WO2024055130A1 - A heat-fluid-fluid-torque (hfft) propulsion system - Google Patents

A heat-fluid-fluid-torque (hfft) propulsion system Download PDF

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Publication number
WO2024055130A1
WO2024055130A1 PCT/CA2023/051237 CA2023051237W WO2024055130A1 WO 2024055130 A1 WO2024055130 A1 WO 2024055130A1 CA 2023051237 W CA2023051237 W CA 2023051237W WO 2024055130 A1 WO2024055130 A1 WO 2024055130A1
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Prior art keywords
fluid
propelled
powered
stream
hfft
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PCT/CA2023/051237
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French (fr)
Inventor
Frederick Churchill
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Organoworld Inc.
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Publication of WO2024055130A1 publication Critical patent/WO2024055130A1/en

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01BMACHINES OR ENGINES, IN GENERAL OR OF POSITIVE-DISPLACEMENT TYPE, e.g. STEAM ENGINES
    • F01B21/00Combinations of two or more machines or engines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D13/00Combinations of two or more machines or engines
    • F01D13/02Working-fluid interconnection of machines or engines

Definitions

  • the present invention relates to a new technology in the field of propulsion systems for producing shaft torque wherein the input power/energy applied by a propulsor and by transferring external heat/cooling energy to a limited supply of fluid, creates a first propelled-fluid stream that then transfers part of its pressure energy to a second powered-fluid stream of limited supply that, in turn, powers a fluid-turbine(s) rotor to produce rotating shaft torque that drives an independent rotating equipment.
  • HFFT Heat-Fluid-Fluid-Torque
  • a third application is the development of a smaller, mobile propulsor, called the HFT (Heat-Fluid-Torque) configuration, that uses only the propelled-fluid in a single-circuit, that drives a mechanical converter that drives an equipment-application.
  • HFT Heat-Fluid-Torque
  • this configuration of the HFFT process suits the need for torque of a market centered around transportation.
  • thermophysical properties of fluids and is partially related to pressure-volume work achievable from mechanical propulsion accompanied by heating and cooling.
  • the present application describes a system and a process that were developed to decrease the amount of electricity, fuel, heat, or power consumed to drive rotating equipment.
  • the names 'HFFT propulsor’ and 'HFFT propulsion system’ and 'FPU (OO)ZP’ are considered synonyms.
  • the mostly heat powered HFFT propulsion system operates as a thermally driven system involving the conversion of multiple, different heat energies to pressure/velocity energy using custom engineered fluids designed to absorb heat energy more easily and to convert said heat energy more efficiently to pressure energy.
  • This concept will be the first fluid propulsion system employing pressurized circuits that does not use steam (water vapor) as the fluid for absorbing the heat energy and transferring said heat energy to nonthermal related (force related) pressure energy of a second fluid by the use of a pressure energy transfer mechanism and then producing rotational shaft-torque in a turbine-rotor using said non-thermal related pressure energy.
  • the HFFT propulsion system is also unique for its operation at lower fluid temperatures but higher fluid pressures than steam-based propulsors. This is made possible by using a mix of input power, waste heat, heat pumps and heat transfer strategies to drive an engineered, propelled-fluid in a first circuit that is made of components with different thermophysical properties than those of water (steam).
  • the heat sources used in an HFFT propulsor can be at lower temperatures and the heated fluids can be at higher corresponding pressures than those involved in the operations of steam thermal power applications that include nuclear, combustion-type fired-boilers and gas-turbines.
  • the HFFT development could support being named ‘COLD-FORCE’ TORQUE.
  • the HFT configuration and the HFFT propulsor does not use steam (water) as a propelled-fluid stream, it could support being named ‘DRY FLUID’ TORQUE.
  • an FTF-PET takes places between 2 fluid bodies of limited supply, over 2 sealed membrane-interfaces, located within 2 isolated flow circuits, within 2 piston-cylinders, that are connected through their end-shafts, whereby one piston is propelled by a propelled-fluid stream generated by thermal gradients and a powered propulsor of the first circuit and the other piston is powered by said propelled-piston to generate a powered-fluid stream, and said powered-fluid stream of the second circuit is directed to a fluid-turbine to generate torque at the end of the shaft of its turbine-rotor that drives all types of rotary, independent equipmentapplications.
  • Two properties of the 2 fluids that are of interest concern their capacity to be propelled/compressed and accept positive work, as indicated by the values of compression energy (MJ/kg) versus pressure (bar) and their values of specific weight versus pressure.
  • compression energy MJ/kg
  • bar pressure
  • specific weight versus pressure.
  • gases and liquids When gases and liquids are heated, they expand, and this effect can be exploited to use the expansion of a volume of a first propelled-fluid to produce additional work by transferring its change in volume to displace a second powered-fluid stream. If the volume is fixed, the increase in temperature increases the pressure and this will also be used to increase the pressure of the second stream.
  • the energy input involved in obtaining the required volume and pressure of the propelled-fluid stream equals the energy required to create the propelled-fluid stream of equivalent volume & pressure, plus fluid friction losses of the propelled & powered streams. Given the incompressible nature of liquids, they are questionable for use as a propelled-fluid; as such, a performing fluid-to-fluid transfer will probably exclude transfers that are liquid- to-liquid or liquid-to-gas.
  • a technique is defined as a way of carrying out a particular task and, in this case, the preferred technique is to transfer pressure energy from a highly pressurized- fluid stream to a lesser pressurized-fluid stream using a process transfer that is fluid-to-fluid.
  • the energy transfer starts by converting a source of power to rotating torque that is applied to the rotatable shaft of a propulsor.
  • the propulsor transfers energy to a limited source of fluid supply that becomes the first fluid stream (the ‘propelled-fluid’).
  • the transfer from the first fluid stream to the second fluid stream (the ‘powered-fluid’) is by applying mechanical force (pressure) on two, interconnected 'sealed, membrane-interfaces’, that transfer pressure energy based on the differential pressure between the 2 fluid streams.
  • Both top-faces of the 2 pistons and (facing) rod-faces of the 2 pistons are either high pressure or low pressure (return) at the same times.
  • the first circuit (or propelled-fluid circuit) is feeding a HP, propelled-fluid to its piston/cylinder that is also discharging a return, propelled-fluid
  • the second circuit (or powered-fluid circuit) is discharging a HP, powered-fluid from its piston/cylinder and being fed a return-powered-fluid.
  • both the propelled and the powered-fluid streams are traveling through independent pressurized chambers or cylinders that contain a sealed, membraneinterface created by a piston & seals or other appropriate sealing.
  • the membrane-interfaces and interconnected piston rods serve to transfer the pressure energy of the propelled-fluid stream to the powered-fluid stream.
  • Double-action diaphragm PET assembly operations are slightly different. There is a left and a right diaphragm, that create two separate chambers that separate the propelled-fluid from the powered-fluid.
  • a source of compressed air is used as the HP, propelled-fluid.
  • Check valves installed at the inlet and discharge of the powered-fluid chambers are used to control its inlet and outlet flows as the pressure energy of the propelled-fluid is exerted either on the left diaphragm or the right diaphragm.
  • a multi-way controller directs the back-and-forth movement of a double-action diaphragm assembly that includes a left-side diaphragm forming a first propelled-fluid sealed cavity and a first powered-fluid sealed cavity.
  • the similar right-side diaphragm forms a second propelled-fluid sealed cavity and a second powered-fluid sealed cavity.
  • the 2 diaphragms form 4 cavities, 2 left-side cavities, and 2 right-side cavities.
  • the flows from the controller are directed to an adapted double-action piston that serves to increase the pressure that is applied to either the left or the right diaphragm cavity through flow channels connecting the piston chamber to the cavities.
  • the propelled-fluid piston and or the propelled-fluid controller may be located as an attachment to the frame of the double-action diaphragm or as a remote unit.
  • the flows of powered-fluid into 2 of said 4 cavities is controlled by 2 inlet check valves, one on the suction-end of each cavity and by 2 outlet check valves, one installed on the discharge-end of each cavity.
  • a rod may interconnect the inside faces (propelled-fluid) of the two diaphragms.
  • the multi-way controller feeds the propelled-fluid to a first sealed cavity and simultaneously vents the propelled-fluid from a second sealed cavity.
  • Each face of the diaphragm forms one of the walls of the 4 cavities so that the pressure within one cavity is applied to one face of the diaphragm and the opposite face executes a pressure energy transfer (PET) from the propelled-fluid to the powered-fluid in the second cavity on the opposite face of the diaphragm.
  • PET pressure energy transfer
  • the recycling of the propelled-fluid follows the same format for piston-type or diaphragm-type or other types of mechanisms for executing a pressure energy transfer between two fluids.
  • the powered- fluid discharge from all PET mechanisms will be directed to the distribution and conditioning assembly (50)/A, and from there discharged to feed the powered-fluid turbine (60)/A.
  • Piston/cylinders with piston rods working as a system and piston/cylinders working with diaphragms and connecting rods both constitute a technique of the type-'sealed, membrane-interface’ and are central to the operation of a preferred embodiment.
  • the ‘piston/cylinder’-type mechanism it is the back-and-forth movement of the piston, its seal rings and the piston rod, that create the sealed, membraneinterface and that serves to execute the pressure energy transfer between the 2 isolated fluid circuits.
  • the energy performance of the HFFT propulsion system will depend on the fluids employed. In the case of gaseous fluids, their compressibility factors, boiling points, and energy of compression, as well as their specific weight at their operating conditions plays an important role in the amount of input energy required for their propulsion as well as having a significant impact on the output energy produced in the powered-fluid turbine.
  • This application refers to gases, or compressible fluids that are in a gaseous state at STP conditions (standard temperature and pressure). If, at the stated operating conditions, the phase of the fluid changes from a gas to a gas-liquid or to a liquid, we are referring to the fluid being in its 'as-is-phase' or 'operating phase’.
  • the efficiency of reversing heat pumps and their EER ratings is an example of how more output work can be accomplished by using fluid compression/expansion cycles. Air conditioners and heat pumps can transfer 300 % more energy than they consume.
  • FTF-PET fluid-to-fluid
  • a PET occurs when the HP, propelled-fluid stream is transferring part of its pressure energy to create a HP, powered-fluid stream to drive a powered-fluid turbine.
  • FTF FTF as two selected fluids are recirculating, under pressure and as they never leave the system, they are not being pumped but re-energized.
  • a HFFT propulsion system comprises the equipment and components starting from the input of power from a source to the output shaft-end torque of the powered-fluid turbine '/z coupling. Creation of the system involved the conception of integrated functional process-units (FPUs) that require operations to transfer energy through 3 transitions.
  • FPUs integrated functional process-units
  • an external power source is transferred to drive the propulsor that is then transferred to a limited fluid supply to create the first HP, propelled-fluid stream.
  • a part of its pressure and velocity energy is then transferred to produce a second transition whereby a limited fluid supply is converted into a HP, powered-fluid stream.
  • the energy continues to change its medium, from a 'HP, powered-fluid’ to a 'shaft end-torque’.
  • the PET mechanism discharges HP, powered-fluid into the turbine inlet where a nozzle configuration converts much of the pressure energy to velocity energy.
  • the HP powered-fluid stream passing through the flow elements of the turbine-rotor transfers momentum from the input powered-fluid stream to produce as outputs; 1) a rotating shaft-end torque and, 2) a return, powered-fluid stream, 3) heat.
  • the return, powered-fluid stream that is collected in the sump of the turbine can have pressure energy of approximately 2-5 atm and is recycled back from the discharge outlet of the sump of the turbine to the inlet for return, powered-fluid located on the PET equipment-assembly (30)/A.
  • the pressure of the propelled-fluid at the discharge of the propulsor has a direct impact on the increase in the pressure of the powered-fluid stream.
  • the diameter of the pistons of the propelled-fluid can be larger than those of the powered-fluid; heat may be injected into the pressurized, propelled-fluid stream; or the powered-fluid pistons may be operated in series with the diameter of one or multiple propelled-fluid pistons having a larger diameter than the corresponding powered-fluid pistons.
  • the electricity can be from any regular source such as power grid, rechargeable battery, renewables, or the input energy for the propulsor may be in the form of shaft-torque from a diesel engine, water turbine, steam turbine, etc.
  • the pressure energy is being distributed through the system by a continual recycling of the return, propelled-fluid stream from the discharge of the FTF-PET mechanism, back through the propelled-fluid distribution assembly to the inlet of the propulsor and then from the discharge outlet of the propulsor back to the propelled- fluid distribution and finally from the discharge outlet of said propelled fluid distribution to the HP, propelled-fluid inlet of the PET equipment-assembly.
  • the return, powered-fluid is being discharged from the powered-fluid turbine sump discharge and then re-converted into a 'HP, powered-fluid stream’ by passing through the FTF-PET equipmentassembly (30)/A wherein energy is transferred from the HP, propelled-fluid to the return, powered-fluid turbine thus producing a HP, powered-fluid stream to drive the turbine-rotor.
  • this HP, powered-fluid stream can also be in recirculation between the input and output of a process application.
  • the objective in this situation is simply to reduce the cost of propelling a process fluid stream to higher pressure energy (for example, feeding a HP, boiler feedwater, feeding RO desalination plants or simply to satisfy most high-pressure pump applications).
  • the preferred embodiment employs a mechanism based on one or multiple pairs of synchronized, doubleaction pistons, whereby one piston & cylinder operate on a closed circuit of propelled-fluid and the other half of the pair is operating on a closed circuit of powered-fluid.
  • the propelled & powered-fluid streams operate in closed loops as recycle circuits with external heating and/or cooling applied to control the fluid stream temperatures.
  • the temperature control can also be obtained by bleeding a part of the propelled & powered-fluid streams to the atmosphere and replacing it by a cooler make-up stream; however, the circuit is now operating in open or atmospheric mode which is less efficient and more polluting.
  • the propel led-fl u id cooling unit is required to control the maximum operating temperatures due to the heat injected by the energy applied by the propulsor. There is, however, a need for both higher and lower operating temperatures in the propelled-fluid stream.
  • the heat source may be electric elements but preferably is waste heat from external processes or from heat pumps or inexpensive heat from renewable energy. External heat transfers use thermal fluids to decrease the size of the exchangers.
  • the functional process unit FPU (03)/S is about energy transfer and involves various process functions required to execute an FTF-PET.
  • FPU (03)/S is about energy transfer and involves various process functions required to execute an FTF-PET.
  • Four different mechanisms developed around 2 techniques that involve either a ‘sealed, membrane-interface' or a ‘mixing and separate fluids' are presented as solutions.
  • the propelled & powered- fluid streams involved in FPU (03)/S, their distribution in closed circuits and the pressure energy transfer that needs to occur between said fluid streams are illustrated as process-functions in Figure 1.
  • the legacy configuration of an ‘electric motor coupled to an equipment-application’ that comprises one motor driving one rotating equipment-application is the simplest to operate and the cheapest to install.
  • Other legacy drive configurations to power rotating equipment include power auxiliaries such as a combination of a ‘motorized hydraulic pump coupled to hydraulic motors coupled to an independent equipment application’ and a ‘motorized air compressor coupled to air motors coupled to an independent equipment-application’.
  • auxiliary hydraulic and air motors are different to that of the electric motor driving the respective fluid pumps.
  • the application of these auxiliary drives is, however, not to directly decrease the energy consumed by the electric motor, but to convert the torque produced by the motor shaft into an equivalent level of power at a different torque and rpm.
  • the ratio of the motor output shaft power to the independent equipment-application input shaft power changes only slightly.
  • a device that has some physical resemblance to a ‘double-acting, piston-based equipment-assembly' ((30.1/A or (30.2/A)), is the ‘double-action cylinder pump'.
  • a piston is attached to a motorized piston rod cycling back and forth in a cylinder with appropriate seals and end plates.
  • Such a cylinder pump is illustrated in Figure 1b.
  • Another example of an existing application that demonstrates the applicability of this technology is the multi- MW diesel generator that is frequently used in island-nations to power their electrical grid.
  • the input power is rotating shaft torque from a diesel-powered engine.
  • the pumping energy required is the product of the volume (V) and the specific gravity (SG) of the liquid pumped, multiplied by its increase in static pressure (delta P), multiplied by mass density of water (MDW) times the propulsor efficiency (E). Accordingly, according to science, the power (P) required to obtain a HP, powered-fluid stream will equal the product of (V x SG x delta P x MDW x E).
  • the 2 fluids are not pumped but propelled in recirculation mode in closed loops and only one stream is propelled as the second recirculating stream is powered by the transfer of energy of the first stream that is propelled by the propulsor.
  • the single propulsor is driving both fluid streams.
  • the determination of the state of a fluid, whether gas, liquid or solid, is according to its properties at STP conditions; that will be 0 degrees Celsius and 1 atm pressure, alternatively, at STP conditions one mole of ideal gas has a volume of 22.4 liters.
  • the specific weights/mass-densities of the fluid flow streams are those determined at their operating conditions within their process streams.
  • the ‘HFFT propulsion system FPU (OO)ZP' refers to the ‘principal function' that is part of a system or grouping that includes a series of secondary functional process-units numbered FPU (01 )/S to FPU (06)/S.
  • the code letter 7P' designates a principal function and the code letter 7S', designates a secondary function that is a part of the sous- systems of the principal function.
  • FIG. 1 illustrates the second level of secondary functions and specifies the 4 secondary functions related to the inlet and outlet flow streams that drive the FTF-PET mechanism.
  • the hierarchy and sequence of operation of the FPUs of the HFFT propulsion system are illustrated in Figure 2.
  • the propulsion system to be described is based on principles of fluid mechanics and may involve work done by gases or, namely, pressure-volume work.
  • Work is the energy required to move something against a force and it has units of Joules (J):
  • J Joules
  • the energy of a system can change due to work and other forms of energy transfer such as heat.
  • a first propelled-fluid that is suitable for this invention is compressible at STP conditions, whereas a suitable second powered-fluid is non-compressible at STP conditions.
  • This HFFT propulsion system comprises two parallel systems, one of functional process-units (FPUs) and one of physical equipment-assemblies.
  • FPUs functional process-units
  • the system exists at first as a configuration of multiple ‘process-units' whose function corresponds to the following question: What is the process function to be accomplished by this processunit in operation? Another way to interpret the role of the functions is that they structure the ‘needs to be physically fulfilled' by an operating process.
  • This propulsion system also comprises a second configuration of ‘equipment-assemblies' and components that are designed to physically fulfill or emulate the function(s) of a process-unit. It is the configuration of the functions contained in the FPUs combined with the physical reality contained in the configuration of the equipment-assemblies that describe and constitute this HFFT propulsion system.
  • the code letter 7A' designates an assembly of components, equipment, or an assembly of assemblies.
  • the configuration of the assemblies describes how the equipment and components selected to build the propulsion system are interfacing. Numbers without brackets or letters are simply the standard components that have been configured into specific assemblies applicable for this propulsion system.
  • the equipment-assemblies of Figure 3a comprises the assemblies of equipment and components that were configured to physically achieve the functionality specified in the FPUs.
  • the four alternatives of equipment-assemblies that were developed to perform the pressure energy transfer are indicated as the preferred embodiment or as optional embodiments.
  • the 4 equipment-assemblies related to the ‘pressure energy transfer' are depicted on Figures 3c, 3d, 3e and 3f.
  • the equipment-assemblies are a process structured grouping of the required equipment and auxiliary components such as valves, lines, and connections. Another aspect of the assemblies includes items referred to as system infrastructure or simply as infrastructure.
  • the energy transition 2) is integrated into the fluid supply propulsion function, the transition 3) is integrated into the pressure energy transfer function, the transitions 4), 5) & 6) are integrated into the fluid-turbine functions.
  • the energy losses incurred over each energy transition are estimated at 5-8 percent.
  • this propulsion system uses the electric drive motor to operate a fluid-propulsor as one of its sous- systems. Instead of increasing the pressure energy of the powered-fluid stream by driving a pump with an electric motor (as per prior art), this operation is centered around succeeding a PET between 2 selected fluid streams.
  • a second circuit of a powered-fluid stream is created by the back-and-forth movements of the second piston and this circuit drives the turbine rotor.
  • the configuration of the PET equipment-assembly (30)/A, is as depicted in Figure 3c.
  • the functionality of the PET mechanism is a major building block for operating the HFFT propulsion system.
  • the preferred embodiment of the PET mechanisms involves one or more units of PET equipment-assembly (30)/A being mounted on a common baseplate.
  • Each synchronized-pair of (30)/A assembly comprises 1 piston-based, propelled-fluid, PET equipment assembly (30.1)/A and 1 piston-based, powered-fluid, PET equipment-assembly (30.2)/A. Together, the 2 piston-based assemblies create a mechanism over which the PET takes place. To produce a more uniform output, 2 or more (30)/A units are operated together with an offset in their cycles.
  • Mechanism 1 , 2 and 3 are of a sealed, membrane-interface type, whereas mechanism 4 is of the ‘mix and separate fluids'-type.
  • Mechanism 1) is the preferred embodiment, whereas mechanisms 2) and 3) and 4) are embodiments providing the required functionality of a PET mechanism but have disadvantages not present in mechanism 1).
  • a double-action cylinder pump ( Figure 1c) does resemble physically a HFFT double-action, piston based, fluid stream equipment assembly; however, the functionalities of the two applications have no resemblance.
  • the drive motor of the cylinder pump pumps only the one fluid that needs to be pumped, so there is no need for a second synchronized, double-acting cylinder. This is preferred and leads to a long question that concerns any pumping application that may appear to resemble the piston-based PET mechanisms.
  • the simple double-acting cylinder pump with an appropriate drive is the preferred solution and not a PET mechanism with 2 independent, recycle fluid circuits and with one propulsor driving a powered-fluid turbine to produce a source of rotary torque.
  • the HFFT propulsion system does not pump fluids; it recirculates 2 independent supplies of 2 different fluids of limited supply, at high pressures using 1 propulsor for the intention of producing shaft torque to drive various rotating equipment.
  • a volume of a HP propel led-fluid of one circuit has powered a volume of a different return, powered- fluid stream of a second circuit to drive a powered-fluid turbine to drive a rotary equipment and the fluids involved have specific required properties.
  • a double-action cylinder is a cylinder in which a single working fluid acts alternatively on both sides of a piston.
  • a motor drives a piston rod back-and-forth, that drives its associated piston.
  • Check valves allow fluid from a supply to be drawn into the cylinder on a retraction piston stoke and then, on the extraction stoke, the pressure of the face of the piston facing in its direction of travel propels the same liquid.
  • the movement of fluid streams in each circuit during the cycling of the piston may be controlled by a multi-way, directional control valve that serves to provide different inlet and outlet functionalities at the cylinder ports.
  • a pressure energy transfer (PET) mechanism such as a single-acting piston
  • PET pressure energy transfer
  • the mechanism identified as ‘mix & separate fluids' were to be used there would be a thorough contamination of the fluid streams as the mechanism of this assembly involves the action of mixing and then separating the 2 fluid streams.
  • the diaphragm solution offers better sealing, but diaphragms deteriorate, and the seal can be lost.
  • the diaphragm solution may have several variants but the one chosen for this application involves a double-action, pistontype assembly operating in the propelled-fluid circuit and a double-action diaphragm operating in the powered-fluid circuit.
  • a volume of a light fluid is displacing a volume of a heavier fluid and the energy required to increase the pressure energy of the lighter fluid is basically less than the energy spent to increase the pressure energy of the heavier density fluid.
  • the required input energy can, however, be decreased further by using heat to expand the lighter gas to a higher pressure before the PET and then cooling the lighter stream with a cooler before it repasses through the propulsor.
  • W (work) F (force) x D (displacement) and given the force and displacement of the two fluids are the same, the amount of positive work and negative work accomplished are the same, but by using a fluid stream of lower mass density and executing a PET the energy input required to accomplish the HP, powered-fluid stream is decreased.
  • a sufficiently propelled-fluid stream of low specific weight is fed via a multiway, directional control valve to the faces of a first ‘double-action, piston-based, propelled-fluid equipment-assembly'.
  • the piston rod of the first assembly drives the piston rod connected to a second piston in a second ‘doubleacting, piston-based, powered-fluid equipment-assembly'.
  • the faces of both pistons are traveling in synchronized reciprocating strokes and the energy of the HP, propelled-fluid is propelling the return, powered-fluid stream.
  • One single-action, piston-based, fluid equipment-assembly, like equipment-assembly (36)1 A could be installed as a stand-alone PET or it could serve to connect the pistons of the circuits of each of the propelled-flu id and powered- fluid equipment-assemblies of (30)/ A.
  • This arrangement however can lead to various shaft and shaft seal maintenance problems, and there may be cross-contamination of the two circuits as a large area of the cylinder inner wall is in contact with both liquids.
  • the arrangement of the single-action piston is depicted in Figure 3d.
  • the double-action diaphragm-type assembly (40)/A uses a ‘sealed membrane-interface' to transfer pressure energy that does not physically resemble that of a piston-type but operationally the flow mechanisms are similar. As the pressurized cavities of the powered-fluid diaphragms are much more irregular in shape than those of a piston cylinder, the adjustments of flow and pressure are less linear. This is another reason why the piston-type is the preferred technique.
  • a schematic of the operation of a diaphragm-type assembly (40)/A is depicted in Figure 3e.
  • the first and second design involves the use of a sealed membrane-interface technique based on pistons as illustrated in Figures 3c and 3d.
  • the third design involves a sealed membrane-interface based on diaphragms as illustrated in Figure 3e and the fourth design involves a ‘mix and separate fluids' technique as illustrated in Figure 3f.
  • a return, powered-fluid stream of a certain pressure energy and a HP, propelled-fluid stream with a pressure energy higher than that of the return, powered- fluid stream are injected into a pressurized recipient/cavity.
  • the apparatus proposed for injecting the propelled and powered-fluid streams into the pressurized recipient is using a rotary valve 41 , with multiple sealed cavities.
  • the pressure in the recipient is held constant by balancing the volume of HP, propelled-fluid entering versus the volume of return, propelled & powered-fluids leaving the recipient. There has incurred an increase in the pressure energy of the powered-liquid stream and a decrease in the pressure energy of the propelled-fluid stream leaving the pressurized recipient. To minimize the input energy required the operating pressure of the propelled-fluid needs to be minimized. [000131 ] To produce the required torque output, the flow variables of the system that are adjusted include the fluid flow rates and the fluids pressure energies.
  • a compact configuration for multiple units of (30)/A is a radial mount with a central rotating crankshaft, whereas for an application requiring only a single pressure energy transfer propulsion equipment-assembly, the preferred embodiment is by connecting the ends of two piston rods by a central half-coupling 35.1 & 35.2.
  • the pistons may be connected to each other by directly coupling the ends of opposing propelled-fluid and powered-fluid piston rods (30.1)/A & (30.2)/A or by connecting multiple pressure energy transfer equipment-assemblies to a common crankshaft and arranging the pistons in a linear or radial configuration, like those used in radial and in-line automobile engines.
  • the radial crankshaft serves to connect the ends of multiple piston rods around a central circumference and this configuration saves space.
  • a radial configuration of multiple (30.1)/A propelled-fluid and (30.2)/ A powered-fluid PET equipment-assembly are depicted in Figure 3g.
  • one method of decreasing the energy input through the propulsor is to heat the propelled-fluid before the PET inlet, or, interstage, while it passes through, the PET equipment-assembly.
  • the heating is achieved by installing heating units 23.1 in the interstage HP, propelled-fluid connecting lines. This serves to decrease the required pressure in the HP, propelled-fluid at the propulsor discharge to reach the required pressure in the HP, powered-fluid stream.
  • Another approach for decreasing the required propelled-fluid pressure is to operate multiple PET units in parallel. Operating in parallel stages, the discharge of the propelled-fluid stream of the first stage of the PET equipmentassembly (30)/A becomes the feed to the next stage rather than returning directly to the propelled-fluid distribution equipment-assembly (20)/A. The diameter of the piston of the propelled-fluid is increased. Intra-stage heating of the propelled-fluid stream is again possible, but this will be a question of its effectiveness with the second fluid.
  • the principal function of the HFFT propulsion system is to produce rotating shaft torque.
  • the FTF-PET functions only produce a supply of HP, powered-fluid that needs to be converted to useable torque.
  • the next section of the system involves passing the HP, powered-fluid stream over the flow elements mounted on a turbine-rotor to produce the desired torque.
  • the fluid turbine involved in a HFFT system is driven by a powered-fluid in a circuit that recycles the flow, it can be referred to as a powered-fluid turbine.
  • the entrainment of air in the fluid circuits may be a problem that can be solved by operating a deaerator, wherein the accept header of the deaerator is held under vacuum by a compressor with its suction connected to a deaerator accept header.
  • the inner housing of the powered-fluid turbine, including its sump, can be sealed and held under controlled pressure depending upon the specific operation.
  • the rotating shaft of the powered-fluid turbine may directly drive the shaft of an equipment-application, or a gear reducer may be required to increase or decrease the speed of rotation at which the shaft of the equipmentapplication is being driven.
  • the feed and discharge arrangement of a powered-fluid turbine equipment-assembly (60)/A is depicted in Figure 5.
  • This propulsion system process begins wherein a motorized fluid propulsor produces a HP, propelled-fluid stream in a circuit using a compressible fluid.
  • the pressure energy of the propelled-fluid decreases and the pressure energy of the powered-fluid stream increases by approximately the same proportions.
  • the physical size of the propulsion system and its components and the volumes of the propelled and powered-fluids are important to reduce the cost of a production unit and to be able to accommodate space limitations that could limit its applicability.
  • the most important criteria for designing a process that can efficiently operate is obtaining a high-pressure energy in the propelled and powered-fluids stream at the minimum cost of energy.
  • the discharge velocity of the feed nozzle of the powered-fluid turbine is also important, but its value is proportional to its pressure energy.
  • the compressibility factor Z for gases normally increases continually above 1.0 as the HP, propelled-fluid pressure increases, and this will increase the energy input per kilogram required by the propulsor.
  • preferred propelled-fluids have a low compressibility factor at low and high pressures.
  • the energy per kilogram increases as the pressure energy increases, there is a distinct advantage to operate at the lowest possible HP' propelled-fluid pressure that meets the required thrust output.
  • the propelled and powered-fluid circuits operate between 90-120 bar.
  • a proper selection of the propelled-fluid is important in order to minimize the energy required per kilogram to obtain the maximum pressure in the propelled-fluid circuit.
  • the propelled-fluid may be steam. Steam will always have the problem of burning a lot of fuel to obtain a sufficient operating temperature and pressure.
  • the steam discharge stream from the PET can be vented to the atmosphere, much like the original steam locomotive, as recycling the steam may require a steam condenser and this complicates the operation. If steam replaces electricity, the propulsion acronym changes from HFFT to SFFT.
  • the diameter of the propelled-fluid pistons can be larger than the diameter of the powered-fluid piston, but this will increase the volume of the propelled-fluid to be propelled and will decrease somewhat the differential pressure available for energy transfer in the PET mechanism.
  • a modified configuration of the HFFT propulsion system can operate as a distributed propulsion system whereby multiple local HFFT fluid turbines each drive one of multiple equipment-applications.
  • This system operates based on one large PET equipment-assembly, driving multiple powered-fluid turbines that each provide torque to only one equipment-application, as illustrated in Figure 6.
  • a central propulsor/compressor equipment-assembly (10)/ A, a central propelled-fluid distribution equipment assembly (20)/A and a central power energy transfer equipment-assembly (30)/A are installed as a central unit and the central HP, powered-fluid stream distribution equipment-assembly (50)/A feeds multiple fluid-turbine equipment-assemblies (60)/A.
  • Propelled-fluid circuits can be of two types: either free flow or recycle/recirculation.
  • free flow mode the propelled-fluid leaving the outlet of the propelling equipment is not returned to its inlet.
  • recirculation mode the discharge or outlet stream of the equipment-assembly returns to the inlet of the source of propulsion.
  • part of the recycle flow could be discharged, and the volume discharged is replaced by an equivalent volume of cooler fluids, such as air or water from an exterior source.
  • Recycle mode is a preferred operation as it is invariably more energy efficient and less polluting than a comparable operation in free flow mode. Recycle mode will involve cooling of the fluid streams as compression adds heat to a fluid stream and heat is also generated through friction and drag.
  • the propelled-fluid In the case of the propelled-fluid, it would operate at its highest possible temperature as increasing its temperature decreases its mass density. For operations outside in cold climates, the propelled-fluid circuits may be insulated to conserve heat. In the case of the powered-fluid stream, the operating temperatures of the mixture will depend on the additives used to adjust its thermophysical properties.
  • the HFFT propulsion system would be highly suitable to replace large, exterior equipment applications.
  • the equipment assemblies can be mounted on a common baseplate (91) supported by structural members (92) and enclosed in a protective housing (93).
  • the housing may be insulated, and its inside atmosphere can be controlled by internal or open-air (roof-top) HVAC units.
  • Bearings and stuffing boxes that are high maintenance elements are monitored for wear and information on the ongoing operations are all sent to a central programmable controller with an operator interface (95). Information and control are transmitted off-site via a telecommunications assembly (94).
  • a rechargeable battery is installed (11.5) on the propulsion system baseplate for portable or movable platforms (96) or for emergency-type operations.
  • This process for producing torque should be packaged such that it offers other, more intangible benefits, such as more reliable, better safety protection from theft and vandalism damage and better resistance against extreme climate.
  • HFFT propulsion system between a legacy power generator that comprises a diesel engine and its electrical generators.
  • This HFFT propulsion system unit will reduce the load and the consumption of diesel fuel. There are few limits on where this technology can be exploited.
  • a propulsor is acting as a pump that creates recirculation and as a compressor that adds heat to the propelled-fluid circuit.
  • a second source of external heat may be transferred into the propel led-fl ui d stream and this heat energy will further increase the operating stream pressure (higher fluid compression obtained with less mechanical compression).
  • Additional work can be performed by removing additional heat from the return, propelled-fluid that will further lower the return, propelled-fluid pressure, thereby creating a higher-pressure differential between the inlet and outlet connections of the propelled-fluid piston assembly.
  • the addition of heat to the propelled-fluid can be obtained by, 1) using more electrical energy to apply more compression by the propulsor, or 2) by powering a heat pump that has a better efficiency in generating heat than a fluid compressor and then transferring the heat energy into the propelled-fluid stream or, 3) by transferring heat into the propelled-fluid stream from an external source of waste heat or a source of inexpensive heat such as solar heat.
  • Figure 7a illustrates a HFFT propulsion system schematic and the equipment and interconnections to integrate heat pumps into its operations.
  • waste heat is available, and of sufficient quality and quantity, it is the most interesting approach from an economic viewpoint as its production cost is often close to zero and its use reduces its negative environmental impact.
  • An excellent example of suitable low-cost waste heat is that being discharged through the exhausts and cooling effluents of thermal power plants that have thermal efficiencies in the range of 33-45%.
  • the heating of the propelled fluid using waste heat is normally achieved by a direct transfer from the waste heat stream to the propelled and powered-fluid streams using a countercurrent heat exchanger or equivalent.
  • the necessary cooling of the said return, propelled-fluid can be obtained by, 1) dropping the pressure of the fluid in the return line by venting (poor efficiency), 2) transferring heat out the system using a reverse (cooling) heat pump (a vapor-compression chiller), or 3) use of waste heat energy from an external thermal process, or heat energy from solar energy to drive a vapor-absorption chiller.
  • a colder fluid stream is achieved by using an absorption-vapor chiller driven by waste heat that produces chilled water.
  • the larger propelled-fluid and smaller powered-fluid cooling can take place in an exchanger within the chiller or by remote exchangers.
  • Waste heat used for heating and cooling has a low cost, and as discussed, cooling (heat removal) can be used to produce significant differential pressure in the propelled-fluid circuit of the PET mechanism.
  • CHP Combined Heat and Power
  • FIG. 7b illustrates a typical heat load for a 2,500 MW, heat generation thermal power plant producing 1 ,000 MW of electrical power. The waste heat load is evaluated at 1 ,500 MW or 40% overall efficiency.
  • Figure 7c illustrates the necessary interconnections and equipment to integrate the 1 ,500 MW waste heat load into the operations of a CHP-HFFT propulsion system.
  • Concentrated solar power can also be an excellent thermal driver for the operation of a HFFT propulsion system and can result in a large quantity of power sites that can be sized to a specific application that can be either small or large and will be classified as zero-emission, zero-carbon.
  • the amount of hydraulic power per unit of volume produced by the powered-fluid as it passes through the fluid turbine will be a function of the specific gravity of the fluid. Miniaturization will be an important issue as it impacts the cost of the propulsion systems, and the physical size of the fluid-turbine could limit its ability to replace an electric motor that is the compact, legacy source of torque.
  • Increasing the SG increases the energy of momentum that can be carried per unit of volume. This is analogous to the use of thermal fluids. Thermal fluids are engineered to carry maximum heat energy; the powered-fluid should be engineered to carry maximum energy.
  • the turbine is sealed and operates with a controlled working-pressure inside the housing and sump and with pressurized, inlet feed and discharge return lines. As the powered-fluid is recycled, changes made to its temperature, chemistry and solids content are not lost in a discharge effluent stream.
  • the boiling point of the fluid, the dissipation of generated heat and the dissolved/entrained air content versus temperature are also variables which are not considered in the context of operating legacy, one-pass hydraulic turbines.
  • the pressure drops and velocity of the powered-fluid may also change due to the different capacity and environment of the installations (such as altitude, ambient temperature, and throughput). Stabilizers, buffers, and surfactants are part of the solution as operating the fluid turbine at a maximum SG is an important operating factor.
  • the propelled-fluid is also engineered to be as efficient as possible, said propelled-fluid is a selected, engineered fluid mixture of one or more fluids that exhibit physio-thermal properties within the following ranges.
  • HFT HEAT-FLUID-TORQUE CONFIGURATION USING A SINGLE-CIRCUIT PET
  • HFT Heat-Fluid-Torque
  • HFT propulsion system A smaller, more compact configuration of the HFT configuration was developed to eliminate the powered-fluid circuit and the powered-fluid turbine and to use a mechanical converter to convert the linear motion of the shaft of the singlecircuit PET to rotating motion in the form of torque to drive independent equipment-applications.
  • the HFT configuration uses a simpler design as it employs the same propelled-fluid and first-fluid circuit PET, but does not use the powered-fluid, the second-circuit PET used in the HFFT propulsor; as such the preferred HFFT propulsor is a double-circuit PET, while the HFT configuration is a single circuit PET.
  • the single-circuit configuration of the HFT is illustrated in Figure 7d.
  • a high energy-density heat source such as a combustion burner running on a stored supply of gasoline, natural gas, or hydrogen or, as an alternative, the use of stored electrical energy from an on-bord rechargeable battery.
  • the high energy density heat is required to assure an operation with a very HP, propelled-fluid.
  • the burner heat would supplement the heat energies from on-bord heat pumps or local heat sources.
  • the larger, double-circuit HFFT might fit into large mobile applications where there is more room, such as for the drives of big transport vehicles.
  • the propulsor can be installed between the back of the sleeper section and the front of the van. In the case of buses, they can be installed in the back of the bus.
  • the new FPU (07)/S of the HFT configuration also corresponds to the previous equipment assembly (30.1)/A of the preferred HFFT propulsor. The only difference is in the numbering of the output shaft couplings that were originally 35.1 and 35.2, which now read as 35.1 and 35.3. The same equipment-assembly is illustrated in Figure 3c.
  • the mechanical converter drives the inlet shaft of a speed reducer 98.4 that drives an equipmentapplication inlet shaft 74.1.
  • Figure 7e illustrates the integration of the HFT configuration identified by the number FPU (99)/P, which now comprises the same equipment-assemblies as the HFFT propulsor (10.1 )/A, (10)/A, (20)/A, (30.1 )/A and (70)/A.
  • the new equipment-assembly number for the single-circuit PET is (30.4)/A (only the coupling has changed) and the equipment-assembly number for the mechanical-converter is (98.0)/A.
  • FPU functional process units
  • the preferred embodiment for the PET mechanism is the equipment-assembly (30)/A.
  • a list of equipment-assemblies for the HFFT propulsion system is in Table 3 below.
  • a HFFT propulsion system FPU (00)/P comprising an electric motor driving a propulsor to produce, at the beginning, a HP, propelled-fluid, and at the end, a fluid-turbine producing rotational torque from a HP, powered-fluid stream for driving an equipment-application, wherein the electrical power input of the electric motor shaft will be less than the power input required to drive the fluid turbine without the use of a HFFT propulsor.
  • a HFFT propulsion system FPU (00)/P comprising an electric motor that drives a propulsor that generates a HP, propelled-fluid stream in a fluid circuit and also comprising a powered-fluid circuit and the HP, propelled-fluid circuit drives the powered-fluid circuit, and the HP, powered-fluid circuit drives either a powered-fluid turbine to produce rotor shaft torque or, the HP, powered-fluid stream may be used directly as part of the feed to an operational unit-process operation.
  • a HFFT propulsion system FPU (00)/P comprising a fluidturbine assembly that can transfer the pressure of the HP, powered-fluid stream to torque by passing the liquid stream over impulse/reaction flow elements that are connected to the central rotation shaft of the turbine-rotor and the momentum transferred from the flow elements will result in torque at the end of the rotor shaft.
  • a HFFT propulsion system FPU (00)/P comprising a fluidturbine assembly that operates with part of the return, powered-fluid stream being pumped through a deaerator to decrease the content of dissolved air in said stream, or the dissolved air content is maintained by chemical additions.
  • a HFFT propulsion system FPU (00)/P comprising a fluidturbine with the wetted area of the turbine housing being sealed and operating under a controlled internal pressure.
  • the discharges of the first stage of powered-fluid pistons now feed the second stage of powered-fluid turbines.
  • a HFFT propulsion system FPU (00)/P comprising an engineered, powered-fluid that comprises a fluid in which solids have been dissolved to increase its specific gravity, wherein the fluid temperature and pH are controlled to maximize the solubility of the solids, and to control the fluid viscosity, and wherein necessary additives are employed to avoid deposits forming on the interior surfaces of the fluid turbine.
  • a HFFT propulsion system FPU (00)/P comprising multiple pairs of synchronized piston-based equipment assemblies mounted radially around a common crankshaft to operate as a compact, high-capacity, single PET unit. It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising an engineered propelled-fluid that includes a fluid or fluids, selected based on their thermophysical properties that operate as a propelled-fluid in a first-circuit PET, that were selected to provide the best possible heat transfer at the lowest temperature and to produce the highest circuit pressure at said lowest temperature.
  • Figure 1 illustrates the propelled & powered-fluid streams that are part of FPU (03)/S and how these flow streams interact with the other functional process units of the HFFT propulsion system FPU (00)/P according to an embodiment of the present invention.
  • the chosen pressure energy transfer mechanism should execute the required pressure energy changes as the flow streams indicated are moving through the selected operational equipmentassembly, the preferred embodiment for executing FPU (03)/S being the piston-based equipment-assembly (30)/A.
  • Figure 1a shows 3 examples of the prior art for 3 different configurations of electric motor propulsion systems intended to provide torque to an equipment-application.
  • Excluding steam, prior art in the field of electrical propulsion processes is essentially an electric motor that direct drives an equipment-application that may have a speed reducer attached to the application inlet shaft, or an auxiliary drive with the electric motor powering a hydraulic system drive or an electric motor powering an air compressor drive that all serve to power specific equipment-applications.
  • each example either shows an electric motor transmitting torque directly from the shaft of the motor to the equipment-application or depending on the torque requirements, a fluid assembly such as a hydraulic oil assembly or a compressed air assembly is inserted into the chain of the drive to get a torque versus rpm profile that is different than that available from using only the motor itself.
  • a fluid assembly such as a hydraulic oil assembly or a compressed air assembly is inserted into the chain of the drive to get a torque versus rpm profile that is different than that available from using only the motor itself.
  • Figure 1 b illustrates an example of a double-acting cylinder pump.
  • the retraction and extraction movements of the piston are pressurizing a same liquid in a same circuit.
  • components of this device may resemble those of the double-action piston equipment-assembly of the propulsion system, the functionality of this device bears no resemblance to the HFFT, propulsion system FPU (00)/P.
  • Figure 1c illustrates a prior art configuration, that being a large diesel engine 96.1 driving an electrical generator 96.2.
  • the HFFT propulsion system FPU (00)/P is installed between the diesel engine and the generator such that the diesel engine is now driving the propulsor of the propelled-fluid circuit and the output shaft of the powered- liquid turbine is driving the generator.
  • the result of operating the propulsion unit as part of the diesel generator is that the load decreases for operating the diesel engine.
  • Figure 1 c illustrates how this propulsion system can be used in the context of applications that are not powered by electricity and an electric motor, but rather by mechanical torque from a combustion engine.
  • Figure 2 identifies the principal function FPU (00)/P and the sous-systems and their secondary functions (01)/S to (06)/S in the order of execution that constitutes a functional HFFT propulsion system, according to an embodiment of the present invention.
  • Figure 3a illustrates the configuration of the equipment-assemblies and includes the preferred embodiments and the 4 alternative mechanisms proposed to perform the function of an FTF-PET.
  • the HFFT propulsion unit also comprises a group of infrastructure equipment-assemblies, identified as (80)/A to operate under numerous possible operational, physical, and environmental situations related to specific equipment-applications.
  • Figure 3b illustrates the configuration of the equipment-assemblies but also indicates the configuration of the components of the equipment-assemblies. To provide a less loaded diagram, some of the equipment-assemblies are documented on separate sheets including Figures 3c, 3d, 3e & 3f.
  • Figures 3c, 3d, 3e,3f are depicting the equipment-assemblies respectively identified as (30)/A, (36)/A, (40)/A and 45/A.
  • the infrastructure equipment-assemblies, numbers 81 to 86, that are part of the infrastructure assembly (80)/A are integral parts of all described assemblies
  • Figure 3c illustrates the synchronized-pair, piston-based, propelled & powered-fluid PET equipmentassembly for completing a ‘fluid-to-fluid’, pressure energy transfer. Neither of the propelled & powered-fluid piston rods are connected to a mechanical driver. This operates as a 1 st PET mechanism and is the preferred embodiment.
  • HP, propelled fluid 31 .9 is delivered to the cylinder body of the first-circuit through the port 31 .7 and return, propelled-fluid is being discharged via the port 31.6 towards the propulsor inlet.
  • HP, powered-fluid 33.8 is being discharged toward the fluid turbine through the cylinder port 33.7 and return, powered fluid is delivered to the cylinder body via port 33.6.
  • Figure 3d illustrates a similar piston-type energy transfer to that of Figure 3c, but the transfer is accomplished using a single-action piston.
  • This can operate as a 2end PET mechanism, wherein the two faces of the single-action piston are each in contact with a different fluid.
  • One side is propelled-fluid, and the other side is powered-fluid.
  • the propel led-l iquid flow is vented by the manifold to the inlet line of the compressor and the forces of the low inlet pressure of the propulsor inlet and the compressed spring, return the propelled-fluid piston face to its start position.
  • Figure 3e shows a double-action diaphragm equipment-assembly (40)/A that can operate as a 3rd PET mechanism. It has 1 controller that feeds propelled-fluid to a piston assembly that applies the propelled fluid to one side of each diaphragm and this propelled air is of sufficient pressure to drive powered fluid through the chambers on the other side of the diaphragm.
  • Figure 3f shows a ‘mix and separate' fluids technique to operate as an equipment-assembly (45)/A that can operate as a 4th PET mechanism.
  • a rotor valve with sealed cavities is used to receive, mix and discharge the propelled- & powered fluids
  • Figure 3g shows a further embodiment of the FTF-PET in which the propelled & powered-fluid stream doubleaction pistons are mounted radially around a circular, rotating crankshaft.
  • the pistons are mounted as synchronized pairs at 180 degrees from each other.
  • This arrangement of the pistons can form a compact arrangement for multiple process-units executing the function of a pressure energy transfer. It is estimated that 8 or more pistons can be assembled around the same circumference.
  • Figure 4a shows a parallel arrangement of multiple, synchronous, double-action, piston-type equipmentassemblies. It is advantageous to operate FTF-PET equipment-assemblies (30)/A in several parallel stages instead of just one stage. This lowers the maximum required pressure energy of the HP, propelled-fluid stream and permits interstage heating of the HP, propelled-fluid stream that will increase the efficiency of the pressure transfer process.
  • Figure 4b illustrates how multiple units of FTF-PET equipment-assemblies (30)/A can also be operated ‘in series'. This serves to decrease the required pressure in the HP, propelled-fluid stream to reach the required pressure in the HP, powered-fluid stream.
  • the discharge of the HP, powered-fluid stream of the first FTF-PET equipment assembly becomes the feed of the second mechanism and the diameter of the piston of the propelled-fluid is increased. Intra-stage heating of the propelled-fluid stream is again possible.
  • Figure 5 illustrates a powered-fluid turbine equipment-assembly (60)/A used to convert the pressure energy of the HP, powered-fluid stream to rotating shaft torque.
  • the HP, powered-fluid stream is converted by a nozzle configuration into a high velocity stream to drive the central turbine-rotor of the fluid-turbine.
  • the housing of the turbine is sealed to allow for operations under possible negative pressure and the discharge from the sump of the liquid-turbine is recycled via the powered-fluid stream distribution equipment-assembly (50)/A to the return, powered-fluid stream inlet of the PET equipment-assembly (30)/A.
  • the end of the turbine-shaft is connected to the end of the shaft of the equipment-application and drives the rotating equipment-application.
  • the flow rate and pressure energy of the powered stream are adjusted to control the speed of rotation of the turbine-rotor.
  • Figure 6 illustrates a distributed configuration of the HFFT propulsion system wherein multiple units of the fluid-turbine are fed from a central PET equipment-assembly. This is advantageous when there are multiple small equipment-applications to be powered. It is preferred that the powered-fluid distribution system send out feed and return lines to multiple power-fluid turbines, each driving an independent equipment-application.
  • Figure 7a illustrates the configuration by integrating a vapor-compression heat pump 215 and a vaporcompression chiller pump 210 into the operations of an HFFT propulsor FPU (00)/P.
  • a concentrated solar 230 or geothermal heat production unit 231 can be used to supplementing the capacity of the heat pump 215.
  • Figure 7b illustrates a typical thermal power plant with indications of the heat loads and heat emissions.
  • Figure 7c illustrates the configuration by integrating the waste heat of the thermal power plant of figure 7b. into the operations of an HFFT propulsor FPU (00)/P
  • the cooling load 227 is divided between a waste heat unit 205 and a vapor-absorption chiller unit 200.
  • a concentrated solar 230 or geo-thermal heat production unit 231 can be used to supplement the capacity of the waste heat unit 205 and the vapor- absorption chiller unit 200.
  • Figure 7d illustrates a single-circuit PET, FPU (07)/S of the HFT configuration that is connected to a mechanical-converter FPU (08)/S for converting linear motion to rotary motion to drive the input of a speed reducer whose output drives an equipment application FPU (09)/S.
  • Figure 7e illustrates the similarity of the configurations between the vapor absorption chiller unit 200 and the waste heat unit 205 of a thermal power plant and the propelled-fluid circuits of the HFFT propulsor and the HFT configuration.
  • FIG. 1 that illustrates the activities of the PET related to functional process-unit FPU (03)/S that transitions the propelled-fluid functions (01 )/S and (02)/S to the powered-fluid functions (04)/S, (05)/S and (06)/S.
  • the function (06)/S is the equipment-application function that accepts torque from the end shaft of the fluidturbine.
  • the function (03)/S executes a PET from a HP, propelled-fluid stream to a return, powered-fluid stream while the streams are moving from the fluid stream inlets of the PET equipment-assembly to its fluid stream outlets.
  • the preferred embodiment to execute the PET is through synchronized-pair, piston-type, propelled & powered-fluid, PET equipment-assembly (30)/A.
  • the FTF-PET is accomplished by 4 different mechanisms that are based on the technique wherein a HP, propelled-fluid stream, that was generated by a propulsor, transfers part of its pressure energy to a return, powered-fluid stream to convert it to a HP, powered-fluid stream.
  • FIG. 1a there is shown 3 illustrations of existing prior art for legacy torque propulsion systems and all 3 are using an electric motor as a source of input power.
  • an electric motor is either directly driving the process equipment or driving an auxiliary propulsor to create a pressurized fluid stream that in turn will provide drive torque to an independent equipment-application through various types of hydraulic and gas driven motors connected to said independent equipment-applications.
  • the torque produced by the electric motor directly drives an equipment.
  • the motor drives auxiliary equipment in the form of a pump or compressor that produces a fluid stream, and the shaft of a satellite equipment is driven by the respective fluid stream that in turn drives the equipment.
  • FIG. 1b it illustrates a double-action, cylinder pump assembly (90)/ A that is part of prior- art for pumping a liquid from point a to point b.
  • the components listed are standard for a cylinder pump or for one of thousands of applications using various combinations of fluids and piston/cylinders to transfer electrical power to pressure energy.
  • the components listed include: 91 a double-action piston & cylinder, 92 discharge check valves, 93 feed check valves, 94 piston shaft, and 95 piston seals.
  • This cylinder pump plays no role in the operation of a HFFT propulsion system as there are no functions that requires a liquid to simply be propelled from a point a to a point b and no energy transition between two different fluids take place in a cylinder pump as the piston rod is motorized.
  • FIG. 1c there is shown a prior art for a propulsion system equipment-application 96 that depicts a diesel motor 96.1 driving a multi-MW electrical generator 96.2.
  • the equipment- application is to drive an electrical generator using the mechanical torque produced from a motor burning diesel fuel.
  • This equipmentapplication is common in remote areas that include the Arctic and Antarctic, Island nations such as the Caribbean and other sparsely populated areas.
  • FIG. 2 the functional process-units that constitute the operations of a HFFT propulsion system according to an embodiment of the present invention are illustrated in the order in which they are configured to operate; FPU (01 .1)/S motorize power to torque, FPU (01)/S propel a selected, limited fluid supply, FPU (02)/S distribute and condition the propelled-fluid stream, FPU (03)/S execute a pressure energy transfer, FPU (04)/S distribute and condition the powered-fluid stream, FPU (05)/S operates powered-fluid turbine producing torque from HP, powered- fluid stream and FPU (06) supply torque to an equipment-application.
  • FPU (01 .1)/S motorize power to torque
  • FPU (01)/S propel a selected, limited fluid supply
  • FPU (02)/S distribute and condition the propelled-fluid stream
  • FPU (03)/S execute a pressure energy transfer
  • FPU (04)/S distribute and condition the powered-fluid stream
  • FPU (05)/S operates powered
  • the selection of the fluids used is based on the thermo-physical properties of the fluids to obtain a most efficient propulsor energy transfer to the return, propelled-fluid and from HP, propelled- fluid to the return, powered-fluid and from the HP, powered-fluid to the turbine rotor.
  • the propelled-fluid stream can operate both heated and chilled and the powered-fluid operates normally chilled.
  • the chilling is preferred to remove the heat of propulsion and the heat of the powered-fluid turbine. Cooling water can be used but this creates a negative environmental impact associated with discharging heated effluent.
  • FIG. 3a it illustrates the configuration of the equipment-assemblies in the order in which they operate and includes the preferred embodiment and optional embodiments of the mechanisms proposed to perform the functions related to a PET.
  • equipment-assemblies (30)/A, (36)/A, (40)/A, (45)/A are the equipment-assemblies (30)/A, (36)/A, (40)/A, (45)/A.
  • the equipment-assembly (30)/A is the preferred embodiment but it could be replaced by either the mechanism (36)/A or (40)/A or (45)/A, which are identified as optional alternative embodiments to 30/A, or by any other mechanism that meets the requirements of the functional process unit (03)/S in the propulsion system FPU (00)/P.
  • the equipment-assembly (30)/A comprises integration via coupling of the 2 pistonbased assemblies (30.1 )/A and (30.2)/A.
  • the equipment-assemblies involved in Figure 3b are (10)/A, (10.1)/A, (20)/A, (50)/A, (60)/A, (70)/A & (80)/A.
  • the 4 PET equipment-assemblies are documented on Figure 3c, Figure 3d, Figure 3e, Figure 3f.
  • FIG. 3b A partial schematic of the HFFT propulsion system depicted on Figure 3b shows a fluid propulsor 11, the main component of the fluid supply propulsion equipment-assembly (10)/A, that is driven by an electric drive motor 11 .4.
  • the electric motor that may be variable speed, receives its power from the electrical utility 11 .7 or from a local rechargeable battery 11 .5 or from a source of power torque.
  • the propelled-fluid distribution assembly (20)/A operates in recycle mode but is also possible to operate in partial or full free flow mode. It comprises a configuration of HP, feed lines 24, and recycle/return lines 24.1 , to construct a sealed, propelled-fluid recycle circuit.
  • the outlet of the propulsor 11.1 feeds HP, propelled-fluid into a feed surge tank 21 to reduce line pulsations and flow and pressure variations.
  • the HP, propelled-fluid will be heated between the discharge outlet of the propulsor 11.1 and the discharge of HP, propelled-fluid from the outlet of the PET mechanism (30)/A.
  • the outlet discharge of said feed surge tank feeds uniform HP, propelled-fluid to an inlet port of the multi-way, directional control valve (32) that is part of the PET equipment-assembly (30.1 )/A.
  • An outlet port of the multi-way, directional control valve 32 discharges into a return line 24.1 that feeds the inlet of the cooling unit 23 for return propelled-fluid (end of Figure 3c).
  • the discharge of the cooling unit 23 then feeds the return, propelled-fluid to the inlet of a return surge tank 22 that is designed to remove any pressure or velocity surges.
  • the discharge of the return surge tank feeds the return line (24) that discharges return, propelled-fluid into the inlet of the propulsor 11 .2.
  • connection 25 that allows all, or part of the return, propelled-fluid, to be discharge to atmosphere 25.2 by opening the discharge valve 25.1 .
  • free flow valve 25.3 is opened to allow atmospheric air feed into the propulsor inlet.
  • the powered-fluid distribution equipment-assembly (50)/A operates in full recycle mode. It comprises a configuration of feed HP, powered-fluid streams 54 and return powered-fluid line 54.1 to operate as a closed loop, recycle circuit.
  • the discharge of the surge tank feeds a return, powered-fluid stream 54.1 to a feed inlet port 34.2 on the multi-way directional control valve 34 located on the pressure energy transfer assembly (30)/A.
  • the discharge from the cooling unit 54.1 also feeds a discharge connection 56.
  • a discharge connection 56 On this line there is a normally closed isolation valve 56.1 , that when this valve is open part or all the return powered-fluid stream from the sump is sent to atmosphere 56.2.
  • the reserve tank for powered-fluid make-up 55 will maintain supply of powered-fluid to the powered-fluid, PET equipment-assembly.
  • Figure 3c (synchronized, piston-based, propelled & powered-fluid, PET equipment-assembly, (30)/A)) is an illustration of the equipment-assembly (30)/A comprising 1 unit of piston-based, propelled-fluid, PET equipment assembly (30.1 )/A and 1 unit of piston-based, powered-fluid, PET equipment-assembly (30.2)/A connected at the ends of their piston rods by a 1 /2 coupling 35.1 & 35.2.
  • the feed and discharge to the ports of the piston-cylinders are controlled by a propelled-fluid, multi-port directional control valve 32.0 and by a powered-fluid, multi-port directional control valve 34.0.
  • the piston 31.2, piston cylinder 31.1 , piston rod 31.4, piston rings 31.3, piston rod seal 31.5, a cylinder port 31.6, and a cylinder port 31.7 operate on propelled-fluid as a double-action piston/cylinder.
  • the feed HP, propelled-fluid from the propulsor is delivered by feed distribution line 24 and the return, propelled-fluid is sent to the propulsor return inlet via return propelled-fluid distribution line 24.1.
  • piston 33.2, piston cylinder 33.1 , piston rod 33.4, piston rings 33.3, piston rod seal 33.5, a cylinder port 33.6, and a cylinder port 33.7 operate on a powered-fluid stream as a double-action piston/cylinder.
  • Feed propelled-fluid from the outlet of the propulsor is fed to the inlet port of the manifold 32.1 via the propelled-fluid distribution line 24 and the return propelled-fluid travels through a propelled-fluid distribution return line 24.1 through the port 32.2 and returns the propelled-fluid to the propulsor inlet.
  • the multi-port manifold provides the sequencing of the ports to supply either feed propelled-fluid or return propelled-fluid to the appropriate cylinder ports.
  • the cycle of the propelled-fluid piston is extension-retraction, and the cycle of the powered-fluid piston is always synchronized as the propelled and powered-fluid piston rods are connected. If multiple units are used, there will be a short time delay between the start of the piston cycles.
  • the propelled-fluid piston port 31 .7 is receiving HP, propelled-fluid and the powered-fluid piston is compressing a powered-fluid stream and discharging it as a HP, powered-fluid stream via port 33.7.
  • the return, powered-fluid stream from the sump of the powered-fluid turbine is fed to the inlet port of the manifold 34.2 via the powered-fluid stream distribution line 54.1 and the HP, powered-fluid stream discharges to a powered-fluid stream distribution return line 54 through the port 34.1 and feeds to the powered-fluid turbine inlet.
  • the multi-port manifold provides the sequencing of the ports to supply either return powered-fluid stream or HP, powered-fluid stream to the appropriate cylinder ports.
  • both pistons may have the same diameter; however, the propelled-fluid piston could be larger in diameter than the powered-fluid piston.
  • a propelled-fluid piston with a larger diameter can decrease the propelled-fluid pressure required to obtain the desired powered-fluid stream pressure, but the volume of propelled- fluid required will increase in proportion to the increase in the piston diameter.
  • the piston seals 31 .3 and 33.3 act as a sealed membrane interface that divides each piston cylinder into 2 separate cavities.
  • the cavities for the propelled-fluid circuit are 32.3 and 32.4 whereas the 2 cavities for the powered-fluid circuit are 34.3 and 34.4.
  • the inlet and outlet fluid streams are identified as follows: 1) HP, propelled- fluid (31.9); 2) return, propelled-fluid (31.8); 3) HP, powered-fluid (33.8); and 4) return, powered-fluid (33.9). It is understood that when the illustrated 'extension cycle’ ends and the 'retraction cycle’ begins, the inlet and outlet ports of the HP and return fluid streams will reverse.
  • Figure 3d (a single-action piston assembly, (36)/A)) is an illustration of the single-acting piston assembly (36)/A comprising 1 unit of single-acting piston assembly.
  • This assembly is an embodiment to perform the function related to a PET mechanism FPU (30)/S.
  • the role of the feed and discharge to the ports of the piston-cylinders are controlled by a propelled-fluid, multi-way directional control valve 38.0 and by a powered-fluid, multi-way directional control valve 39.0.
  • the piston 36.0, piston cylinder 36.1 , piston rod 36.2, piston rings 36.4, piston rod seal 36.5 and a cylinder port 36.6 operate on propelled-fluid as a single-acting piston/cylinder.
  • the piston 37.0, piston cylinder 37.1, piston rod 37.2 piston rings 37.4 piston rod seal 37.5 a cylinder port 37.6 operate on powered-fluid as a single-action piston/cylinder.
  • the return, powered-fluid stream from the turbine sump is delivered by return distribution line 54.1 to the inlet port of the powered-fluid, multi-way controller 39.1 and the HP, powered-fluid stream is fed to the turbine via the exit port 39.2 to the feed distribution line 54.
  • propelled-fluid from the outlet of the propulsor is fed to the inlet port of the manifold 38.1 via the propelled-fluid distribution line 24 and the return propelled-fluid returns to a propelled-fluid distribution return line 24.1 through the port 38.2 and returns the gas to the propulsor inlet.
  • the multi-port manifold provides the sequencing of the ports to supply either feed propelled-fluid or return propelled-fluid to the appropriate cylinder ports.
  • the cycle of the propelled-fluid piston is extension-retraction, and the cycle of the powered-fluid piston is always synchronized as the propelled & powered-fluid piston rods are the same rod and share the same cylinder.
  • the propelled-fluid piston port 36.6 is receiving HP, propelled-fluid and the powered-fluid piston is compressing a powered-fluid stream and discharging it as a HP, powered-fluid stream via port 37.6.
  • the return, powered-fluid stream from the sump of the turbine is fed to the inlet port of the manifold 39.1 via the powered-fluid stream distribution line 54.1 and the return HP, powered-fluid stream discharges to a fluid stream distribution return line 54 through the port 39.2 and returns to the powered-fluid turbine inlet.
  • the multi-way manifold provides the sequencing of the ports to supply either feed HP, powered-fluid stream or return, powered- fluid stream to the appropriate cylinder ports.
  • the travelling piston seals cannot remove 100% of the film of liquid that adheres to the inner face of the cylinder as each retraction/extraction cycle is repeated and during the retraction by the spring no powered-fluid is being compressed so that the process is not continuous but as-per-half-cycle.
  • a second unit operating at 180 degrees to the first unit will provide a continuous supply.
  • Figure 3e is an illustration of the equipment-assembly ‘double-action diaphragmtype, propeiied & powered-fluid, PET assembly’ (40)/A.
  • This assembly is an embodiment to perform the function related to a PET mechanism FPU (30)/S.
  • the double-action diaphragm is not acting as a pump but as a PET mechanism. It is being fed HP, propelled-fluid from the line 24 of the propelled-fluid distribution & condition assembly (20)/A and feeding return, propelled-fluid via line 24.1 . Line 24 is feeding the controller inlet line 43.2 and after the controller it is directed by line 43.3 to the chamber-right of propelled-fluid 41.4.
  • the propelled-fluid is being fed to a double-action piston/cylinder 41.8 that directs propelled-fluid to the inner surface of either the left or right diaphragm.
  • the pressurized-fluid flow is directed to the outlet line 40.1 and the return, powered-fluid is fed to the diaphragms through the return, powered-fluid line 40.2.
  • the inlet and outlet flow of powered-fluid are controlled by 4 check valves 41.3.
  • FIG. 40.1 is an illustration of the 'mix and separate fluids’ assembly (45)/A comprising 1 unit of a rotary valve 49.6 and 1 pressurized recovery tank 49.
  • the rotary valve is divided into 4 distinct rotating cavities that have inlet or outlet connections to each cavity numbered, 45, 46, 47 and 48 and each cavity has either an inlet or an outlet port that opens and closes by a respective controller 45.1 , 46.1 , 47.1 , & 48.1.
  • the rotary valve itself has a stationary outer housing 49.7 that is attached to a baseplate.
  • the outer housing can be divided into 8 quadrants of 4 cavities and 4 filled zones and openings in the outer wall allow material to be injected into the cavities, or the cavities can discharge material through an outlet connection.
  • the rotor 49.5 is also divided into 8 equal segments; 4 segments are hollow and the 4 spaces between the cavities are occupied by a filled zone.
  • the filled zone prevents any flow between the cavities and seals are installed on their outer circumference to seal the space between the outer walls of the cavities and rotating segments.
  • the role of the feed and discharge to the inlet and outlet ports are controlled by their respective controller.
  • a pressurized, receiving tank that has a recovery chamber for lighter propelled-fluid 49.3 and a recovery chamber for HP, powered-fluid stream 49.2. It receives a mix of powered-fluid and propelled-fluid through port 45. As soon as the mix inters the recipient, the propelled-fluid begins to separate from the powered-fluid stream based on their different mass densities. Within the recipient the liquid level is controlled by a level control loop.
  • the discharge on the tank 49.1 connects with the HP, powered-fluid line 54 of the powered-fluid stream distribution and conditioning assembly.
  • the discharge of the propelled-fluid space 49.3 connects with the return, propelled-fluid line 24.1 of the propelled-fluid distribution and conditioning assembly (20)/A.
  • the upper section of the recipient is full of propelled-fluid and the bottom is full of powered- fluid.
  • the 4 cavities, numbered #1 to #4, are located at the 12, 9, 6, and 3 o’clock positions and the rotor turns counterclockwise. The function of each cavity is as follows.
  • Cavity 46 is controlled via port controller 46.1 ;
  • Figure 3g shows a further embodiment of the piston-based, propelled & powered-fluid PET equipmentassembly (30)/A that comprises 1 propelled-fluid piston assembly driving 1 powered-fluid piston assembly.
  • Two synchronized units of equipment-assembly (30)/A are now mounted radially around a circular, non-central, rotating crankshaft. This is a more compact arrangement as the units instead of being connected on a horizontal plain are now concentrated around a vertical circumference.
  • FIG. 4a it depicts the use of multiple stages of the piston-based, propelled & powered- fluid, PET assembly (30)/A.
  • the return, propelled-fluid flows of each stage are fed to the inlet connections for propelled-fluid on the next stage.
  • the diameter of each succeeding propelled-fluid piston increases to apply an equal pressure on the corresponding powered-fluid piston.
  • the return, propelled-fluid pressure energy from the discharge of the last stage is now much less when it reaches the propulsor inlet.
  • Interstage heaters 23.1 are used to use heat to minimize the loss in pressure as the volume of the piston cylinder increases.
  • the arrangement of ‘multi-stage’ piston based, (30)/A assemblies are depicted in Figure 4a.
  • operating PET assemblies 'in-series is another strategy to reduce the energy input required to produce work done by a piston-type, PET assembly.
  • the objective is to minimize the pressure of the propelled-fluid stream while maximizing the pressure of the powered-fluid stream.
  • the H P, powered-fluid of the first stage is feeding the inlet of the return, powered-fluid of the second stage and the diameter of the piston of the propelled-fluid stream is now larger than the diameter of the piston of the powered-fluid piston. This serves to minimize the required pressure applied by the propelled-fluid and maximize the pressure of the powered-fluid.
  • FIG. 5 is an illustration of a powered-fluid turbine equipment-assembly (60)/A that is being fed with the HP, powered-fluid stream.
  • the role of the powered-fluid turbine equipment-assembly is to complete a pressure energy transfer from the HP, powered-fluid stream into torque that will be delivered via the central rotating shaft 61 , to a speed reducer 67 and coupled 66 to the rotating shaft of the equipment-application 72.
  • a powered-fluid distribution pipe 64 directs the HP, powered-fluid stream that was fed into its inlet into one or multiple high-velocity jet streams created using nozzles 64.1.
  • the flow elements 61.3 are attached to a support ring 61.2 that is attached to a runner 61.1.
  • the flow elements convert the velocity of the liquid stream into a force applied against the runner that continues the transfer to the rotating shaft 61 where it becomes torque.
  • the wetted surfaces of the inside of the housing are held under controlled working pressure by a compressor 63.2 driven by variable speed motor 63.3.
  • the compressor outlet is connected to an inlet connection mounted on the outside surface of the turbine housing 64.2.
  • the controlled pressure serves to adjust (to increase) the boiling point of the HP, powered-fluid as the temperature of the HP, powered-fluid may be held fairly high to maximize the solubility of the dissolved solids in the powered fluid stream.
  • the inlet powered-fluid stream falls by gravity into the turbine sump 65.
  • the return line of the turbine sump 65.1 feeds a return, powered-fluid line 54.1 in the powered-fluid distribution and conditioning equipment-assembly (50)/A.
  • fluid turbines may have vertical or horizontal shafts, impulse or reaction type blades, convergent and diffuser-type casings, a pressurized or non-pressurized casing, one or multiple stages of flow elements (blades, buckets, cavities etc.) and recirculating or non-recirculating flow streams, Also the variation in the capacities of the HFFT propulsors and the different environments will have some impact on the appropriate turbine design.
  • FIG. 6 it illustrates that, rather than install a complete HFFT propulsion system for each equipment-application, it is possible to install one central, pressure energy transfer assembly with the capacity to deliver an HP, powered-fluid stream to multiple, distributed units of the fluid-turbine and each individual fluid turbine drives an independent equipment-application.
  • each equipment application has its own fluid-turbine to drive it and it is important to connect each equipment application with a feed and return line for transporting the HP, powered-fluid stream and the return, powered-fluid stream.
  • This eliminates electric motors and all the power wiring, electrical switchgear, and motor control centers. It also eliminates the loss of electrical power and heat that is related to running an electric motor.
  • Figure 7a illustrates an -HFFT installation wherein 2 heat pumps are providing a mix of hot and cold energy transfers to the propelled & powered-fluid circuits. Each of the heat pumps can supply both heat and chilling transfer to both fluid circuits.
  • a motorized vapor-compression chiller 210 and a motorized vapor-compression heat pump 215 are supplying chilled thermal fluid and hot thermal fluid respectively to the return, propelled and return, powered-fluid circuits and to the HP, propelled and HP, powered-fluid circuits.
  • a heating thermal fluid supply line 216 distributes heat from the heat pump 215 to fluid feed line 217 that feeds the HP, propelled-fluid exchanger 23.1 that provides heat to the HP, propelled-fluid circuit, and supply line 217 also connects to heating fluid feed line 218 that provides heat to the HP, powered-fluid exchanger 53.1 .
  • the heat pump has a hot air exhaust line to atmosphere 219.
  • a chilled thermal fluid supply line 211 distributes cold thermal fluid from the vapor-compression chiller 210 to chiller fluid feed line 212 that feeds the return, powered-fluid exchanger 23 that provides chilling to the return, powered-fluid circuit and supply line 211 also connects to chilling fluid feed line 213 that provides chilling to the return, powered-fluid exchanger 53.
  • the chiller has a hot air exhaust line to atmosphere 214.
  • the advantage of employing the heat pumps is that the required differential pressures or fluid temperatures required can be obtained with a less expensive and more efficient thermal energy input than if the same conditions were obtained strictly by mechanical compression.
  • Concentrated solar and geo-thermal are sources of inexpensive thermal energy.
  • a unit of concentrated solar 230 and a unit of geothermal 231 are depicted and their heat provided is being added to the thermal energy that is being produced by the vapor-compression heat pump via line 216.
  • Figure 7b and Figure 7c pertain to the operation of a HFFT system in a context wherein the waste heat provided for heating and cooling the propelled and powered fluids are from a thermal power installation.
  • the values indicated for the available heat loads in terms of MW of electrical power are order-of-magnitude for pre-feasibility level analysis.
  • Figure 7b depicts a thermal power plant that does not incorporate a HFFT propulsion system and will serve as a comparative model. It is assumed this production facility has a gross thermal capacity of 2,500 MW, at 40% thermal efficiency. As such, it produces 1 ,000 MW of electricity and 1,500 MW of thermal losses in the form of waste heat load that leaves the plant to the environment and simply assumed as a 1,500 MW effluent load (no losses to atmosphere).
  • Figure 7c depicts the same power plant as Figure 7b, however, the waste heat load has been integrated to create a Combined Heat and Power or CHP-HFFT propulsion system. This new operation produces some 100 MW of torque and 250 MW of electrical power that will have consumed 700 MW of waste heat required to accomplish the necessary work-done to produce the torque and power.
  • the thermal power plant 225 has an overall heat generation capacity of 2,500 MW that in turn produces some 1 ,000 MW of electricity in its generating unit 226 and produces some 1 ,500 MW of waste-heat load 227.
  • the waste-heat load is distributed via a first HP, waste-heat supply line 222 to a vapor-absorption chiller and the return, waste heat is returned to the waste-heat load 27 via return line 223.
  • waste heat load 227 is distributed by a second HP, waste-heat supply line 220 to a waste-heat heat exchanger and the return waste-heat is returned to the waste-heat load via return line 221 .
  • a waste-heat vapor-absorption chiller 200 and a waste-heat heat exchanger 205 are supplying chilled thermal fluid and hot thermal fluid respectively to the return, propelled and return, powered-fluid circuits and to the HP, propelled and HP, powered-fluid circuits.
  • a heating thermal fluid supply line 206 distributes heat from the waste-heat exchanger 205 to hot fluid feed line 207 that feeds the HP, propelled-fluid exchanger 23.1 that provides heat to the HP, propelled-fluid circuit, and heating supply line 206 also connects to heating fluid feed line 207 that provides heat to the HP, powered-fluid exchanger 53.1.
  • the heat pump has a hot air exhaust line to atmosphere 219.
  • a chilled thermal fluid supply line 201 distributes cold thermal fluid from the vapor-compression chiller 200 to chiller fluid feed line 202 that feeds the return, powered-fluid exchanger 23 that provides chilling to the return, powered-fluid circuit and supply line 201 also connects to chilling fluid feed line 203 that provides chilling to the return, powered-fluid exchanger 53.
  • a unit of solar heat 230 and a unit of geo-thermal heat 231 are used to increase the quality and/or the quality of the waste heat source 205.
  • Figure 7d illustrates the configuration of a single-circuit PET with a mechanical-converter and this constitutes a simplification in the configuration with the HFFT propulsor. This simplification does result in lower system efficiencies calculated as a higher ratio of “the input power to the propelled-fluid’7”output torque (power) from the powered-fluid turbine”; however, the propulsion system is more compact and less costly to build.
  • the propelled-fluid and the first-circuit of the PET (30.4)/A that is illustrated is the same unit used by the HFFT propulsor in Figure 3c (30.1 )/A with the exception that instead of applying the pressure energy (force) of the propelled-fluid against the shaft of the piston of the powered-fluid circuit (30.2)/A, it is now applying its pressure energy against an inlet shaft 98.3 of a mechanical-converter.
  • the function of a mechanical-converter is to convert the linear, back and forth output of a shaft 31 .4 into rotary motion using said mechanical-converter 98.9.
  • the FPU (07)/S describes the functions performed by the mechanical-converter and the FPU (08)/S describes the functions of the speed reducer and equipment-application.
  • the equipment assemblies that serve to physically deliver the process requirements are (30.4)/A for the FPU (03.0)/S and equipment-assembly (98)/A for the FPU (07)/S and FPU (08)/S.
  • Figure 7e depicts a scenario whereby the thermal power plant 225 introduced in Figure 7c is now suppling waste heat to a stationary HFT configuration, FPU (99)/P.
  • this HFT configuration FPU (99)/P that comprises the equipment-assemblies (10.1)/A, (10)/A, (20)/A, (30.4)/A, (70)/A, (80)/A (not depicted) and (98)/A, is applicable to all types of HFT configuration installations.
  • the concentrated solar unit 230 and geo-thermal unit 231 can supplement the supply of the waste heat supply unit 205 and this unit can supplement the supply to the vapor-absorption chiller 200 by sending heat energy via lines 221 & 222.
  • the vapor-absorption chiller can supply cooling to the propelled-fluid circuit via lines 201 & 202 that will supply the cooling exchanger 23.
  • the propelled-fluid circuit can be heated by transferring waste heat via line 206 & 207 to feed the exchanger 23.1
  • the equipment-assembly for the single-circuit PET is (30.4)/A and as mentioned closely resembles the first circuit equipment assembly (30.1)/A of the HFFT.
  • the equipment assembly (98)/A comprises the 2 new equipment additions that include a mechanical-converter 98.9 and an associated gear box 98.8. It is the output shaft of the reducer 98.5 that transmits its output to a transmission belt 98.7 that powers the input shaft 74 of an equipment application 74.
  • the term "about” has its ordinary meaning. In embodiments, it may mean plus or minus 10% or plus or minus 5% of the numerical value qualified.
  • 72 equipment-applications includes pumps, fans, diesel & electric generators, compressors, rotating machines, rotating grinders, rotating machines, etc. (includes 72.1)
  • HFT configurations (includes 74.1)

Abstract

A heat-fluid-fluid-torque (HFFT) propulsion system is provided, wherein a passive compressible fluid of limited supply is propelled through the transfer of external electrical power to a propulsor. In this process, the motorized propulsor propels a first recycle circuit of the propelled-fluid stream to a specific pressure that then transfers pressure energy to propel a second, recycle circuit of a limited source of incompressible fluid to produce a powered-fluid stream. The differential pressure between the propelled-fluid and powered-fluid streams will in turn drive the production of rotating torque in a powered-fluid turbine. Heat under pressure to expands the propelled-fluid stream to produce work based on the change in volume that leads to a pressure energy transfer mechanism that generates the incompressible powered-fluid stream. The energy of the powered-fluid stream is transferred to the rotor of a fluid-turbine to produce torque to drive rotary equipment-applications.

Description

TITLE OF THE INVENTION
A HEAT-FLUID-FLUID-TORQUE (HFFT) PROPULSION SYSTEM
FIELD OF THE INVENTION
[0001] The present invention relates to a new technology in the field of propulsion systems for producing shaft torque wherein the input power/energy applied by a propulsor and by transferring external heat/cooling energy to a limited supply of fluid, creates a first propelled-fluid stream that then transfers part of its pressure energy to a second powered-fluid stream of limited supply that, in turn, powers a fluid-turbine(s) rotor to produce rotating shaft torque that drives an independent rotating equipment.
[0002] This process, called the HFFT (Heat-Fluid-Fluid-Torque) Propulsor results in a reduction in said input power/energy applied as compared to prior art that involves an electric motor shaft driving an equipment shaft.
[0003] Another application of this technology will serve to reduce the energy/power required to propel high pressure (HP), process fluid streams used within industrial applications. This technology can be part of a new installation or retrofitted to replace a legacy propulsion system.
[0004] A third application is the development of a smaller, mobile propulsor, called the HFT (Heat-Fluid-Torque) configuration, that uses only the propelled-fluid in a single-circuit, that drives a mechanical converter that drives an equipment-application. Although its efficiency is lower, this configuration of the HFFT process suits the need for torque of a market centered around transportation.
[0005] The basis of this HFFT propulsion system and of its HFT configuration involves the thermophysical properties of fluids and is partially related to pressure-volume work achievable from mechanical propulsion accompanied by heating and cooling. In a preferred embodiment, the 2 selected fluids involved in the transfer of pressure energy are recirculating in closed loops and the fluids have been selected, amongst other criteria, based on their differences in compressibility, which is related to their capacities to produce positive or negative work based on the formulae: positive work = P (delta V) and negative work = -P (delta V).
BACKGROUND OF THE INVENTION
[0006] Producing torque to drive rotary equipment applications became rather simple with the development of electrical power grids and electrical motors. In the beginning of the 19th century, it was horses and humans that produced the torque necessary for transportation and to drive most equipment. This era was followed using steam power.
[0007] Once the electrification of society began, the accepted standard process to supply torque was to install an electric motor and connect its shaft to the shaft of the equipment to be driven.
[0008] To this day, electrical motor shafts coupled to equipment shafts is the obvious solution for most needs for rotating torque. The growth of the population and size of industries required to produce the necessary foods and services now demands quantities of shaft torque to the point where the planet is seeing great environmental stress. Much of the electricity that produces rotational torque is produced from the combustion of carbon-based fuels that powers motors and re-charges batteries.
[0009] Society needs to start reducing the energy consumed to produce rotating torque, and reducing the energy consumed is more efficient in reducing emissions than simply converting the power generation processes to renewable energies.
OBJECTS OF THE INVENTION
[00010] The present application describes a system and a process that were developed to decrease the amount of electricity, fuel, heat, or power consumed to drive rotating equipment. For this application the names 'HFFT propulsor’ and 'HFFT propulsion system’ and 'FPU (OO)ZP’ are considered synonyms. To begin, some of the operational features that support its classification as a novel, innovative development are introduced.
[00011] The mostly heat powered HFFT propulsion system operates as a thermally driven system involving the conversion of multiple, different heat energies to pressure/velocity energy using custom engineered fluids designed to absorb heat energy more easily and to convert said heat energy more efficiently to pressure energy.
[00012] This concept will be the first fluid propulsion system employing pressurized circuits that does not use steam (water vapor) as the fluid for absorbing the heat energy and transferring said heat energy to nonthermal related (force related) pressure energy of a second fluid by the use of a pressure energy transfer mechanism and then producing rotational shaft-torque in a turbine-rotor using said non-thermal related pressure energy.
[00013] The HFFT propulsion system is also unique for its operation at lower fluid temperatures but higher fluid pressures than steam-based propulsors. This is made possible by using a mix of input power, waste heat, heat pumps and heat transfer strategies to drive an engineered, propelled-fluid in a first circuit that is made of components with different thermophysical properties than those of water (steam).
[00014] Assuming the powered-fluid of the second circuit will be a water mixture, its properties will also be engineered to increase its efficiency in transferring the pressure energy from the propelled-fluid stream into mechanical rotary-torque.
[00015] The concepts of the larger, double-circuit, HFFT propulsor and its smaller, single-circuit, HFT configuration will result in cost effective torque production for large or small, as well as stationary or mobile, equipment-applications.
[00016] This is a unique thermal propulsion system that isolates the first-fluid, first-circuit, first-process of transferring external heat energy to a first-fluid from the second-fluid, second-circuit, second-process of transferring velocity energy to a turbine-rotor to produce shaft torque.
[00017] This is the first, ‘dry’ hybrid-powered propulsor that can operate using inputs of electrical and heat energies comprising ; 100% electric, 0% electric, or a mixture of electric, waste heat, thermal & electrical renewables, steam heating, compressed-vapor heat pumps, and/or mechanical power, and this achieved without using steam as the propelled-fluid.
[00018] Given the ability of the HFFT to operate at lower temperatures and due to the thermal energy produced at low-cost, both geo-thermal and concentrated solar energies work well with the HFFT propulsor and the HFT configuration to produce clean, renewable electrical energy.
[00019] The heat sources used in an HFFT propulsor can be at lower temperatures and the heated fluids can be at higher corresponding pressures than those involved in the operations of steam thermal power applications that include nuclear, combustion-type fired-boilers and gas-turbines.
[00020] Based on the use of colder-temperatures and higher force-driven pressure energies, the HFFT development could support being named ‘COLD-FORCE’ TORQUE. As the HFT configuration (and the HFFT propulsor) does not use steam (water) as a propelled-fluid stream, it could support being named ‘DRY FLUID’ TORQUE.
[00021] What follows is the definition of the inventors’ understanding of the scope of the invention that is referred to in the present application as a heat-to-fluid-to-fluid-to-torque (HFFT) propulsion system identified as; FPU (00)/P. One of its inventive elements involves a new concept; a fluid-to-fluid (FTF), pressure energy transfer (PET) mechanism, also referred to hereafter as an FTF-PET mechanism or as a PET mechanism.
[00022] In preferred embodiments, an FTF-PET takes places between 2 fluid bodies of limited supply, over 2 sealed membrane-interfaces, located within 2 isolated flow circuits, within 2 piston-cylinders, that are connected through their end-shafts, whereby one piston is propelled by a propelled-fluid stream generated by thermal gradients and a powered propulsor of the first circuit and the other piston is powered by said propelled-piston to generate a powered-fluid stream, and said powered-fluid stream of the second circuit is directed to a fluid-turbine to generate torque at the end of the shaft of its turbine-rotor that drives all types of rotary, independent equipmentapplications.
[00023] The benefit of this system is in the fact that the same level of output torque is achieved with a lower required input of energy using a HFFT propulsion system than by producing said level of output torque with simply a legacy electric motor drive. As the title indicates, the process is centered around the use of 2 different fluid streams; that being a propelled-fluid stream and a powered-fluid stream.
[00024] Two properties of the 2 fluids that are of interest concern their capacity to be propelled/compressed and accept positive work, as indicated by the values of compression energy (MJ/kg) versus pressure (bar) and their values of specific weight versus pressure. When gases and liquids are heated, they expand, and this effect can be exploited to use the expansion of a volume of a first propelled-fluid to produce additional work by transferring its change in volume to displace a second powered-fluid stream. If the volume is fixed, the increase in temperature increases the pressure and this will also be used to increase the pressure of the second stream. [00025] The energy input involved in obtaining the required volume and pressure of the propelled-fluid stream equals the energy required to create the propelled-fluid stream of equivalent volume & pressure, plus fluid friction losses of the propelled & powered streams. Given the incompressible nature of liquids, they are questionable for use as a propelled-fluid; as such, a performing fluid-to-fluid transfer will probably exclude transfers that are liquid- to-liquid or liquid-to-gas.
[00026] An efficient way to obtain this additional work output is not only by mechanical compression but also by applying heat and cold to the propelled-fluid stream to obtain its expansion or compression (at a higher pressure). Gases and liquids are both considered as fluids. As the line between which gas or which fluid will provide the best result is not obvious, one should consider simply that 2 fluids are involved and that one will be the propelled-fluid and the other will be the powered-fluid.
[00027] The unique series of input to output process functions of the HFFT propulsion system proceeds as follows.
1 ) convert consumed, external power or internal battery energy to rotating shaft torque of a propulsor,
2) propel a fluid stream from a limited supply into a HP, propelled-fluid stream using said rotating shaft torque of a propulsor,
3) distribute and condition by heat transfer the HP, propelled-fluid stream, discharged from the propulsor, in a pressurized, recycle circuit and feed to the inlet of an FTF- PET mechanism and then recycle the propelled-fluid discharge from said FTF-PET mechanism to the inlet of said propulsor,
4) execute a FTF-PET within an appropriate mechanism to generate an HP, powered- fluid stream by transferring the pressure energy of the HP, propelled-fluid stream to the powered-fluid stream. The single propulsor is now driving the recirculation of both streams; propelled & powered-fluids,
5) distribute and condition by heat transfer the HP, powered-fluid stream, discharged from the PET mechanism in a pressurized, recycle circuit, to the inlet of a ‘powered- fluid’ turbine and continue recycling the powered-fluid stream from the discharge of the turbines sump to its return inlet on the PET mechanism,
6) convert the pressure energy of the HP, powered-fluid stream to rotating shaft torque, as it transfers momentum passing over the impulse or reaction type fluid flow elements attached to the turbine-rotor,
7) drive the shafts of rotating, independent equipment-applications coupled with the end-shaft of said turbine-rotor.
[00028] Energy transfer takes place when energy moves from one place to another, and pressure defines the mechanical force that will cause a necessary energy transfer. A technique is defined as a way of carrying out a particular task and, in this case, the preferred technique is to transfer pressure energy from a highly pressurized- fluid stream to a lesser pressurized-fluid stream using a process transfer that is fluid-to-fluid.
[00029] The energy transfer starts by converting a source of power to rotating torque that is applied to the rotatable shaft of a propulsor. The propulsor transfers energy to a limited source of fluid supply that becomes the first fluid stream (the ‘propelled-fluid’). The transfer from the first fluid stream to the second fluid stream (the ‘powered-fluid’) is by applying mechanical force (pressure) on two, interconnected 'sealed, membrane-interfaces’, that transfer pressure energy based on the differential pressure between the 2 fluid streams.
[00030] This is accomplished by coupling together the shaft-ends of two double-action pistons of similar stroke to synchronize the movement of their pistons so that the extension cycles and retraction cycles of both pistons are the same.
[00031] During the extraction cycle, the 'top face’ of the piston of the left is being 'fed’ HP, propelled-fluid at the same time the 'top face’ of the piston on the right is 'discharging’ HP, powered-fluid. During the retraction cycle, the 'rod face’ of the piston on the left is now being fed HP, propelled-fluid, while the 'rod face’ of the piston on the left is 'discharging’ HP, powered-fluid.
[00032] Both top-faces of the 2 pistons and (facing) rod-faces of the 2 pistons are either high pressure or low pressure (return) at the same times. The first circuit (or propelled-fluid circuit) is feeding a HP, propelled-fluid to its piston/cylinder that is also discharging a return, propelled-fluid, whereas the second circuit (or powered-fluid circuit) is discharging a HP, powered-fluid from its piston/cylinder and being fed a return-powered-fluid.
[00033] In the case of a synchronized, piston-type, PET assembly, both the propelled and the powered-fluid streams are traveling through independent pressurized chambers or cylinders that contain a sealed, membraneinterface created by a piston & seals or other appropriate sealing. The membrane-interfaces and interconnected piston rods serve to transfer the pressure energy of the propelled-fluid stream to the powered-fluid stream.
[00034] Double-action diaphragm PET assembly operations are slightly different. There is a left and a right diaphragm, that create two separate chambers that separate the propelled-fluid from the powered-fluid. In legacy, diaphragm units used for pumping, a source of compressed air is used as the HP, propelled-fluid. Check valves installed at the inlet and discharge of the powered-fluid chambers are used to control its inlet and outlet flows as the pressure energy of the propelled-fluid is exerted either on the left diaphragm or the right diaphragm.
[00035] A multi-way controller directs the back-and-forth movement of a double-action diaphragm assembly that includes a left-side diaphragm forming a first propelled-fluid sealed cavity and a first powered-fluid sealed cavity. The similar right-side diaphragm forms a second propelled-fluid sealed cavity and a second powered-fluid sealed cavity. In total the 2 diaphragms form 4 cavities, 2 left-side cavities, and 2 right-side cavities.
[00036] The flows from the controller are directed to an adapted double-action piston that serves to increase the pressure that is applied to either the left or the right diaphragm cavity through flow channels connecting the piston chamber to the cavities. The propelled-fluid piston and or the propelled-fluid controller may be located as an attachment to the frame of the double-action diaphragm or as a remote unit.
[00037] Whereas said controller directs the flows of propelled-fluid, the flows of powered-fluid into 2 of said 4 cavities is controlled by 2 inlet check valves, one on the suction-end of each cavity and by 2 outlet check valves, one installed on the discharge-end of each cavity. To assist in synchronizing the back-and-forth action of the cavities a rod may interconnect the inside faces (propelled-fluid) of the two diaphragms.
[00038] As someone familiar with the transfer of pressure energy over a diaphragm would understand, neither the number, shape, or configuration of the powered-fluid diaphragms and/or its related cavities, nor the number, shape or configuration of the propelled-fluid, piston-type PET mechanism and/or its related cavities, add any additional uniqueness to the HFFT Propulsion System FPU (00)/S as described in this application.
[00039] The multi-way controller feeds the propelled-fluid to a first sealed cavity and simultaneously vents the propelled-fluid from a second sealed cavity. Each face of the diaphragm forms one of the walls of the 4 cavities so that the pressure within one cavity is applied to one face of the diaphragm and the opposite face executes a pressure energy transfer (PET) from the propelled-fluid to the powered-fluid in the second cavity on the opposite face of the diaphragm.
[00040] The recycling of the propelled-fluid follows the same format for piston-type or diaphragm-type or other types of mechanisms for executing a pressure energy transfer between two fluids. In all instances, the powered- fluid discharge from all PET mechanisms will be directed to the distribution and conditioning assembly (50)/A, and from there discharged to feed the powered-fluid turbine (60)/A.
[00041] Piston/cylinders with piston rods working as a system and piston/cylinders working with diaphragms and connecting rods both constitute a technique of the type-'sealed, membrane-interface’ and are central to the operation of a preferred embodiment. As mentioned, in the case of the ‘piston/cylinder’-type mechanism, it is the back-and-forth movement of the piston, its seal rings and the piston rod, that create the sealed, membraneinterface and that serves to execute the pressure energy transfer between the 2 isolated fluid circuits.
[00042] In the case of the 'double-action diaphragm’-type pump, it is the back-and-forth movement of the sealed diaphragm driven by the pressure energy of the propelled-fluid, that creates the 'sealed, membrane-interface’ and the corresponding transfer of differential pressure energy over the diaphragm located between the chambers of the powered-fluid stream and the propelled-fluid stream.
[00043] The 2 membrane-interfaces that were considered in this application are built around pistons and diaphragms. As a knowledgeable expert in the field of pumping will understand, there may exist other types of membrane-interfaces and other configurations of pistons and diaphragms suitable for this application, and that those cited are simply the most common examples.
[00044] There exist examples of types of the 'sealed membrane-interfaces’ that are common to pumping liquids such as those that exist in hydraulic power systems and in various pumping systems. The ‘synchronized-pair, piston-based, propelled & powered-fluid, PET equipment-assembly (30)/A’ employed to transfer pressure energy between fluids in a HFFT propulsion system, is, however, not related to hydraulic power systems. Legacy hydraulic power systems operate with one fluid circuit that uses piston/cylinders to produce a force in a forward or backward direction, but there is no ‘fluid-to-fluid, pressure energy transfer’ (FTF-PET).
[00045] Another prior art example of this type of sealed, membrane-interface being used to pump a fluid is demonstrated by a double-action diaphragm pump, wherein a supply of compressed air (propelled-fluid) is fed to a piston assembly that produces a powered-fluid stream on each side of a membrane-interface that is displaced by a motorized piston rod.
[00046] In both above-mentioned cases of prior art, a more efficient means of producing rotating torque to obtain a reduction in the required energy input are not related to their performance. One explanation, for this situation is there is no prior art in the field of the application of the thermo-physical properties of fluids to reduce the energy required to produce torque. The prior art available only concerns applications that simply address the pumping or transport of a single fluid.
[00047] There is some standard equipment used in other fields that are common to this technology and physically resemble the equipment being used to transfer energy between fluid streams, such as basic hydraulic components. The prior art cited, however, relates to the application of electrical power to produce a standard amount of rotating torque. It is 'prior art’ with regard to 'geometry of shape of components and applied fluid mechanics’, but it is not 'prior art’ regarding a common use of neither applied science nor inventive intended purpose.
[00048] The energy performance of the HFFT propulsion system will depend on the fluids employed. In the case of gaseous fluids, their compressibility factors, boiling points, and energy of compression, as well as their specific weight at their operating conditions plays an important role in the amount of input energy required for their propulsion as well as having a significant impact on the output energy produced in the powered-fluid turbine.
[00049] This application refers to gases, or compressible fluids that are in a gaseous state at STP conditions (standard temperature and pressure). If, at the stated operating conditions, the phase of the fluid changes from a gas to a gas-liquid or to a liquid, we are referring to the fluid being in its 'as-is-phase' or 'operating phase’.
[00050] Another consideration in choosing a compressible fluid is its expansion coefficient. The work obtained by the expansion of a gas stream through the introduction of heat energy to increase the work produced may be more economical through propulsion by torque applied to a shaft. Expansion obtained by injecting heat into a stream will likely require de-compression by chilling the stream and/or additional propulsion.
[00051] The efficiency of reversing heat pumps and their EER ratings (energy efficiency rating) is an example of how more output work can be accomplished by using fluid compression/expansion cycles. Air conditioners and heat pumps can transfer 300 % more energy than they consume.
[00052] If heat energy is intentionally injected before fluid expansion and is neutralized by chilling the fluid stream before re-compression, the net saving in the reduction of the energy consumed will increase. The energy required by the compressible fluid to produce the work on the incompressible fluid should be as low as possible as this is where the economy of input energy takes place.
[00053] The terminology used in describing this propulsion system is the ‘fluid-to-fluid’, 'pressure energy transfer’ or FTF-PET. In this system, a PET occurs when the HP, propelled-fluid stream is transferring part of its pressure energy to create a HP, powered-fluid stream to drive a powered-fluid turbine. It is FTF as two selected fluids are recirculating, under pressure and as they never leave the system, they are not being pumped but re-energized.
[00054] A HFFT propulsion system comprises the equipment and components starting from the input of power from a source to the output shaft-end torque of the powered-fluid turbine '/z coupling. Creation of the system involved the conception of integrated functional process-units (FPUs) that require operations to transfer energy through 3 transitions.
[00055] In the first transition, an external power source is transferred to drive the propulsor that is then transferred to a limited fluid supply to create the first HP, propelled-fluid stream. As the HP, propelled-fluid stream travels through the PET mechanism, a part of its pressure and velocity energy is then transferred to produce a second transition whereby a limited fluid supply is converted into a HP, powered-fluid stream.
[00056] In its third transition stage, the energy continues to change its medium, from a 'HP, powered-fluid’ to a 'shaft end-torque’. The PET mechanism discharges HP, powered-fluid into the turbine inlet where a nozzle configuration converts much of the pressure energy to velocity energy. The HP powered-fluid stream passing through the flow elements of the turbine-rotor transfers momentum from the input powered-fluid stream to produce as outputs; 1) a rotating shaft-end torque and, 2) a return, powered-fluid stream, 3) heat.
[00057] The return, powered-fluid stream that is collected in the sump of the turbine can have pressure energy of approximately 2-5 atm and is recycled back from the discharge outlet of the sump of the turbine to the inlet for return, powered-fluid located on the PET equipment-assembly (30)/A.
[00058] The pressure of the propelled-fluid at the discharge of the propulsor has a direct impact on the increase in the pressure of the powered-fluid stream. To achieve maximum pressure in the powered-fluid stream using minimal propelled-fluid pressure, the diameter of the pistons of the propelled-fluid can be larger than those of the powered-fluid; heat may be injected into the pressurized, propelled-fluid stream; or the powered-fluid pistons may be operated in series with the diameter of one or multiple propelled-fluid pistons having a larger diameter than the corresponding powered-fluid pistons.
[00059] As the maximum pressure drops, the stream flow rates will increase proportionally as P1V1 = P2V2. What is important for minimizing the required input energy is using a single-fluid or mixture-of-fluids wherein the input energy required to pressurize the fluid stream increases as little as possible as the fluid pressure increases. Hydrogen, that is a low mass-density fluid, requires a lot of input energy (MJ/kg) that increases as the pressure increases. It remains, however, a good selection of a fluid for use in this technology for its thermophysical properties. [00060] If an electric motor drives the system, the electricity can be from any regular source such as power grid, rechargeable battery, renewables, or the input energy for the propulsor may be in the form of shaft-torque from a diesel engine, water turbine, steam turbine, etc.
[00061] As the HP, propelled-fluid moves from the inlet to the outlet of the FTF-PET mechanism, its pressure energy decreases, and this energy is transferred to the powered-fluid stream as it moves from its feed inlet to its discharge outlet within the FTF-PET mechanism. This process resembles a countercurrent heat exchanger, but pressure energy rather than heat energy is the dominant variable involved in the energy transfer. Essentially, the magnitude of the differential pressure between the 2 fluid streams is driving this pressure energy transfer.
[00062] The pressure energy is being distributed through the system by a continual recycling of the return, propelled-fluid stream from the discharge of the FTF-PET mechanism, back through the propelled-fluid distribution assembly to the inlet of the propulsor and then from the discharge outlet of the propulsor back to the propelled- fluid distribution and finally from the discharge outlet of said propelled fluid distribution to the HP, propelled-fluid inlet of the PET equipment-assembly.
[00063] In similar fashion, the return, powered-fluid is being discharged from the powered-fluid turbine sump discharge and then re-converted into a 'HP, powered-fluid stream’ by passing through the FTF-PET equipmentassembly (30)/A wherein energy is transferred from the HP, propelled-fluid to the return, powered-fluid turbine thus producing a HP, powered-fluid stream to drive the turbine-rotor.
[00064] Rather than feeding the HP, powered-fluid stream to the turbine, this HP, powered-fluid stream can also be in recirculation between the input and output of a process application. The objective in this situation is simply to reduce the cost of propelling a process fluid stream to higher pressure energy (for example, feeding a HP, boiler feedwater, feeding RO desalination plants or simply to satisfy most high-pressure pump applications).
[00065] The technologies and equipment used to execute the required energy transfer have led to the creation of multiple FTF-PET mechanisms. Of those presented, 3 mechanisms are of the type 'sealed, membrane-interface’ and one is the type; 'mix & separate fluids’.
[00066] The preferred embodiment employs a mechanism based on one or multiple pairs of synchronized, doubleaction pistons, whereby one piston & cylinder operate on a closed circuit of propelled-fluid and the other half of the pair is operating on a closed circuit of powered-fluid.
[00067] In preferred embodiments, the propelled & powered-fluid streams operate in closed loops as recycle circuits with external heating and/or cooling applied to control the fluid stream temperatures. The temperature control can also be obtained by bleeding a part of the propelled & powered-fluid streams to the atmosphere and replacing it by a cooler make-up stream; however, the circuit is now operating in open or atmospheric mode which is less efficient and more polluting. [00068] The propel led-fl u id cooling unit is required to control the maximum operating temperatures due to the heat injected by the energy applied by the propulsor. There is, however, a need for both higher and lower operating temperatures in the propelled-fluid stream.
[00069] Higher propelled-fluid temperatures in the PET equipment-assembly will increase the volume or pressure of the fluid according to PV=nRT, and this will increase the pressure energy available for transfer. Lower fluid temperatures at the entrance to the propulsor will increase the required input energy as the propelled-fluid becomes denser and this increases the differential pressure over the PET that transfers more work to the powered-fluid stream.
[00070] It is advantageous to operate FTF-PET equipment-assemblies (30)/A in several parallel stages instead of just one stage. This lowers the maximum required pressure energy of the HP, propelled-fluid stream and permits interstage heating of the H P, propelled-fluid stream that will increase the efficiency of the pressure transfer process. The heat source may be electric elements but preferably is waste heat from external processes or from heat pumps or inexpensive heat from renewable energy. External heat transfers use thermal fluids to decrease the size of the exchangers.
FUNCTIONAL PROCESS UNITS (FPUS) THAT DEFINE THE SYSTEM OPERATIONS
[00071] The functional process unit FPU (03)/S is about energy transfer and involves various process functions required to execute an FTF-PET. Four different mechanisms developed around 2 techniques that involve either a ‘sealed, membrane-interface' or a ‘mixing and separate fluids' are presented as solutions. The propelled & powered- fluid streams involved in FPU (03)/S, their distribution in closed circuits and the pressure energy transfer that needs to occur between said fluid streams are illustrated as process-functions in Figure 1.
[00072] The propelling of fluids (liquids & gases) is used extensively in process industries, in power generation, and in commercial and urban infrastructure applications. Three examples of prior art suitable for the propulsion of most rotating equipment that uses an electric drive motor to produce the required torque are illustrated in Figure 1a.
[00073] The legacy configuration of an ‘electric motor coupled to an equipment-application’ that comprises one motor driving one rotating equipment-application is the simplest to operate and the cheapest to install. Other legacy drive configurations to power rotating equipment include power auxiliaries such as a combination of a ‘motorized hydraulic pump coupled to hydraulic motors coupled to an independent equipment application’ and a ‘motorized air compressor coupled to air motors coupled to an independent equipment-application’.
[00074] The torque delivered from the auxiliary hydraulic and air motors are different to that of the electric motor driving the respective fluid pumps. The application of these auxiliary drives is, however, not to directly decrease the energy consumed by the electric motor, but to convert the torque produced by the motor shaft into an equivalent level of power at a different torque and rpm. The ratio of the motor output shaft power to the independent equipment-application input shaft power changes only slightly.
[00075] A device that has some physical resemblance to a ‘double-acting, piston-based equipment-assembly' ((30.1/A or (30.2/A)), is the ‘double-action cylinder pump'. In a cylinder pump application, a piston is attached to a motorized piston rod cycling back and forth in a cylinder with appropriate seals and end plates. Such a cylinder pump is illustrated in Figure 1b.
[00076] Another example of an existing application that demonstrates the applicability of this technology is the multi- MW diesel generator that is frequently used in island-nations to power their electrical grid. In this example, the input power is rotating shaft torque from a diesel-powered engine.
[00077] The HFFT propulsion system, without an electric motor, is installed between the existing diesel engine and the generator, with the effect that the diesel engine load once coupled to the HFFT propulsion system decreases by some 20 percent. Had it been a HFFT propulsion system with an electric motor, but without a diesel engine, the load on the motor would incur a similar drop in load at the equivalent generator output. The physical arrangement of the converted prior art is illustrated in Figure 1c. [00078] As most fluids that are liquid at atmospheric pressure have a high mass density (units of kg/m3), the energy/unit of volume required for their propel I i ng/pumping will be high. The pumping energy required is the product of the volume (V) and the specific gravity (SG) of the liquid pumped, multiplied by its increase in static pressure (delta P), multiplied by mass density of water (MDW) times the propulsor efficiency (E). Accordingly, according to science, the power (P) required to obtain a HP, powered-fluid stream will equal the product of (V x SG x delta P x MDW x E).
[00079] In simple pumping applications, the fluid involved is imposed; one cannot replace the need to pump water by say - gasoline, simply because it requires less energy to pump. In pumping applications, one transfers a mass-volume of fluid from point a to point b. The pumping energy consumed per kilogram-pumped is what is of some importance.
[00080] But in this case, the 2 fluids are not pumped but propelled in recirculation mode in closed loops and only one stream is propelled as the second recirculating stream is powered by the transfer of energy of the first stream that is propelled by the propulsor. The single propulsor is driving both fluid streams.
[00081] In the context of this application, the determination of the state of a fluid, whether gas, liquid or solid, is according to its properties at STP conditions; that will be 0 degrees Celsius and 1 atm pressure, alternatively, at STP conditions one mole of ideal gas has a volume of 22.4 liters. The specific weights/mass-densities of the fluid flow streams are those determined at their operating conditions within their process streams.
[00082] The ‘HFFT propulsion system FPU (OO)ZP', refers to the ‘principal function' that is part of a system or grouping that includes a series of secondary functional process-units numbered FPU (01 )/S to FPU (06)/S. The code letter 7P' designates a principal function and the code letter 7S', designates a secondary function that is a part of the sous- systems of the principal function.
[00083] As in all process systems, there is a process breakdown structure wherein the hierarchy of the process functional units of the system are configured based on their relative dependence. The functional process-units (FPUs) describe the process operations to be executed during the operation of said propulsion system.
[00084] In the case of FPU (03)/S, its primary function is to execute a process of pressure energy transfer identified as FTF-PET. Figure 1 illustrates the second level of secondary functions and specifies the 4 secondary functions related to the inlet and outlet flow streams that drive the FTF-PET mechanism. The hierarchy and sequence of operation of the FPUs of the HFFT propulsion system are illustrated in Figure 2.
[00085] The propulsion system to be described is based on principles of fluid mechanics and may involve work done by gases or, namely, pressure-volume work. Work is the energy required to move something against a force and it has units of Joules (J): 1-J = force of 1 Newton-meter that also = 1-(kg.m2/s2). Several key points that are the basis for performing work by a gas stream or transferring work energy from a gas stream to a liquid stream need to be understood. • The energy of a system can change due to work and other forms of energy transfer such as heat. The work accomplished by a constant force is W = F (force) x D (displacement). With gas streams the most common measure of the force (F) they apply is measured as the pressure it applies against an object to displace it.
• Gases do expansion or compression work following the equations: negative work = -P (delta V), gas does work, and delta V is positive, or more than 1 , positive work = P (delta V), work is done on the gas, and delta V is negative, or less than 1 ,
• When the gas expands against an external pressure, it transfers energy to the surroundings, negative work decreases the overall energy of the gas.
• When gas is compressed, energy is transferred to the gas, so the energy of the gas increases due to positive work. The gain in heat energy from compression of a gas is a phenomenon that will improve the performance of this system as it lowers the specific weight of the propelled gas.
[00086] Without limiting the possibilities, in general, a first propelled-fluid that is suitable for this invention is compressible at STP conditions, whereas a suitable second powered-fluid is non-compressible at STP conditions.
[00087] This HFFT propulsion system, comprises two parallel systems, one of functional process-units (FPUs) and one of physical equipment-assemblies. As such, the system exists at first as a configuration of multiple ‘process-units' whose function corresponds to the following question: What is the process function to be accomplished by this processunit in operation? Another way to interpret the role of the functions is that they structure the ‘needs to be physically fulfilled' by an operating process.
[00088] The process functions are determined by combining a verb, a noun and some details that describe a desired result, such as ‘compress an air stream' or ‘transfer the static pressure'. The numbered FPUs, their functions and activities are summarized below in Table 1.
[00089] Table i
Functions and Activities of the HFFT Propulsion System
Figure imgf000015_0001
Figure imgf000016_0001
Figure imgf000017_0001
Figure imgf000018_0001
Figure imgf000019_0001
[00090] This propulsion system also comprises a second configuration of ‘equipment-assemblies' and components that are designed to physically fulfill or emulate the function(s) of a process-unit. It is the configuration of the functions contained in the FPUs combined with the physical reality contained in the configuration of the equipment-assemblies that describe and constitute this HFFT propulsion system.
[00091] The code letter 7A' designates an assembly of components, equipment, or an assembly of assemblies. The configuration of the assemblies describes how the equipment and components selected to build the propulsion system are interfacing. Numbers without brackets or letters are simply the standard components that have been configured into specific assemblies applicable for this propulsion system.
[00092] The required functions of the unit operations of the propulsion system are achieved using a configuration of equipment-assemblies. A flow diagram of the interaction between the different equipment-assemblies of the propulsion system is illustrated in Figure 3a.
[00093] The equipment-assemblies of Figure 3a comprises the assemblies of equipment and components that were configured to physically achieve the functionality specified in the FPUs. The four alternatives of equipment-assemblies that were developed to perform the pressure energy transfer are indicated as the preferred embodiment or as optional embodiments. As indicated, the 4 equipment-assemblies related to the ‘pressure energy transfer' are depicted on Figures 3c, 3d, 3e and 3f. [00094] The equipment-assemblies are a process structured grouping of the required equipment and auxiliary components such as valves, lines, and connections. Another aspect of the assemblies includes items referred to as system infrastructure or simply as infrastructure. The person of skill in the art would understand that such items are used for operations such as baseplates, electrical power & control hardware, instruments, etc. and are identified under the assembly (80)/A. The components that are part of the less complicated equipment-assemblies are illustrated in Figure 3b.
[00095] From the inlet to the outlet of the propulsion system, energy transitions occur within the process units. In the prior art, the only energy transition that takes place is identified in Table 2 below by the number 1). The number 6) is not precisely an energy transition but is a result common to both the prior art and to the HFFT propulsion system.
[00096] The energy transition 2) is integrated into the fluid supply propulsion function, the transition 3) is integrated into the pressure energy transfer function, the transitions 4), 5) & 6) are integrated into the fluid-turbine functions. The energy losses incurred over each energy transition are estimated at 5-8 percent.
[00097] Table 2
Figure imgf000020_0001
Figure imgf000020_0002
[00098] The above operations confirm that rather than directly drive an end equipment-application through the end of the shaft of a motor, this propulsion system uses the electric drive motor to operate a fluid-propulsor as one of its sous- systems. Instead of increasing the pressure energy of the powered-fluid stream by driving a pump with an electric motor (as per prior art), this operation is centered around succeeding a PET between 2 selected fluid streams.
[00099] To perform or physically execute the needed activities of the FPU (03)/S, 2 units of ‘synchronized, doubleaction, piston-based, PET equipment-assemblies’ (30.1)/A & (30.2)/ A) are connected by their shafts and have their operable directional control valves synchronized. One of the piston assemblies (30.1 )/A operates on the first circuit of HP, propelled-fluid, that transfers part of its pressure energy through the shafts of the connected piston rods to the faces of the second piston assembly (30.2)/A.
[000100] A second circuit of a powered-fluid stream is created by the back-and-forth movements of the second piston and this circuit drives the turbine rotor. The configuration of the PET equipment-assembly (30)/A, is as depicted in Figure 3c.
[000101 ] The functionality of the PET mechanism is a major building block for operating the HFFT propulsion system. The preferred embodiment of the PET mechanisms involves one or more units of PET equipment-assembly (30)/A being mounted on a common baseplate.
[000102] Each synchronized-pair of (30)/A assembly comprises 1 piston-based, propelled-fluid, PET equipment assembly (30.1)/A and 1 piston-based, powered-fluid, PET equipment-assembly (30.2)/A. Together, the 2 piston-based assemblies create a mechanism over which the PET takes place. To produce a more uniform output, 2 or more (30)/A units are operated together with an offset in their cycles.
[000103] The 4 mechanisms that presently exist to achieve a PET are identified as 1) synchronized-pair, double-action piston, 2) single-action piston, 3) double-action diaphragm and 4) mix & separate fluids. Mechanism 1 , 2 and 3 are of a sealed, membrane-interface type, whereas mechanism 4 is of the ‘mix and separate fluids'-type. Mechanism 1) is the preferred embodiment, whereas mechanisms 2) and 3) and 4) are embodiments providing the required functionality of a PET mechanism but have disadvantages not present in mechanism 1).
[000104] As mentioned, a double-action cylinder pump (Figure 1c) does resemble physically a HFFT double-action, piston based, fluid stream equipment assembly; however, the functionalities of the two applications have no resemblance. To start, the drive motor of the cylinder pump pumps only the one fluid that needs to be pumped, so there is no need for a second synchronized, double-acting cylinder. This is preferred and leads to a long question that concerns any pumping application that may appear to resemble the piston-based PET mechanisms.
[000105] Having put into operation a cylinder pump, driven by an electric motor to pump a fluid to its point of application, why then put into operation another cylinder pump with the same fluid in another circuit and then determine some mechanism to use the energy of the first fluid circuit in an energy transfer to power the second circuit? The result is that the energy consumed to pump the first fluid to the same place is greatly increased and 2 fluid circuits and a pressure transfer mechanism are now useless.
[000106] If the principal function of a system is simply to pump a fluid from point a to point b with a certain pressure energy, then the simple double-acting cylinder pump with an appropriate drive is the preferred solution and not a PET mechanism with 2 independent, recycle fluid circuits and with one propulsor driving a powered-fluid turbine to produce a source of rotary torque. [000107] The HFFT propulsion system does not pump fluids; it recirculates 2 independent supplies of 2 different fluids of limited supply, at high pressures using 1 propulsor for the intention of producing shaft torque to drive various rotating equipment.
[000108]The double-action cylinder pump (the prior art of Figure 1c) and the double-acting, piston-based, equipmentassembly (30)/A of Figure 3c have zero system, functional or operational resemblance.
[000109] Rather than the situation in the cylinder pump, whereby a volume of a liquid, that is drawn on a retraction stroke, is used to propel a similar volume of the same liquid on its extraction stroke; in this preferred embodiment of a PET mechanism, a volume of a HP, propel led-fluid of one circuit has powered a volume of a different return, powered- fluid stream of a second circuit to drive a powered-fluid turbine to drive a rotary equipment and the fluids involved have specific required properties.
[000110] A double-action cylinder is a cylinder in which a single working fluid acts alternatively on both sides of a piston. A motor drives a piston rod back-and-forth, that drives its associated piston. Check valves allow fluid from a supply to be drawn into the cylinder on a retraction piston stoke and then, on the extraction stoke, the pressure of the face of the piston facing in its direction of travel propels the same liquid.
[00011 1] Rather than using check valves, the movement of fluid streams in each circuit during the cycling of the piston may be controlled by a multi-way, directional control valve that serves to provide different inlet and outlet functionalities at the cylinder ports.
[000112]The return, propelled-fluid stream is transformed back to a HP, propelled-fluid stream by the action of the propulsor. The above recirculating, pressurized flow stream functions, the FTF-PET mechanism and the use of a powered-fluid turbine are unique to the FPU (00)/P propulsion system.
[000113] The work produced by the transfer of pressure energy from a propelled-fluid stream to a powered-fluid stream through the expansion of the propelled-fluid requires less energy than had the work been produced by adding the work energy directly to the powered-fluid stream by other means.
[000114] In the preferred embodiment that incorporates 2 synchronized double-acting piston-based equipmentassemblies ((30.1 )/S & 30.2)/S), the 2 recirculating fluid streams are always isolated (not only sealed) from each other. This is one of the advantages of the preferred embodiment over the single-action piston and double-action diaphragm solutions. Diaphragms do isolate the flows until the diaphragm leaks or bursts due to wear.
[000115] If a pressure energy transfer (PET) mechanism, such as a single-acting piston, was to be used, there would be slight contamination between the 2 streams, and if the mechanism identified as ‘mix & separate fluids' were to be used there would be a thorough contamination of the fluid streams as the mechanism of this assembly involves the action of mixing and then separating the 2 fluid streams. [000116]The diaphragm solution offers better sealing, but diaphragms deteriorate, and the seal can be lost. The diaphragm solution may have several variants but the one chosen for this application involves a double-action, pistontype assembly operating in the propelled-fluid circuit and a double-action diaphragm operating in the powered-fluid circuit.
[000117] As someone knowledgeable in devices involving types of double-action diaphragm and double-acting piston, there are multiple designs available to suit differing operating and maintenance conditions. The designs proposed are simply the most common and adaptable of the multiple legacy designs available.
[000118] This contamination may be acceptable as the desired pressure energy transfer function is completed in all 4 PET mechanisms, but there are operational risks. The fluid energy pressures will be high, the cycle rates of the pistons and diaphragms will be high, and the service factor is applicable to industrial use. This partially explains why the synchronized, double-action, piston-based equipment-assembly is the preferred embodiment for executing a PET in accordance with FPU (03)/S.
[000119]The general principal remains common for all 4 embodiments: A volume of a light fluid is displacing a volume of a heavier fluid and the energy required to increase the pressure energy of the lighter fluid is basically less than the energy spent to increase the pressure energy of the heavier density fluid. The required input energy can, however, be decreased further by using heat to expand the lighter gas to a higher pressure before the PET and then cooling the lighter stream with a cooler before it repasses through the propulsor.
[000120] Based on said equation, W (work) = F (force) x D (displacement) and given the force and displacement of the two fluids are the same, the amount of positive work and negative work accomplished are the same, but by using a fluid stream of lower mass density and executing a PET the energy input required to accomplish the HP, powered-fluid stream is decreased.
[000121]To illustrate the operability of this propulsion process, a sufficiently propelled-fluid stream of low specific weight is fed via a multiway, directional control valve to the faces of a first ‘double-action, piston-based, propelled-fluid equipment-assembly'.
[000122]The piston rod of the first assembly drives the piston rod connected to a second piston in a second ‘doubleacting, piston-based, powered-fluid equipment-assembly'. The faces of both pistons are traveling in synchronized reciprocating strokes and the energy of the HP, propelled-fluid is propelling the return, powered-fluid stream.
[000123]The pressure energy of the HP, propelled-fluid stream is transmitted to the powered-fluid stream minus the friction losses incurred by the distance of the travel of the two pistons and loss in system efficiency. The pressure energy of the return, powered-fluid stream, that was lower than that that of the HP, propelled-fluid stream, has been increased or 'transferred' by the forces transmitted by the faces of the second piston. [000124]The process of a pressure energy transfer between 2 fluid circuits using a combination of a ‘synchronized, double-action, piston-based, propel led-fluid, PET equipment-assembly’ (30.1)/A’ in one circuit and transferring its pressure energy to a powered-fluid stream in the other circuit via a ‘synchronized, double-action, piston-based, powered-fluid, PET equipment-assembly’ (30.2)/A’ completes the activities and the functionality required by the FPU (03)/S.
[000125] One single-action, piston-based, fluid equipment-assembly, like equipment-assembly (36)1 A could be installed as a stand-alone PET or it could serve to connect the pistons of the circuits of each of the propelled-flu id and powered- fluid equipment-assemblies of (30)/ A. This arrangement however can lead to various shaft and shaft seal maintenance problems, and there may be cross-contamination of the two circuits as a large area of the cylinder inner wall is in contact with both liquids. The arrangement of the single-action piston is depicted in Figure 3d.
[000126]The double-action diaphragm-type assembly (40)/A uses a ‘sealed membrane-interface' to transfer pressure energy that does not physically resemble that of a piston-type but operationally the flow mechanisms are similar. As the pressurized cavities of the powered-fluid diaphragms are much more irregular in shape than those of a piston cylinder, the adjustments of flow and pressure are less linear. This is another reason why the piston-type is the preferred technique. A schematic of the operation of a diaphragm-type assembly (40)/A is depicted in Figure 3e.
[000127]To achieve the desired pressure energy transfers, 4 designs of mechanisms have been developed. The first and second design involves the use of a sealed membrane-interface technique based on pistons as illustrated in Figures 3c and 3d. The third design involves a sealed membrane-interface based on diaphragms as illustrated in Figure 3e and the fourth design involves a ‘mix and separate fluids' technique as illustrated in Figure 3f.
[000128] In applying a ‘mix and separate fluids' technique, a return, powered-fluid stream of a certain pressure energy and a HP, propelled-fluid stream with a pressure energy higher than that of the return, powered- fluid stream are injected into a pressurized recipient/cavity. The apparatus proposed for injecting the propelled and powered-fluid streams into the pressurized recipient is using a rotary valve 41 , with multiple sealed cavities.
[000129]The mixing of equal volumes of the two fluid streams in a pressurized recipient produces a common pressure energy for both streams that is higher than the original pressure energy of the return, powered-fluid stream. The propelled-fluid stream is separated from the mixture based on the differences in the fluid densities between the propelled and the powered-fluid streams.
[000130]The pressure in the recipient is held constant by balancing the volume of HP, propelled-fluid entering versus the volume of return, propelled & powered-fluids leaving the recipient. There has incurred an increase in the pressure energy of the powered-liquid stream and a decrease in the pressure energy of the propelled-fluid stream leaving the pressurized recipient. To minimize the input energy required the operating pressure of the propelled-fluid needs to be minimized. [000131 ] To produce the required torque output, the flow variables of the system that are adjusted include the fluid flow rates and the fluids pressure energies. A compact configuration for multiple units of (30)/A, is a radial mount with a central rotating crankshaft, whereas for an application requiring only a single pressure energy transfer propulsion equipment-assembly, the preferred embodiment is by connecting the ends of two piston rods by a central half-coupling 35.1 & 35.2.
[000132]To produce more shaft torque for larger torque applications, the number of flow circuits or the fluid flow rates per circuit are increased. The pistons may be connected to each other by directly coupling the ends of opposing propelled-fluid and powered-fluid piston rods (30.1)/A & (30.2)/A or by connecting multiple pressure energy transfer equipment-assemblies to a common crankshaft and arranging the pistons in a linear or radial configuration, like those used in radial and in-line automobile engines.
[000133]The radial crankshaft serves to connect the ends of multiple piston rods around a central circumference and this configuration saves space. A radial configuration of multiple (30.1)/A propelled-fluid and (30.2)/ A powered-fluid PET equipment-assembly are depicted in Figure 3g.
[000134] As, discussed, one method of decreasing the energy input through the propulsor is to heat the propelled-fluid before the PET inlet, or, interstage, while it passes through, the PET equipment-assembly. The heating is achieved by installing heating units 23.1 in the interstage HP, propelled-fluid connecting lines. This serves to decrease the required pressure in the HP, propelled-fluid at the propulsor discharge to reach the required pressure in the HP, powered-fluid stream.
[000135] Another approach for decreasing the required propelled-fluid pressure is to operate multiple PET units in parallel. Operating in parallel stages, the discharge of the propelled-fluid stream of the first stage of the PET equipmentassembly (30)/A becomes the feed to the next stage rather than returning directly to the propelled-fluid distribution equipment-assembly (20)/A. The diameter of the piston of the propelled-fluid is increased. Intra-stage heating of the propelled-fluid stream is again possible, but this will be a question of its effectiveness with the second fluid.
[000136]These two effects can be accomplished by operating multiple FTF-PET equipment-assemblies (30)/A in parallel and this is depicted in Figure 4a.
[000137] Another technique to reduce the required level of pressure energy in the propelled-fluid is to operate multiple, powered-fluid PET equipment-assemblies in series. An illustration of multiple assemblies of (30)/A operating in series is depicted in Figure 4b.
[000138]The principal function of the HFFT propulsion system is to produce rotating shaft torque. The FTF-PET functions only produce a supply of HP, powered-fluid that needs to be converted to useable torque. The next section of the system involves passing the HP, powered-fluid stream over the flow elements mounted on a turbine-rotor to produce the desired torque. As the fluid turbine involved in a HFFT system is driven by a powered-fluid in a circuit that recycles the flow, it can be referred to as a powered-fluid turbine.
[000139]The process stream feeding the fluid turbine is propelled through nozzles creating high velocity jet streams that apply force (F) against the area of the face of elements (A) installed on a runner that is attached to the liquidturbine central rotatable shaft. The moment (M) developed on the face of the elements will be equal to M = F x A. As the elements are connected to the rotating shaft of diameter Y, the torque generated (T in newton meters, Nm) will be equal to T = M x Y.
[000140]The entrainment of air in the fluid circuits may be a problem that can be solved by operating a deaerator, wherein the accept header of the deaerator is held under vacuum by a compressor with its suction connected to a deaerator accept header. The inner housing of the powered-fluid turbine, including its sump, can be sealed and held under controlled pressure depending upon the specific operation.
[000141]The rotating shaft of the powered-fluid turbine may directly drive the shaft of an equipment-application, or a gear reducer may be required to increase or decrease the speed of rotation at which the shaft of the equipmentapplication is being driven. The feed and discharge arrangement of a powered-fluid turbine equipment-assembly (60)/A is depicted in Figure 5.
[000142]This propulsion system process begins wherein a motorized fluid propulsor produces a HP, propelled-fluid stream in a circuit using a compressible fluid. During the PET, the pressure energy of the propelled-fluid decreases and the pressure energy of the powered-fluid stream increases by approximately the same proportions. The physical size of the propulsion system and its components and the volumes of the propelled and powered-fluids are important to reduce the cost of a production unit and to be able to accommodate space limitations that could limit its applicability.
[000143] In this regard, the most important criteria for designing a process that can efficiently operate is obtaining a high-pressure energy in the propelled and powered-fluids stream at the minimum cost of energy. The higher the inlet pressure and the pressure drop of the propelled-fluid over the PET mechanism, the lower the volumes of fluids that need to be propelled & powered to produce a specific torque output at the turbine. The discharge velocity of the feed nozzle of the powered-fluid turbine is also important, but its value is proportional to its pressure energy.
[000144] For this technology to be adopted, only sufficiently high-pressure energy conditions and low mass volume flow rate will reduce the input consumption of electrical power by the propulsor to reach a level wherein the energy savings justify the capital costs of implementing the propulsion system.
[000145]The compressibility factor Z for gases normally increases continually above 1.0 as the HP, propelled-fluid pressure increases, and this will increase the energy input per kilogram required by the propulsor. As such, preferred propelled-fluids have a low compressibility factor at low and high pressures. As the energy per kilogram increases as the pressure energy increases, there is a distinct advantage to operate at the lowest possible HP' propelled-fluid pressure that meets the required thrust output.
[000146] In preferred embodiments, the propelled and powered-fluid circuits operate between 90-120 bar.
[000147] A proper selection of the propelled-fluid is important in order to minimize the energy required per kilogram to obtain the maximum pressure in the propelled-fluid circuit.
[000148]The propelled-fluid may be steam. Steam will always have the problem of burning a lot of fuel to obtain a sufficient operating temperature and pressure. The steam discharge stream from the PET can be vented to the atmosphere, much like the original steam locomotive, as recycling the steam may require a steam condenser and this complicates the operation. If steam replaces electricity, the propulsion acronym changes from HFFT to SFFT.
[000149]To further minimize the pressure required from the propulsor, the diameter of the propelled-fluid pistons can be larger than the diameter of the powered-fluid piston, but this will increase the volume of the propelled-fluid to be propelled and will decrease somewhat the differential pressure available for energy transfer in the PET mechanism.
[000150] If sufficiently high fluid pressures are required, it may be advantageous to operate ‘pressure energy transfer equipment-assemblies' in series, with or without the use of larger diameter pistons in the propelled-fluid circuit than in the powered-fluid circuit. The advantage of using 2 diameters of pistons being that the propelled-fluid will operate at a higher flow rate but also at a lower pressure energy.
[000151]The design of the fluid-turbine equipment-assembly (60)/A used to produce shaft torque also incorporates features to produce an improved and efficient operation. It is complicated to distribute the shaft torque output of one turbine-shaft to drive multiple equipment-applications.
[000152] A modified configuration of the HFFT propulsion system can operate as a distributed propulsion system whereby multiple local HFFT fluid turbines each drive one of multiple equipment-applications. This system operates based on one large PET equipment-assembly, driving multiple powered-fluid turbines that each provide torque to only one equipment-application, as illustrated in Figure 6.
[000153] So, as per Figure 6, a solution does exist for economically powering multiple equipment-applications that have small power demand. A central propulsor/compressor equipment-assembly (10)/ A, a central propelled-fluid distribution equipment assembly (20)/A and a central power energy transfer equipment-assembly (30)/A are installed as a central unit and the central HP, powered-fluid stream distribution equipment-assembly (50)/A feeds multiple fluid-turbine equipment-assemblies (60)/A.
[000154] Propelled-fluid circuits can be of two types: either free flow or recycle/recirculation. In free flow mode, the propelled-fluid leaving the outlet of the propelling equipment is not returned to its inlet. In recirculation mode, the discharge or outlet stream of the equipment-assembly returns to the inlet of the source of propulsion. There is a third hybrid alternative wherein part of the recycle flow could be discharged, and the volume discharged is replaced by an equivalent volume of cooler fluids, such as air or water from an exterior source.
[000155] Recycle mode is a preferred operation as it is invariably more energy efficient and less polluting than a comparable operation in free flow mode. Recycle mode will involve cooling of the fluid streams as compression adds heat to a fluid stream and heat is also generated through friction and drag.
[000156] In the case of the propelled-fluid, it would operate at its highest possible temperature as increasing its temperature decreases its mass density. For operations outside in cold climates, the propelled-fluid circuits may be insulated to conserve heat. In the case of the powered-fluid stream, the operating temperatures of the mixture will depend on the additives used to adjust its thermophysical properties.
[000157]The HFFT propulsion system would be highly suitable to replace large, exterior equipment applications. The equipment assemblies can be mounted on a common baseplate (91) supported by structural members (92) and enclosed in a protective housing (93). The housing may be insulated, and its inside atmosphere can be controlled by internal or open-air (roof-top) HVAC units.
[000158] Bearings and stuffing boxes that are high maintenance elements are monitored for wear and information on the ongoing operations are all sent to a central programmable controller with an operator interface (95). Information and control are transmitted off-site via a telecommunications assembly (94). A rechargeable battery is installed (11.5) on the propulsion system baseplate for portable or movable platforms (96) or for emergency-type operations.
[000159] Industries, including major pipeline companies, cities and utilities involved in the processing and/or distribution of oil, natural gas, drinking, irrigation and cooling water, water desalination & treatment, have almost all large pumping stations. Some are located within buildings, but many are located outside and in remote areas. The HFFT propulsion system would be of interest as the conversion of such large equipment would have an important positive impact on reducing their power consumption.
[000160] This process for producing torque should be packaged such that it offers other, more intangible benefits, such as more reliable, better safety protection from theft and vandalism damage and better resistance against extreme climate.
[000161] lt is possible install a HFFT propulsion system between a legacy power generator that comprises a diesel engine and its electrical generators. This HFFT propulsion system unit will reduce the load and the consumption of diesel fuel. There are few limits on where this technology can be exploited.
[000162] Operating with a single fluid in both fluid circuits will not produce an improvement in the overall energy performance of the application. The propelled-fluid should be lighter and more compressible than the powered-fluid. The success of this technology depends on exploiting the thermodynamic properties of fluids. [000163]The following calculation explains the operandum of this new technology. A 75 kW (100 hp) motor drawing electricity at a cost of 0.15$/kWh that has a utilization factor of .90 will have energy costs, assuming 24/7, of approximately 11.25$/hr. or 88,600$/yr. A reduction in the motor energy consumption of 20% by installing a HFFT propulsion represents a saving of 17,700$ per year.
[000164] At an installed conversion cost of $45,000 per 75 kW unit, assuming the re-use of the existing motor circuitry, will produce a simple payback of 2.5 years. At a cost of 0.20$/kWh the simple payback period decreases to 1 .9 years and with performance improvements in the HFFT propulsion system over time of 15%, the payback will drop to below 1 .7 years. The HFFT propulsion system FPU (00)/P meets basic economic feasibility criteria. The result, however, will depend on the loss of efficiency incurred over each of the 3 energy transitions.
[000165]The transfer of electrical energy to torque to drive rotating equipment is one of the world's most common process-unit operations: The prior-art principally based on motor shafts direct-driving equipment shafts dominates the market. This new technology offers a pathway to decreased energy consumption.
WASTE HEAT, CHP, AND SOLAR ENERGY INTEGRATED INTO THE FTF-PET MECHANISM
[000166] Heat and pressure are forms of energy that can both be thought of as a measure of the intensity of molecules in motion and their inter-relation is dictated by the universal gas law PV = nRT. Accordingly, changes at constant volume in either the pressure or in the temperature of a fluid will lead to a proportional response in ‘P’ and in T.
[000167] As the performance of this propulsion system is based on the thermal-physical properties of 2 selected fluids, the sources, the quantities and the cost of energies for maintaining the operating temperatures and pressures will have a significant effect on system performance.
[000168] In a preferred embodiment, a propulsor is acting as a pump that creates recirculation and as a compressor that adds heat to the propelled-fluid circuit. In addition, a second source of external heat may be transferred into the propel led-fl ui d stream and this heat energy will further increase the operating stream pressure (higher fluid compression obtained with less mechanical compression).
[000169] As such, 2 different technologies for modifying the pressure energy of the propelled-fluid circuit are 1) increase its pressure through mechanical-vapor compression and 2) increase its pressure by transferring heat energy into the propelled-fluid stream. A decrease in pressure and temperature does occur in the PET by allowing said propelled-fluid to expand and perform work, said work that will be equal to the incurred energy loss by expansion-cooling.
[000170] Additional work can be performed by removing additional heat from the return, propelled-fluid that will further lower the return, propelled-fluid pressure, thereby creating a higher-pressure differential between the inlet and outlet connections of the propelled-fluid piston assembly.
[000171]The addition of heat to the propelled-fluid can be obtained by, 1) using more electrical energy to apply more compression by the propulsor, or 2) by powering a heat pump that has a better efficiency in generating heat than a fluid compressor and then transferring the heat energy into the propelled-fluid stream or, 3) by transferring heat into the propelled-fluid stream from an external source of waste heat or a source of inexpensive heat such as solar heat.
[000172] Figure 7a illustrates a HFFT propulsion system schematic and the equipment and interconnections to integrate heat pumps into its operations.
[000173] If waste heat is available, and of sufficient quality and quantity, it is the most interesting approach from an economic viewpoint as its production cost is often close to zero and its use reduces its negative environmental impact. An excellent example of suitable low-cost waste heat is that being discharged through the exhausts and cooling effluents of thermal power plants that have thermal efficiencies in the range of 33-45%.
[000174] By transferring such waste heat into the propelled-fluid stream, the electrical energy consumed by motorized, mechanical compression decreases and is being replaced by the equivalent energy of the waste heat that has a much lower cost.
[000175]The heating of the propelled fluid using waste heat is normally achieved by a direct transfer from the waste heat stream to the propelled and powered-fluid streams using a countercurrent heat exchanger or equivalent.
[000176]There will be a decrease in the pressure and temperature as the propelled-fluid passes through the PET and transfers pressure energy to the HP, powered-fluid that constitutes work done. The pressure drops available by the cooling effect of the work done may be insufficient for the required application; however, as stated, the differential pressure can be increased by decreasing the temperature of the return, propelled-fluid.
[000177]The necessary cooling of the said return, propelled-fluid can be obtained by, 1) dropping the pressure of the fluid in the return line by venting (poor efficiency), 2) transferring heat out the system using a reverse (cooling) heat pump (a vapor-compression chiller), or 3) use of waste heat energy from an external thermal process, or heat energy from solar energy to drive a vapor-absorption chiller.
[000178] A colder fluid stream is achieved by using an absorption-vapor chiller driven by waste heat that produces chilled water. The larger propelled-fluid and smaller powered-fluid cooling can take place in an exchanger within the chiller or by remote exchangers.
[000179]The use of waste heat to power a HFFT propulsion system is another embodiment of the HFFT propulsor concept that operates partially on mechanical or electrical energy but without electrically driven heat pumps. Waste heat used for heating and cooling has a low cost, and as discussed, cooling (heat removal) can be used to produce significant differential pressure in the propelled-fluid circuit of the PET mechanism.
[000180] As someone experienced in the field of heat pumps and waste heat will understand, there are many other forms of CHP (Combined Heat and Power) systems available that could be integrated into the design of the HFFT propulsion system used to produce torque at lower cost.
[000181]0ne drawback is that there are few sites offering waste heat of sufficient quality. Examples of favorable existing sites for integrating CHP into HFFT propulsion include thermal power plants such as coal, NG and nuclear, and industries involved in producing metals and chemicals. [000182] Figure 7b illustrates a typical heat load for a 2,500 MW, heat generation thermal power plant producing 1 ,000 MW of electrical power. The waste heat load is evaluated at 1 ,500 MW or 40% overall efficiency. Figure 7c illustrates the necessary interconnections and equipment to integrate the 1 ,500 MW waste heat load into the operations of a CHP-HFFT propulsion system.
[000183] Concentrated solar power can also be an excellent thermal driver for the operation of a HFFT propulsion system and can result in a large quantity of power sites that can be sized to a specific application that can be either small or large and will be classified as zero-emission, zero-carbon.
[000184] Solar power, however, works less than 12 hours a day, and works poorly with cloud cover. To provide heat during periods without sunlight, the established solution is the storage of solar heat using molten salts as the storage medium. Solar power could be used to boost the output and efficiency of waste heat installations or mixed with heat pumps that run on off-peak power. Internal battery storage would also provide some overlap and back-up.
ENGINEERING THE PROPELLED AND POWERED-FLUIDS
[000185] As previously indicated, the amount of hydraulic power per unit of volume produced by the powered-fluid as it passes through the fluid turbine will be a function of the specific gravity of the fluid. Miniaturization will be an important issue as it impacts the cost of the propulsion systems, and the physical size of the fluid-turbine could limit its ability to replace an electric motor that is the compact, legacy source of torque.
[000186] Assume 2 fluid flows of equal volume, velocity, and viscosity but with different specific gravities (SG) are passing through similar designs of turbines. If the ratio of their specific gravities equals 1.5, for the same amount of power, the volume of the fluid pumped will be 1/3 smaller at the higher SG.
[000187] Increasing the SG increases the energy of momentum that can be carried per unit of volume. This is analogous to the use of thermal fluids. Thermal fluids are engineered to carry maximum heat energy; the powered-fluid should be engineered to carry maximum energy.
[000188] With a few minor exceptions, all existing hydraulic turbines operate using water that has a specific gravity of 1 .0 and passes through a single-pass turbine with a gravity feed and discharge. One innovation of a HFFT fluid turbine is the recycling of the powered-fluid stream from a sump located in the base of the fluid turbine.
[000189]The turbine is sealed and operates with a controlled working-pressure inside the housing and sump and with pressurized, inlet feed and discharge return lines. As the powered-fluid is recycled, changes made to its temperature, chemistry and solids content are not lost in a discharge effluent stream.
[000190] It is possible to increase the SG of a solution by dissolving solids in the fluid to create a solution with a higher SG than the original fluid. The solubility of the dissolved solid in the fluid will be dependent on the temperature and the pH of the solution.
[000191 ] The boiling point of the fluid, the dissipation of generated heat and the dissolved/entrained air content versus temperature are also variables which are not considered in the context of operating legacy, one-pass hydraulic turbines. [000192]The pressure drops and velocity of the powered-fluid may also change due to the different capacity and environment of the installations (such as altitude, ambient temperature, and throughput). Stabilizers, buffers, and surfactants are part of the solution as operating the fluid turbine at a maximum SG is an important operating factor.
[000193] It is the solubility of the dissolved solids in the fluid and the fluid boiling point that will be key process-control issues. The physical and chemical properties of the powered-fluid that require control include the following.
1) Addition of dissolved solids to increase the SG
2) Sealed fluid turbine with a controlled working pressure over the wetted surfaces.
3) Control of entrained air content
4) Control of temperature, pH and viscosity
5) Surface treatments to limit deposits on the wetted surfaces of the powered-fluid circuit. [000194]The propelled-fluid is also engineered to be as efficient as possible, said propelled-fluid is a selected, engineered fluid mixture of one or more fluids that exhibit physio-thermal properties within the following ranges.
1) a mass-density at STP between 1 .9 and 50 kg/m3, and/or
2) a boiling point between minus 10 and minus 275 degrees Celsius, and/or
3) a specific heat value (at constant pressure) at 1 atmosphere and 0 degrees Celsius between 0.08 and 2.30 kJ/kg K,
HFT (HEAT-FLUID-TORQUE) CONFIGURATION USING A SINGLE-CIRCUIT PET
[000195]The ‘HFT (Heat-Fluid-Torque) configuration uses a simplified design of the HFFT propulsion system. A smaller, more compact configuration of the HFT configuration was developed to eliminate the powered-fluid circuit and the powered-fluid turbine and to use a mechanical converter to convert the linear motion of the shaft of the singlecircuit PET to rotating motion in the form of torque to drive independent equipment-applications.
[000196] The HFT configuration uses a simpler design as it employs the same propelled-fluid and first-fluid circuit PET, but does not use the powered-fluid, the second-circuit PET used in the HFFT propulsor; as such the preferred HFFT propulsor is a double-circuit PET, while the HFT configuration is a single circuit PET. The single-circuit configuration of the HFT is illustrated in Figure 7d.
[000197] For the HFT configuration to operate successfully, the quality of the heat energy and cold energy transferred to the propelled-fluid circuit needs to be exceptional and the differential pressure over the PET needs to be higher than for the HFFT Propulsor.
[000198]This implies that the propelled-fluid mixture of the HFT configuration needs to have a maximized pressure versus temperature response and a minimum energy input or heat capacity requirement (kJ/kgK). Waste-heat is not applicable to mobile units of the HFT configuration, but motorized vapor-compression heat pumps can still be used. [000199] Whereas the preferred HFFT propulsor output torque is only limited by the heat supply and size of the site (multiple MW), the HFT is suitable for smaller torque demands. The HFT configuration will be less efficient than a HFFT as it operates with a single-circuit PET and, as such, will have higher production costs per unit of torque.
[000200] A case can be made for a mobile HFT configuration including a high energy-density heat source such as a combustion burner running on a stored supply of gasoline, natural gas, or hydrogen or, as an alternative, the use of stored electrical energy from an on-bord rechargeable battery. The high energy density heat is required to assure an operation with a very HP, propelled-fluid. The burner heat would supplement the heat energies from on-bord heat pumps or local heat sources.
[000201]The larger, double-circuit HFFT might fit into large mobile applications where there is more room, such as for the drives of big transport vehicles. The propulsor can be installed between the back of the sleeper section and the front of the van. In the case of buses, they can be installed in the back of the bus.
[000202]The functional process units that constitute the single-circuit PET and the mechanical-converter for converting the linear motion of the PET output shaft to rotary motion are illustrated in Figure 7d.
[000203]The new FPU (07)/S of the HFT configuration also corresponds to the previous equipment assembly (30.1)/A of the preferred HFFT propulsor. The only difference is in the numbering of the output shaft couplings that were originally 35.1 and 35.2, which now read as 35.1 and 35.3. The same equipment-assembly is illustrated in Figure 3c.
[000204] As illustrated, the mechanical converter drives the inlet shaft of a speed reducer 98.4 that drives an equipmentapplication inlet shaft 74.1.
[000205] Figure 7e illustrates the integration of the HFT configuration identified by the number FPU (99)/P, which now comprises the same equipment-assemblies as the HFFT propulsor (10.1 )/A, (10)/A, (20)/A, (30.1 )/A and (70)/A.
[000206]The new equipment-assembly number for the single-circuit PET is (30.4)/A (only the coupling has changed) and the equipment-assembly number for the mechanical-converter is (98.0)/A.
SOURCES OF HEAT AND WASTE HEAT FOR THE HFFT & HFT
[000207]There exist multiple combinations for the sources of heating and cooling energies that can be transferred in majority to the propelled-fluid stream and marginally to the powered-fluid stream. Below is a summary of the potential sources and their applicability.
1) The application of unlimited external or limited internal power to drive the propulsor and generate required heat by compression, mechanical friction and fluid drag in the propelled-fluid flow stream and the use of an airstream and/or water stream to cool the propelled and powered-fluid circuits. If required, supplementary indirect heating through exchangers is possible from electric and combustion-driven thermal power. 2) A limited use of power to drive the propulsor as per 1) and including motorized vaporcompression units for heating and cooling the propelled and powered-fluid circuits, probably at an energy cost less than article 1 above.
3) The limited use of power to drive the propulsion system as per 2) and/or including the transfer of waste heat to add heat energy to the HP, propelled and powered-fluid streams, and to drive a vapor-absorption chiller that serves to cool the return, propelled-fluid flow and the return, powered-fluid probably at a cost less than article 2 above.
4) The limited use of power to drive the propulsion system as per 3) and including the use of concentrated solar energy or geo-thermal sites to drive the heating and cooling of the propelled and powered-fluid circuits, probably at an energy cost less than articles 1 & 2 above.
[000208]As a professional with an expertise in the supply of various forms of energy to power installations would understand, the cases listed above represent only the most common applications of different sources and combinations and that different combinations of the energy sources listed above, as well as other sources of energy, are possible.
SUMMARY OF THE INVENTION
[000209] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a complete set of the configuration of the functional process units (FPUs) numbered (01)/S to (06)/S that describes all process operations within the system and includes the function FPU (03)/S that describes the needs & activities related to completing a ‘fluid-to-fluid’, pressure energy transfer. A list of FPU's for the HFFT propulsion system is in Table 1 above.
[000210] It is an object of the present invention to provide a HFFT propulsion system, FPU (00)/P, comprising a second complete set of the configuration of equipment-assemblies numbered (10)/A to (80)/A that includes a ‘piston-based, propelled & powered-fluids, PET equipment-assembly (30)/A’ that physically executes a 'fluid-to-fluid', pressure energy transfer from a HP, propelled-fluid stream to the return, powered-fluid stream. The preferred embodiment for the PET mechanism is the equipment-assembly (30)/A. A list of equipment-assemblies for the HFFT propulsion system is in Table 3 below.
[000211] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising one centralized pressure energy transfer unit wherein one central, oversized, PET equipment-assembly feeds multiple powered-fluid turbines that provides torque to multiple independent equipment-applications.
[000212] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, to select two fluids that have the best thermo-physical properties to operate in a HFFT propulsion system.
[000213] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a larger diameter propelled-fluid piston than its corresponding powered-fluid piston to reduce the propelled-fluid pressure energy required to achieve a required powered-fluid pressure energy.
[000214] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising the functional capability to integrate transitions in the medium of the energy being transmitted between functional process units and will include the applicable energy transitions of Table 2 above.
[000215] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising at least 4 possible mechanisms to achieve the required 'fluid-to-fluid', pressure energy transfer.
[000216] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising its system principal function and the secondary functions of its sous-systems such that the FPUs describe the process operations of the HFFT propulsion system.
[000217] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising an electric motor driving a propulsor to produce, at the beginning, a HP, propelled-fluid, and at the end, a fluid-turbine producing rotational torque from a HP, powered-fluid stream for driving an equipment-application, wherein the electrical power input of the electric motor shaft will be less than the power input required to drive the fluid turbine without the use of a HFFT propulsor.
[000218] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P comprising an electric motor that drives a propulsor that generates a HP, propelled-fluid stream in a fluid circuit and also comprising a powered-fluid circuit and the HP, propelled-fluid circuit drives the powered-fluid circuit, and the HP, powered-fluid circuit drives either a powered-fluid turbine to produce rotor shaft torque or, the HP, powered-fluid stream may be used directly as part of the feed to an operational unit-process operation.
[000219] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a propelled-fluid stream and a powered-fluid stream and, at STP, the ratio of the value of the specific weight of the non- compressible, powered-fluid is more than 5 times the value of the specific weight of the compressible, propelled-fluid.
[000220] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a propulsor that operates in a closed loop, recycle mode propelled-fluid circuit wherein the propulsor inlet is connected to a return, propelled-fluid line and the propelled-fluid circuit is recycling.
[000221] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a powered-fluid circuit that is operated as a pressurized, recycle loop wherein the return, powered-fluid stream discharging from the sump of the fluid turbine is cooled.
[000222] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a propelled-fluid circuit and a powered-fluid stream and the HP, propelled-fluid stream has high-pressure energy prior to feeding the inlet of the PET mechanism, followed by a lower pressure energy after having passed through the PET mechanism, whereas the return, powered-fluid stream has a lower pressure energy at the inlet to the PET mechanism followed by a higher pressure energy after having passed through the PET mechanism.
[000223] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a pressure energy transfer between 2 isolated fluid stream circuits that are inter-connected through pistons and diaphragms that operate as sealed, membrane-interfaces.
[000224] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising at least 1 piston, at least 1 piston rod and at least 1 cylinder operating on propelled-fluid and at least 1 piston, at least 1 piston rod and at least 1 cylinder of powered-fluid and providing one interface between the 2 fluid circuits for the purpose of transferring pressure energy.
[000225] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising at least 1 single-action piston with the propelled-fluid circuit and the powered-fluid circuit sharing a common piston and cylinder to execute a ‘fluid-to-fluid’, pressure energy transfer between the fluids. [000226] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising at least 1 double action diaphragm pump that comprises a recycle, propelled-fluid stream and a recycle powered-fluid stream and is powered by a propelled-fluid that is fed from a propulsor that passes through a multi-port controller to produce a back-and-forth movement of the diaphragms.
[000227] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a pressure energy transfer between a HP, propelled-fluid stream and a return, powered-fluid stream by mixing the two fluid streams together in the cavities of a rotary valve and then separating the propelled-fluid stream from the HP, powered-fluid stream such that only the HP, powered-fluid stream continues either to the turbine-rotor to produce rotary shaft torque or it passes directly to feed a process-application.
[000228] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising heat exchangers on the HP, propelled-fluid circuit and on the HP, powered-fluid circuit and cooling exchangers for chilling the return, propelled-fluid stream and the return, powered-fluid stream to maintain the desired operating temperatures throughout the circuits.
[000229] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a ‘fluid- to-fluid' pressure energy transfer by ‘mixing and separating fluids' of similar volumes of a propelled-fluid and a powered- fluid stream in a pressurized recipient of sufficient volume to create a defined propelled-fluid space on the top and a powered-fluid space in the bottom.
[000230] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a ‘HP, powered-fluid-stream-to-torque' transfer from said HP, powered-fluid stream to a powered-fluid turbine equipmentassembly (60)/A to produce an output torque at the end of the powered-fluid turbine rotor shaft sufficient to drive designated independent equipment-applications.
[000231] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a fluidturbine, for converting the pressure energy of the HP, powered-fluid stream to rotating shaft torque of the turbine-rotor and then coupling the shaft ends to drive a rotating independent equipment-application.
[000232] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a fluidturbine assembly that can transfer the pressure of the HP, powered-fluid stream to torque by passing the liquid stream over impulse/reaction flow elements that are connected to the central rotation shaft of the turbine-rotor and the momentum transferred from the flow elements will result in torque at the end of the rotor shaft.
[000233] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a fluidturbine assembly that operates with part of the return, powered-fluid stream being pumped through a deaerator to decrease the content of dissolved air in said stream, or the dissolved air content is maintained by chemical additions. [000234] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a fluidturbine with the wetted area of the turbine housing being sealed and operating under a controlled internal pressure.
[000235] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising said HP, propelled-fluid circuit that is powered by a propulsor driven by a motor that consumes electricity from a grid or by an integrated rechargeable battery.
[000236] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising an operable set of functional process units that can be mounted on a mobile, motorized support platform to drive said motorized platform or be mounted on a fixed support platform.
[000237] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a HP, powered-fluid stream that is powered by a continuous pressure energy transfer from the propelled-fluid circuit to the powered-fluid circuit.
[000238] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a preferred embodiment of the mechanism for executing a pressure energy transfer using a synchronized-pair of double-acting pistons, wherein the 2 piston rods are connected by a coupling and the propelled-fluid piston is driving the powered- fluid piston.
[000239] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising multiple pairs of synchronized, piston-based equipment-assemblies operating ‘in parallel' to increase the total volume of the streams involved in the propulsion system.
[000240] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising multiple pairs of synchronized, piston-based, equipment-assemblies operating ‘in-series'.
[000241] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising multiple pairs of synchronized piston-based equipment-assemblies operating in stages wherein the diameter of the propelled- fluid pistons can be larger than the powered-fluid pistons and the discharges of the first stage propelled-fluid pistons feed the second stage and continues as such to the final stage.
[000242] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising multiple pairs of synchronized piston-based equipment-assemblies operating in-stages in-series, wherein the diameter of the propelled-fluid pistons can be larger than the powered-fluid pistons. The discharges of the first stage of powered-fluid pistons now feed the second stage of powered-fluid turbines.
[000243] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising specific parameters for the volume and pressure of the propelled and powered fluid streams as miniaturization is preferable. Minimum operating pressures are preferable for the propelled-fl uid that dictates a propel led-fl uid operating pressure at greater than 5 Bar.
[000244] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising design criteria in the form of FPU that permit the HFFT propulsion system to have the ability to operate universally: for example, fixed or portable mountings; inside or outside; power grid or rechargeable battery; land, sea air, or outer space; small or large capacity.
[000245] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising the use of motorized heat pumps to add heat to the HP, propelled-fluid circuit and to the HP, powered-fluid circuit and to remove heat (chill) from the return, propelled-fluid circuit and from the return, powered-fluid circuit.
[000246] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising the use of waste heat from industrial processes and particularly from thermal power plants to add heat to the HP, propelled- fluid circuit and to the HP, powered-fluid circuit and to remove heat (chill) from the return, propelled-fluid circuit and from the return, powered-fluid circuit.
[000247] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising the use of heat from concentrated solar power installations to add heat to the HP, propelled-fluid circuit and to the HP, powered- fluid circuit and to remove heat (chill) from the return, propelled-fluid circuit and from the return, powered-fluid circuit.
[000248] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising the use of waste heat from industrial and commercial plants and/or heat from concentrated solar operations to drive a vaporabsorption chiller to remove heat (chill) from the return, propelled-fluid circuit and from the return, powered-fluid circuit. [000249] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising an engineered, powered-fluid that comprises a fluid in which solids have been dissolved to increase its specific gravity, wherein the fluid temperature and pH are controlled to maximize the solubility of the solids, and to control the fluid viscosity, and wherein necessary additives are employed to avoid deposits forming on the interior surfaces of the fluid turbine.
[000250] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising multiple pairs of synchronized piston-based equipment assemblies mounted radially around a common crankshaft to operate as a compact, high-capacity, single PET unit. It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising an engineered propelled-fluid that includes a fluid or fluids, selected based on their thermophysical properties that operate as a propelled-fluid in a first-circuit PET, that were selected to provide the best possible heat transfer at the lowest temperature and to produce the highest circuit pressure at said lowest temperature. [000251] It is an object of the present invention to provide a HFFT propulsion system FPU (00)/P, comprising a simpler process that involves only a first-circuit, first-fluid, propelled-fluid PET, without a second-circuit, powered- fluid and this simplified PET process will be identified as ‘HFT configuration' and will bear the number FPU (99)/A. [000252] It is an object of the present invention to provide a HFT configuration comprising a mechanical converter that serves to transfer the linear output of a single-circuit PET to the input shaft of a speed reducer and the output shaft of the speed reducer will drive the input shaft of an equipment-application.
[000253] It is an object of the present invention to provide an HFT configuration that operates with a propelled-fluid with a mass-density below 100 kg/m3 at STP conditions, that excludes the use of steam and water with a mass density of 1 ,000 kg/m3 at STP.
[000254] It is an object of the present invention to provide an HFFT propulsor and an HFT configuration that operates with an internal supply of energy to permit autonomous operation for a period.
BRIEF DESCRIPTION OF THE DRAWINGS
[000255] Figure 1 illustrates the propelled & powered-fluid streams that are part of FPU (03)/S and how these flow streams interact with the other functional process units of the HFFT propulsion system FPU (00)/P according to an embodiment of the present invention. The chosen pressure energy transfer mechanism should execute the required pressure energy changes as the flow streams indicated are moving through the selected operational equipmentassembly, the preferred embodiment for executing FPU (03)/S being the piston-based equipment-assembly (30)/A.
[000256] Figure 1a shows 3 examples of the prior art for 3 different configurations of electric motor propulsion systems intended to provide torque to an equipment-application. Excluding steam, prior art in the field of electrical propulsion processes is essentially an electric motor that direct drives an equipment-application that may have a speed reducer attached to the application inlet shaft, or an auxiliary drive with the electric motor powering a hydraulic system drive or an electric motor powering an air compressor drive that all serve to power specific equipment-applications.
[000257] In the prior art, each example either shows an electric motor transmitting torque directly from the shaft of the motor to the equipment-application or depending on the torque requirements, a fluid assembly such as a hydraulic oil assembly or a compressed air assembly is inserted into the chain of the drive to get a torque versus rpm profile that is different than that available from using only the motor itself. Within these three examples, there is no effort to reduce the power input requirement of the electric motor.
[000258] Figure 1 b illustrates an example of a double-acting cylinder pump. The retraction and extraction movements of the piston are pressurizing a same liquid in a same circuit. Although components of this device may resemble those of the double-action piston equipment-assembly of the propulsion system, the functionality of this device bears no resemblance to the HFFT, propulsion system FPU (00)/P.
[000259] Figure 1c illustrates a prior art configuration, that being a large diesel engine 96.1 driving an electrical generator 96.2. The HFFT propulsion system FPU (00)/P is installed between the diesel engine and the generator such that the diesel engine is now driving the propulsor of the propelled-fluid circuit and the output shaft of the powered- liquid turbine is driving the generator. The result of operating the propulsion unit as part of the diesel generator is that the load decreases for operating the diesel engine.
[000260] Figure 1 c illustrates how this propulsion system can be used in the context of applications that are not powered by electricity and an electric motor, but rather by mechanical torque from a combustion engine.
[000261] Figure 2 identifies the principal function FPU (00)/P and the sous-systems and their secondary functions (01)/S to (06)/S in the order of execution that constitutes a functional HFFT propulsion system, according to an embodiment of the present invention.
[000262] Figure 3a illustrates the configuration of the equipment-assemblies and includes the preferred embodiments and the 4 alternative mechanisms proposed to perform the function of an FTF-PET. The HFFT propulsion unit also comprises a group of infrastructure equipment-assemblies, identified as (80)/A to operate under numerous possible operational, physical, and environmental situations related to specific equipment-applications.
[000263] Figure 3b illustrates the configuration of the equipment-assemblies but also indicates the configuration of the components of the equipment-assemblies. To provide a less loaded diagram, some of the equipment-assemblies are documented on separate sheets including Figures 3c, 3d, 3e & 3f.
[000264] Figures 3c, 3d, 3e,3f are depicting the equipment-assemblies respectively identified as (30)/A, (36)/A, (40)/A and 45/A. The infrastructure equipment-assemblies, numbers 81 to 86, that are part of the infrastructure assembly (80)/A are integral parts of all described assemblies
[000265] Figure 3c illustrates the synchronized-pair, piston-based, propelled & powered-fluid PET equipmentassembly for completing a ‘fluid-to-fluid’, pressure energy transfer. Neither of the propelled & powered-fluid piston rods are connected to a mechanical driver. This operates as a 1st PET mechanism and is the preferred embodiment.
[000266]The HP, propelled fluid 31 .9 is delivered to the cylinder body of the first-circuit through the port 31 .7 and return, propelled-fluid is being discharged via the port 31.6 towards the propulsor inlet. At the same time, HP, powered-fluid 33.8 is being discharged toward the fluid turbine through the cylinder port 33.7 and return, powered fluid is delivered to the cylinder body via port 33.6.
[000267]The pressure differential over the propulsor plus the pressure differential between the ports 31.7 and 31.6 is driving all 4 above-mentioned fluid streams. The temperature differential between the propelled-fluid at port 31.7 and the return, propelled-fluid will drive the pressure differential and change in fluid mass-density. The compressible, HP, propelled-fluid stream is high temperature and high pressure, whereas relatively the incompressible HP, powered-fluid stream is at a much lower temperature but only a slightly lower pressure.
[000268]The force of the pressure of the propelled-fluid is transferred via piston rod to the face of the powered-fluid piston and the powered-fluid in the righthand cylinder is compressed. The propelled & powered-fluids directional manifolds reverse the direction of the flows to the inlets and outlets of each respective piston to produce a synchronized, repetitive cycling and a near continuous flow of fluids.
[000269] Figure 3d illustrates a similar piston-type energy transfer to that of Figure 3c, but the transfer is accomplished using a single-action piston. This can operate as a 2end PET mechanism, wherein the two faces of the single-action piston are each in contact with a different fluid. One side is propelled-fluid, and the other side is powered-fluid. Once the propelled-fluid piston has reached its maximum extension, the propel led-l iquid flow is vented by the manifold to the inlet line of the compressor and the forces of the low inlet pressure of the propulsor inlet and the compressed spring, return the propelled-fluid piston face to its start position.
[000270] Figure 3e shows a double-action diaphragm equipment-assembly (40)/A that can operate as a 3rd PET mechanism. It has 1 controller that feeds propelled-fluid to a piston assembly that applies the propelled fluid to one side of each diaphragm and this propelled air is of sufficient pressure to drive powered fluid through the chambers on the other side of the diaphragm.
[000271] Figure 3f shows a ‘mix and separate' fluids technique to operate as an equipment-assembly (45)/A that can operate as a 4th PET mechanism. A rotor valve with sealed cavities is used to receive, mix and discharge the propelled- & powered fluids
[000272] Figure 3g shows a further embodiment of the FTF-PET in which the propelled & powered-fluid stream doubleaction pistons are mounted radially around a circular, rotating crankshaft. The pistons are mounted as synchronized pairs at 180 degrees from each other. This arrangement of the pistons can form a compact arrangement for multiple process-units executing the function of a pressure energy transfer. It is estimated that 8 or more pistons can be assembled around the same circumference.
[000273] Figure 4a shows a parallel arrangement of multiple, synchronous, double-action, piston-type equipmentassemblies. It is advantageous to operate FTF-PET equipment-assemblies (30)/A in several parallel stages instead of just one stage. This lowers the maximum required pressure energy of the HP, propelled-fluid stream and permits interstage heating of the HP, propelled-fluid stream that will increase the efficiency of the pressure transfer process.
[000274] Operating in parallel stages, the discharge of the propelled-fluid stream of the first stage of the PET equipment-assembly (30)/A becomes the feed to the next stage rather than returning directly to the propelled-fluid distribution equipment-assembly (20)/A.
[000275] Figure 4b illustrates how multiple units of FTF-PET equipment-assemblies (30)/A can also be operated ‘in series'. This serves to decrease the required pressure in the HP, propelled-fluid stream to reach the required pressure in the HP, powered-fluid stream. The discharge of the HP, powered-fluid stream of the first FTF-PET equipment assembly becomes the feed of the second mechanism and the diameter of the piston of the propelled-fluid is increased. Intra-stage heating of the propelled-fluid stream is again possible. [000276] Figure 5 illustrates a powered-fluid turbine equipment-assembly (60)/A used to convert the pressure energy of the HP, powered-fluid stream to rotating shaft torque. The HP, powered-fluid stream is converted by a nozzle configuration into a high velocity stream to drive the central turbine-rotor of the fluid-turbine.
[000277]The housing of the turbine is sealed to allow for operations under possible negative pressure and the discharge from the sump of the liquid-turbine is recycled via the powered-fluid stream distribution equipment-assembly (50)/A to the return, powered-fluid stream inlet of the PET equipment-assembly (30)/A.
[000278] The end of the turbine-shaft is connected to the end of the shaft of the equipment-application and drives the rotating equipment-application. The flow rate and pressure energy of the powered stream are adjusted to control the speed of rotation of the turbine-rotor.
[000279] Figure 6 illustrates a distributed configuration of the HFFT propulsion system wherein multiple units of the fluid-turbine are fed from a central PET equipment-assembly. This is advantageous when there are multiple small equipment-applications to be powered. It is preferred that the powered-fluid distribution system send out feed and return lines to multiple power-fluid turbines, each driving an independent equipment-application.
[000280] This requires a revision of the powered-fluid distribution equipment assembly to handle the numerous additional HP & return, powered-fluid lines. The equipment assemblies covering the propulsion, distribution and FTF- PET mechanism are simply designed with a higher flow capacity.
[000281] Figure 7a illustrates the configuration by integrating a vapor-compression heat pump 215 and a vaporcompression chiller pump 210 into the operations of an HFFT propulsor FPU (00)/P. A concentrated solar 230 or geothermal heat production unit 231 can be used to supplementing the capacity of the heat pump 215.
[000282] Figure 7b illustrates a typical thermal power plant with indications of the heat loads and heat emissions.
[000283] Figure 7c illustrates the configuration by integrating the waste heat of the thermal power plant of figure 7b. into the operations of an HFFT propulsor FPU (00)/P The cooling load 227 is divided between a waste heat unit 205 and a vapor-absorption chiller unit 200. A concentrated solar 230 or geo-thermal heat production unit 231 can be used to supplement the capacity of the waste heat unit 205 and the vapor- absorption chiller unit 200.
[000284] Figure 7d illustrates a single-circuit PET, FPU (07)/S of the HFT configuration that is connected to a mechanical-converter FPU (08)/S for converting linear motion to rotary motion to drive the input of a speed reducer whose output drives an equipment application FPU (09)/S.
[000285] Figure 7e illustrates the similarity of the configurations between the vapor absorption chiller unit 200 and the waste heat unit 205 of a thermal power plant and the propelled-fluid circuits of the HFFT propulsor and the HFT configuration. DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[000286] Referring to Figure 1, that illustrates the activities of the PET related to functional process-unit FPU (03)/S that transitions the propelled-fluid functions (01 )/S and (02)/S to the powered-fluid functions (04)/S, (05)/S and (06)/S.
[000287] The function (06)/S is the equipment-application function that accepts torque from the end shaft of the fluidturbine. The function (03)/S executes a PET from a HP, propelled-fluid stream to a return, powered-fluid stream while the streams are moving from the fluid stream inlets of the PET equipment-assembly to its fluid stream outlets. The preferred embodiment to execute the PET is through synchronized-pair, piston-type, propelled & powered-fluid, PET equipment-assembly (30)/A.
[000288]As stated, the FTF-PET is accomplished by 4 different mechanisms that are based on the technique wherein a HP, propelled-fluid stream, that was generated by a propulsor, transfers part of its pressure energy to a return, powered-fluid stream to convert it to a HP, powered-fluid stream.
[000289] Referring to Figure 1a there is shown 3 illustrations of existing prior art for legacy torque propulsion systems and all 3 are using an electric motor as a source of input power. In all cases, an electric motor is either directly driving the process equipment or driving an auxiliary propulsor to create a pressurized fluid stream that in turn will provide drive torque to an independent equipment-application through various types of hydraulic and gas driven motors connected to said independent equipment-applications.
[000290] In all 3 cases the transition of energy over the system is either electricity to torque, or electricity to torque to liquid to torque, or electricity to torque to compressed air to torque. These differ from a HFFT propulsion system in that: 1) There are no propelled-fluids, nor powered-fluids in the sense of a HFFT propulsion system, 2) In the prior art illustrated, there is no energy transition between a propelled-fluid and a powered-fluid. 3) There is no fluid-to-fluid pressure energy transfer, 4) there is no powered-fluid turbine to feed HP, powered-fluid.
[000291] In prior art, the addition of an auxiliary propulsor is not intended to decrease the electrical power consumed but rather to obtain a more suitable torque output or to provide power to an equipment-application that dimensionally or, due to the torque required by the application, cannot accommodate an electric motor for its required input torque.
[000292] In the first case, the torque produced by the electric motor directly drives an equipment. In the second and third cases, the motor drives auxiliary equipment in the form of a pump or compressor that produces a fluid stream, and the shaft of a satellite equipment is driven by the respective fluid stream that in turn drives the equipment.
[000293] Referring to Figure 1b, it illustrates a double-action, cylinder pump assembly (90)/ A that is part of prior- art for pumping a liquid from point a to point b. The components listed are standard for a cylinder pump or for one of thousands of applications using various combinations of fluids and piston/cylinders to transfer electrical power to pressure energy. The components listed include: 91 a double-action piston & cylinder, 92 discharge check valves, 93 feed check valves, 94 piston shaft, and 95 piston seals. [000294] Given the presence of a piston, a cylinder, and a piston rod, there is some physical resemblance to the doubleaction, equipment-assembly (30)/A employed in a HFFT propulsion system. This cylinder pump plays no role in the operation of a HFFT propulsion system as there are no functions that requires a liquid to simply be propelled from a point a to a point b and no energy transition between two different fluids take place in a cylinder pump as the piston rod is motorized.
[000295] Referring to Figure 1c there is shown a prior art for a propulsion system equipment-application 96 that depicts a diesel motor 96.1 driving a multi-MW electrical generator 96.2. In this instance the equipment- application is to drive an electrical generator using the mechanical torque produced from a motor burning diesel fuel. This equipmentapplication is common in remote areas that include the Arctic and Antarctic, Island nations such as the Caribbean and other sparsely populated areas.
[000296] In the lower illustration of Figure 1c, a unit of a HFFT propulsion system has been installed between the diesel motor and the generator so that the diesel motor, and not an electrical motor, is driving the propulsor. The resulting effect, however, will be the same had the drive been an electrical motor. The power output required from the diesel generator will be up to 20% less than that required to turn the generator without the HFFT propulsion system.
[000297] Referring to Figure 2, the functional process-units that constitute the operations of a HFFT propulsion system according to an embodiment of the present invention are illustrated in the order in which they are configured to operate; FPU (01 .1)/S motorize power to torque, FPU (01)/S propel a selected, limited fluid supply, FPU (02)/S distribute and condition the propelled-fluid stream, FPU (03)/S execute a pressure energy transfer, FPU (04)/S distribute and condition the powered-fluid stream, FPU (05)/S operates powered-fluid turbine producing torque from HP, powered- fluid stream and FPU (06) supply torque to an equipment-application.
[000298] Within these above listed functional process-unit operations, many of the functional needs are completely new to the existing prior art drive configurations, and these needs include:
1) Executing a fluid-to-fluid pressure energy transfer based on the energy transitions from electrical energy to rotational shaft torque, to propelling a limited supply, to HP, propelled-fluid pressure energy, to powered-fluid pressure energy, to fluid velocity energy to fluid-turbine shaft torque to drive an equipment-application.
2) The selection of the fluids used is based on the thermo-physical properties of the fluids to obtain a most efficient propulsor energy transfer to the return, propelled-fluid and from HP, propelled- fluid to the return, powered-fluid and from the HP, powered-fluid to the turbine rotor.
3) With and without direct contact of the 2 fluid streams, executing a continuous transfer of the pressure energy of a HP, propelled-fluid stream to generate a HP, powered-fluid stream. 4) Distribution of the propelled & powered-fluids in 2 closed loop circuits, in recycle mode.
5) Employ a propelled-fluid, piston-based equipment-assembly to drive a powered-fluid, piston-based equipment-assembly.
6) The use of a fluid-turbine that is sealed and under negative pressure to convert the pressure energy of the HP, powered-fluid stream to rotating shaft torque for the propulsion of an independent equipment-application.
7) The use of heating/cooling circuits that serve to obtain the most effective expansion-contraction of the 2 fluids to maximize the propulsion system efficiency. The propelled-fluid stream can operate both heated and chilled and the powered-fluid operates normally chilled. The chilling is preferred to remove the heat of propulsion and the heat of the powered-fluid turbine. Cooling water can be used but this creates a negative environmental impact associated with discharging heated effluent.
8) The need to integrate external sources of heat for compression (positive work) and cooling for removing heat (de-compression or negative work) into the HFFT operations that will use either waste heat or concentrated solar heat to drive the transfers.
[000299] The above operations of this new system are important to exploit the advantages in terms of propulsion energy that are offered by the thermodynamics of the fluids chosen. For this advantage to be sufficient to reach a point of technical/economic feasibility the pressures employed in the HP, propelled-fluid stream and in the HP, powered-fluid stream will exceed 5 atmospheres.
[000300] Referring to Figure 3a, it illustrates the configuration of the equipment-assemblies in the order in which they operate and includes the preferred embodiment and optional embodiments of the mechanisms proposed to perform the functions related to a PET.
[000301] Listed are the equipment-assemblies (30)/A, (36)/A, (40)/A, (45)/A. The equipment-assembly (30)/A is the preferred embodiment but it could be replaced by either the mechanism (36)/A or (40)/A or (45)/A, which are identified as optional alternative embodiments to 30/A, or by any other mechanism that meets the requirements of the functional process unit (03)/S in the propulsion system FPU (00)/P.
[000302] As illustrated in Figure 3c, the equipment-assembly (30)/A comprises integration via coupling of the 2 pistonbased assemblies (30.1 )/A and (30.2)/A.
[000303] As illustrated, the list of equipment-assemblies that constitute a HFFT propulsion system FPU (00)/P are listed in Table 3. [000304]Table 3
List of equipment-assemblies
Figure imgf000047_0001
[000305]Table 4
Programming of the inlet/outlet ports by directional control valve or check valves
Figure imgf000047_0002
Figure imgf000048_0001
[000306] Referring to Figure 3b, it documents the configuration and the interfaces between the equipmentassemblies, the equipment, and the components, all configured/designed to fill the needs of the process operations.
[000307]The equipment-assemblies involved in Figure 3b are (10)/A, (10.1)/A, (20)/A, (50)/A, (60)/A, (70)/A & (80)/A. The 4 PET equipment-assemblies are documented on Figure 3c, Figure 3d, Figure 3e, Figure 3f.
[000308]As per Figure 3b, the component electric motor 11 .4 and electrical power supply 11 .7 appear as part of Figure 3a and Figure 3b, as the electric motor with its electrical supply, are part of the HFFT propulsion system FPU (00)/P as the electricity consumed drives the propulsion system. But as has already been mentioned, external power supplied in the form of torque can also be the power supply 11 .8.
[000309] Electrical energy supplied and its transition to torque is an important part of embodiments of the overall HFFT propulsion system and, as such, is treated as a component of the propulsion system and not simply an element of the supporting infrastructure. The integrated rechargeable battery 11.5 is considered as an internal component of the system. Steam energy, diesel energy, and mechanical energy, and grid and battery electricity that are consumed to drive the propulsor are considered as the 'supplied power’ & part of the propulsion system.
[000310]A partial schematic of the HFFT propulsion system depicted on Figure 3b shows a fluid propulsor 11, the main component of the fluid supply propulsion equipment-assembly (10)/A, that is driven by an electric drive motor 11 .4. The electric motor, that may be variable speed, receives its power from the electrical utility 11 .7 or from a local rechargeable battery 11 .5 or from a source of power torque.
[000311 ]The propelled-fluid distribution assembly (20)/A operates in recycle mode but is also possible to operate in partial or full free flow mode. It comprises a configuration of HP, feed lines 24, and recycle/return lines 24.1 , to construct a sealed, propelled-fluid recycle circuit. The outlet of the propulsor 11.1 feeds HP, propelled-fluid into a feed surge tank 21 to reduce line pulsations and flow and pressure variations.
[000312]The HP, propelled-fluid will be heated between the discharge outlet of the propulsor 11.1 and the discharge of HP, propelled-fluid from the outlet of the PET mechanism (30)/A. There may be one heating unit shown as 23.1 or there may be interstage-units of 23.1 installed within the PET mechanism if interstage assemblies are used. [000313](Continuing on Figure 3c.) The outlet discharge of said feed surge tank feeds uniform HP, propelled-fluid to an inlet port of the multi-way, directional control valve (32) that is part of the PET equipment-assembly (30.1 )/A. An outlet port of the multi-way, directional control valve 32, discharges into a return line 24.1 that feeds the inlet of the cooling unit 23 for return propelled-fluid (end of Figure 3c).
[000314]The discharge of the cooling unit 23 then feeds the return, propelled-fluid to the inlet of a return surge tank 22 that is designed to remove any pressure or velocity surges. The discharge of the return surge tank feeds the return line (24) that discharges return, propelled-fluid into the inlet of the propulsor 11 .2.
[000315] Between the cooling unit and the return surge tank, there is connection 25 that allows all, or part of the return, propelled-fluid, to be discharge to atmosphere 25.2 by opening the discharge valve 25.1 . At the same time, free flow valve 25.3 is opened to allow atmospheric air feed into the propulsor inlet.
[000316]The powered-fluid distribution equipment-assembly (50)/A operates in full recycle mode. It comprises a configuration of feed HP, powered-fluid streams 54 and return powered-fluid line 54.1 to operate as a closed loop, recycle circuit.
[00031 /[(Continuing on Figure 3c) The outlet port of the multi-way, directional control valve powered-fluid stream 34 feeds the HP, powered-fluid stream via line 34.1 into line 54 that feeds the HP, powered-fluid stream to feed surge tank 51 . The inlet port 34.2 is connected to line 54.1 that is the return, powered-fluid stream from the return surge tank 52. (End of Figure 3c)
[000318]The discharge of the surge tank feeds a return, powered-fluid stream 54.1 to a feed inlet port 34.2 on the multi-way directional control valve 34 located on the pressure energy transfer assembly (30)/A.
[000319]The discharge from the cooling unit 54.1 also feeds a discharge connection 56. On this line there is a normally closed isolation valve 56.1 , that when this valve is open part or all the return powered-fluid stream from the sump is sent to atmosphere 56.2. The reserve tank for powered-fluid make-up 55 will maintain supply of powered-fluid to the powered-fluid, PET equipment-assembly.
[000320] After the connection for a free flow discharge, the line continues to feed the inlet of a return surge tank (52) whose role is to reduce pulsations and flow variations in the return powered-fluid stream. The pressure energy lost by the fluid stream in passing through the powered-fluid turbine is continuously replaced by the pressure energy transferred from the HP, propelled-fluid stream as it passes through the powered-fluid, PET equipmentassembly (30)/A.
[000321 [Figure 3c, (synchronized, piston-based, propelled & powered-fluid, PET equipment-assembly, (30)/A)) is an illustration of the equipment-assembly (30)/A comprising 1 unit of piston-based, propelled-fluid, PET equipment assembly (30.1 )/A and 1 unit of piston-based, powered-fluid, PET equipment-assembly (30.2)/A connected at the ends of their piston rods by a 1/2 coupling 35.1 & 35.2. The feed and discharge to the ports of the piston-cylinders are controlled by a propelled-fluid, multi-port directional control valve 32.0 and by a powered-fluid, multi-port directional control valve 34.0. [000322]The piston 31.2, piston cylinder 31.1 , piston rod 31.4, piston rings 31.3, piston rod seal 31.5, a cylinder port 31.6, and a cylinder port 31.7 operate on propelled-fluid as a double-action piston/cylinder. The feed HP, propelled-fluid from the propulsor is delivered by feed distribution line 24 and the return, propelled-fluid is sent to the propulsor return inlet via return propelled-fluid distribution line 24.1.
[000323]The piston 33.2, piston cylinder 33.1 , piston rod 33.4, piston rings 33.3, piston rod seal 33.5, a cylinder port 33.6, and a cylinder port 33.7 operate on a powered-fluid stream as a double-action piston/cylinder.
[000324]As pressure is applied to the full face of the propelled-fluid piston, there is extension of the piston that transfers the pressure along the piston rods to the full face of the powered-fluid piston and that incurs a similar displacement of the powered-fluid piston. The face of the powered-fluid piston applies force against the powered- fluid in the cylinder to produce a HP, powered-fluid stream. At the end of the extension the manifold control valves reconfigure to feed propelled-fluid to the rod face of the propelled-fluid piston and thereby the propelled-fluid piston and powered-fluid pistons retract together.
[000325] Feed propelled-fluid from the outlet of the propulsor is fed to the inlet port of the manifold 32.1 via the propelled-fluid distribution line 24 and the return propelled-fluid travels through a propelled-fluid distribution return line 24.1 through the port 32.2 and returns the propelled-fluid to the propulsor inlet. The multi-port manifold provides the sequencing of the ports to supply either feed propelled-fluid or return propelled-fluid to the appropriate cylinder ports.
[000326]The cycle of the propelled-fluid piston is extension-retraction, and the cycle of the powered-fluid piston is always synchronized as the propelled and powered-fluid piston rods are connected. If multiple units are used, there will be a short time delay between the start of the piston cycles. On extension, the propelled-fluid piston port 31 .7 is receiving HP, propelled-fluid and the powered-fluid piston is compressing a powered-fluid stream and discharging it as a HP, powered-fluid stream via port 33.7.
[000327] Both sides of the pistons have their maximum surface area transferring pressure on the same cycle. On retraction, port 31.6 is now receiving HP, propelled-fluid and the powered-fluid piston is compressing the return powered-fluid stream and is discharging a HP, powered-fluid stream via port 33.6.
[000328]The return, powered-fluid stream from the sump of the powered-fluid turbine is fed to the inlet port of the manifold 34.2 via the powered-fluid stream distribution line 54.1 and the HP, powered-fluid stream discharges to a powered-fluid stream distribution return line 54 through the port 34.1 and feeds to the powered-fluid turbine inlet. The multi-port manifold provides the sequencing of the ports to supply either return powered-fluid stream or HP, powered-fluid stream to the appropriate cylinder ports.
[000329]As mentioned, both pistons may have the same diameter; however, the propelled-fluid piston could be larger in diameter than the powered-fluid piston. A propelled-fluid piston with a larger diameter can decrease the propelled-fluid pressure required to obtain the desired powered-fluid stream pressure, but the volume of propelled- fluid required will increase in proportion to the increase in the piston diameter. [000330]The piston seals 31 .3 and 33.3 act as a sealed membrane interface that divides each piston cylinder into 2 separate cavities. The cavities for the propelled-fluid circuit are 32.3 and 32.4 whereas the 2 cavities for the powered-fluid circuit are 34.3 and 34.4. The inlet and outlet fluid streams are identified as follows: 1) HP, propelled- fluid (31.9); 2) return, propelled-fluid (31.8); 3) HP, powered-fluid (33.8); and 4) return, powered-fluid (33.9). It is understood that when the illustrated 'extension cycle’ ends and the 'retraction cycle’ begins, the inlet and outlet ports of the HP and return fluid streams will reverse.
[000331 [Decreasing the pressure of the propelled-fluid will normally lower the energy demand of the propulsor if the compressibility factor Z is not linear. For this reason, depending on the fluid being compressed, the diameter of the propelled-fluid piston could be larger than that of the powered-fluid piston.
[000332] Figure 3d, (a single-action piston assembly, (36)/A)) is an illustration of the single-acting piston assembly (36)/A comprising 1 unit of single-acting piston assembly. This assembly is an embodiment to perform the function related to a PET mechanism FPU (30)/S. The role of the feed and discharge to the ports of the piston-cylinders are controlled by a propelled-fluid, multi-way directional control valve 38.0 and by a powered-fluid, multi-way directional control valve 39.0.
[000333] The piston 36.0, piston cylinder 36.1 , piston rod 36.2, piston rings 36.4, piston rod seal 36.5 and a cylinder port 36.6 operate on propelled-fluid as a single-acting piston/cylinder. The piston 37.0, piston cylinder 37.1, piston rod 37.2 piston rings 37.4 piston rod seal 37.5 a cylinder port 37.6 operate on powered-fluid as a single-action piston/cylinder.
[000334]The return, powered-fluid stream from the turbine sump is delivered by return distribution line 54.1 to the inlet port of the powered-fluid, multi-way controller 39.1 and the HP, powered-fluid stream is fed to the turbine via the exit port 39.2 to the feed distribution line 54.
[000335]As pressure is applied to the full face of the propelled-fluid piston via cylinder port 36.6, there is extension of the piston that transfers the pressure along the piston rods to the full face of the powered-fluid piston that incurs a similar extension/displacement.
[000336]The face of the powered-fluid piston applies force against the powered-fluid in the cylinder to produce a HP, powered-fluid stream. At the end of the extension the directional control valves 38 and 39 reconfigure to return propelled-fluid from the rod-face of the propelled-fluid piston and both pistons retract together.
[000337] HP, propelled-fluid from the outlet of the propulsor is fed to the inlet port of the manifold 38.1 via the propelled-fluid distribution line 24 and the return propelled-fluid returns to a propelled-fluid distribution return line 24.1 through the port 38.2 and returns the gas to the propulsor inlet. The multi-port manifold provides the sequencing of the ports to supply either feed propelled-fluid or return propelled-fluid to the appropriate cylinder ports.
[000338]The cycle of the propelled-fluid piston is extension-retraction, and the cycle of the powered-fluid piston is always synchronized as the propelled & powered-fluid piston rods are the same rod and share the same cylinder. On extension, the propelled-fluid piston port 36.6 is receiving HP, propelled-fluid and the powered-fluid piston is compressing a powered-fluid stream and discharging it as a HP, powered-fluid stream via port 37.6.
[000339] Both sides of the pistons have their rod face (a reduced piston surface area) transferring pressure on the same cycle. On retraction, port 36.7 is now receiving HP, propelled-fluid and the powered-fluid piston is compressing powered-fluid stream and is feeding a return, powered-fluid stream via port 37.5.
[000340]The return, powered-fluid stream from the sump of the turbine is fed to the inlet port of the manifold 39.1 via the powered-fluid stream distribution line 54.1 and the return HP, powered-fluid stream discharges to a fluid stream distribution return line 54 through the port 39.2 and returns to the powered-fluid turbine inlet. The multi-way manifold provides the sequencing of the ports to supply either feed HP, powered-fluid stream or return, powered- fluid stream to the appropriate cylinder ports.
[000341 ]The travelling piston seals cannot remove 100% of the film of liquid that adheres to the inner face of the cylinder as each retraction/extraction cycle is repeated and during the retraction by the spring no powered-fluid is being compressed so that the process is not continuous but as-per-half-cycle. A second unit operating at 180 degrees to the first unit will provide a continuous supply.
[000342] Both pistons will always have the same diameter, which is another disadvantage of this configuration.
[000343] Figure 3e (diaphragm or (40)/A) is an illustration of the equipment-assembly ‘double-action diaphragmtype, propeiied & powered-fluid, PET assembly’ (40)/A. This assembly is an embodiment to perform the function related to a PET mechanism FPU (30)/S.
[000344]The double-action diaphragm is not acting as a pump but as a PET mechanism. It is being fed HP, propelled-fluid from the line 24 of the propelled-fluid distribution & condition assembly (20)/A and feeding return, propelled-fluid via line 24.1 . Line 24 is feeding the controller inlet line 43.2 and after the controller it is directed by line 43.3 to the chamber-right of propelled-fluid 41.4.
[000345]The propelled-fluid is being fed to a double-action piston/cylinder 41.8 that directs propelled-fluid to the inner surface of either the left or right diaphragm. The pressurized-fluid flow is directed to the outlet line 40.1 and the return, powered-fluid is fed to the diaphragms through the return, powered-fluid line 40.2. The inlet and outlet flow of powered-fluid are controlled by 4 check valves 41.3.
[000346]As per the illustration, return, propelled-fluid from chamber-left is flowing through line 43.4 to the inlet connection of the controller 43. This circuit is operating in a similar fashion to the equipment assembly (30.1 )/A that also treats propelled-fluid. This piston does not use a piston rod to transfer energy but rather transports the propelled-fluid to the inside face of the diaphragm. The pressure within the channels 41.6 and 41.7 is exerted on the inside surface of the diaphragms 41 .1 & 41 .2, and the force of the diaphragms produces HP, powered-fluid.
[000347]The line 40.1 feeds HP, powered-fluid to line 54 of the powered-fluid distribution assembly (04)/A and line 54.1 of (04)/A feeds return, powered-fluid to return line 40.2. [000348] Figure 3f or (45)/A, is an illustration of the 'mix and separate fluids’ assembly (45)/A comprising 1 unit of a rotary valve 49.6 and 1 pressurized recovery tank 49. The rotary valve is divided into 4 distinct rotating cavities that have inlet or outlet connections to each cavity numbered, 45, 46, 47 and 48 and each cavity has either an inlet or an outlet port that opens and closes by a respective controller 45.1 , 46.1 , 47.1 , & 48.1. The rotary valve itself has a stationary outer housing 49.7 that is attached to a baseplate.
[000349]The outer housing can be divided into 8 quadrants of 4 cavities and 4 filled zones and openings in the outer wall allow material to be injected into the cavities, or the cavities can discharge material through an outlet connection. The rotor 49.5 is also divided into 8 equal segments; 4 segments are hollow and the 4 spaces between the cavities are occupied by a filled zone.
[000350] The filled zone prevents any flow between the cavities and seals are installed on their outer circumference to seal the space between the outer walls of the cavities and rotating segments. The role of the feed and discharge to the inlet and outlet ports are controlled by their respective controller.
[000351] Located below the rotary valve is a pressurized, receiving tank that has a recovery chamber for lighter propelled-fluid 49.3 and a recovery chamber for HP, powered-fluid stream 49.2. It receives a mix of powered-fluid and propelled-fluid through port 45. As soon as the mix inters the recipient, the propelled-fluid begins to separate from the powered-fluid stream based on their different mass densities. Within the recipient the liquid level is controlled by a level control loop.
[000352]The discharge on the tank 49.1 connects with the HP, powered-fluid line 54 of the powered-fluid stream distribution and conditioning assembly. The discharge of the propelled-fluid space 49.3 connects with the return, propelled-fluid line 24.1 of the propelled-fluid distribution and conditioning assembly (20)/A.
[000353] In operation, the upper section of the recipient is full of propelled-fluid and the bottom is full of powered- fluid. In the illustration, the 4 cavities, numbered #1 to #4, are located at the 12, 9, 6, and 3 o’clock positions and the rotor turns counterclockwise. The function of each cavity is as follows.
1) Fill to 50% the cavity 48 with return, powered-fluid from the sump of the powered-fluid turbine that is controlled via port controller 48.1 ;
2) Inject HP, propelled-fluid from the propelled-fluid distribution line 24 to pressurize the cavity 47 that is controlled via port controller 47.1 ;
3) Discharge the powered-fluid and propelled-fluid of cavity #3 into the pressurized recovery tank 49 that is controlled via port controller 45.1 ;
4) Connect the cavity 46 to the inlet of the propulsor by passing through the propelled-fluid recovery chamber 49.3 to remove as much air as possible. Cavity 46 is controlled via port controller 46.1 ; and
5) Repeat the cycle beginning with activity 1 ). [000354]This first mixing stage via cavity 47 is followed by a second separation stage during which the mix is transferred to a pressurized recipient 49, operating at a lower controlled pressure. Within the recipient there exists a propelled-fluid space and a powered-fluid space that is the result of the differences in density of the fluids. The propelled-fluid portion is thereby separated from the powered-fluid portion by differences in their density. The return, propelled-fluid is returned to the propulsor inlet and the HP, powered-fluid stream 49.1 is fed to the powered- fluid turbine inlet via line 54.
[000355] Figure 3g shows a further embodiment of the piston-based, propelled & powered-fluid PET equipmentassembly (30)/A that comprises 1 propelled-fluid piston assembly driving 1 powered-fluid piston assembly. Two synchronized units of equipment-assembly (30)/A are now mounted radially around a circular, non-central, rotating crankshaft. This is a more compact arrangement as the units instead of being connected on a horizontal plain are now concentrated around a vertical circumference.
[000356] Referring to Figure 4a, it depicts the use of multiple stages of the piston-based, propelled & powered- fluid, PET assembly (30)/A. However, in this instance the return, propelled-fluid flows of each stage are fed to the inlet connections for propelled-fluid on the next stage. The diameter of each succeeding propelled-fluid piston increases to apply an equal pressure on the corresponding powered-fluid piston. The return, propelled-fluid pressure energy from the discharge of the last stage is now much less when it reaches the propulsor inlet.
[000357] Interstage heaters 23.1 are used to use heat to minimize the loss in pressure as the volume of the piston cylinder increases. The arrangement of ‘multi-stage’ piston based, (30)/A assemblies are depicted in Figure 4a.
[000358] Referring to Figure 4b, operating PET assemblies 'in-series’ is another strategy to reduce the energy input required to produce work done by a piston-type, PET assembly. In this situation, the objective is to minimize the pressure of the propelled-fluid stream while maximizing the pressure of the powered-fluid stream.
[000359] The H P, powered-fluid of the first stage is feeding the inlet of the return, powered-fluid of the second stage and the diameter of the piston of the propelled-fluid stream is now larger than the diameter of the piston of the powered-fluid piston. This serves to minimize the required pressure applied by the propelled-fluid and maximize the pressure of the powered-fluid.
[000360] Figure 5 is an illustration of a powered-fluid turbine equipment-assembly (60)/A that is being fed with the HP, powered-fluid stream. The role of the powered-fluid turbine equipment-assembly is to complete a pressure energy transfer from the HP, powered-fluid stream into torque that will be delivered via the central rotating shaft 61 , to a speed reducer 67 and coupled 66 to the rotating shaft of the equipment-application 72. A powered-fluid distribution pipe 64 directs the HP, powered-fluid stream that was fed into its inlet into one or multiple high-velocity jet streams created using nozzles 64.1.
[000361 ]The flow elements 61.3 are attached to a support ring 61.2 that is attached to a runner 61.1. The flow elements convert the velocity of the liquid stream into a force applied against the runner that continues the transfer to the rotating shaft 61 where it becomes torque. [000362]The wetted surfaces of the inside of the housing are held under controlled working pressure by a compressor 63.2 driven by variable speed motor 63.3. The compressor outlet is connected to an inlet connection mounted on the outside surface of the turbine housing 64.2. The controlled pressure serves to adjust (to increase) the boiling point of the HP, powered-fluid as the temperature of the HP, powered-fluid may be held fairly high to maximize the solubility of the dissolved solids in the powered fluid stream.
[000363]The inlet powered-fluid stream falls by gravity into the turbine sump 65. The return line of the turbine sump 65.1 feeds a return, powered-fluid line 54.1 in the powered-fluid distribution and conditioning equipment-assembly (50)/A.
[000364]To help reduce the level of entrained air in the HP, powered-fluid (as it will cause pumping problems) some of the entrained air will be removed by a cyclone-type deaerator 68 or equivalent.
[000365]A small pump independent of the main powered-fluid flow stream will pump powered-fluid through the cyclone, and vacuum will be applied to the overflow header 68.1 of the cyclone.
[000366]ln the equipment-assembly (70)/A of Figure 3b, there is illustrated a process-application 71 and an independent equipment-application 72. There is a connection to the process application 71.1 that feeds an isolation valve 71.2 that is connected to an inlet connection on the process-application. These elements serve to supply the process-unit with a HP, powered-fluid stream. The torque produced by the turbine rotating shaft 61 is transmitted to the equipment application 72 via a coupling 66 that connects the shaft ends and, if necessary, a gearbox 67 is also employed between the turbine end shaft and the application end shaft.
[000367] As someone experienced in the design and operation of fluid turbines will understand, there exists multiple variants of the configurations of fluid turbines, They may have vertical or horizontal shafts, impulse or reaction type blades, convergent and diffuser-type casings, a pressurized or non-pressurized casing, one or multiple stages of flow elements (blades, buckets, cavities etc.) and recirculating or non-recirculating flow streams, Also the variation in the capacities of the HFFT propulsors and the different environments will have some impact on the appropriate turbine design.
[000368]This application is based on the premise that the HP, powered-fluid stream that leaves the discharge of the pressure energy transfer (PET) mechanism will enter an appropriate fluid-turbine of such a configuration that it suits the requirements of the independent equipment-application to which it will be supplying input torque.
[000369] Referring to Figure 6, it illustrates that, rather than install a complete HFFT propulsion system for each equipment-application, it is possible to install one central, pressure energy transfer assembly with the capacity to deliver an HP, powered-fluid stream to multiple, distributed units of the fluid-turbine and each individual fluid turbine drives an independent equipment-application.
[000370]ln this distributed arrangement, each equipment application has its own fluid-turbine to drive it and it is important to connect each equipment application with a feed and return line for transporting the HP, powered-fluid stream and the return, powered-fluid stream. This eliminates electric motors and all the power wiring, electrical switchgear, and motor control centers. It also eliminates the loss of electrical power and heat that is related to running an electric motor.
HFFT PROPULSION SYSTEM WITH INTEGRATED HEAT PUMPS
[000371] Figure 7a illustrates an -HFFT installation wherein 2 heat pumps are providing a mix of hot and cold energy transfers to the propelled & powered-fluid circuits. Each of the heat pumps can supply both heat and chilling transfer to both fluid circuits.
[000372]Two units are illustrated as it may be difficult to obtain the desired ratio of heating and chilling capacity with only a single unit operating in only a single mode. A motorized vapor-compression chiller 210 and a motorized vapor-compression heat pump 215 are supplying chilled thermal fluid and hot thermal fluid respectively to the return, propelled and return, powered-fluid circuits and to the HP, propelled and HP, powered-fluid circuits.
[000373] A heating thermal fluid supply line 216 distributes heat from the heat pump 215 to fluid feed line 217 that feeds the HP, propelled-fluid exchanger 23.1 that provides heat to the HP, propelled-fluid circuit, and supply line 217 also connects to heating fluid feed line 218 that provides heat to the HP, powered-fluid exchanger 53.1 . The heat pump has a hot air exhaust line to atmosphere 219.
[000374] A chilled thermal fluid supply line 211 distributes cold thermal fluid from the vapor-compression chiller 210 to chiller fluid feed line 212 that feeds the return, powered-fluid exchanger 23 that provides chilling to the return, powered-fluid circuit and supply line 211 also connects to chilling fluid feed line 213 that provides chilling to the return, powered-fluid exchanger 53. The chiller has a hot air exhaust line to atmosphere 214.
[000375]As discussed, the advantage of employing the heat pumps is that the required differential pressures or fluid temperatures required can be obtained with a less expensive and more efficient thermal energy input than if the same conditions were obtained strictly by mechanical compression.
[000376]Concentrated solar and geo-thermal are sources of inexpensive thermal energy. A unit of concentrated solar 230 and a unit of geothermal 231 are depicted and their heat provided is being added to the thermal energy that is being produced by the vapor-compression heat pump via line 216.
[000377]As indicated by the equipment-assembly (80)/A, this installation and all installations of HFFT propulsors will require a customized set of infrastructures to support the operations and control of the systems involved whether they be part of HFFT system operations, or an external process integrated into its operations.
HFFT PROPULSION SYSTEM WITH INTEGRATED WASTE HEAT FROM POWER PLANTS
[000378] Figure 7b and Figure 7c pertain to the operation of a HFFT system in a context wherein the waste heat provided for heating and cooling the propelled and powered fluids are from a thermal power installation. The values indicated for the available heat loads in terms of MW of electrical power are order-of-magnitude for pre-feasibility level analysis.
[000379] Figure 7b depicts a thermal power plant that does not incorporate a HFFT propulsion system and will serve as a comparative model. It is assumed this production facility has a gross thermal capacity of 2,500 MW, at 40% thermal efficiency. As such, it produces 1 ,000 MW of electricity and 1,500 MW of thermal losses in the form of waste heat load that leaves the plant to the environment and simply assumed as a 1,500 MW effluent load (no losses to atmosphere).
[000380] Figure 7c depicts the same power plant as Figure 7b, however, the waste heat load has been integrated to create a Combined Heat and Power or CHP-HFFT propulsion system. This new operation produces some 100 MW of torque and 250 MW of electrical power that will have consumed 700 MW of waste heat required to accomplish the necessary work-done to produce the torque and power.
[000381 ]The heat loss to atmosphere from the chillers will be of the order of 150 MW. As such the overall effluent heat load has been cut by some 57%, (850/1 ,500 = 0.566). Thermal power plants discharge vast quantities of waste-heat as hot water, and this causes severe environmental impact.
[000382]The thermal power plant 225 has an overall heat generation capacity of 2,500 MW that in turn produces some 1 ,000 MW of electricity in its generating unit 226 and produces some 1 ,500 MW of waste-heat load 227. The waste-heat load is distributed via a first HP, waste-heat supply line 222 to a vapor-absorption chiller and the return, waste heat is returned to the waste-heat load 27 via return line 223.
[000383]The waste heat load 227 is distributed by a second HP, waste-heat supply line 220 to a waste-heat heat exchanger and the return waste-heat is returned to the waste-heat load via return line 221 .
[000384]Two thermal energy production units are illustrated, one for heating and one for cooling. A waste-heat vapor-absorption chiller 200 and a waste-heat heat exchanger 205 are supplying chilled thermal fluid and hot thermal fluid respectively to the return, propelled and return, powered-fluid circuits and to the HP, propelled and HP, powered-fluid circuits.
[000385] A heating thermal fluid supply line 206 distributes heat from the waste-heat exchanger 205 to hot fluid feed line 207 that feeds the HP, propelled-fluid exchanger 23.1 that provides heat to the HP, propelled-fluid circuit, and heating supply line 206 also connects to heating fluid feed line 207 that provides heat to the HP, powered-fluid exchanger 53.1. The heat pump has a hot air exhaust line to atmosphere 219.
[000386] A chilled thermal fluid supply line 201 distributes cold thermal fluid from the vapor-compression chiller 200 to chiller fluid feed line 202 that feeds the return, powered-fluid exchanger 23 that provides chilling to the return, powered-fluid circuit and supply line 201 also connects to chilling fluid feed line 203 that provides chilling to the return, powered-fluid exchanger 53.
[000387]A unit of solar heat 230 and a unit of geo-thermal heat 231 are used to increase the quality and/or the quality of the waste heat source 205.
[000388]As the rotating torque produced by the fluid turbines of the CHP-HFFT system can be distributed to drive rotating equipment, it would be possible to build a new power plantwithout any secondary electrical power required to drive the process. The electrical motors are replaced by HFFT fluid drives.
[000389]0 n ly lighting, instrumentation, process controls and communications need be wired. The risks associated with electrical fires and process equipment flooding are largely eliminated. Heat losses from electrical equipment and motors are also eliminated.
THE HFT CONFIGURATION WITH WASTE HEAT [0003901 Figure 7d illustrates the configuration of a single-circuit PET with a mechanical-converter and this constitutes a simplification in the configuration with the HFFT propulsor. This simplification does result in lower system efficiencies calculated as a higher ratio of “the input power to the propelled-fluid’7”output torque (power) from the powered-fluid turbine”; however, the propulsion system is more compact and less costly to build.
[000391 ]The propelled-fluid and the first-circuit of the PET (30.4)/A that is illustrated is the same unit used by the HFFT propulsor in Figure 3c (30.1 )/A with the exception that instead of applying the pressure energy (force) of the propelled-fluid against the shaft of the piston of the powered-fluid circuit (30.2)/A, it is now applying its pressure energy against an inlet shaft 98.3 of a mechanical-converter. The function of a mechanical-converter is to convert the linear, back and forth output of a shaft 31 .4 into rotary motion using said mechanical-converter 98.9.
[000392]As the HFFT propulsor and the HFT configuration are similar, but serve different applications, the numbering of 2 FPUs and 2 equipment-assemblies of an HFT configuration were changed, but the components of its equipment-assemblies remain unchanged.
[000393]The physical change is replacing the powered-fluid distribution circuit (equipment-assembly (50)/A) and the fluid turbine (equipment-assembly (60)/A)) by a mechanical-converter (equipment-assembly (98)/A), wherein both configurations produce output, rotary torque from the same input energy.
[000394]ln the case of the FPU number for the propelled-fluid circuit, for the HFFT propulsor the number FPU (03)/S becomes, the number FPU (03.0)/S for the HFT configuration. Similarly, the equipment-assembly for the propelled-fluid circuit has changed from (30.1)/A for the HFFT propulsor to (30.4)/A for the HFT configuration. These changes are depicted in Figure 7d.
[000395]As mentioned, all of the FPUs and equipment assemblies upstream of the 1/2 coupling 35.3 remain unchanged, whereas this coupling connects the output of the single-circuit PET to the input of the mechanicalconverter.
[000396] Referring now only to the HFT configuration application as per figure 7d, as the propelled-fluid 31.9 is injected into the piston cylinder via the cylinder port 31,7, the force generated by the hydraulic pressure is transferred by the piston shaft 31 .4 to the input shaft 98.3, that is connected to the periphery of the outer wheel 98.1 of the mechanical-converter.
[000397]As the shaft of the piston 31 .4 moves back and forth the outer wheel of the converter is forced to rotate and this rotating wheel converts the inlet linear motion to an output of rotary motion. The output shaft of the converter 98.2 transfers its rotating torque to a transmission belt 98.6 that in turn drives the input shaft 98.4 of the speed reducer 98.8. The output shaft of the speed reducer 98.5 in turn transmits the output torque of the speed reducer via a transmission belt 98.7 to drive the input shaft 74.1 of the independent equipment application 74.
[000398]The FPU (07)/S describes the functions performed by the mechanical-converter and the FPU (08)/S describes the functions of the speed reducer and equipment-application. The equipment assemblies that serve to physically deliver the process requirements are (30.4)/A for the FPU (03.0)/S and equipment-assembly (98)/A for the FPU (07)/S and FPU (08)/S.
[000399]The Functions and Activities of the HFT configuration are listed in Table 5 below and the list of equipment assemblies are listed in Table 6 below. [000400]Table 5
Functions and Activities of the HFT configuration
Figure imgf000059_0001
Figure imgf000060_0001
Figure imgf000061_0001
[000401] Table 6
List of equipment-assemblies, HFT configuration
Figure imgf000061_0002
Figure imgf000062_0001
[000402] Figure 7e depicts a scenario whereby the thermal power plant 225 introduced in Figure 7c is now suppling waste heat to a stationary HFT configuration, FPU (99)/P. Although the role of the HFT configuration is more for mobile applications than for this stationary example, this HFT configuration FPU (99)/P that comprises the equipment-assemblies (10.1)/A, (10)/A, (20)/A, (30.4)/A, (70)/A, (80)/A (not depicted) and (98)/A, is applicable to all types of HFT configuration installations.
[000403] Except for equipment assembly (98)/A that includes the mechanical-converter and that the assembly (30.4)/A is only a single-circuit PET rather than a double-circuit PET, The HFT configuration produces torque from some electrical energy; however, the majority of the energy comes from transferring heat and waste heat into the PET fluid-circuits.
[000404]The concentrated solar unit 230 and geo-thermal unit 231 can supplement the supply of the waste heat supply unit 205 and this unit can supplement the supply to the vapor-absorption chiller 200 by sending heat energy via lines 221 & 222.
[000405]The vapor-absorption chiller can supply cooling to the propelled-fluid circuit via lines 201 & 202 that will supply the cooling exchanger 23. The propelled-fluid circuit can be heated by transferring waste heat via line 206 & 207 to feed the exchanger 23.1 The equipment-assembly for the single-circuit PET is (30.4)/A and as mentioned closely resembles the first circuit equipment assembly (30.1)/A of the HFFT. The equipment assembly (98)/A comprises the 2 new equipment additions that include a mechanical-converter 98.9 and an associated gear box 98.8. It is the output shaft of the reducer 98.5 that transmits its output to a transmission belt 98.7 that powers the input shaft 74 of an equipment application 74.
[000406]As indicated by the equipment-assembly (80)/A, this installation and all installations of HFT configurations will require a customized set of infrastructures to support the operations and control of the systems involved whether they be part of HFT configuration operations or an external process integrated into its operations.
[000407]The HFFT propulsor and the HFT configuration are a new approach to generating torque from heat. As any expert familiar with the thermo-physical properties of fluids would understand, selecting the appropriate fluids and operating under appropriate conditions can have a large impact on the performance of the HFFT Propulsion System.
[000408]The existing empirical data of chemical handbooks allowed the inventor to make a judicious engineered selection of fluids suitable for this invention. The scope of the claims should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole.
DEFINITIONS [000409]The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.
[000410]The terms "comprising", "having", "including", and "containing" are to be construed as open-ended terms (/.e., meaning "including, but not limited to") unless otherwise noted.
[000411] Recitations of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All subsets of values within the ranges are also incorporated into the specification as if they were individually recited herein.
[000412]AII methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
[000413]The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed.
[000414] No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[000415]Herein, the term "about" has its ordinary meaning. In embodiments, it may mean plus or minus 10% or plus or minus 5% of the numerical value qualified.
[000416] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
LIST OF FUNCTIONAL PROCESS-UNITS (FPU) FOR HFFT PROPULSOR & HFT CONFIGURATION
(00)/P HFFT propulsion system FPU (00)/P
(01 )/S propel a selected fluid supply to generate HP, propelled-fluid
(01.1 )/S motorize power to torque
(02)/S distribute and condition the propelled-fluid streams
(03)/S execute a double-circuit pressure energy transfer (includes (30.1 )/A and (30.2)/A)
(03.0J/S execute a single-circuit, pressure energy transfer (includes (30.1 )/A plus 35.3)
(03.1 )/S return, propelled-fluid from the PET mechanism
(03.2J/S feed HP, propelled-fluid to the PET mechanism
(03.3J/S return, powered-fluid to the PET mechanism
(03.4J/S discharge HP, powered-fluid from the PET mechanism
(04)/S distribute and condition the powered-fluid streams
(05)/S operate the liquid-turbine producing torque from HP, powered-fluid
(06)/S equipment-application (07)/S mechanical converter-linear to rotary motion, HFT configuration
(08)/S speed reducer, output shaft to equipment-application, HFT configuration
(99)/P HFT configuration FPU (99)/P
LIST OF EQUIPMENT-ASSEMBLIES, FOR HFFT PROPULSOR & HFT CONFIGURATION
(10)/A fluid supply propulsor, equipment-assembly,
(1O.1J/A power to torque, equipment-assembly
(20)/A propelled-fluid distribution & conditioning equipment-assembly,
(30)/A synchronized-pair, piston-based, propelled & powered-fluid, PET equipment-assembly
(30.1J/A piston-based, propelled-fluid, PET equipment-assembly
(30.2J/A piston-based, powered-fluid, PET equipment-assembly
(30.3)/A radial mounted, synchronized-pair, piston-based, PET equipment-assembly
(30.4J/A piston-based, single circuit, propelled-fluid PET, equipment-assembly, HFT configuration
(30.6J/A multistage, piston-based propelled and powered fluid, PET equipment-assembly
(36)/A single-action, piston-based, propelled & powered-fluid, PET equipment-assembly,
(40)/A double-action diaphragm-based, propelled and powered-fluids, PET equipmentassembly
(45)/A ’mix & separate fluids’, fluid density-based, PET equipment-assembly,
(50)/A powered-fluid distribution & conditioning, equipment-assembly,
(60)/A powered-fluid turbine, equipment-assembly,
(70)/A equipment-applications
(80)/A infrastructure, equipment-assembly
(90)/A prior art
(98)/A mechanical-converter - linear to rotary motion, HFT configuration
LIST OF EQUIPMENT-ASSEMBLIES AND THEIR COMPONENTS
(10)/A fluid supply propulsor, equipment-assembly ’ (items 11 to 11.3)
(10.1 )/A powerto torque (items 11.4 to 11.8)
11 fluid supply, - propulsor
11.1 outlet, HP, - propelled-fluid
11.2 inlet, return - propelled-fluid
11.3 pressure controller - HP, propelled-fluid
11.4 electric motor - propulsor
11.5 internal rechargeable battery/energy supply
11.6 coupling - motor to propulsor
11.7 supply of consumed electricity
11.8 power supplied as torque
(20)/A propelled-fluid distribution & conditioning, equipment-assembly" (items 21 to 26.1) 21 surge tank - HP, propelled-fluid
22 surge tank - return, propelled-fluid
23 cooling exchange unit - propelled-fluid
23.1 heating exchange unit - propelled-fluid
24 feed line - HP, propelled-fluid
24.1 return line - return, propelled-fluid
25 connection - discharge free-flow mode - return, propelled-fluid
25.1 discharge valve - free-flow mode
25.2 outlet discharge - atmosphere
25.3 inlet - free flow fluid make-up
26 reserve tank - fluid makeup
26.1 pressure regulator - discharge reserve tank
(30)/A synchronized-pair, piston-based, propelled & powered-fluids, PET equipment-assembly
(Includes items (30.1)/A & (30.2/A)
(30.1 )/A synchronized, piston-based, propelled-fluid, PET equipment-assembly
(Includes items 31.1 to 31.7, 32.0 to 32.2, & 35.1)
(30.2J/A synchronized, piston-based, powered-fluid, PET equipment-assembly
(Includes items 33.1 to 33.7 & 34.0 to 34.2, & 35.2)
(30.3)/A radial mounted, piston-based, propelled & powered-fluids, PET equipment-assembly
(Includes assembly (30)/A and component 30.5 below)
(30.4J/A single-circuit PET, HFT configuration
(Includes equipment-assembly (30.1 )/A plus 1/2 coupling 35.3 below)
30.5 central rotating crankshaft
(30.6)/A multistage, piston-based propelled and powered fluid, PET equipment-assembly
(includes 3 stages of equipment-assembly (30)/A)
31.1 piston cylinder & ends - propelled-fluid
31.2 piston
31.3 piston seals - sealed membrane interface
31.4 piston rod
31.5 piston rod seals
31.6 cylinder port - HP, propelled-fluid & return, propelled-fluid
31.7 cylinder port - return, propelled-fluid & HP, propelled-fluid
31.8 return, propelled fluid , first cicuit
31.9 HP, propelled-fluid, first-circuit
32 multiple-way, directional control valve - propelled-fluid
32.1 inlet port - directional control valve
32.2 exit port - directional control valve 32.3 sealed chamber- HP, propelled-fluid
32.4 sealed chamber - return, propelled-fluid
33.1 piston cylinder - powered-fluid
33.2 piston
33.3 piston seals - sealed membrane-interface
33.4 piston rod
33.5 piston rod seals
33.6 cylinder port - HP, powered-fluid & return, powered-fluid
33.7 cylinder port - return, powered-fluid & HP, powered-fluid
33.8 HP, powered-fluid, second-circuit
33.9 return, powered-fluid, second circuit
34 multiple-way, directional control valve - powered-fluid
34.1 inlet port - directional control valve
34.2 exit port - directional control valve
34.3 sealed chamber - return, powered-fluid
34.4 sealed chamber - HP, powered-fluid
35.1 end-to-end coupling - propelled-fluid
35.2 end-to-end coupling - powered-fluid stream
35.3 end-to-end coupling, mechanical-converter - linear to rotary motion
(36)/A single-action piston-based, propeiied & powered-fluids, PET equipment-assembly ' ,
(items 36.1 to 39.2)
36.1 piston cylinder and ends - propelled-fluid
36.2 piston
36.3 piston seals
36.4 piston rod
36.5 piston rod - seal
36.6 cylinder port - HP, propelled-fluid & return, propelled-fluid
36.7 cylinder port - return, propelled fluid & HP, propelled-fluid
37.0 piston - powered-fluid
37.1 piston cylinder & ends - powered-fluid
37.2 piston rod
37.3 piston seals
37.4 piston rod seals
37.5 cylinder port - HP, powered-fluid stream & return, powered-fluid
37.6 cylinder port - return, powered-fluid & HP, powered-fluid
37.7 return spring
38 multiple-way, directional control valve - propelled-fluid 38.1 inlet port, HP, propelled-fluid
38.2 exit port, return-propelled-fluid
39 multiple-way, directional control valve - powered-fluid
39.1 inlet port - HP, powered-fluid stream
39.2 exit port - return, powered-fluid
(40)M double-action diaphragm-based, propeiied & powered-fluids, PET equipment-assembly, (items 40.1 to 44.2)
40.1 discharge line diaphragm chamber left & right - HP, powered-fluid
40.2 feed line to diaphragms chamber left & right - return, powered-fluid
41 casing, double-action diaphragm - PET mechanism
41.1 diaphragm chamber left - HP, powered-fluid & return, powered-fluid
41.2 diaphragm chamber right - return, powered-fluid & HP, powered-fluid
41.3 check valves - 2 inlets & 2 outlets, powered-fluid
41.4 piston chamber right - propelled-fluid
41.5 piston chamber left - propelled-fluid
41.6 fluid channel right - piston chamber to diaphragm chamber
41.7 fluid channel left - piston chamber to diaphragm chamber
41.8 double-action piston/cylinder - propelled-fluid
43 controller multi-way manifold - propelled-fluid
43.1 return line controller - propelled-fluid
43.2 feed line controller - HP, propelled-fluid
43.3 feed line - controller to double-action piston
43.4 return line - double-action piston to controller
(45)/A mix & separate fluids-type, propelled & powered-fluids, PET equipment-assembly (items
45.1 to 49.7)
45.1 discharge port - rotating cavity#3, mixed return, propelled-fluid & HP, powered-fluid
45.2 controller - valve
46 discharge port - rotating cavity#4, return, propelled-fluid recovery
46.1 controller - valve
47 feed port - rotating cavity#2, HP, propelled-fluid
47.1 controller - valve
48 feed port - rotating cavity#1 , return, powered-fluid
48.1 controller/valve
49 recovery chamber - HP, powered-fluid
49.1 discharge - HP, powered-fluid
49.2 recovery tank - mixed return, propelled-fluid and HP, powered-fluid 49.3 recovery chamber - return, propel led-fl u id
49.4 discharge - return, propelled-fluid
49.5 rotary airlock
49.6 rotary airlocks
49.7 rotary valve, outer wall
(50)/A powered-fluid stream distribution equipment-assembly (items 51 to 57.2)
51 surge tank, HP, powered-fluid
52 surge tank - return, powered-fluid
53 cooling exchange unit - return, powered-fluid
53.1 heating exchange unit - HP, powered-fluid
54 feed line, HP, powered-fluid
54.1 return line, return, powered-fluid
55 reserve tank, powered-fluid makeup
56 connection, discharge free flow
56.1 valve, discharge free flow mode
56.2 outlet, discharge atmosphere
56.3 inlet, make-up water
(60)/A powered-fluid turbine equipment-assembly ’ (items 61 to 68.1 )
61 rotatable shaft - turbine-rotor
61.1 runner - turbine-rotor
61.2 support ring, turbine-rotor
61.3 flow elements, turbine-rotor
61.4 output torque - turbine rotor
61.5 end of shaft - turbine rotor
62 turbine housing
62.1 outlet turbine housing - return, powered-fluid
63.0 vacuum compressor - deaerator
63.2 air compressor - turbine working-pressure
63.3 turbine working-pressure controller
64 feed line - HP, powered-fluid
64.1 jet nozzles - flow elements
64.2 vacuum line
65 return sump - return, powered-fluid stream
65.1 discharge return sump
66 coupling - gear box to equipment-application
67 gear box
68 deaerator 68.1 deaerator overflow
(70)/A ‘equipment-applications ’ assembly (items 71 to 72)
71 process-application
71.1 connection process-application, HP, powered-fluid
71.2 isolation valve, process-application
71.3 inlet, process-application
72 equipment-applications; includes pumps, fans, diesel & electric generators, compressors, rotating machines, rotating grinders, rotating machines, etc. (includes 72.1)
72.1 input shaft, equipment-assembly
72.2 input torque, equipment-assembly
74 independent equipment-applications, HFT configurations (includes 74.1)
74.1 input shaft, independent equipment-applications
74.2 input torque, independent equipment-applications
(80)/A ‘infrastructures, equipment-assembly ’ (items 81 to 87)
81 baseplate equipment-assembly
82 structural support framing equipment-assembly
83 enclosure equipment-assembly
84 telecommunications equipment-assembly
85 process-control equipment-assembly
86 fixed-platform equipment-assembly
87 mobile-platform equipment-assembly
90 prior art
91 double-action, piston/cylinder
92 discharge check valves - powered-fluid
93 feed check valves - powered-fluid
94 piston shaft
95 piston seals
96 prior art, diesel generator
96.1 diesel motor
96.2 electrical generator
(98)/A equipment assembly, mechanical-converter and speed reducer, HFT configuration
98.1 outer wheel, converter
98.2 output shaft, converter
98.3 input shaft converter plus 1/2 coupling 35.3
98.4 input shaft, gear box
98.5 output shaft, gear box
98.6 transmission belt, output shaft converter to input shaft gear box 98.7 transmission belt, output shaft gear box to input shaft equipment-assembly
98.8 gear box, HFT configuration
98.9 mechanical-converter, HFT configuration
INTEGRATED CHP-HFFT PROPULSION SYSTEM AND CHP-HFT CONFIGURATION
200 waste-heat, vapor-absorption chiller
201 waste-heat, chiller supply - propelled and powered-fluid circuit
202 waste-heat, chiller feed - return, propelled-fl u id exchanger (23)
203 waste-heat, chiller feed - return, powered-fluid exchanger (53)
205 waste-heat, heat exchanger
206 waste-heat, heat supply - propelled and powered-fluid circuit
207 waste-heat, heat feed - HP, propelled-fluid exchanger (23.1)
208 waste-heat, heat feed - HP, powered-fluid exchanger (53.1)
210 motorized, vapor-compression chiller
211 chilled fluid supply - propelled and powered-fluid circuit
212 chilled fluid feed - return, propelled-fluid exchanger (23)
213 chilled fluid feed - return, powered-fluid exchanger (53)
214 hot air exhaust to atmosphere
215 motorized, vapor-compression heat pump
216 heating fluid supply - propelled and powered-fluid circuit
217 heating fluid feed - HP, propelled-fluid exchanger (23.1)
218 heating fluid feed - HP, powered-fluid exchanger (53.1)
219 hot air exhaust to atmosphere
220 waste-heat load supply
221 waste-heat load - return
222 waste-heat load - HP supply
223 waste-heat load - return
225 TPP, thermal power plant - 2,500 MW heat generation
226 TPP, generating unit - 1 ,000 MW electricity generation
227 TPP, cooling load - 1,500 MW
230 concentrated solar energy unit
231 geo-thermal energy unit

Claims

1 . A Heat-Fluid-Fluid-Torque (HFFT) propulsion system, wherein a first-fluid, a first-circuit, and a first-process of transferring external heat energy to the first-fluid is isolated from a second-fluid, a second-circuit, and a second-process of transferring velocity energy to a turbine-rotor to produce shaft torque, the first-fluid being a propelled-fluid and the second-fluid being a powered-fluid, wherein the system comprises a ‘fluid-to-fluid’ pressure energy transfer (PET) mechanism ((30)/A) for transferring pressure energy from the first-fluid of the first circuit stream to the second-fluid of the second circuit stream.
2. The HFFT propulsion system of claim 1, wherein the Heat-Fluid-Fluid-Torque (HFFT) propulsion system FPU (00)/P is for producing rotating torque configured to drive the input shaft of independent equipmentapplications (72.1) comprising sources/supplies of mechanical or electrical energy (11.7,11.8) for driving a fluid propulsor (11) and sources/supplies of thermal energies (23, 23.1 , 53, 53.1) for controlling fluid temperatures, the propelled-fluid being driven by the energies of said sources of energies, the propelled-fluid and the powered-fluid recirculating in 2 pressurized fluid circuit streams, wherein the ‘fluid-to-fluid’ pressure energy transfer (PET) mechanism ((30)/A) is for transferring pressure energy from the inlet (31 .7) of the HP, propelled-fluid (31.9) of the first circuit stream to the HP, powered-fluid (33.8) of the second circuit stream, said HP, powered-fluid discharged from an outlet (33.7) of the pressure energy transfer (PET) mechanism configured to drive an appropriate fluid turbine equipment-assembly ((60)/A) configured to drive an independent equipment-application (72).
3. The HFFT propulsion system of claim 1 or 2, further comprising a ‘fluid-to-torque’ pressure energy transfer from a HP, powered-fluid, second circuit stream directed to pass over flow elements (61 .3) mounted on the periphery of the turbine rotor (61) of the said appropriate fluid turbine to produce an output torque (61.4) at an end of the shaft (61 .5) of said turbine rotor configured to drive an input shaft (72.1) of a said independent equipment-application with an optional input gear box (67), and wherein return, powered-fluid (33.9) discharged from a sump (65) of said appropriate fluid turbine being directed to an inlet (33.6) of the pressure energy transfer (PET) mechanism and return, propelled-fluid (31.8) discharged from the outlet (31.6) of pressure energy transfer (PET) mechanism is being directed to the inlet (11.1) of the said fluid propulsor.
4. The HFFT propulsion system of any one of claim 3, wherein the pressure energy transfer (PET) mechanism for transferring pressure energy from the first circuit stream to the second circuit stream is achieved according to the following steps:
- a consumed source of power drives a propulsor located within the first circuit stream;
- a limited supply of a fluid in the first circuit stream is propelled by said propulsor to generate a HP, propelled-fluid stream;
- the HP, propelled-fluid and the return powered-fluid participate in a fluid-to-fluid, pressure energy transfer, wherein said HP, propelled-fluid, first circuit stream is transferring part of its pressure energy to generate a HP, powered-fluid in the second circuit stream; and
- the H P-propel led-fl uid stream generated by the propulsor can receive a transfer of thermal energy from a source that will serve to further increase the pressure energy of the HP, propelled-fluid stream, and the transfer of thermal energy can take place before the inlet of the HP, propelled-fluid located on the pressure energy transfer (PET) mechanism or between the stages of a multiple stage pressure energy transfer (PET) mechanism ((30.6)/A). The HFFT propulsion system of any one of claims 1 to 4, wherein a ‘fluid-to-fluid’, pressure energy transfer from a first circuit stream to a second circuit stream is achieved according to the following step:
- using one or more sealed membrane interfaces (31.3, 33.3) and operating in one or more pressurized cavities such that the membrane interfaces divide the cavities into 2 sealed chambers (32.3, 32.4, 34.3, 34.4), that alternatively fill and discharge with either HP, propelled-fluid and return, propelled-fluid or HP, powered-fluid and return, powered-fluid, and if more than one membrane interface is used, the opposing ends of the shafts are connected (35.1, 35.2) to synchronize their actions . The HFFT propulsion system of any one of claims 1 to 5, wherein a ‘fluid-to-fluid’, pressure energy transfer from a first circuit stream to a second circuit stream is achieved according to the following steps:
- at least one multi-way, directional manifold control valve (32 or 34) is operatively connected to inlet & outlet ports of each cavity, or one or more of the cavities (41.1 , 41.2) has an inlet and discharge flow managed using check valves located at the inlets and outlets of the cavities (41.3); and
- the at least one multiway, directional control valve and/or the check valves are programmed to produce the following conditions at 2 ports of 2 piston/cylinders of a Synchronized, Double-Acting Piston Assembly;
- at a piston end of a propelled-fluid port, a HP, propelled-fluid stream feed is open and a return, propelled- fluid stream feed is closed;
- at a rod end of a propelled-fluid port, a return, propelled-fluid stream feed is open, and a HP, propelled- fluid stream feed is closed;
- at a rod end of a powered-fluid port, a return, powered-fluid stream feed is open, and a HP, powered-fluid stream feed is closed; and
- at a piston end of a powered-fluid port, a HP, powered-fluid stream feed is open, and a return, powered- fluid stream feed is closed. The HFFT propulsion system of any one of claims 1 to 6, wherein the system performs the following energy transitions during operation thereof:
- input power (electrical energy, steam energy, diesel energy, a rotating torque, or any form of work-done) is transferred to drive a fluid propulsor;
- energy of the fluid propulsor is transformed to HP, propelled-fluid stream pressure energy;
- energy of the propelled-fluid stream is increased as required by the exchange of heat and/or waste heat;
- HP, propelled-fluid stream pressure energy is transformed to HP, powered-fluid stream pressure energy;
- HP, powered-fluid stream pressure energy is transformed to HP, powered-fluid velocity energy;
- HP, powered-fluid velocity energy is transformed to fluid-turbine rotational shaft torque,
- fluid turbine rotational shaft torque is transformed to end-shaft, rotational torque of the independent, equipment-application; and
- additional heat energy is applied as required to obtain the operational pressures and temperatures. The HFFT propulsion system of any one of claims 1 to 7, wherein the pressure energy transfer (PET) mechanism is:
- a synchronized-pair, double-action piston assembly ((30)/A);
- a single-action piston assembly ((36)/A);
- a double-action diaphragm-type assembly ((40)/A), or
- a mix and separate fluids-type assembly ((45)/A). The HFFT propulsion system of any one of claims 1 to 8, wherein the housing (62) of the fluid -turbine is sealed, and the inner housing and its sump are sealed and operating under controlled pressure. The HFFT propulsion system of any one of claims 1 to 9, comprising the following operating conditions:
- excluding a warm-up period on starting operations, an operating temperature of the HP, propelled-fluid circuit that exceeds 90 degrees Celsius, and an operating temperature of the HP, powered-fluid circuit that exceeds 50 degrees Celsius,
- an operating pressure of the HP, propelled-fluid stream and of the HP, powered-fluid stream that operates at a pressure energy in the range of 40 to 100 Bar.
- a ratio of a mass density (kg/m3) of the powered-fluid stream divided by a mass density of the propelled- fluid stream of greater than 10-times with both fluids at STP conditions. The HFFT propulsion system of any one of claims 1 to 10, wherein the following streams are cooled:
- the flow stream between the discharge of the turbine sump and the inlet connection for return, powered- fluid on the PET mechanism; and/or
- the flow stream between the discharge outlet on the PET mechanism for return, propelled-fluid and the feed inlet on the propulsor. The HFFT propulsion system of any one of claims 1 to 11 , wherein the powered-fluid is an engineered solution with a maximized specific gravity such that fluid pressure, temperature and pH are controlled to maintain maximum dissolved solids solubility. The HFFT propulsion system of any one of claims 1 to 12, wherein the total input energy delivered to the HFFT propulsion system will be a mix of at least 2 of the following sources; electricity, indirect waste heat/cooling or indirect vapor-compression heat/cooling, or renewable solar and geo-thermal energy. A Heat-Fluid-Torque (HFT) configuration, FPU (99)/P for producing rotating torque configured to drive the input shaft of independent equipment-applications (74.1) comprising sources/supplies of mechanical or electrical energy and sources/supplies of thermal energies, said system comprising a single-fluid mixture of limited supply, that is driven by said sources of mechanical, electrical and thermal energies, creating a HP, propelled-fluid (31.9), said HP, propelled-fluid recirculating in a pressurized, recirculating, single-circuit, said single-circuit comprising a single circuit, PET mechanism (30.4J/A) for transferring pressure energy from the HP, propelled-fluid to the linear motion of a reciprocating shaft (31.4) within the PET mechanism and said reciprocating shaft is connected to the input shaft (98.3) of a mechanical-converter (98.9), and said single-fluid mixture has a mass-density below 100 kg/m3 at STP conditions, producing a ratio of (mass density water)/(mass density propelled-fluid) of at least 10. The Heat-Fluid-Torque (HFT) configuration of claim 14 comprising a circulating propelled-fluid, said propelled-fluid is an engineered fluid mixture of one or more fluids that individually exhibit thermophysical properties within the following ranges:
1 ) a mass-density at STP between 1 .9 and 100 kg/m3,
2) a boiling point between minus 10 and minus 275 degrees Celsius, and/or
3) a specific heat value (at constant pressure) at 1 atmosphere and 0 degrees Celsius of between 0.08 and/or 2.30 kJ/kg K. The Heat-Fluid-Torque (HFT) configuration of claim 14 or 15 comprising a single-circuit, PET mechanism to transfer the pressure energy of the HP, propelled fluid to the reciprocating output shaft of the PET, said reciprocating shaft being connected to the input shaft of a mechanical-converter and said mechanicalconverter converts the linear motion of PET shaft into rotary motion and the output shaft of said mechanical converter (98.2) transmits its output motion via belting (98.6) to the input shaft (98.4) of a gear box (98.8) and the output shaft (98.5) of said gear box is configured to transmit its output shaft motion via belting (98.7) to the input shaft (74.1) of an independent equipment-application. The HFFT propulsion system of any one of claims 1 to 13, or the Heat-Fluid-Torque (HFT) configuration of any one of claims 15 to 17 for producing rotating torque comprising a mobile or motorized platform (87) and a source of energy supply/storage (11 .5) located on said platforms to power the HFT configuration and/or to create the heat & cooling energy required to maintain operational conditions for a designated period. The HFFT propulsion system of any one of claims 1 to 13 or 17, or the Heat-Fluid-Torque (HFT) configuration of any one of claims 14 to 16 for producing rotating torque comprising: a single-circuit PET mechanism wherein most of the thermal energy for heating and cooling the propelled-fluid stream is applied through heat exchangers located within the propelled-fluid, single-circuit and through the creation of frictional heat by the mechanical compression of the driven propulsor and by internal fluid drag. he HFFT propulsion system of any one of claims 1 to 13 or 17 to 18, or the Heat-Fluid-Torque (HFT) configuration of any one of claims 14 to 16, wherein the fluid propulsor providing the HP, propelled-fluid is operating with an electrified drive and the source of the electricity is either with utility, commercial or private power, with rechargeable battery power, or with renewable energies. The HFFT propulsion system of any one of claims 1 to 13 or 17 to 18, or the Heat-Fluid-Torque (HFT) configuration of any one of claims 14 to 16, wherein the HP, propelled-fluid streams between the propulsor outlet discharge and the PET equipment-assembly outlet discharge for return, propelled-fluid are heated. The HFFT propulsion system of any one of claims 1 to 13 or 17 to 18, or the Heat-Fluid-Torque (HFT) configuration of any one of claims 14 to 16, wherein cooling streams employed to chill the return, propelled- fluid circuit and the return, powered-fluid circuit are generated by powered heat pumps and/or vapourabsorption chillers.
PCT/CA2023/051237 2022-09-16 2023-09-18 A heat-fluid-fluid-torque (hfft) propulsion system WO2024055130A1 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2986005A (en) * 1959-04-24 1961-05-30 Boeing Co Engine starting system
US3797247A (en) * 1972-08-10 1974-03-19 E Schwartzman Compound brayton-cycle engine

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2986005A (en) * 1959-04-24 1961-05-30 Boeing Co Engine starting system
US3797247A (en) * 1972-08-10 1974-03-19 E Schwartzman Compound brayton-cycle engine

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