EP3420204B1 - Direkter wärmetauscher für organische rankine-kreislauf-systeme - Google Patents

Direkter wärmetauscher für organische rankine-kreislauf-systeme Download PDF

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Publication number
EP3420204B1
EP3420204B1 EP17711334.7A EP17711334A EP3420204B1 EP 3420204 B1 EP3420204 B1 EP 3420204B1 EP 17711334 A EP17711334 A EP 17711334A EP 3420204 B1 EP3420204 B1 EP 3420204B1
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Prior art keywords
heat exchanger
tubes
working fluid
manifold
rankine cycle
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EP17711334.7A
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English (en)
French (fr)
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EP3420204A1 (de
Inventor
Roberto Bini
Mario Gaia
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Turboden SpA
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Turboden SpA
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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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B15/00—Water-tube boilers of horizontal type, i.e. the water-tube sets being arranged horizontally
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B21/00—Water-tube boilers of vertical or steeply-inclined type, i.e. the water-tube sets being arranged vertically or substantially vertically
    • F22B21/02—Water-tube boilers of vertical or steeply-inclined type, i.e. the water-tube sets being arranged vertically or substantially vertically built-up from substantially straight water tubes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B21/00—Water-tube boilers of vertical or steeply-inclined type, i.e. the water-tube sets being arranged vertically or substantially vertically
    • F22B21/40—Water-tube boilers of vertical or steeply-inclined type, i.e. the water-tube sets being arranged vertically or substantially vertically built-up from water tubes arranged in a comparatively long vertical shaft, i.e. tower boilers

Definitions

  • the present invention relates to a direct heat exchanger for an
  • Organic Rankine Cycle (ORC).
  • ORC Organic Rankine Cycle
  • the subject system is functional in applications using biomass or in the presence of combustion fumes or recovery or very hot gaseous effluents.
  • the working fluid of the ORC turbo-generators is not directly exposed to the hot source, but it typically exchanges heat with a thermal oil circuit.
  • the thermal oil due to its good thermo-chemical stability, is capable of withstand high temperatures without deteriorating, and therefore without compromising its hear carrier function. This is extremely important, for example, in applications with a biomass, where the fumes reach temperatures near 900°C.
  • document DE3542803C1 describes a waste heat boiler for the recovery of waste heat from a dust-laden hot gas, in particular a circuit gas from a coke drying cooler, with at least one boiler flue which is flowed towards from the side via at least one horizontally extending connection channel and flowed through downwards by the diverted gas. There is arranged in the transition region from connection channel to boiler flue an accelerating nose for the hot gas flowing into the boiler flue.
  • Document US2009188448 describes an apparatus that extracts energy from processed agriculture residue such as biomass fuel combusted in a vertically elongated combustion chamber.
  • thermo oil film does not exceed, for example, 310-320°C, and then mineral or better synthetic oils of normal production can be used.
  • An intermediate thermal oil circuit however, has some disadvantages, such as a greater cost of the circuit, a higher electrical absorption by the relative auxiliary equipment (for example, the oil circulation pump), a significant environmental impact in case of spills or leakages, the introduction of an intermediate heat exchange phase which inevitably reduces the thermal power absorbed by the ORC (at the same minimum temperature minimum of the working fluid, the minimum fume temperature is still higher due to the presence of two different temperatures, the one between the ORC fluid and the thermal oil, the other between thermal oil and fumes), risk of oil flammability.
  • a solution of a system with a kind of direct heat exchange, i.e. with the working ORC fluid which exchanges heat directly with the hot source, would allow a reduction of investment costs and an increase in efficiency.
  • the working fluids are organic substances which have a limit of thermal stability comparable to that of the thermal oil. Above a certain temperature (dependent on the substance, but approximately equal to 300-400°C) they tend to react to form new organic compounds which degrade the system performances, up to require a replacement of the entire working fluid in the worst cases.
  • Direct heat exchange ORC systems from recovery fumes are rare and limited to cases in which the fumes are clean (for example the recovery of gases from MCI or gas turbines) and have relatively low temperatures.
  • the direct heat exchanger must provide some measures to limit the temperature of the fluid film, such as, for example, the injection of air from the environment or of any other colder gas, and the recirculation of already cooled and collected fumes downstream of the direct heat exchanger or according to the size of the direct heat exchanger with relatively low heat exchange coefficients of the fumes.
  • some measures cause an inevitable increase in the size of the direct heat exchanger compared to an optimal sizing of the exchanger, in the absence of the limits dictated by the maximum fluid temperature.
  • the injection and recirculation of air reduce the fume temperature (with a decrease of ⁇ T_log) and therefore involve an increase of S.
  • the fume flow rate must increase: equal to U, i.e. substantially at the same speed, the gas passage sections increase.
  • U the choice of the size the exchanger with low fume coefficients (reduction of U) causes an increase in the exchange surface S.
  • the exchange coefficients of fumes are naturally already relatively low compared to the inner side, where the organic fluid is present.
  • the use of vanes is unadvisable because it facilitates the deposit of the powders on the exchange surfaces.
  • the heat exchanger for direct heat exchange from high temperature fumes therefore represents a very cumbersome component in an ORC system, especially due to its height.
  • Figure 1 shows by a countercurrent heat exchanger of known type.
  • the organic liquid enters a manifold at the base of the exchanger and is distributed into the different rows of tubes; the vapor is then collected in a manifold located at the opposite end.
  • the heat exchanger could have greater dimensions (in height) so as being incompatible with the system layout or make it impossible to transport the same as a single body already assembled and welded at the factory.
  • Subject of the present invention is therefore a novel direct heat exchanger for organic Rankine cycle systems, with a layout having reduced height size, as specified in the attached independent claim.
  • the heat exchanger 100 is configured so as to have a more compact encumbrance in height compared to known embodiments.
  • the heat exchanger has a vertical axis and works, as in other known embodiments, in countercurrent with the organic fluid at the inside of the tube bundles 200, 201 and with the fumes outside.
  • the heat exchanger comprises on the opposite sides of the axis, two portions: a first portion 101 conventionally also called “right portion” and a second portion 102 conventionally also called “left and portion.
  • the term "high” means the edge of the heat exchanger provided with inlet and outlet of fumes.
  • fumes enter from above of the left portion, run through the heat exchanger 100 downward along the second portion 102, up to the right side and then raise back along the first portion 101, coming out again at the top.
  • the organic fluid enters the inlet manifold 103 at the top on the right side, runs in countercurrent the heat exchanger 100 and particularly to the right side 101, where it is collected in an intermediate manifold 104, placed downwards, and it is again distributed to the next section (second portion 102) and finally it is collected in the outlet manifold 105 to the left side in form of vapor.
  • the inlet manifold 103 of the fluid is placed at the outlet of the fumes and the outlet manifold 105 of the fluid is placed at the inlet of the fumes, a "once-through" countercurrent heat exchanger is produced.
  • the evaporation will preferably occur only in the second portion 102 of the heat exchanger, so as to exploit the natural tendency of vapor to rise upwards of the heat exchanger, due to the lower density of the vapor with respect to the liquid.
  • the heat exchanger shown in Figure 3 is configured in an equivalent inlet and outlet arrangement of fumes (with a 90° rotation with respect to a vertical axis).
  • the two portions 101, 102 of the heat exchanger and of the respective tube bundles 200, 201 can have a number, a pitch and a different geometry of the tubes 106.
  • the tubes 106 could be made with greater through sections in order to limit the crossing speed of vapor, which has a significantly lower density than the liquid.
  • the first portion 101 in contact with the hotter fumes has a first heat exchange section of a radiation instead of a convection type, made for example with a arrangement of tubes 106 parallel to the flow of fumes and with a wall structure 108 made by means of tubes 106 connected together by flat surfaces 107.
  • FIGS. 2 to 4 show the heat exchanger configurations permitting the numerous benefits not only in terms of encumbrance.
  • connection between the two tube bundles 200 and 201 can occur through two intermediate manifolds placed at the base of each section 101 and 102, or a single intermediate manifold 104.
  • the exchange tubes 106 are distributed between the two portions of the heat exchanger so that the last row of tubes 110 of the inlet portion 101 of the organic fluid are placed at the same height of the first row of tubes 111 of the next portion 102.
  • the heat exchanger 100 therefore has a single intermediate manifold 104. This single manifold can also be exploited for installation of a single drain line of the heat exchanger.
  • the intermediate manifold 104 can also be entirely absent and in such case the heat exchanger would take the configuration of Figure 7 with the consequent tube distribution: each tube of the tube bundle 200 exits from the portion 101 and continues through the portion 102 without any intermediate manifold, up to the outlet manifold 105.
  • the two portions 101, 102 are further placed apart in order to allow to perform installation and maintenance phases.
  • the presence of two separate portions 101, 102 of the direct heat exchanger 100 facilitates the application of methods for controlling the temperature of the organic fluid films, which must remain below a certain limit in order to avoid phenomena of thermal chemical decay 20. Obviously, such control must be targeted in order to limit the film temperatures in the most critical point of the heat exchanger, occurring in the first rows of tubes (starting from upwards) of the left portion 102 in Figures 2-3 or in the highest portion of the tubes of the walls 108 in Figure 4 .
  • ORC fluid therefore, it present in vapor phase (as it is well known, heat is exchanged with lower exchange coefficients with respect to the liquid phase) and finds outside the fumes at the highest temperature.
  • the preheated fluid then passes into the first portion 101 of the heat exchanger and the runs through the same as already described in the previous cases.
  • Another possible configuration employing heat exchange banks is represented in Figure 6 , where the organic fluid initially passed through the first portion 101 up to the intermediate manifold 104', from where it passes into the second portion 102 but enters at an intermediate level 125 (not necessarily coincident with the intermediate level 124) and running along the rows of tubes 106 upwards (and then to the inlet area of the fumes, or where the fumes are warmer). Finally, the organic liquid is brought downwards to the manifold 104 and runs along the remaining part of the left portion until exiting from it (into the manifold 105) at a level positioned at an intermediate height. In this way the most critical area of the heat exchanger is not exclusively run by vapor, but by the organic fluid in biphasic conditions (the vaporization being just at the beginning) or by a fluid still in the liquid state.
  • the direct heat exchanger 100 is connected to a ORC system, comprising a pump 2, a condenser 4, a turbine 5, an electric generator or other mechanical users, a possible regenerator 3 (provided schematically in Fig. 8 ) and is supplied by the entire flow of organic fluid worked by the pump 2.
  • a ORC system comprising a pump 2, a condenser 4, a turbine 5, an electric generator or other mechanical users, a possible regenerator 3 (provided schematically in Fig. 8 ) and is supplied by the entire flow of organic fluid worked by the pump 2.
  • the first portion 101 of the heat exchanger is supplied only by a fraction of the flow 112, 113 worked by the pump 2, as another portion of the same is introduced in the intermediate manifold 104. Said portion can be taken downstream ( Fig. 9a ) or upstream ( Fig. 9b ) of the regenerator 3.
  • the flow rate 113 worked by the pump 2 is divided in a first section 112 and a second section 114 which bypasses the first portion 101 of the heat exchanger.
  • the flow rate percentages of the pump are controlled by means of respective first valve 112' and second valve 114'.
  • Such configuration permits to reduce the maximum film temperature reached by the organic fluid.
  • the portion of flow rate 113 bypassing the first portion 101 of the heat exchanger 100 will remain at the pump outlet temperature or the exit temperature of the regenerator.
  • the remaining portion flowing into the first portion 101 having a lower speed, recovers less power from the fumes but slightly increases its outlet temperature.
  • a flow rate of fluid will be reached entering the second portion 102 at a lower temperature with respect to the configuration shown in Figure 7 .
  • the outlet temperature of the organic vapor will be the lower, as higher the bypassed flow rate.
  • the configuration shown in Figure 8 can be applied during normal operation or only in particular situations, for example if an excessive temperature of the organic vapor is registered.
  • FIG. 10 A further functional configuration in order to counteract sudden increases of temperature is shown in Figure 10 .
  • the organic fluid through a three-way valve 115' or more valves, partially or totally bypasses the regenerator 3, and then enters at a lower temperature in the direct heat exchanger 100 and consequently reaches a lower maximum temperature.
  • Such solution can be adopted singly or in combination with the previous ones.
  • a more or less abundant fraction of the organic fluid exiting the heat exchanger can still be in the liquid state.
  • a separator 116 shown in Figure 11 in a simplified way: vapor is directed to the turbine or to the bypass duct, whereas the liquid fraction is deposited at the base of the separator.
  • valve 117 which is periodically opened or left always at least partially open, depending on the liquid flow rate reaching the separator, or is left open according to a control of level 118 in the separator 116.
  • the separator 10 can be realized with a specially designed tank or more simply as a tube with increased diameter.
  • a further advantage of the configuration with two portions regards the fouling of the exchange surfaces.
  • the reversal of the fumes flow at the base of the heat exchanger 100 is useful for reducing the content of dust and other solid particles which may be contained in the gaseous flow: in fact, the fumes change their direction with an angle of substantially 180°.
  • the heaviest particles have difficulties to follow the flow as they tend to impact against lower surfaces and deposit by gravity.
  • the inversion zone can be realized as a hopper, to permit the extraction of powders using tools such as clapet valves or screw feeders and with an increased section, with respect to the passage section at the outlet of section 102, so as to reduce the gas speed and facilitate the deposit of the powders.
  • powder deposits tend to collect, which are removed through the cleaning systems of the tubes, made for example of compressed air lances.
  • the intermediate removal of bigger particles reduces fouling of the second portion of the heat exchanger (which could be realized with finned tubes, non usable in the first section in case of very dirty fumes), in addition to reducing the powder load to be treated downstream with sleeve filters, electro-filters or other removal means.
  • the subject heat exchanger comprises a plurality of sacrificial tubes, or tubes or sheet metal made of high-temperature resistant material, which are not crossed by the organic fluid. These sacrificial tubes can be installed in front of the first row of tubes, which is exposed to the hottest fumes. These sacrificial tubes act as a shield with respect to the first rows of heat exchange tubes, so reducing the erosive effect due the impact of powders and contribute to a more uniform distribution of temperatures.
  • the heat exchange tubes can be arranged in line or staggered rows, with outer diameters which may vary approximately between 38 mm and 60 mm.
  • the arrangement and the distance among tubes is chosen in function of the temperature and the level of powders contained in the gaseous flow.
  • the Applicant has verified the convenience of adopting a gap between a tube and another one approximately comprised between 10 and 50 mm; greater distances will be applied in case of fumes with a high powder content. In case that finned tubes are used, such gap must be considered between the ends of the fins of adjacent tubes.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Claims (17)

  1. Wärmetauscher (100), zur Lenkung eines Wärmeaustausches zwischen heißen Gasen einer Hochtemperaturquelle und einem Arbeitsfluid eines Organic-Rankine-Cycle-Systems, umfassend mindestens zwei Rohrbündel (200, 201) mit einer Vielzahl von Rohren (106), die derart angepasst sind, dass das Arbeitsfluid in ihrem Inneren fließt, einen Einlasskrümmer (103), aus dem das Arbeitsfluid eintritt, und einen Auslasskrümmer (105), aus dem das Arbeitsfluid in der Dampfphase austritt, umfassend:
    - einen ersten Teil (102), der von den heißen Gasen nach unten entlang der vertikalen Richtung des Wärmetauschers (100) durchquert wird
    - einen zweiten Teil (101), der von den heißen Gasen entlang der vertikalen Richtung des Wärmetauschers (100) nach oben durchquert wird, ausgehend vom Teil (102), dadurch gekennzeichnet, dass
    - ein Zwischenkrümmer (104) zwischen einer letzten Rohrreihe (110) des zweiten Teils (101) und einer ersten Rohrreihe (111) des ersten Teils (102) positioniert ist und dadurch, dass der Wärmetauscher (100) ferner eine Vielzahl von Opferrohren umfasst, die Metallrohre oder -bleche sind, die aus einem gegen hohe Temperaturen beständigen Material hergestellt sind und so konfiguriert sind, dass sie nicht von dem Arbeitsfluid durchquert werden.
  2. Wärmetauscher (100) nach Anspruch 1, wobei der zweite Teil (101) eine Anordnung von Rohren (106) parallel zum Strom von heißen Gases und eine Wandstruktur (108) umfasst, die durch miteinander durch ebene Flächen (107) verbundene Rohre gebildet ist.
  3. Wärmetauscher (100) nach Anspruch 2, wobei die Rohre (106) zwischen dem ersten Teil (102) und einem zweiten Teil (101) des Wärmetauschers (100) verteilt sind, wobei die letzte Rohrreihe (110) des zweiten Teils (101) sich auf gleicher Höhe wie die erste Rohrreihe (111) des ersten Teils (102) befindet.
  4. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei erster Teil (102) und zweiter Teil (101) des Wärmetauschers (100) hinsichtlich Anzahl, Teilung und Geometrie der Rohre voneinander verschieden sind, und können sich unabhängig voneinander ausdehnen.
  5. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei der erste Teil (102) des Wärmetauschers Rohre mit Querschnitten umfasst, die größer sind als der Querschnitt der Rohre des zweiten Teils (101), um die Dampfdurchgangsgeschwindigkeit zu ermöglichen.
  6. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei das Rohrbündel (201) des ersten Teils (102) gerade Rohre umfasst und das Rohrbündel (200) des zweiten Teils (101) gerippte Rohre umfasst.
  7. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei der Zwischenkrümmer (104) einstückig oder durch zwei getrennte Teile gebildet ist.
  8. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei er ferner eine Pumpe umfasst, die das Arbeitsfluid von dem Zwischenkrümmer (104) zu dem Einlasskrümmer (103) drückt, um so eine Rezirkulation das Arbeitsfluid in einer flüssigen Phase zu bwirken.
  9. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei der Einlasskrümmer (103) des Arbeitsfluids in dem Gasauslass untergebracht ist und der Auslasskrümmer (105) des Arbeitsfluids in der Nähe des Gaseinlasses untergebracht ist. wodurch ein Gegenstromwärmetauscher entwickelt wird.
  10. Wärmetauscher (100) nach einem der vorhergehenden Ansprüche, wobei der Einlasskrümmer (103) des Arbeitsfluids in der Nähe des ersten Teils (102) auf einem Zwischenniveau (124) angeordnet ist.
  11. Wärmetauscher (100) nach einem der Ansprüche 1 bis 10, wobei der erste Teil (102) derart konfiguriert ist, dass das Arbeitsfluid zunächst eine Zwischenebene (125) entlang der Rohrreihen (106) durchströmt. nach oben und zweitens durch einen Teil (104'') des Zwischenkrümmers (104) bis zu dem Zwischenniveau (125).
  12. Wärmetauscher (100) nach einem der vorangehenden Ansprüche, wobei die Rohrbündel (200, 201) Rohre umfassen, die in einer Linie oder in Quincunx angeordnet sind, mit Durchmessern zwischen 38 mm und 60 mm und mit einem Abstand zwischen 10 mm und 50mm.
  13. Organic Rankine Cycle System (1), umfassend eine Pumpe (2), einen Kondensator (4), einen Regenerator (3), eine Turbine (5) und den Wärmetauscher (100) nach einem der vorhergehenden Ansprüche.
  14. Organic Rankine Cycle System (1) nach Anspruch 13, wobei das System so konfiguriert ist, dass ein erster Teil des Wärmetauschers durch einen von der Pumpe (2) geförderten Strömungsteil (114) gespeist wird, wobei der Teil (114) vom Regenerator (3) nach unten oder oben gezogen und in den Zwischenkrümmer (104) eingeleitet.
  15. Organic Rankine Cycle System (1) nach Anspruch 13, wobei das Arbeitsfluid den Regenerator (3) teilweise oder vollständig umgeht und kälter in den Wärmetauscher (100) eintritt, durch ein Dreiwegeventil (115') oder durch mehrere Ventile.
  16. Organic Rankine Cycle System (1) nach Anspruch 13, wobei das System (1) einen Abscheider (116) des Arbeitsfluids der flüssigen oder Dampfphase umfasst, der ein Ventil (117) aufweist, um den Durchgang zur flüssigen Phase zum Kondensator (4) zu ermöglichen.
  17. Organic Rankine Cycle System (1) nach Anspruch 16, wobei das Ventil (117) in Abhängigkeit von dem im Abscheider (116) verfügbaren Regelniveau (118) gesteuert wird.
EP17711334.7A 2016-02-25 2017-02-22 Direkter wärmetauscher für organische rankine-kreislauf-systeme Active EP3420204B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITUB2016A000984A ITUB20160984A1 (it) 2016-02-25 2016-02-25 Scambiatore di calore diretto per impianti a ciclo rankine organico
PCT/IB2017/050993 WO2017145057A1 (en) 2016-02-25 2017-02-22 Direct heat exchanger for organic rankine cycle systems

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EP3420204A1 EP3420204A1 (de) 2019-01-02
EP3420204B1 true EP3420204B1 (de) 2022-08-17

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB429680A (en) * 1932-11-30 1935-05-30 Siemens Ag Improvements relating to tubulous steam generators
FR2513741B1 (fr) * 1981-09-25 1986-05-16 Creusot Loire Chaudiere de recuperation equipant une installation de gazeification de combustibles solides
DE3542803C1 (de) * 1985-12-04 1987-01-29 L. & C. Steinmueller Gmbh, 5270 Gummersbach, De
US7806090B2 (en) * 2008-01-28 2010-10-05 Mcburney Sr John Curtis Boiler apparatus for combusting processed agriculture residues (PAR) and method

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WO2017145057A1 (en) 2017-08-31
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