EP2378089A1 - Umwandlungssystem zum Umwandeln der Abwärme auf die Schaftleistung - Google Patents

Umwandlungssystem zum Umwandeln der Abwärme auf die Schaftleistung Download PDF

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Publication number
EP2378089A1
EP2378089A1 EP10159727A EP10159727A EP2378089A1 EP 2378089 A1 EP2378089 A1 EP 2378089A1 EP 10159727 A EP10159727 A EP 10159727A EP 10159727 A EP10159727 A EP 10159727A EP 2378089 A1 EP2378089 A1 EP 2378089A1
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EP
European Patent Office
Prior art keywords
waste heat
conversion system
working fluid
evaporator
orc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10159727A
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English (en)
French (fr)
Inventor
Thomas Börrnert
Thomas Bürki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Schweiz AG
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ABB Schweiz AG
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Publication date
Application filed by ABB Schweiz AG filed Critical ABB Schweiz AG
Priority to EP10159727A priority Critical patent/EP2378089A1/de
Publication of EP2378089A1 publication Critical patent/EP2378089A1/de
Withdrawn legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K25/00—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
    • F01K25/08—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours
    • F01K25/14—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours using industrial or other waste gases

Definitions

  • the invention relates to the field of waste heat recovery, and is particularly concerned with conversion of waste heat from an industrial waste heat source to shaft power.
  • Industrial processes generally produce waste heat, e.g. by gas condensation or cooling fluids, or comprised in exhaust gases or cooling air from cement, chemical, glass, paper or steel production processes, from waste incineration processes, or from fuel combustion in internal combustion engines such as gas turbines or reciprocating engines. Such waste heat is commonly discharged to the atmosphere.
  • a bottoming cycle for recovering the waste heat is commonly used. Bottoming cycles usually require high exhaust temperatures, yet an example of a bottoming cycle which requires lower exhaust temperatures is the Organic Rankine Cycle (ORC).
  • ORC produces shaft power from lower temperature waste heat sources by using an organic working fluid with a boiling temperature suited to the heat source.
  • the closed rankine cycle comprises an evaporator or boiler for the evaporation of a working fluid, a turbine fed with vapour from the evaporator to drive a generator or other load, a condenser for condensing the exhaust vapour from the turbine and means, such as a pump, for recycling the condensed working fluid to the evaporator.
  • rankine cycle systems are used for the purpose of generating electrical power.
  • the patent US 6,880,344 describes a closed rankine cycle that can efficiently use waste heat from several sources in a reciprocating or gas turbine engine system.
  • WO 2008/074637 discloses a system for converting waste heat from a waste heat source into shaft power, comprising a closed rankine cycle system including an evaporator for evaporating a working fluid and heated by the waste heat, a turbine driven by the evaporated working fluid and connected to a shaft, and a condenser fluidly interconnected between the turbine and the evaporator.
  • the waste heat temperature at the evaporator is below 350°C, and the pressure of the evaporated working fluid does not exceed 8 bar.
  • the working fluid e.g. known as R-245fa, adapted to these conditions is organic, non-toxic and fluorinated. As a consequence, fluorinated fluid may escape.
  • the fluid is chemically stable and is a green house gas, i.e. it contributes to climate change, and thus might be subject to environmental regulations. Ultimately specific and costly measures may be required on the system to avoid working fluid residues to escape to the atmosphere.
  • a conversion system for converting waste heat from an industrial waste heat source to shaft power having a closed rankine cycle system, comprising an evaporator heated by the waste heat, a turbine connected to a shaft and driven by an ORC working fluid evaporated in the evaporator, and a condenser fluidly interconnected between the turbine and the evaporator, wherein the ORC working fluid is organic, non-toxic, and non-fluorinated. Reverting to an ORC working fluid without fluorine reduces environmental concerns without requiring dedicated leakage prevention, and thus contributes to the public acceptance of the waste heat conversion system.
  • the ORC working fluid consists of pure hydrocarbon compounds such as isobutane (C 4 H 10 ) and pentane (C 5 H 12 ), or a combination thereof.
  • Such ORC working fluids circulate in the rankine cycle at a pressure above ambient pressure, both in the gaseous and in the liquefied phase. This improves the black-start capabilities, as no vacuum has to be produced after the turbine to start up the system.
  • industrial waste heat source refers to industrial plants having a primary goal other than producing or exploiting the waste heat. This in particular excludes geothermal heat sources and renewable-based heat sources such as wood chips fired boilers.
  • Exemplary waste heat sources include exhaust gas from fuel combustion in internal combustion engines such as gas turbines or reciprocating engines; stack gas or waste gas from e.g. waste incineration processes and expelled through a chimney; cooling air from cement, chemical, glass, paper, or steel production processes; or cooling water from industrial processes or combustion engines.
  • clinker cooler air of a cement plant and waste gas of a pre-heater tower of a same cement plant may be considered.
  • availability of the waste heat of an industrial plant for producing shaft power has to be balanced against other possible uses of the same waste heat, both plant-internal, e.g. for drying, or plant-external, e.g. for district heating.
  • the system comprises an intermediate circuit for transferring waste heat to the evaporator.
  • the intermediate circuit comprises a heat exchanger for heating, by the waste heat, of an intermediate circuit working fluid such as pressurized water.
  • the heated intermediate circuit working fluid is then circulated to the evaporator, where the waste heat is further transferred to the ORC working fluid.
  • the intermediate circuit is particularly preferred in case of high dust load in the heat source such as in cement plants.
  • the working fluid of the intermediate circuit is pressurized water. Hence, no evaporation occurs in the heat exchanger, and the surfaces of the latter may remain comparatively small.
  • the intermediate circuit provides for increased flexibility, and in particular allows connecting a plurality of heat sources to one single rankine cycle evaporator.
  • distinct heat sources such as clinker cooler air or waste gas of a pre-heater tower of a same cement plant may be series or parallel connected in the intermediate circuit.
  • a plate-and-shell type heat exchanger with optimized surface to volume ratio is used in the evaporator in connection with the intermediate circuit.
  • Exemplary plate-and-shell heat exchangers which due to an innovative welding process as e.g. described in WO2009068119 are well suited to withstand pressures in the ORC cycle in excess of 40 bar are available from GESMEX GmbH, Schwerin, Germany.
  • the conversion system comprises a control unit for controlling all aspects of the waste heat conversion process, including the supply of electrical power from the generator to an electrical grid.
  • the control unit is connected to sensors as well as actuators in order to adapt the operation of the conversion system to meet the operating conditions of the industrial plant and/or the abundance of the waste heat.
  • actuators include variable speed drive fluid pumps arranged in the working fluid circuits, condenser fans, a trip valve for tripping the turbine, and variable inlet guide vanes enabling the turbine to operate in a broader load range.
  • the control unit may even interact with the waste heat generating process, in order to optimize the waste heat conversion within the limits imposed by the operating conditions of the industrial plant.
  • a conversion system for converting waste heat from an industrial waste heat source to shaft power having an intermediate circuit with an intermediate circuit working fluid heated by the waste haste and a closed rankine cycle system with any suitable organic working fluid and comprising a plate-and-shell type heat exchanger for evaporating the organic working fluid by the heated intermediate circuit working fluid.
  • the closed rankine cycle system further comprises a turbine driven by the organic working fluid evaporated in the plate/shell heat exchanger and a condenser fluidly interconnected between the turbine and the plate/shell heat exchanger.
  • the preferred intermediate circuit working fluid is water
  • the organic working fluid of the closed rankine cycle may be a toxic or non-toxic, fluorinated or non-fluorinated working fluid.
  • a closed rankine cycle system is powered with waste heat that is provided e.g. in the form of a hot cooling fluid or a flow of residual heat gas having a temperature of less than 400°C, eventually less than 250°C and in some circumstances even less than 200°C.
  • waste heat e.g. in the form of a hot cooling fluid or a flow of residual heat gas having a temperature of less than 400°C, eventually less than 250°C and in some circumstances even less than 200°C.
  • a suitable working fluid is evaporated and heated to a temperature of less than about 170°C at a pressure of less than 40 bar, and eventually even less than 8 bar, and subsequently fed to a turbine for producing shaft power that in turn may drive a compressor or generator.
  • Fig.1 shows a schematic illustration of a conversion system 30 with a closed organic rankine cycle (ORC) 16 comprising, in a clockwise flow direction of an ORC working fluid as indicated by the arrows, an evaporator 1 or boiler for the evaporation of the ORC working fluid, a turbine 2 fed with vapour from the evaporator to drive, via a common shaft 3, a generator 4 connected to an electric power network or any other load, a condenser 5 for condensing the exhaust ORC vapours from the turbine and means, such as a pump 6, for recycling the condensed ORC working fluid to the evaporator 1.
  • ORC closed organic rankine cycle
  • a control unit 15 for controlling the conversion of waste heat is connected to generator 4 and to sensor 14 monitoring the heat generation process, as well as to pump 6 as exemplary actuator.
  • the system may further comprise an internal heat recovery system for cooling the vapour after the turbine and preheating the condensed working fluid.
  • the evaporator 1 recovers heat from a waste heat source 7 such as a stream of residual heat gas or hot exhaust gas entering the evaporator 1 at a temperature below 400°C at ambient pressure, and being released to the ambient via chimney 8.
  • a waste heat source 7 such as a stream of residual heat gas or hot exhaust gas entering the evaporator 1 at a temperature below 400°C at ambient pressure, and being released to the ambient via chimney 8.
  • the ORC working fluid is heated up to 170°C at a pressure of less than 40 bar, and expanded in the turbine 2 to a pressure where it is still gaseous, at a temperature close to ambient temperature.
  • Fig.2 depicts a system with an intermediate circuit 17 (dashed line).
  • a first heat exchanger 9 is placed in the exhaust gas stream in chimney 8 where water as the working fluid of the intermediate circuit is being heated up a first time.
  • the heated water is then circulated to a second heat exchanger 9B that is e.g. arranged in a residual heat gas stream constituting a second waste heat source of generally higher temperature than the exhaust gas stream in chimney 8, and heated up a second time.
  • the hot water is conducted to evaporator 1 and then cycled back to the first heat exchanger 9 by means of a water pump 10.
  • the turbine 2 is connected, via shaft 3, to a compressor 12 instead of a generator, and the shaft power is used to generate pressurized gases.
  • the evaporator 1 depicted in Fig. 2 consists of a serial arrangement of distinct stages, i.e. a liquid-liquid pre-heater stage 1A for pre-heating the liquid ORC working fluid, an evaporator stage 1B for evaporating the ORC working fluid, and a liquid-vapour superheater stage 1C for superheating the evaporated ORC working fluid.
  • the liquid intermediate circuit 17 working fluid and the ORC working fluid traverse this arrangement in opposite directions.
  • Fig.3 schematically depicts details of a preferred geometrical arrangement of the elements of the conversion system 30 for converting waste heat from a waste heat source 7 to shaft power.
  • the elements of the system are assigned to, and mounted within, a bottom floor module 31 (turbine 2, generator 4), a top floor module 32 (condenser 5) being arranged above the bottom floor module 31, and a middle floor module 33 (pump 6, internal heat recovery heat exchanger 1D, exemplary piping 35) being arranged between the bottom floor module 31 and the top floor module 32.
  • the evaporator 1 is placed in a waste gas stream at a distance from the remaining components.
  • the working fluid passes directly from the evaporator 1 to the turbine 2, from there via the vapour-liquid type internal heat recovery heat exchanger 1D to the condensers 5, and back via the pump 6 to the internal heat exchanger 1D and then to the evaporator 1.
  • Fig.4 schematically depicts a similar geometrical arrangement of the elements of a conversion system 30 with an intermediate water circuit 17.
  • a heat exchanger 9 is placed in the exhaust gas stream in chimney 8 where water is being heated up by heat from the residual gas.
  • the water is conducted to a super-heater 1C, an evaporator 1B, and a pre-heater 1A, which are all assigned to the middle floor module 33.
  • the working fluid is preheated, evaporated, and superheated before it is transferred to the turbine 2.
  • the water of the intermediate water circuit 17 is cycled back to the water heat exchanger 9 by means of a water pump 10 likewise mounted on the middle floor module 33.
  • the three aforementioned modules each include a steel frame of standard container size, onto which the assigned elements are mounted. These modules may be pre-fabricated and tested at factory site, and comprise standardized connections or flanges for interconnecting corresponding piping sections of the respective modules.
  • the mutual arrangement of the elements or components of the system within one of the aforementioned modules in turn is likewise based on a modular concept.
  • Specific elements, such as the turbine are selected according to the specification of the conversion system in a particular industrial plant.
  • the elements are then mounted, and/or later exchanged if needed, via standardized connections such as a locking snap connection, a clamping connection, a screw-thread connection.
  • standardized connections such as a locking snap connection, a clamping connection, a screw-thread connection.
  • the condenser is advantageously composed of a number of standardized units that matches the system's power rating.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Engine Equipment That Uses Special Cycles (AREA)
EP10159727A 2010-04-13 2010-04-13 Umwandlungssystem zum Umwandeln der Abwärme auf die Schaftleistung Withdrawn EP2378089A1 (de)

Priority Applications (1)

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EP10159727A EP2378089A1 (de) 2010-04-13 2010-04-13 Umwandlungssystem zum Umwandeln der Abwärme auf die Schaftleistung

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EP10159727A EP2378089A1 (de) 2010-04-13 2010-04-13 Umwandlungssystem zum Umwandeln der Abwärme auf die Schaftleistung

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EP2378089A1 true EP2378089A1 (de) 2011-10-19

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201900023025A1 (it) * 2019-12-05 2021-06-05 Mario Ghiringhelli Apparecchiatura di recupero calore a ciclo rankine con fluidi organici per produrre energia elettrica su una macchina per la produzione di carta tissue

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1016775A2 (de) * 1998-12-31 2000-07-05 Ormat Industries, Ltd. Abhitzewiedergewinnung in einem organischen Energiewandler mittels einem Zwischenflüssigkeitskreislauf
US6880344B2 (en) 2002-11-13 2005-04-19 Utc Power, Llc Combined rankine and vapor compression cycles
US20060048515A1 (en) * 2000-07-17 2006-03-09 Ormat Technologies, Inc. Method of and apparatus for producing power from a heat source
DE102005061328A1 (de) * 2005-12-20 2007-06-28 Lurgi Ag Verfahren und Vorrichtung zur Rückgewinnung von Wärmemengen aus einem Prozess-Gasstrom
WO2008013843A2 (en) * 2006-07-26 2008-01-31 Praxair Technology, Inc. Oxygen enhanced combustion in industrial processes
WO2008074637A1 (en) 2006-12-20 2008-06-26 Abb Technology Ag Use of a turbocharger and waste heat conversion system
US20080289313A1 (en) * 2005-10-31 2008-11-27 Ormat Technologies Inc. Direct heating organic rankine cycle
WO2009068119A1 (de) 2007-11-26 2009-06-04 Gesmex Gmbh Verfahren zum verbinden von mindestens zwei wärmetauscherplatten

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1016775A2 (de) * 1998-12-31 2000-07-05 Ormat Industries, Ltd. Abhitzewiedergewinnung in einem organischen Energiewandler mittels einem Zwischenflüssigkeitskreislauf
US20060048515A1 (en) * 2000-07-17 2006-03-09 Ormat Technologies, Inc. Method of and apparatus for producing power from a heat source
US6880344B2 (en) 2002-11-13 2005-04-19 Utc Power, Llc Combined rankine and vapor compression cycles
US20080289313A1 (en) * 2005-10-31 2008-11-27 Ormat Technologies Inc. Direct heating organic rankine cycle
DE102005061328A1 (de) * 2005-12-20 2007-06-28 Lurgi Ag Verfahren und Vorrichtung zur Rückgewinnung von Wärmemengen aus einem Prozess-Gasstrom
WO2008013843A2 (en) * 2006-07-26 2008-01-31 Praxair Technology, Inc. Oxygen enhanced combustion in industrial processes
WO2008074637A1 (en) 2006-12-20 2008-06-26 Abb Technology Ag Use of a turbocharger and waste heat conversion system
WO2009068119A1 (de) 2007-11-26 2009-06-04 Gesmex Gmbh Verfahren zum verbinden von mindestens zwei wärmetauscherplatten

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
GERICKE B ET AL: "WIRKUNGSGRADSTEIGERNDE MASSNAHMEN DURCH INTEGRIERTE ABWAERMENUTZUNGBEI FESTSOFFBEFEUERTEN INDUSTRIEDAMPFERZEUGERN UND BEI ABHITZEKESSELN", VGB KRAFTWERKSTECHNIK, VGB KRAFTWERKSTECHNIK GMBH. ESSEN, DE, vol. 79, no. 4, 1 January 1999 (1999-01-01), pages 38 - 44, XP000804127, ISSN: 0372-5715 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201900023025A1 (it) * 2019-12-05 2021-06-05 Mario Ghiringhelli Apparecchiatura di recupero calore a ciclo rankine con fluidi organici per produrre energia elettrica su una macchina per la produzione di carta tissue

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