Heat engine and heat to electricity systems and methods with working fluid mass management control

• US 8,613,195 B2
• Filed: 10/21/2011
• Issued: 12/24/2013
• Est. Priority Date: 09/17/2009
• Status: Active Grant

• Current Assignee: Echogen Power Systems, LLC
• Original Assignee: Echogen Power Systems, LLC
• Inventors: Held, Timothy J., Hostler, Stephen, Miller, Jason D., Vermeersch, Michael, Xie, Tao
• Primary Examiner(s): NGUYEN, HOANG M
• Application Number:
  US13/278,705
• Publication Number:
  US 20120047892A1
• Time in Patent Office: 795 Days
• Field of Search: 606/45, 606/54, 606/55, 60682-683, 606/60, 606/66, 606/67
• US Class Current: 60/660
• 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 7/08 Control means specially adapted therefor
• CPC Class Codes: F24H 2240/12 with thermodynamic cycle for converting thermal energy to mechanical power to produce electrical energy

Abstract

Various thermodynamic power-generating cycles employ a mass management system to regulate the pressure and amount of working fluid circulating throughout the working fluid circuits. The mass management systems may have a mass control tank fluidly coupled to the working fluid circuit at one or more strategically-located tie-in points. A heat exchanger coil may be used in conjunction with the mass control tank to regulate the temperature of the fluid within the mass control tank, and thereby determine whether working fluid is either extracted from or injected into the working fluid circuit. Regulating the pressure and amount of working fluid in the working fluid circuit helps selectively increase or decrease the suction pressure of the pump, which can increase system efficiency.

Claims

1. A heat engine system for converting thermal energy into mechanical energy, comprising:

a working fluid circuit configured to circulate a working fluid through a high pressure side and a low pressure side of the working fluid circuit, the working fluid circuit further comprises;

a heat exchanger configured to be coupled to and in thermal communication with a heat source and to transfer thermal energy from the heat source to the working fluid within the high pressure side;

an expander in fluid communication with the heat exchanger and fluidly arranged between the high and low pressure sides;

a recuperator fluidly coupled to the expander and configured to transfer thermal energy between the high and low pressure sides;

a cooler in fluid communication with the recuperator and configured to control a temperature of the working fluid in the low pressure side; and

a pump fluidly coupled to the cooler and configured to circulate the working fluid through the working fluid circuit; and

a mass management system fluidly coupled to the working fluid circuit and configured to regulate a pressure and an amount of the working fluid within the working fluid circuit, the mass management system further comprises;

a mass control tank fluidly coupled to the high pressure side at a first tie-in point located upstream of the expander and to the low pressure side at a second tie-in point located upstream of an inlet of the pump; and

a control system communicably coupled to the working fluid circuit at a first sensor disposed upstream to the inlet of the pump and at a second sensor disposed downstream from an outlet of the pump, and communicably coupled to the mass control tank at a third sensor arranged either within or adjacent the mass control tank.

2. The system of claim 1, wherein the working fluid comprises carbon dioxide.

3. The system of claim 1, wherein the mass management system further comprises a heat exchanger coil configured to transfer heat to and from the mass control tank.

4. The system of claim 3, wherein the heat exchanger coil is disposed within the mass control tank.

5. The system of claim 3, wherein the heat exchanger coil is fluidly coupled to the cooler and configured to use thermal fluid derived from the cooler to heat or cool the working fluid in the mass control tank.

6. The system of claim 3, wherein the heat exchanger coil is fluidly coupled to the working fluid circuit downstream from the pump and configured to use the working fluid discharged from the pump to heat or cool the working fluid in the mass control tank.

7. The system of claim 1, further comprising:

a first valve arranged between the mass control tank and the first tie-in point; and

a second valve arranged between the mass control tank and the second tie-in point.

8. The system of claim 7, wherein the control system is operatively coupled to and configured to selectively actuate the first and second valves in response to operating parameters derived from the first, second, and third sensors.

9. The system of claim 7, wherein the mass control tank is further fluidly coupled to the high pressure side of the working fluid circuit at a third tie-in point arranged downstream from the pump, a third valve is disposed between the mass control tank and the third tie-in point, and the control system is operatively coupled to and configured to selectively actuate the third valve in response to operating parameters derived from the first, second, or third sensors.

10. The system of claim 1, wherein the mass management system further comprises a transfer pump arranged between the mass control tank and the second tie-in point, wherein the transfer pump is configured to pump the working fluid from the mass control tank and into the working fluid circuit via the second tie-in point.

11. The system of claim 1, wherein the mass management system further comprises a vapor compression refrigeration cycle having a vapor compressor and a condenser fluidly coupled to the mass control tank.

12. The system of claim 1, wherein the mass management system further comprises an external heater communicable with the mass control tank to transfer thermal energy thereto.

13. A method for regulating a pressure and an amount of a working fluid in a thermodynamic cycle, comprising:

placing a thermal energy source in thermal communication with a heat exchanger arranged within a working fluid circuit, the working fluid circuit having a high pressure side and a low pressure side;

circulating the working fluid through the working fluid circuit with a pump;

expanding the working fluid in an expander to generate mechanical energy;

sensing operating parameters of the working fluid circuit with first and second sensor sets communicably coupled to a control system, wherein the first sensor set is configured to sense at least one of a pressure and a temperature proximate an inlet of the pump, and the second sensor set is configured to sense at least one of the pressure and the temperature proximate an outlet of the pump;

extracting the working fluid from the working fluid circuit at a first tie-in point arranged upstream of the expander in the high pressure side, wherein the first tie-in point is fluidly coupled to a mass control tank; and

injecting the working fluid from the mass control tank into the working fluid circuit via a second tie-in point arranged upstream of an inlet of the pump to increase a suction pressure of the pump.

14. The method of claim 13, further comprising extracting additional working fluid from the working fluid circuit at a third tie-in point arranged between the pump and the heat exchanger.

15. The method of claim 13, wherein injecting the working fluid from the mass control tank into the working fluid circuit via the second tie-in point further comprises pumping the working fluid into the working fluid circuit with a transfer pump arranged between the second tie-in point and the mass control tank.

16. The method of claim 13, further comprising sensing operating parameters of the mass control tank with a third sensor set configured to sense at least one of the pressure and the temperature either within or adjacent the mass control tank, wherein the third sensor set is communicably coupled to the control system.

17. The method of claim 13, further comprising cooling the working fluid within the mass control tank with a vapor compression refrigeration cycle having a vapor compressor and a condenser fluidly coupled to the mass control tank.

18. The method of claim 13, further comprising heating the working fluid within the mass control tank with an external heater in communication with the mass control tank.