRVG) subsystem are adapted to heat and vaporize the lean working fluid stream and the rich working fluid stream from heat derived directly and/or indirectly from an external flue gas stream, where the energy extraction subsystem is adapted to extract energy from the lean working fluid stream and the rich working fluid stream in separate turbine or turbine stages, where the CTCSS subsystem is adapted to condense a spent rich stream to form the fully condensed incoming multi-component stream, where a flue gas flow rate is the same throughout the entire HRVG subsystem or is different in different portions of the HRVG subsystem and where an initial hot flue gas stream is cooled by a re-circulated portion of a spent flue gas stream exiting the HRVG subsystem prior to the flue gas stream entering the HRVG subsystem. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 25, 26)
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11. A cascade power system comprising:
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a separation subsystem adapted to produce a lean working fluid stream and a rich working fluid stream from a fully condensed, rich incoming working fluid stream, where the fully condensed, rich incoming working fluid stream comprises a lower boiling component and a higher boiling component, where the lean working fluid stream comprises a lower concentration of the lower boiling component and the rich stream has a higher concentration of the lower boiling component, a heat exchange subsystem is adapted to heat and vaporize the rich working fluid stream indirectly from heat derived from a hot flue gas stream, a heat recovery vapor generator (HRVG) subsystem is adapted to vaporize the lean working fluid stream and to superheat the rich working fluid streams directly from heat derived from a cooled flue gas stream comprising a hot flue gas stream and a re-circulated portion of a spent flue gas stream exiting the HRVG subsystem, an energy extraction subsystem adapted to convert a portion of the thermal energy in the rich working fluid stream and the lean working fluid stream to a usable form of energy, and a condensation thermal compression (CTCSS) subsystem adapted to fully condensing a spent rich stream to form the fully condensed, rich incoming working fluid stream, where the system establishes two interacting working fluid cycles, a lean stream cycle and a rich stream cycle adapted to improve the efficiency of energy conversion of thermal energy from the external flue gas stream. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for efficient extraction of energy from a hot flue gas stream comprising the steps of:
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establishing two interacting vaporization and energy extraction cycles, where one cycle utilizes a multi-component fluid stream having a higher concentration of a lower boiling component of the multi-component fluid, a rich working fluid stream, and the other cycle utilizes a multi-component fluid stream having a higher concentration of a higher boiling component of the multi-component fluid, a lean working fluid stream, each stream being derived from a fully condensed incoming multi-component working fluid stream; vaporizing the lean and rich working fluid streams utilized in the two interacting cycles from heat derived directly and/or indirectly form a hot flue gas stream, where the direct heat transfer occurs between a cooled flue gas stream comprising a hot flue gas stream and a portion of a cool flue gas stream and the lean and rich working fluid streams, substreams thereof and stream derived therefrom; converting a portion of thermal energy associated with a stream derived from the rich and the lean working fluid streams and the rich working fluid stream to a usable form of energy to form a spent rich working fluid stream and a spent lean working fluid stream, separating a portion of the spent lean working fluid stream to form the lean working fluid stream and make-up stream, where the make-up stream has a composition the same or substantially the same as the incoming multi-component working fluid stream; and condensing the spent rich working fluid stream to form the fully condensed incoming multi-component working fluid stream in a condensation unit or a condensation thermal compression. - View Dependent Claims (22, 23, 24)
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27. A method comprising:
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combining a fully condensed incoming work fluid stream comprising a lower boiling point component and a higher boiling component and a pressurized fully condensed mixed stream to form a fully condensed rich working fluid stream, where the fully condensed incoming work fluid stream and the pressurized fully condensed mixed stream have the same or substantially the same composition; bringing the fully condensed rich working fluid stream into a first heat exchange relationship with a mixed stream to form a fully condensed mixed stream and a heated rich working fluid stream; bringing the heated rich working fluid stream into a second heat exchange relationship with a first cooled spent enriched lean working fluid substream to form a hotter rich working fluid stream and a cooler first cooled spent enriched lean working fluid substream; splitting the hotter rich working fluid stream into a first hotter rich working fluid substream and a second hotter rich working fluid substream; bringing the first hotter rich working fluid substream into a third heat exchange relationship with a spent enriched lean working fluid stream to form a first fully vaporized rich working fluid substream and a cooled spent enriched lean working fluid stream; bringing the second hotter rich working fluid substream into a forth heat exchange relationship with a lower pressure rich working fluid stream to form a second fully vaporized rich working fluid substream and a cooled lower pressure rich working fluid stream; combining the first fully vaporized working fluid substream and second rich working fluid substream to form a fully vaporized rich working fluid stream; splitting the fully vaporized rich working fluid stream into a third fully vaporized rich working fluid substream and a fourth fully vaporized rich working fluid substream; bringing the third fully vaporized rich working fluid substream into a fifth heat exchange relationship with a cooled external flue gas stream in a top part of a heat recovery vapor generator to form a superheated rich working fluid steam; adjusting a pressure of the superheated rich working fluid stream to a pressure of a high pressure turbine to form a pressure adjusted superheated rich working fluid stream; converting a portion of thermal energy in the pressure adjusted superheated rich working fluid stream into a first amount of a usable form of energy in the high pressure turbine to form the lower pressure rich working fluid stream; converting a portion of thermal energy in the cooled lower pressure rich working fluid stream into a second amount of a usable form of energy in a low pressure turbine to form a spent rich working fluid stream; adjusting a pressure of the fourth fully vaporized rich working fluid substream to a pressure of a partially vaporized, pressurized lean working fluid stream to form a pressure adjusted fourth fully vaporized rich working fluid substream; combining the pressure adjusted fourth fully vaporized rich working fluid substream with the partially vaporized, pressurized lean working fluid stream in a middle portion of the heat recovery vapor generator to form an enriched, partially vaporized, lean working fluid stream; bringing the enriched, partially vaporized, lean working fluid stream into a sixth heat exchange relationship with the cooled external flue gas stream in an upper part of the heat recovery vapor generator to form a fully vaporized, enriched lean working fluid stream; adjusting a pressure of the fully vaporized, enriched lean working fluid stream to a pressure of a low concentration working stream turbine to form a pressure adjusted fully vaporized, enriched lean working fluid stream; converting a portion of thermal energy in the pressure adjusted fully vaporized, enriched lean working fluid stream into a third amount of a usable form of energy in the low concentration working stream turbine to form the spent enriched lean working fluid stream; splitting the cooled spent enriched lean working fluid stream into the first cooled spent enriched lean working fluid substream and a second cooled spent enriched lean working fluid substream; bringing a pressurized liquid lean working fluid stream into a seventh heat exchange relationship with the cooled external flue gas stream in a lower part of the heat recovery vapor generator to form the partially vaporized, pressurized lean working fluid stream and a spent flue gas stream; scrubbing the second cooled spent enriched lean working fluid substream introduced in a lower part of a scrubber and a pressurized first lean liquid separator substream introduced in a top of the scrubber to form a lean liquid working fluid stream taken form a bottom of the scrubber and a rich vapor scrubber stream taken from a upper part of the scrubber; pressurizing the lean liquid working fluid stream to a desired higher pressure to form the pressurized lean liquid working fluid stream; combining the rich vapor scrubber stream and the cooler first cooled spent enriched lean working fluid substream to form a separator feed stream; separating the separator feed stream in a separator to form a lean liquid separator stream and a rich vapor separator stream; splitting the lean liquid separator stream into a first lean liquid separator substream and a second lean liquid separator substream; pressurizing the first lean liquid lean separator substream to a pressure sufficient to lift the stream to the top of the scrubber to form the pressurized first lean liquid separator substream; combining the second lean liquid separator substream and the rich vapor separator stream to form the mixed stream; condensing the spent rich working fluid stream to form the fully condensed incoming working fluid stream in a condenser or a condensation thermal compression (CTCSS); pressurizing the fully condensed mixed stream to a pressure the same or substantially the same as the fully condensed incoming working fluid stream to form the pressurized fully condensed mixed stream; splitting the spent external flue gas stream into a recycle external flue gas stream and a discard spent flue gas stream; pressurizing the recycle external flue gas stream in a re-circulation fan to form a pressurized external flue gas stream; and combining a hot external flue gas stream with the pressurized recycle external flue gas stream to form the cooled external flue gas stream. - View Dependent Claims (28, 29, 30)
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31. A method comprising:
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combining a fully condensed incoming work fluid stream comprising a lower boiling point component and a higher boiling component and a pressurized fully condensed mixed stream to form a fully condensed rich working fluid stream, where the fully condensed incoming work fluid stream and the pressurized fully condensed mixed stream have the same or substantially the same composition; bringing the fully condensed rich working fluid steam into a first heat exchange relationship with a mixed stream to form a fully condensed mixed stream and a heated rich working fluid steam; bringing the heated rich working fluid stream into a second heat exchange relationship with a first cooled spent enriched lean working fluid substream to form a hotter rich working fluid stream and a cooler first cooled spent enriched lean working fluid substream; splitting the hotter rich working fluid stream into a first hotter rich working fluid substream and a second hotter rich working fluid substream; bringing the first hotter rich working fluid substream into a third heat exchange relationship with a spent enriched lean working fluid stream to form a first fully vaporized rich working fluid substream and a cooled spent enriched lean working fluid steam; bringing the second hotter rich working fluid substream into a forth heat exchange relationship with a lower pressure rich working fluid stream to form a second fully vaporized rich working fluid substream and a cooled lower pressure rich working fluid stream; combining the first and second fully vaporized rich working fluid substreams to form a fully vaporized rich working fluid stream; splitting the fully vaporized rich working fluid stream into a third fully vaporized rich working fluid substream and a fourth fully vaporized rich working fluid substream; bringing the third fully vaporized rich working fluid substream into a fifth heat exchange relationship with a cooled external flue gas stream in a top part of a heat recovery vapor generator to form a superheated rich working fluid stream; adjusting a pressure of the superheated rich working fluid stream to a pressure of a high pressure turbine to form a pressure adjusted superheated rich working fluid stream; converting a portion of thermal energy in the pressure adjusted superheated rich working fluid stream into a first amount of a usable form of energy in the high pressure turbine to form the lower pressure rich working fluid stream; converting a portion of thermal energy in the cooled lower pressure rich working fluid stream into a second amount of a usable form of energy in a low pressure turbine to form a spent rich working fluid stream; splitting the fourth fully vaporized rich working fluid substream into a fifth fully vaporized rich working fluid substream and a sixth fully vaporized rich working fluid substream; combining the fifth fully vaporized rich working fluid substream with a partially vaporized, enriched lean working fluid stream in a middle portion of the heat recovery vapor generator to form an enriched, partially vaporized, pressurized lean working fluid stream; bringing the partially vaporized, enriched lean working fluid stream into a sixth heat exchange relationship with the cooled external flue gas stream in an upper part of the heat recovery vapor generator to form a fully vaporized, enriched lean working fluid stream; adjusting a pressure of the fully vaporized, enriched lean working fluid stream to a pressure of a low concentration working stream turbine to form a pressure adjusted fully vaporized, enriched lean working fluid stream; converting a portion of thermal energy in the pressure adjusted fully vaporized, enriched lean working fluid stream into a third amount of a usable form of energy in the low concentration working stream turbine to form the spent enriched lean working fluid stream; splitting the cooled spent enriched lean working fluid stream into-the first cooled spent enriched lean working fluid substream and a second cooled spent enriched lean working fluid substream; combining the sixth fully vaporized rich working fluid substream with a pressurized lean working fluid stream to form an enriched lean working fluid stream; bringing the enriched lean working fluid stream into a seventh heat exchange relationship with the cooled external flue gas stream to form the partially vaporized, enriched lean working fluid stream and a spent flue gas stream; scrubbing the second cooled spent enriched lean working fluid substream introduced in a lower part of a scrubber and a pressurized first lean liquid separator substream introduced in a top of the scrubber to form a lean liquid working fluid stream taken from a bottom of the scrubber and a rich vapor scrubber stream taken from a upper part of the scrubber; pressurizing the lean liquid working fluid stream to a desired higher pressure to form the pressurized lean liquid working fluid stream; combining the rich vapor scrubber stream and the cooler first cooled spent enriched lean working fluid substream to form a separator feed stream; separating the separator feed stream in a separator to form a lean liquid separator stream and a rich vapor separator stream; splitting the lean liquid separator stream into a first lean liquid separator substream and a second lean liquid separator substream; pressurizing the first lean liquid lean separator substream to a pressure sufficient to lift the stream to the top of the scrubber to form the pressurized first lean liquid separator substream; combining the second lean liquid separator substream and the rich vapor separator stream to form the mixed stream; condensing the spent rich working fluid stream to form the fully condensed incoming working fluid stream in a condenser or a condensation thermal compression (CTCSS); pressurizing the fully condensed mixed stream to a pressure the same or substantially the same as the fully condensed incoming working fluid stream to form the pressurized fully condensed mixed stream; splitting the spent external flue gas stream into a recycle external flue gas stream and a discard spent flue gas stream; pressurizing the recycle external flue gas stream in a re-circulation fan to form a pressurized external flue gas stream; and combining a hot external flue gas stream with the pressurized recycle external flue gas stream to form the cooled external flue gas stream. - View Dependent Claims (32, 33, 34)
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35. A method comprising:
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combining a fully condensed incoming work fluid stream comprising a lower boiling point component and a higher boiling component and a pressurized fully condensed mixed stream to form a fully condensed rich working fluid stream, where the fully condensed incoming work fluid stream and the fully condensed mixed steam have the same or substantially the same composition; bringing the fully condensed rich working fluid stream into a first heat exchange relationship with a mixed stream to form a fully condensed mixed stream and a heated rich working fluid stream; bringing the heated rich working fluid stream into a second heat exchange relationship with a first cooled spent enriched lean substream to form a hotter rich working fluid stream and a cooler first spent enriched lean working fluid substream; splitting the hotter rich working fluid stream into a first hotter rich working fluid substream and a second hotter rich working fluid substream; bringing the first hotter rich working fluid substream into a third heat exchange relationship with a spent enriched lean working fluid stream to form a first fully vaporized rich working fluid substream and the cooled spent enriched lean working fluid stream; bringing the second hotter rich working fluid substream into a forth heat exchange relationship with a lower pressure rich working fluid stream to form a second fully vaporized rich working fluid substream and a cooled lower pressure rich working fluid stream; combining the first and second fully vaporized rich working fluid substreams to form a fully vaporized rich working fluid steam, splitting the fully vaporized rich working fluid stream into a third fully vaporized rich working fluid substream and a fourth fully vaporized rich working fluid substream; bringing the third fully vaporized rich working fluid substream into a fifth heat exchange relationship with a cooled external flue gas stream in a top part of a heat recovery vapor generator to form a superheated rich working fluid stream; splitting the superheated rich working fluid stream into a first superheated rich working fluid substream and a second superheated rich working fluid substream; adjusting a pressure of the first superheated rich working fluid stream to a pressure of a high pressure turbine; converting a portion of thermal energy in the first superheated rich working fluid stream into a first amount of a usable form of energy in the high pressure turbine to form the lower pressure rich working fluid stream; converting a portion of thermal energy in the cooled lower pressure rich working fluid stream into a second amount of a usable form of energy in a low pressure turbine to form a spent rich working fluid stream; adjusting a pressure of the fourth vaporized rich working fluid substream to a pressure of a partially vaporized, pressurized lean working fluid stream; combining the pressure adjusted fourth vaporized rich working fluid substream with a pressurized lean working fluid stream to form an enriched lean working fluid stream; bringing the enriched lean working fluid stream into a sixth heat exchange relationship with the cooled external flue gas stream in the heat recovery vapor generator to form a fully vaporized, enriched lean working fluid stream; adjusting a pressure of the fully vaporized, enriched lean working fluid stream to a pressure of a low concentration working stream turbine to form a pressure adjusted fully vaporized, enriched lean working fluid stream; adjusting a pressure of the second superheated rich working fluid stream to the pressure of the low concentration working stream turbine to form a pressure adjusted second superheated rich working fluid stream; combining the pressure adjusted, fully vaporized, enriched lean working fluid stream and the pressure adjusted second superheated rich working fluid stream to form a fully vaporized richer enriched lean working fluid stream; converting a portion of thermal energy in the fully vaporized richer enriched lean working fluid stream into a third amount of a usable form of energy in the low concentration working stream turbine to form the spent enriched lean working fluid stream; splitting the cooled spent enriched lean working fluid stream into the first cooled spent enriched lean working fluid substream and a second cooled spent enriched lean working fluid substream; scrubbing the second cooled spent enriched lean working fluid substream introduced in a lower part of a scrubber and a pressurized first lean liquid separator substream introduced in a top of the scrubber to form a lean liquid working fluid stream taken from a bottom of the scrubber and a rich vapor scrubber stream taken from a upper part of the scrubber; pressurizing the lean liquid working fluid stream to a desired higher pressure to form the pressurized lean liquid working fluid stream; combining the rich vapor scrubber stream and the cooler first cooled spent enriched lean working fluid substream to form a separator feed stream; separating the separator feed stream in a separator to form a lean liquid separator stream and a rich vapor separator stream; splitting the lean liquid separator stream into a first lean liquid separator substream and a second lean liquid separator substream; pressurizing the first lean liquid lean separator substream to a pressure sufficient to lift the stream to the top of the scrubber to form the pressurized first lean liquid separator substream; combining the second lean liquid separator substream and the rich vapor separator stream to form the mixed stream; condensing the spent rich working fluid stream to form the fully condensed incoming working fluid stream in a condenser or a condensation thermal compression (CTCSS); pressurizing the fully condensed mixed stream to a pressure the same or substantially the same as the fully condensed incoming working fluid stream to form the pressurized fully condensed mixed stream; splitting the spent external flue gas stream into a recycle external flue gas stream and a discard spent flue gas stream; pressurizing the recycle external flue gas stream in a re-circulation fan to form a pressurized external flue gas stream and combining a hot external flue gas stream with the pressurized recycle external flue gas stream to form the cooled external flue gas stream. - View Dependent Claims (36, 37, 38)
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Specification