Thermal energy conversion method

• US 8,794,002 B2
• Filed: 12/04/2009
• Issued: 08/05/2014
• 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., Hume, Brian F.
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): MIAN, SHAFIQ A
• Application Number:
  US12/631,400
• Publication Number:
  US 20110061387A1
• Time in Patent Office: 1,705 Days
• Field of Search: 60645-693
• US Class Current: 60/651
• 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: F01K 7/165 Controlling means specially adapted therefor
• CPC Class Codes: F24H 2240/12 with thermodynamic cycle for converting thermal energy to mechanical power to produce electrical energy
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A method for converting thermal energy into mechanical energy in a thermodynamic cycle includes placing a thermal energy source in thermal communication with a heat exchanger arranged in a working fluid circuit containing a working fluid (e.g., sc-CO₂) and having a high pressure side and a low pressure side. The method also includes regulating an amount of working fluid within the working fluid circuit via a mass management system having a working fluid vessel, pumping the working fluid through the working fluid circuit, and expanding the working fluid to generate mechanical energy. The method further includes directing the working fluid away from the expander through the working fluid circuit, controlling a flow of the working fluid in a supercritical state from the high pressure side to the working fluid vessel, and controlling a flow of the working fluid from the working fluid vessel to the low pressure side.

Claims

1. A method for converting thermal energy into mechanical energy with a working fluid in a closed loop 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, and the working fluid comprises carbon dioxide in a supercritical state in the high pressure side;

regulating an amount of working fluid within the working fluid circuit via a mass management system, the mass management system having a working fluid vessel fluidly connected to the low pressure side of the working fluid circuit;

pumping the working fluid through the working fluid circuit by operation of a pump, the pump being configured to supply working fluid in a supercritical or subcritical state;

expanding the working fluid in an expander to generate mechanical energy, the expander being fluidly coupled to the pump in the working fluid circuit;

directing the working fluid away from the expander through the working fluid circuit and back to the pump;

controlling a flow of the working fluid in a supercritical state from the high pressure side of the working fluid circuit to the working fluid vessel; and

controlling an amount of working fluid in a subcritical or supercritical state from the working fluid vessel to the low pressure side of the working fluid circuit and to the pump.

2. The method of claim 1, further comprising:

detecting a temperature of the working fluid in the working fluid circuit; and

controlling the temperature of the working fluid between the working fluid circuit and the working fluid vessel according to detected amounts of working fluid mass in the working fluid circuit.

3. The method of claim 1, further comprising:

detecting a pressure of the working fluid in the working fluid circuit; and

controlling the pressure of the working fluid between the working fluid circuit and the working fluid vessel according to detected amounts of working fluid mass in the working fluid circuit.

4. The method of claim 1, further comprising the step of controlling the thermodynamic cycle in the working fluid circuit to convert thermal energy into mechanical energy under ambient conditions.

5. The method of claim 1, further comprising the step of delivering a portion of the working fluid from the high pressure side of the working fluid circuit to the expander and cooling one or more parts of the expander with the portion of the working fluid.

6. The method of claim 5, further comprising cooling a coupling coupled to the expander with the portion of the working fluid from the high pressure side of the working fluid circuit.

7. The method of claim 5, further comprising cooling a coupling disposed between the expander and an alternator with the portion of the working fluid from the high pressure side of the working fluid circuit.

8. The method of claim 5, further comprising matching a pressure of the portion of the working fluid from the high pressure side of the working fluid circuit with a pressure of the working fluid at an inlet to the expander.

9. The method of claim 1, further comprising increasing a pressure of the working fluid in the high pressure side of the working fluid circuit with the pump, wherein the pump is a positive displacement pump.

10. The method of claim 1, further comprising controlling a rate of operation of the pump to control a mass flow rate of the working fluid in the high pressure side of the working fluid circuit.

11. The method of claim 1, further comprising controlling a speed of operation of the pump with a variable frequency drive.

12. The method of claim 1, further comprising:

regulating a temperature of an alternator operatively coupled to the expander with a cooling system, the alternator also being operatively connected to electrical power electronics; and

controlling the cooling system to control an operating temperature of the electrical power electronics.

13. The method of claim 1, further comprising fluidly coupling the working fluid vessel to the low pressure side of the working fluid circuit upstream of an inlet of the pump.

14. The method of claim 1, further comprising controlling a temperature of the working fluid in the working fluid vessel by operation of a heat exchanger coil.

15. The method of claim 1, further comprising controlling a pressure of the working fluid in the working fluid vessel to be substantially equal to a pressure of the working fluid in the low pressure side of the working fluid circuit.

16. The method of claim 1, further comprising controlling the mass management system such that the working fluid vessel contains working fluid in two or more phases.

17. The method of claim 1, further comprising controlling a flow of the working fluid into and out of the working fluid vessel by operation of one or more valves arranged in conduits disposed between the working fluid vessel and the working fluid circuit.

18. The method of claim 1, further comprising the step of controlling flow of the working fluid in and out of the working fluid vessel by controlling a temperature of the working fluid vessel.

19. The method of claim 17, wherein the operation of the one or more valves is automated.

20. The method of claim 1, wherein the working fluid circuit is disposed on a skid.

21. The method of claim 1, further comprising generating electrical power from an alternator coupled to the expander.

22. A method for converting thermal energy into mechanical energy comprising:

providing a working fluid in a working fluid circuit having components interconnected by conduit through which the working fluid flows, the components comprising;

a pump operative to circulate the working fluid through the working fluid circuit;

a heat exchanger fluidly coupled to the pump for transferring thermal energy to the working fluid;

an expander fluidly coupled to the heat exchanger and operative to convert energy from the working fluid into mechanical energy; and

a mass control tank in fluid communication with a low pressure side and a high pressure side of the working fluid circuit;

controlling flow of the working fluid through the working fluid circuit by operation of the pump;

delivering a portion of the working fluid from the working fluid circuit to the expander and cooling one or more parts of the expander with the portion of the working fluid; and

controlling a rate of operation of the expander and an amount of working fluid in the working fluid circuit by controlling an amount of working fluid mass in the mass control tank.

23. The method of claim 22, further comprising:

controlling a flow of supercritical working fluid from the high pressure side of the working fluid circuit to the mass control tank; and

controlling a flow of subcritical or supercritical working fluid from the mass control tank to the low pressure side of the working fluid circuit.

24. The method of claim 22, further comprising:

detecting a temperature of the working fluid in the working fluid circuit; and

controlling the temperature of the working fluid between the working fluid circuit and the mass control tank according to detected amounts of working fluid mass in the working fluid circuit.

25. The method of claim 22, further comprising:

detecting a pressure of the working fluid in the working fluid circuit; and

controlling the pressure of the working fluid between the working fluid circuit and the mass control tank according to detected amounts of working fluid mass in the working fluid circuit.

26. The method of claim 22, further comprising matching a pressure of the portion of the working fluid from the high pressure side of the working fluid circuit with an inlet to the expander.

27. The method of claim 22, further comprising the step of controlling a rate of operation of the pump to control a mass flow rate of working fluid in a high pressure side of the working fluid circuit.

28. The method of claim 22, further comprising:

regulating a temperature of an alternator operatively coupled to the expander with a cooling system, the alternator also being operatively connected to electrical power electronics; and

controlling the cooling system to control an operating temperature of the electrical power electronics.

29. The method of claim 22, further comprising controlling a temperature of the working fluid in the mass control tank by operation of a heat exchanger coil.

30. The method of claim 22, further comprising controlling a pressure of the working fluid in the mass control tank to be substantially equal to a pressure of the working fluid in a low pressure side of the working fluid circuit.

31. The method of claim 22, further comprising controlling the mass control tank to contain the working fluid in two or more phases within the mass control tank.

32. The method of claim 22, further comprising controlling a flow of the working fluid into and out of the mass control tank by operation of one or more valves arranged in conduits between the mass control tank and the working fluid circuit.

33. The method of claim 22, further comprising the step of controlling flow of the working fluid in and out of the mass control tank by controlling a temperature of the working fluid in the mass control tank.

34. The method of claim 22, further comprising the step of controlling flow of the working fluid in and out of the mass control tank by controlling a pressure of the mass control tank.

35. The method of claim 22, further comprising generating electrical power from an alternator coupled to the expander.

36. The method of claim 22, further comprising controlling a pressure and a density of the working fluid in the working fluid circuit with reference to an ambient temperature.

37. A method of converting thermal energy into mechanical energy with a working fluid in a closed loop 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;

regulating an amount of working fluid within the working fluid circuit via a mass management system, the mass management system having a working fluid vessel fluidly connected to the low pressure side of the working fluid circuit;

pumping the working fluid through the working fluid circuit by operation of a pump, the pump being configured to supply working fluid in a supercritical or subcritical state;

expanding the working fluid in an expander to generate mechanical energy, the expander being fluidly coupled to the pump in the working fluid circuit;

directing the working fluid away from the expander through the working fluid circuit and back to the pump;

controlling a flow of the working fluid in a supercritical state from the high pressure side of the working fluid circuit to the working fluid vessel;

controlling an amount of working fluid in a subcritical or supercritical state from the working fluid vessel to the low pressure side of the working fluid circuit and to the pump; and

delivering a portion of the working fluid from the high pressure side of the working fluid circuit to the expander and cooling one or more parts of the expander with the portion of the working fluid.

38. The method of claim 37, further comprising cooling a coupling coupled to the expander with the portion of the working fluid.

39. The method of claim 37, further comprising cooling a coupling disposed between the expander and an alternator with the portion of the working fluid.

40. The method of claim 37, further comprising matching a pressure of the portion of the working fluid with a pressure of the working fluid at an inlet to the expander.

41. The method of claim 37, further comprising:

detecting a temperature of the working fluid in the working fluid circuit; and

controlling the temperature of the working fluid between the working fluid circuit and the working fluid vessel according to detected amounts of working fluid mass in the working fluid circuit.

42. The method of claim 37, further comprising:

detecting a pressure of the working fluid in the working fluid circuit; and

controlling the pressure of the working fluid between the working fluid circuit and the working fluid vessel according to detected amounts of working fluid mass in the working fluid circuit.

43. The method of claim 37, further comprising the step of controlling the thermodynamic cycle in the working fluid circuit to convert thermal energy into mechanical energy under ambient conditions.

44. The method of claim 37, wherein the working fluid comprises carbon dioxide in a supercritical state in the high pressure side.

45. The method of claim 37, further comprising increasing a pressure of the working fluid in the high pressure side of the working fluid circuit with the pump, wherein the pump is a positive displacement pump.

46. The method of claim 37, further comprising controlling a rate of operation of the pump to control a mass flow rate of the working fluid in the high pressure side of the working fluid circuit.

47. The method of claim 37, further comprising controlling a speed of operation of the pump with a variable frequency drive.

48. The method of claim 37, further comprising:

regulating a temperature of an alternator operatively coupled to the expander with a cooling system, the alternator also being operatively connected to electrical power electronics; and

controlling the cooling system to control an operating temperature of the electrical power electronics.

49. The method of claim 37, further comprising fluidly coupling the working fluid vessel to the low pressure side of the working fluid circuit upstream of an inlet of the pump.

50. The method of claim 37, further comprising controlling a temperature of the working fluid in the working fluid vessel by operation of a heat exchanger coil.

51. The method of claim 37, further comprising controlling a pressure of the working fluid in the working fluid vessel to be substantially equal to a pressure of the working fluid in the low pressure side of the working fluid circuit.

52. The method of claim 37, further comprising controlling the mass management system such that the working fluid vessel contains working fluid in two or more phases.

53. The method of claim 37, further comprising the step of controlling flow of the working fluid in and out of the working fluid vessel by controlling a temperature of the working fluid vessel.