Systems and method for a waste heat-driven turbocharger system

• US 10,830,123 B2
• Filed: 12/14/2018
• Issued: 11/10/2020
• Est. Priority Date: 12/27/2017
• Status: Active Grant

• Current Assignee: Transportation IP Holdings, LLC (Westinghouse Air Brake Technologies Corporation)
• Original Assignee: Transportation IP Holdings, LLC (Westinghouse Air Brake Technologies Corporation)
• Inventors: Homison, Christopher Joseph, Johnson, Lukas, Loringer, Daniel Edward
• Primary Examiner(s): Nguyen, Hoang M
• Application Number:
  US16/220,389
• Publication Number:
  US 20190195121A1
• Time in Patent Office: 697 Days
• Field of Search: 606051-612, 60 39183, 60 3915, 60791, 60792, 60 3919
• 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: F02B 37/007 with exhaust-driven pumps arranged in parallel , e.g. at least one pump supplying alternatively
• CPC Class Codes: F02B 37/013 with exhaust-driven pumps arranged in series
• CPC Class Codes: F02B 37/10 at least one pump being alternatively or simultaneously driven by exhaust and other drive, e.g. by pressurised fluid from a reservoir or an engine-driven pump
• CPC Class Codes: F02C 6/12 Turbochargers, i.e. plants for augmenting mechanical power output of internal-combustion piston engines by increase of charge pressure
• CPC Class Codes: F02C 6/18 using the waste heat of gas-turbine plants outside the plants themselves, e.g. gas-turbine power heat plants using waste heat as source of energy for refrigeration plants F25B27/02; using the waste heat of a gasturbine for steam generation or in a steam cycle see F01K23/10
• CPC Class Codes: F02C 7/10 by means of regenerative heat-exchangers
• CPC Class Codes: F02C 7/143 before or between the compressor stages
• CPC Class Codes: F02C 9/16 Control of working fluid flow F02C9/48 takes precedence; control of air-intake flow F02C7/057
• CPC Class Codes: F02C 9/28 Regulating systems responsive to plant or ambient parameters, e.g. temperature, pressure, rotor speed F02C9/30 - F02C9/38, F02C9/44 take precedence
• CPC Class Codes: F05D 2220/40 in turbochargers
• CPC Class Codes: F05D 2220/62 with energy recovery turbines
• CPC Class Codes: F05D 2260/20 Heat transfer, e.g. cooling
• CPC Class Codes: F05D 2260/42 Storage of energy
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Systems and methods are provided for a waste heat-driven turbocharger system. In one example, a system for use with a power generator having a rotary machine including a combustor and an exhaust passage flowing exhaust gases from the combustor comprises: a heat exchanger positioned in the exhaust passage; and a turbocharger system, comprising: at least one low pressure turbocharger including a low pressure turbine coupled to an outlet of the heat exchanger and a low pressure compressor coupled to an inlet of the heat exchanger; at least one mid-pressure turbocharger including a mid-pressure turbine coupled to the outlet and a mid-pressure compressor coupled to the low pressure compressor; and at least one high pressure turbocharger including a high pressure turbine arranged in series or parallel with the mid-pressure turbine and a high pressure compressor arranged in series with the mid-pressure compressor and coupled to the combustor of the rotary machine.

Claims

1. A system for use with a power generator having a rotary machine including a combustor and an exhaust passage flowing exhaust gases from the combustor, comprising:

a heat exchanger positioned in the exhaust passage; and

a turbocharger system, comprising;

at least one low pressure turbocharger including a low pressure turbine fluidly coupled to an outlet of the heat exchanger and a low pressure compressor fluidly coupled to an inlet of the heat exchanger;

at least one mid-pressure turbocharger including a mid-pressure turbine fluidly coupled to the outlet of the heat exchanger and a mid-pressure compressor fluidly coupled to the low pressure compressor; and

at least one high pressure turbocharger including a high pressure turbine arranged in series or parallel with the mid-pressure turbine and a high pressure compressor arranged in series with the mid-pressure compressor and fluidly coupled to the combustor of the rotary machine.

2. The system of claim 1, wherein the high pressure turbine is arranged in series with the mid-pressure turbine, the high pressure turbine receiving air flow directly from an outlet of the mid-pressure turbine.

3. The system of claim 1, wherein the high pressure turbine is arranged in parallel with the mid-pressure turbine, each of the high pressure turbine and the mid-pressure turbine receiving heated, compressed air flow from the outlet of the heat exchanger.

4. The system of claim 1, further comprising a turbine backpressure valve arranged in a gas flow path downstream of an outlet of the high pressure turbine.

5. The system of claim 4, wherein the turbocharger system is configured to deliver auxiliary compressed air from the high pressure compressor to the combustor of the rotary machine, and further comprising a controller including instructions stored on memory, than when executed during operation of the turbocharger system, cause the controller to:

adjust a position of the turbine backpressure valve based on pressure and flow conditions of the turbocharger system and a desired flow rate of the auxiliary compressed air.

6. The system of claim 1, wherein the rotary machine includes a turbine section and a compressor section separate from the turbocharger system, and each of the at least one low pressure turbocharger, the mid-pressure turbocharger, the high pressure turbocharger, and the rotary machine rotate independently of one another.

7. The system of claim 1, wherein a first intercooler is positioned in a first gas flow path between an outlet of the low pressure compressor and an inlet of the mid-pressure compressor, and a second intercooler is positioned in a second gas flow path between an outlet of the mid-pressure compressor and an inlet of the high pressure compressor.

8. The system of claim 1, wherein the heat exchanger is configured to transfer heat from the exhaust gases flowing in the exhaust passage of the rotary machine to compressed air flowing through the heat exchanger from the low pressure compressor.

9. A method for a turbocharger system of a power generation system, comprising:

at a controller receiving input data from a sensor, adjusting a position of a turbine backpressure valve comprising an actuator and included in the turbocharger system adapted to supply auxiliary compressed air to a rotary machine based on operating conditions of the turbocharger system and the rotary machine, the turbocharger system further including at least one low pressure turbocharger, the at least one low pressure turbocharger supplying compressed air to a heat exchanger arranged in an exhaust passage of the rotary machine, and a high pressure turbocharger including a high pressure turbine, the turbine backpressure valve arranged downstream of the high pressure turbine, and each of the at least one low pressure turbocharger and the high pressure turbocharger receiving heated, compressed air from the heat exchanger to drive rotation of the at least one low pressure turbocharger and the high pressure turbocharger, respectively.

10. The method of claim 9, wherein adjusting the position of the turbine backpressure valve includes decreasing an opening of the turbine backpressure valve in response to a load of the rotary machine decreasing.

11. The method of claim 9, wherein adjusting the position of the turbine backpressure valve includes increasing an opening of the turbine backpressure valve in response to a load of the rotary machine increasing.

12. The method of claim 9, wherein adjusting the position of the turbine backpressure valve includes adjusting the position of the turbine backpressure valve based on pressure and flow conditions of the turbocharger system while supplying the auxiliary compressed air to the rotary machine from a high pressure compressor of the high pressure turbocharger, the high pressure turbine driving rotation of the high pressure compressor.

13. The method of claim 12, further comprising combusting both compressed, ambient air from a compressor of the rotary machine and the auxiliary compressed air at a combustor of the rotary machine and supplying combusted exhaust gases to the heat exchanger, downstream of a turbine of the rotary machine.

14. The method of claim 13, further comprising heating the compressed air from a low pressure compressor of the low pressure turbocharger at the heat exchanger via the combusted exhaust gases flowing through the heat exchanger.

15. The method of claim 9, further comprising supplying heated, compressed air from the heat exchanger to each of a low pressure turbine of the low pressure turbocharger and the high pressure turbine, and wherein adjusting the position of the turbine backpressure valve adjusts an amount of air flowing through each of the low pressure turbine and the high pressure turbine.

16. The method of claim 9, wherein adjusting the position of the turbine backpressure valve includes adjusting the turbine backpressure valve into a plurality of positions between and including fully open and fully closed as the operating conditions of the turbocharger system change, and based on each of a work load distribution between the low pressure turbocharger and the high pressure turbocharger and a choke limit of the high pressure turbocharger.

17. A system for power generation using a rotary machine including a turbine section, compressor section, and combustor, comprising:

a heat exchanger positioned in an exhaust passage of the rotary machine;

a turbocharger system, comprising;

a low pressure turbocharger stage including at least one low pressure turbocharger, an outlet of a compressor of the at least one low pressure turbocharger fluidly coupled to an inlet of the heat exchanger and an inlet to a turbine of the at least one low pressure turbocharger fluidly coupled to an outlet of the heat exchanger;

a mid-pressure turbocharger including a mid-pressure turbine driving rotation of a mid-pressure compressor, the mid-pressure compressor fluidly coupled to the outlet of the compressor of the at least one low pressure turbocharger with a first intercooler positioned therebetween and the mid-pressure turbine fluidly coupled to the outlet of the heat exchanger;

a high pressure turbocharger including a high pressure turbine driving rotation of a high pressure compressor, the high pressure compressor fluidly coupled to an outlet of the mid-pressure compressor with a second intercooler positioned therebetween and the high pressure turbine adapted to receive heated, compressed air from the heat exchanger; and

a turbine backpressure valve positioned in a flow path downstream of the high pressure turbine; and

a controller including instructions stored on memory, than when executed during operation of the turbocharger system, cause the controller to;

adjust a position of the turbine backpressure valve based on pressure and flow conditions of the turbocharger system.

18. The system of claim 17, wherein adjusting the position of the turbine backpressure valve based on the pressure and flow conditions of the turbocharger system includes adjusting the position of the turbine backpressure valve to a further closed position as the high pressure compressor approaches choke conditions.

19. The system of claim 17, wherein the high pressure turbine is fluidly coupled to an outlet of the mid-pressure turbine, the high pressure turbine arranged in series with the mid-pressure turbine.

20. The system of claim 17, wherein the high pressure turbine is fluidly coupled to the outlet of the heat exchanger, the high pressure turbine arranged in parallel with the mid-pressure turbine.