Rotating device for injecting thermal energy into a fluid - Patents.com

Abstract

A rotary device (100) for inputting thermal energy to a fluid medium is provided, the device comprising: a casing (20) with at least one inlet (11) and at least one outlet (12); a rotor including at least one row of rotor blades (3) configured as impulse impeller blades arranged around the entire circumference of a rotor hub (3a) assembled on a rotor shaft (1); at least one stationary nozzle guide vane (2), each disposed upstream of the at least one row of rotor blades; and at least one stationary diffuser vane row (4), each disposed downstream of the at least one row of rotor blades. The device is configured to impart a quantity of thermal energy to a fluid medium flow guided along a flow path formed inside a casing between an inlet and an outlet by a series of energy transformations occurring as said fluid medium flow passes successively through the blade / vane rows formed by the nozzle guide vanes (2), the rotor blades (3) and the diffuser vanes (4), respectively, in which a space (5) formed between an outlet from at least one diffuser vane row (4) and an inlet to at least one nozzle guide vane row (2) in the direction of the flow path formed inside a casing (20) between an inlet (11) and an outlet (12) is variable to adjust the input of thermal energy to the fluid medium flow propagating through the device. Related uses and methods for inputting thermal energy into a fluid medium are further provided.

Description

[Technical field]

[0001] The present invention relates to the field of rotating turbomachines, in particular to a rotating device configured to input thermal energy (heat) into a fluid, related arrangements, methods and uses. [Background technology]

[0002] Industrial process heat, often defined as thermal energy used in the preparation or processing of materials incidental to the production of goods, accounts for two-thirds of the world's total industrial energy consumption. Major industries supporting the global economy utilize high-temperature thermal processes, including, for example, non-metallic mineral processing (mostly cement), production of hydrogen from natural gas, incineration of used plastics, chemical industry high-temperature thermal processes (e.g., core processes for cracking hydrocarbons into bulk chemicals and converting coal rock into cement clinker), iron and steel production (e.g., core processes for melting to form steel), and the use of off-gases so produced as feedstock for bulk chemicals.

[0003] Most of the above mentioned processes require very high temperatures, for example in the range of about 850-1600 degrees Celsius (°C), and are therefore very energy intensive. These processes typically use heating utilities, such as combustion heaters, and have a high demand for thermal energy and therefore heat consumption. To generate heat, these utilities use fossil fuels, such as natural gas and coal. Combustion of fossil fuels is responsible for most greenhouse gas emissions and the production of air pollutants such as soot and smog, which significantly increase the risk of lung cancer, heart disease, and various respiratory diseases among exposed people. Replacing fossil fuels with wood or other biomaterials has significant resource constraints and other environmental implications, such as sustainable land use.

[0004] All the above imposes stringent requirements on the energy sources and technologies used in energy / heat intensive industries. Although attempts have been made to utilize "green" energies such as electricity in some of these processes (e.g. electric arc furnaces for melting steel), in most cases making high-temperature thermal processes more energy-efficient and environmentally friendly would require changes to the fundamental industrial process principles, which would imply not only the use of alternative energy sources but also the redesign of existing equipment. At present, neither the technical nor the economic environment is in place to do so.

[0005] Generally, rotating turbomachines (compressors, fans or pumps) are well known for delivering energy to fluids, however, the amount of work delivered in conventional compressor devices, for example, is relatively low.

[0006] For heating purposes, many rotary solutions have been proposed. Thus, US Patent No. 11,098,725 B2 (Samgen et al.) discloses a hydrodynamic heater pump device operable to selectively generate a flow of heated and / or pressurized fluid. The mentioned hydrodynamic heater pump is designed to be incorporated into an automotive vehicle cooling system in order to provide heat for heating the passenger compartment of the vehicle as well as other capabilities such as window de-icing and engine cooling. The disclosed device can also provide a pressurized fluid flow for cooling the engine. The disclosed technology is based on friction; since the fluid to be heated is a liquid, the presented design is not suitable for conditions involving extreme gas turbulence aerodynamics.

[0007] US Patent No. 7,614,367 B1 (Frick) discloses a system and method for flameless heating, condensing or vaporizing a fluid by converting rotational kinetic energy into heat. The system configured for fluid heating may include a rotational kinetic energy generator, a rotational heating device and a primary heat exchanger, all in closed-loop fluid communication. The rotational heating device may be a water brake dynamometer. The document discloses the use of the system for heating water in an offshore drilling or production platform. However, the presented system is not suitable for heating gaseous media and is not feasible for use at high and very high temperatures (due to liquid stability, vapor pressure, etc.).

[0008] Additionally, turbomachinery type devices are known for implementing hydrocarbon (steam) cracking processes, with the aim of maximizing the yield of target products such as ethylene and propylene.

[0009] None of the above mentioned techniques provide a rational solution to the problems identified above due to the obstacles associated with increasing energy input into high temperature heat intensive processes and associated equipment.

[0010] In this regard, updates in the art relating to the design and manufacture of efficient heating systems, particularly heating systems suitable for high and ultra-high temperature applications, remain desirable in order to address the challenges associated with increasing the temperature of fluid materials in an efficient and environmentally friendly manner. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] U.S. Patent No. 11,098,725B2 [Patent Document 2] U.S. Patent No. 7,614,367B1 Summary of the Invention [Problem to be solved by the invention]

[0012] It is an object of the present invention to solve or at least mitigate each of the problems arising from the limitations and disadvantages of the related art. [Means for solving the problem]

[0013] This object is achieved by various embodiments of a rotating device for inputting thermal energy into a fluid medium. Thus, in one aspect of the invention there is provided a device for inputting thermal energy into a fluid medium as defined in independent claim 1.

[0014] In an embodiment, the apparatus includes: a casing with at least one inlet and at least one outlet; a rotor including at least one row of rotor blades configured as impulse impeller blades arranged around a rotor hub mounted on a rotor shaft; at least one stationary nozzle guide vane arranged upstream of at least one row of rotor blades, respectively; and at least one stationary diffuser vane row arranged downstream of at least one row of rotor blades, respectively; wherein the device is configured to impart a quantity of thermal energy to a fluid medium flow induced along a flow passage formed inside the casing between an inlet and an outlet by a series of energy transformations occurring as said fluid medium flow passes successively through a blade / vane array formed by the nozzle guide vanes, the rotor blades and the diffuser vanes, respectively; and wherein in said device, in the direction of a flow passage formed inside the casing between the inlet and the outlet, a space formed between the exit from at least one diffuser vane row and the entrance to at least one nozzle guide vane row is variable to adjust the thermal energy input into the fluid medium flow propagating through the device.

[0015] In an embodiment, within the apparatus, a space defined between an exit from at least one diffuser vane row and an entrance to at least one nozzle guide vane row in the direction of a flow path defined within the casing between the inlet and the outlet is variable in terms of at least size and shape.

[0016] In an embodiment, the space is vane-free. In an embodiment, the space includes a flow shaping device and / or a flow guide, such as a guide wall.

[0017] In an embodiment, within the apparatus, at least one stationary nozzle guide vane row, at least one rotor blade row, and at least one stationary diffuser vane row are configured to create a condition in which, when the fluid medium flow exits the at least one rotor blade row at supersonic speed and passes through the at least one diffuser vane row where the flow decelerates and dissipates kinetic energy into the internal energy of the fluid medium, and an amount of thermal energy is added to the fluid medium flow, the amount of kinetic energy added to the fluid medium flow by rotating the rotor blades is sufficient to raise the temperature of the fluid medium to a predetermined value.

[0018] In an embodiment, within the apparatus, an amount of thermal energy added to the fluid medium flow propagating through the apparatus is produced by the generation of a shock wave system during the successive propagation of said fluid medium flow through at least one row of stationary nozzle guide vanes, at least one row of rotor blades and at least one row of stationary diffuser vanes in a controlled manner.

[0019] In an embodiment, in the apparatus, at least one stationary nozzle guide vane is configured as a flow conditioner device that directs fluid medium flow toward the row of rotor blades in a circumferential direction opposite the rotor blade rotation to control the level of energy input and velocity of the fluid from the rotor.

[0020] In an embodiment, the stationary nozzle guide vanes are configured to direct the fluid medium flow to enter the rotor blade row at a relative blade angle within a range of about 45 degrees to about 75 degrees when viewed axially.

[0021] In an embodiment, the rotor blades are configured to receive the fluid medium flow from the stationary nozzle guide vanes upon rotation of the rotor and impart mechanical energy to the process fluid by accelerating said flow to supersonic speeds, thus increasing its tangential velocity.

[0022] In an embodiment, the rotor blade row is configured to receive a fluid medium flow entering from any one of an axial, diagonal or radial direction and to cause a change in flow velocity such that the fluid medium flow is accelerated by at least a factor of two.

[0023] In an embodiment, the rotor is configured in terms of the profile and dimensions of the rotor blades and their arrangement on the rotor hub to control the mechanical energy into the fluid medium flow.

[0024] In an embodiment, at least one row of diffuser vanes is configured as an energy converter device that converts mechanical energy of a fluid medium into thermal energy of said fluid medium.

[0025] In an embodiment, the rotor includes a shroud configured to cover at least one row of rotor blades.

[0026] In an embodiment, the stationary nozzle guide vane array, the rotor blade array, and the stationary diffuser vane array establish an energy transfer section configured to mediate a complete energy conversion cycle.

[0027] In an embodiment, the distance (L) between the at least one fixed diffuser vane row and the at least one fixed nozzle guide vane row is variable.

[0028] In an embodiment, the apparatus includes at least two rows of rotor blades disposed consecutively on a rotor shaft.

[0029] In an embodiment, the device includes a number of energy transferring sections, said number of energy transferring sections being at least two.

[0030] In an embodiment, the device includes a number of energy transfer sections arranged in parallel and / or series.

[0031] In an embodiment, within the apparatus, a distance between energy transfer sections, defined as the distance between a fixed diffuser vane row of a first energy transfer section and a fixed nozzle guide vane row of a second energy transfer section adjacent to the first energy transfer section, is variable.

[0032] In an embodiment, the distance between the energy transfer sections is made variable based on required flow conditions, such as mixing levels and / or pressure levels.

[0033] In an embodiment, at least one fixed diffuser vane row of a first energy transfer section and at least one fixed nozzle guide vane row of a second energy transfer section adjacent to the first energy transfer section are joined to form a combined blade row, such that the distance between the first energy transfer section and the adjacent second energy transfer section is set to zero.

[0034] In an embodiment, the apparatus further includes at least one section configured to regulate pressure across a corresponding row of rotor blades.

[0035] In embodiments, within the device, each energy transfer section and each pressure regulation section is established independently of the other sections in terms of its structure and / or its controllability over its operation.

[0036] In an embodiment, within said apparatus, the stationary vanes and / or rotor blades within each section are individually adjustable during operation of the apparatus, at least in terms of their size, alignment and spatial location.

[0037] In an embodiment, the apparatus includes a rotor blade row having a blade radius that is variably configured per section, optionally in the inlet to outlet direction.

[0038] In an embodiment, in the apparatus, at least one inlet or a section including the at least one inlet is configured to receive a fluid medium flow through a radial to axial transition duct or a number of circumferential sectors or pipes with different axial, radial or circumferential inlet velocity components.

[0039] In an embodiment, the at least one outlet or a section including the at least one outlet is configured as a circumferential spiral structure with at least one pipe and / or axial, radial or circumferential duct.

[0040] In an embodiment, the apparatus further includes a turbo expander device disposed downstream of the final energy transfer section.

[0041] In an embodiment, the device is configured to be electrically operated by being driven by at least one electric drive engine.

[0042] In an embodiment, the apparatus further comprises a cooling arrangement, optionally in conjunction with a heat resistant coating and / or components made from a heat resistant material.

[0043] In an embodiment, the apparatus further comprises a number of catalytic surfaces and / or catalytic elements.

[0044] In another aspect, there is provided a use of the device in the production of an accelerated fluid medium in accordance with that defined in independent claim 32 to a temperature essentially equal to or greater than about 500 degrees Celsius (°C). In an embodiment, there is provided a use in the production of a fluid medium heated to a temperature essentially equal to or greater than about 1000°C, preferably essentially equal to or greater than about 1400°C, and more preferably essentially equal to or greater than about 1700°C.

[0045] In an embodiment, use is provided where the achievable temperature increase per energy transfer section is in the range of 10-1000° C. depending on the fluid medium.

[0046] In a further aspect, there is provided an assembly comprising at least two rotating devices according to an embodiment, as defined in independent claim 34. In an embodiment, the devices are at least functionally connected in parallel or in series. In an embodiment, said at least two devices are connected in a mirror image manner to each other, such that their shafts are at least functionally connected.

[0047] In a further aspect there is provided an arrangement comprising at least one rotating device coupled to at least one heat consuming unit as defined in independent claim 36. In an embodiment, the heat consuming unit is any one of a furnace, an oven, a kiln, a heater, a burner, an incinerator, a boiler, a dryer, a conveyor device, a reactor device or a combination thereof.

[0048] In a further aspect, according to what is defined in independent claim 38, there is provided a heat consuming system configured to implement an industrial heat consuming process and comprising at least one rotating device according to an embodiment.

[0049] In an embodiment, the industrial heat consuming process is selected from the group consisting of: steel making; cement making; production of hydrogen and / or synthesis gas, e.g. steam-methane reforming; conversion of methane to hydrogen, fuels and / or chemicals; storage of thermal energy, e.g. high temperature heat storage; processes related to the oil and / or petrochemical industries; catalytic processes for endothermic reactions; processes for disposal of hazardous and / or toxic substances by incineration; and processes for manufacturing high temperature materials, e.g. glass wool, carbon fibres and carbon nanotubes, bricks, ceramic materials, porcelain and tiles.

[0050] In a further aspect, a method for inputting thermal energy into a fluid medium is provided, in accordance with what is defined in independent claim 40.

[0051] The usefulness of the present invention arises for a variety of reasons, depending on each particular embodiment thereof.

[0052] Overall, the present invention provides a rotating fluid heater with the goal of maximizing (and increasing) the amount of work done inside energy consuming machinery. The disclosed apparatus and method allow for the heating of a heating fluid, such as a gas, to high and very high temperatures, e.g., temperatures typically exceeding 500° C., in a cost- and energy-efficient manner. The inventive concept of the rotating device can be used to replace conventional combustion heaters for direct or indirect heating in different heat consuming process applications.

[0053] Thus, the rotary apparatus of the embodiments allows for heating of fluid materials to temperatures in the range of about 500° C. to about 2000° C., temperatures used in a wide range of industrial applications including, but not limited to, bulk chemical production, steel and non-metallic mineral manufacturing, petroleum processing and refining, and other heat consuming processes. Heating of fluids to ultra-high temperature ranges is achieved by utilizing advanced cooling technologies in the implementation of the apparatus solution proposed herein.

[0054] Moreover, the rotating equipment of the present invention can be configured as an electrical heating solution. The benefits of using an electrical heating solution include the elimination or at least significant reduction of greenhouse gas emissions (e.g., NO, CO2, CO, NOx) and other harmful components (e.g., HCl, H2S, SO2, heavy metals, particulate emissions) that come from burning non-renewable fuels in traditional combustion heaters.

[0055] The rotating device allows for electrical heating of fluids up to temperatures of 1700-2000°C and even higher, temperatures which are difficult or impossible to achieve in current electrical heating applications.

[0056] The rotary equipment presented herein can be used for direct heating of various fluids, such as process gases, inert gases, air or any other gas, or for indirect heating of fluids (liquids, steam, gas, steam / liquid mixtures, etc.). The heated fluid generated in the rotary equipment can be used for heating any one of gas, steam, liquid and solid materials. The rotary equipment can at least partially replace or be combined (e.g., as a preheater) with many types of furnaces, heaters, kilns, gasifiers and reactor devices that are traditionally fired or heated by solid, liquid or gas fossil fuels or in some cases biofuels.

[0057] Due to its versatile design and compactness combined with the ability to achieve a wide range of high temperatures in a short time, the rotating equipment and associated assemblies can be used in a variety of industrial applications ranging from steel making to high temperature thermal storage. The present invention further allows for reduced on-site capital costs compared to traditional fossil fuel furnaces.

[0058] The proposed equipment solution is also fully scalable, and the disclosed equipment can be configured for use in essentially any size and capacity of heat-consuming industrial facilities. Scalability means appropriately modifying the size of the individual equipment and its capacity. In general, the scalability of an equipment is directly proportional to its power requirements and / or shaft-rotor speed.

[0059] Moreover, by using the proposed equipment solution it is possible to achieve significantly improved work capacity, which is about ten times higher when compared to conventional compressor devices.

[0060] The term "a number of" as used herein means any positive integer starting with one (1), e.g., one, two, or three. The term "a plurality of" as used herein means any positive integer starting with two (2), e.g., two, three, or four. The terms "first" and "second" are used herein only to distinguish one element from another, without denoting any particular order or importance unless expressly stated otherwise.

[0061] The term "gasified" is used herein to indicate that a substance has been converted into gaseous form by any conceivable means.

[0062] The term "hydrodynamic" is used herein to denote the dynamics of fluids, which in this disclosure are primarily representative of gases. Thus, in this disclosure, the term "hydrodynamic" is used as a synonym for the term "aerodynamic," unless expressly indicated otherwise.

[0063] Different embodiments of the invention will become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0064] [Figure 1A] FIG. 1A illustrates a schematic diagram of an apparatus 100 implemented according to one embodiment. [Figure 1B] FIG. 1B illustrates the arrangement of fixed and rotating blade rows within the apparatus 100. [Figure 1C] FIG. 1C illustrates a schematic of the velocity triangles at the rotor blade entrance and exit within the energy transfer section. [Figure 1D] FIG. 1D illustrates generally the formation of an impingement train upon propagation of a fluid through successive blade rows in an apparatus 100 and the temperature rise across the impingement system, according to an embodiment. [Figure 2A] FIG. 2A illustrates a schematic arrangement of stationary and rotating blade rows in a multi-section configuration of the device 100 (3 blade rows), according to an embodiment. [Figure 2B] FIG. 2B illustrates a schematic of an arrangement of stationary and rotating blade rows in a multi-section configuration of the device 100 (2 blade rows), according to an embodiment. [Figure 3A] FIG. 3A provides a more detailed view of the configurations presented in FIG. 2A, respectively. [Figure 3B] FIG. 3B provides a more detailed view of the configurations presented in FIG. 2B, respectively. [Figure 3C] FIG. 3C illustrates an energy transfer section solution in which the embodiments illustrated in FIGS. 3A and 3B are combined. [Figure 4] FIG. 4 illustrates an apparatus 100 implemented in accordance with some embodiments. [Diagram 5] FIG. 5 illustrates an apparatus 100 implemented in accordance with some embodiments. [Figure 6] FIG. 6 shows an exemplary configuration for the inlet and outlet arrangement for the device 100. [Figure 7] FIG. 7 shows the pressure regulation section inside the device. [Figure 8] FIG. 8 shows devices 100 implemented in single and multi-axis configurations, as well as assemblies 100n containing a number of devices 100. [Figure 9] FIG. 9 illustrates an example implementation for shrouded and unshrouded rotor blades. [Figure 10] FIG. 10 is a graph of the distribution of energy transfer coefficients across a range of possible design parameters with varying flow coefficients and a constant range of rotor blade metal angles at the rotor blade inlet. [Figure 11] FIG. 11 shows an arrangement including at least one device 100 or assembly 100 n and at least one heat consuming unit 101 , a heat consuming system 1000 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0065] Detailed embodiments of the present invention are disclosed herein with reference to the accompanying drawings, in which like reference characters are used throughout to refer to like parts.

[0066] FIG. 1A illustrates generally at 100A one exemplary embodiment of an underlying concept of a rotating device 100, hereafter referred to as the device, for injecting thermal energy into a fluid.

[0067] Overall, the apparatus 100 is configured to implement the fundamental energy conversion principle of turbomachinery, which is a highly efficient means of transferring mechanical energy to a fluid. The apparatus of the present disclosure efficiently transfers the mechanical energy of a rotating shaft to a fluid medium and converts it into the internal energy of the fluid via a set of stationary and rotating blade rows.

[0068] The implementation and operation principle of the device 100 will be further explained using the configuration 100A shown in Figure 1 A. Alternative and / or supplemental modifications of the device 100 will be described throughout this specification.

[0069] The device 100 comprises a rotor shaft 1, also called the central shaft, arranged along a horizontal (longitudinal) axis (X-X'). A rotor is assembled on the rotor shaft 1, comprising at least one rotor blade row 3 arranged over the circumference of a rotor hub 3a. In some configurations, the at least one rotor blade row can be implemented as a separate rotor unit. Such a rotor unit comprises a number of rotor blades arranged over the circumference of a rotor disk.

[0070] The apparatus can be implemented with a single rotor blade row or a single (separate) rotor unit, alternatively the apparatus can include two or more blade rows arranged in series on a common rotor hub, or the apparatus can be implemented with a number of separate rotor units assembled sequentially (one at a time) onto a rotor shaft.

[0071] In an embodiment, the device comprises at least two rotor blade rows arranged successively on a rotor shaft. Implementations with 2 to 10 rotor blade rows / rotor blades assembled on a rotor shaft / separate rotor units can be envisaged.

[0072] The apparatus 100 further includes at least one drive unit (15, see FIG. 8). The drive unit includes at least one drive engine configured to rotate rotor blades and shafts disposed on the rotor hub and / or rotor disk. In an embodiment, the apparatus is configured to be electrically operated. In an embodiment, the at least one drive engine is an electric motor, optionally combined with or replaced by, for example, one of a gas or steam turbine. Any other suitable drive device can be used. For the purposes of this disclosure, any suitable type of electric motor (i.e., a device capable of transferring energy from a power source to a mechanical load) can be utilized. Suitable couplings disposed between the motor drive shaft and the rotor shaft, as well as various devices, such as power converters, controllers, etc., are not described herein.

[0073] The rotor therefore comprises a plurality of rotor blades 3 arranged in at least one row and configured as impulse impeller blades, which may alternatively be considered as an (annular) rotor blade assembly or rotor blade cascade.

[0074] The device 100 further comprises at least one row of stationary or stator blades 2 arranged upstream of the at least one row of rotor blades 3, and at least one fixed blade row 4 arranged downstream of the at least one row of rotor blades 3. For clarity, the fixed blade rows 2, 4 are further referred to as (fixed) vanes. The fixed vane rows 2, 4 are provided as essentially annular assemblies, respectively upstream and downstream of the at least one rotor blade row 3. If the device 100 comprises more than one rotor blade row 3, each said rotor blade row is respectively arranged between the fixed blade / vane rows 2, 4.

[0075] The "upstream" stator vane row 2 preferably consists of a plurality of fixed guide vanes. The "downstream" stationary vane row 4 preferably consists of a plurality of stationary diffuser vanes.

[0076] The terms "upstream" and "downstream" herein refer to the spatial and / or functional arrangement of structural parts or components relative to a predetermined part or component, here the rotor, in the direction of flow of the fluid medium throughout the device 100 from the inlet to the discharge. In some embodiments, the flow follows a direction along the horizontal rotor shaft axis (X-X'), as labeled 4 with an arrow in FIG. 1A. In some other embodiments, the flow follows a more complicated path (see, for example, FIG. 5).

[0077] A stator-rotor-stator (stator-rotor-diffuser) arrangement 2, 3, 4, composed of fixed (2, 4) and rotating (3) blade rows, is illustrated in FIG. 1B (left side). Each blade row is formed of a number of blades (for the fixed components, this is also called "vanes"). Any one of said blades / vanes (2, 3, 4) is formed by a shell that extends at a different and variable radius from a root section to a tip section. The root-tip radius ratio (for rotating blades, also called hub-tip radius ratio) and / or the blade angle are configured to be variable to guide the fluid along the flow path required / desired in each specific implementation of the device 100. Thus, the blade / vane rows 2, 3, 4 can be configured to implement any one of axial, radial or diagonal flow paths, or combinations thereof (e.g. multi-section configurations).

[0078] The shell has two sides (pressure side, PS and suction side, SS) with lateral surfaces joined by a leading edge (LE) at the blade entry (blade inlet) with a defined thickness distribution between them, and by a trailing edge (TE) at the blade exit with symmetric and asymmetric shapes. The rotor blades are attached (at their hub portion) to the rotor hub / rotor disk (hub surface is represented by reference number 3a); whereas the fixed vanes are typically attached directly and / or indirectly to the casing surface (represented by reference number 20). The passage between the pressure and suction sides of adjacent blades is represented by reference number 6.

[0079] The blade / vane design is dependent on the implementation of the device 100. Variable parameters include the blade shape (at PS and / or SS), airfoil profile, blade inlet and blade exit angles, root to tip radius ratio, separation (pitch) between successive blades, etc. By modifying these parameters, variable passage channel geometry between adjacent blades is created to achieve required / desired pressure and / or temperature conditions within the fluid. The space (passage 6) between any one of the blade / vane rows 2, 3 or 4, or between all the blade rows as labeled, can be adjusted as required for flow conditioning purposes.

[0080] Reference is directed back to FIG. 1A. In the device 100, a (three-dimensional) space 5 separates the fixed vane rows 2, 4 from each other. In any configuration, the space 5 may contain a number of additional devices, for example flow shaping / flow directing devices that can be configured as guide walls to split the flow path and create separate paths therein. A configuration with guide walls 7 and flow shaping devices 8 is presented in FIG. 5, which is further detailed below. In an embodiment, the space 5 is vane-free.

[0081] The device 100 further includes a casing or housing 20 with at least one inlet 11 (feed 21) through which the fluid medium to be treated (heated) enters the device and at least one outlet (exit) 12 through which a treated (heated) stream 22 of the fluid medium leaves the device. The inlets and outlets include associated openings / ports in the casing 20 and pipes, sleeves or manifolds associated with each said port. The casing 20 is configured to encase a rotor shaft 1 with at least one rotor blade row. The fixed vane rows 2, 4 are arranged inside the casing and can be fixed directly and / or indirectly to the inner side of the casing. Thus, the fixed vanes can be fixed directly on the walls defining the interior of the device 100 and / or connected thereto by means of auxiliary arrangements such as rings, brackets, etc.

[0082] In general, the apparatus 100 implemented according to different embodiments of the present invention is configured to impart a certain amount of thermal energy (heat) to a fluid medium flow induced along a flow path formed inside the casing 20 between an inlet 11 and an outlet 12. This amount of thermal energy is imparted to the fluid by a series of energy transformations that occur as said fluid medium flow passes successively through the blade / vane rows formed by the fixed guide vanes 2, rotor blades 3 and fixed diffuser vanes 4, respectively, in the direction of fluid flow from the inlet 11 to the outlet 12.

[0083] Thus, the successive blade / vane rows 2, 3 and 4, at least one fixed nozzle guide vane row 2, at least one rotor blade row 3 and at least one fixed diffuser vane row 4 are configured to create a condition in which, when said fluid medium flow exits the rotor blade row at supersonic speed and passes through at least one diffuser vane row where it decelerates and dissipates kinetic energy into the internal energy of the fluid medium, and when an amount of thermal energy is added to the fluid medium flow, the amount of kinetic energy added to the fluid medium flow by rotating the rotor blades is sufficient to raise the temperature of the fluid medium to a predetermined value.

[0084] As the fluid medium flow propagates through the rotary device 100, the amount of thermal energy added to the fluid is produced by the controlled creation of a shock train during the sequential propagation of the flow through a series of blade / vane rows 2, 3 and 4 (2-3-4). The shock train is a three-dimensional system of multiple shocks / shock waves that slow down the flow coming at supersonic speed (from the rotor 3). Although the formation of the shock train and the actual energy conversion essentially occurs upon the propagation of the fluid flow through the diffuser 4, the flow is made supersonic upon propagation through the rotor 3; the fixed guide vanes 2 now prepare the flow to enter the rotor at the required direction / angle.

[0085] In an embodiment, the rotating device 100 is configured to implement a fluid flow between the inlet and the outlet along an essentially axial flow path. In some other embodiments, the device 100 can be configured to implement a fluid flow between the inlet and the outlet according to any one of the following: an essentially helical track formed inside an essentially toroidal casing, as discussed in any one of U.S. Patent No. 9,494,038 to Bushuev and U.S. Patent No. 9,234,140 to Seppalaa et al.; an essentially helical track formed inside an essentially tubular casing, as discussed in U.S. Patent No. 9,234,140 to Seppala et al.; an essentially radial track, as discussed in U.S. Patent No. 10,744,480 to Xu & Rosic; and a flow path established by the fluid medium flow in the form of two helices wound up into vortex rings in a side-to-side direction, as discussed in U.S. Patent No. 7,232,937 to Bushuev.

[0086] In the apparatus 100, the stationary guide vane array 2, the rotor blade array 3 and the stationary diffuser vane array 4 establish an energy transfer section 10 (hereafter section), also called the base section or the work section. Section 10 is indicated by a dashed box in Figure 1A and in more detail in Figure 1C.

[0087] The function of the basic sections is to impart mechanical energy to the fluid and convert it into thermal energy. The sections are therefore configured to mediate a complete energy conversion and energy transfer cycle. As the fluid medium flows through at least one section formed with successive rows 2, 3 and 4 (the "stator-rotor-stator" arrangement 2-3-4), it is heated.

[0088] During the energy conversion / energy transfer cycle, the fixed guide blade row 2 arranged upstream of the rotor blades 3 prepares the required flow conditions at the entrance of the rotor blade row. Within the rotor blade row, the mechanical energy of the shaft and the rotating blades is transferred to the fluid flow. At least in a portion of each rotor blade row 3, the flow of the fluid medium can reach supersonic flow conditions.

[0089] A row of stationary blades (also called diffuser 4) located downstream of the rotor blades 3 converts the mechanical energy of the fluid medium into its thermal energy. The fluid flow leaves the rotor blades 3 at supersonic speed and enters the diffuser 4. If the flow upstream of the diffuser is supersonic, the kinetic energy of the fluid flow is converted into the internal energy of the fluid through multiple shock systems and viscous mixing and dissipation. The flow dissipates its kinetic energy into the internal energy of the fluid flow propagating through the device, thus providing a certain amount of thermal energy to the fluid. As a result of the increase in the internal energy of the fluid, the fluid temperature increases.

[0090] Efficient heating of the fluid passing through the device 100 is achieved with the following blade / vane configuration.

[0091] In an embodiment, the rotor blades 3 are configured to receive the fluid medium flow from the stationary vanes 2 at the time of rotor rotation and impart mechanical energy to the process fluid by accelerating said flow to supersonic speeds and increasing its tangential velocity. Overall, the rotor blades 3 are configured as ultra-high-load impeller blades for high section work. In an impulse impeller, the energy conversion rate is very high as a result of the multiplication of the blade speed with the high relative velocities at the entrance and exit of the rotor blade row with large tangential velocity components.

[0092] See FIG. 1C, which illustrates the velocity triangles at the rotor blade entry (drawn in plane 2; P2) and at the rotor blade exit (drawn in plane 3, P3) inside a single (basic) section. The following designations apply for the parts: C-Absolute flow velocity (m / s) W-Relative flow velocity (m / s) Circumferential speed of the U-blade (m / s) α (alpha) - absolute flow angle (degrees) β (beta) - relative flow angle (degrees) x-axis direction r - radial θ (theta) - Circumferential direction

[0093] Designations P1-P4 are used for the geometric planes (x, r, θ) at the section entrance (P1; fixed guide vane 2 entrance with flow component C1); at the section exit (P4; fixed diffuser vane 4 exit; flow component C4); at the rotor entrance (P2, flow components C2, W2, U2) and at the rotor exit (P3, flow components C3, W3, U3). Corresponding subscripts 1-4 are used. The velocity triangles plotted in planes 2 and 3 similarly indicate the flow parameters at the exit from the fixed guide vane 2 and at the entrance to the fixed diffuser vane 4, respectively. Designation C θ2 and C θ3 represents the circumferential component of the absolute velocity at the rotor inlet and exit. The blade rows 2, 3, 4 are advantageously designed in such a way as to create a large change in absolute circumferential (orbital) velocity at the rotor inlet and exit (vector C θ2 and C θ3 (Note:

[0094] The relationship between absolute and relative velocity is generally defined as follows: C=W+U

[0095] The apparatus 100 operates, for example, within a speed (U) range of about 150 to 300 meters per second (m / s). Other (lower or higher) speeds or speed ranges are not excluded. For example, rotor blade (tip) speeds (U) within a value range of about 300 to 400 m / s can be achieved. The above values ​​are given for illustrative purposes and should not be considered limiting. Thus, rotor speeds and flow velocities can vary depending on the fluid medium, process temperature, materials forming the apparatus 100, and other parameters.

[0096] In an embodiment, the sections are configured such that the flow enters and exits the rotor blades at an angle or range of angles designed to maximize energy input into the fluid. This is illustrated by Figure 10, which shows a graph of the distribution of energy transfer coefficients across a range of possible design parameters, along with a range of rotor blade metal angles (X, chi) at the rotor blade inlet and varying flow coefficients, where the flow coefficient (φ, phi) is defined as: φ=C x / U In the formula, C x represents the axial component of the absolute velocity.

[0097] The graph shown in Figure 10 covers a wide rotor tip speed range (circumferential speed, U) from 160 m / s to 280 m / s. The device can be operated over a wider speed range as well if different energy conversion ratios are required, depending on the operating conditions.

[0098] The energy transfer coefficient (ε) is defined as:

number

number

[0099] The achievable energy transfer coefficient (by the energy transfer section of the system 100) is compared to an equivalent value for a conventional heavily loaded gas turbine compressor section (shown by the horizontal dotted line in the lower portion of the graph).

[0100] Figure 10 clearly demonstrates that increasing the rotor blade metal angle (X) results in higher levels of energy transfer (from the device to the fluid). To maximize energy input (per section), advantageous distributions of metal angles at the rotor inlet and outlet include a range of about 45 to 75 degrees, and in some configurations, a range of about 60 to about 70 degrees. In some configurations, the metal angles at the rotor inlet and outlet are essentially the same (with a variability margin of 1 to 10 degrees).

[0101] Further, it should be noted that for a rotor blade, the inlet metal angle essentially corresponds to the relative inlet flow angle (see FIG. 1C, β2), while its exit metal angle essentially corresponds to the relative exit flow angle (see FIG. 1C, β3). For a stator blade (fixed guide vane), the inlet metal angle (not shown) essentially corresponds to the absolute inlet flow angle (see FIG. 1C, α2), while its exit metal angle essentially follows from the turning path required to align the fluid flow with the downstream rotor leading edge and direct the flow into the rotor blade inlet (see FIG. 1C, β2).

[0102] The above described configuration allows for improved work capacity of the apparatus 100 (over 10 times better work per section compared to conventional compressor devices).

[0103] 1C, at least one rotor blade row 3 receives flow entering from any one of axial, diagonal and radial directions or a combination thereof (e.g., axial-radial). Typically, the rotor hub 3 and casing 20 indirectly define the flow direction; therefore, the flow direction can also be adjusted by modifying the apparatus 100. Modifications can be made by simple up- and down-scaling and / or by implementing the apparatus 100 in a different implementation as described further below.

[0104] The rotor blade row 3 thus receives the fluid medium flow entering from any one of the directions axial, oblique or radial and causes a change in flow velocity (absolute flow speed) in such a way that the fluid medium flow is accelerated by at least a factor of two.

[0105] Overall, in the apparatus 100 described herein, the rotor is configured in terms of the profile and dimensions of the rotor blades and their arrangement on the rotor hub / disk to maximize and optionally control the mechanical energy input into the fluid medium flow.

[0106] The events occurring when the fluid medium passes through the elementary sections (2, 3, 4), in particular through the rotor blade row 3 and the diffuser vane row 4, are illustrated diagrammatically in FIG. 1D. When the flow leaves the very high-load impulse impeller 3 at supersonic speed, a certain amount of (mechanical) energy is transferred from the rotating shaft and the rotor blades to the surrounding medium. In the diffuser blade row 4, the energy conversion occurs through the formation of a complex system of shocks and energy dissipations, as described above, whereby the (static) temperature of the fluid increases across the shock system (steep gradients marked with circles). The stagnation temperature is given as a reference. Values ​​for the temperature change per section are provided below. As an example, the average temperature change for a typical elementary section, where the temperature increase is accompanied by a change in enthalpy (section-specific work) of about 300 kJ / kg.

[0107] Compared to known turbomachines and turbomachine type devices, the arrangement 100 aims to maximize the internal, and optionally per-section, work of the energy-consuming machine. As mentioned above, state-of-the-art compressor devices demonstrate, for example, a per-section work that is about 10 times lower than the arrangement 100 according to the embodiment.

[0108] Using the apparatus 100, it is possible to apply a constant amount of thermal energy to various fluids / fluid media over a relatively short time period to heat the fluids to temperatures essentially above 500 degrees Celsius (°C). In an embodiment, the apparatus 100 can thus be used to generate fluid media essentially heated to temperatures of about 500 degrees Celsius (°C) or higher. In an embodiment, the apparatus 100 can be used to generate fluid media essentially heated to temperatures of about 1000°C or higher. In a further embodiment, the apparatus 100 can be used to generate fluid media essentially heated to temperatures of about 1200°C or higher, preferably essentially to temperatures of about 1400°C or higher, and more preferably essentially to temperatures of about 1700°C or higher. Temperatures up to 2000-2500°C can be achieved.

[0109] The device 100, in different configurations, has the ability to provide a temperature rise in the range of about 10-1000° C. per energy transfer section. Exemplary temperature rise values ​​per section include 50-100° C., 100-500° C., and 500-1000° C. and / or any value within these ranges. The temperature rise per section is highly dependent on the fluid medium being propagated through the device 100 and the technical application in which the device 100 is expected to be used. The above-mentioned temperature rises (per section) can be achieved in less than 1 millisecond, and thus heating of a fluid in a device 100 having, for example, 1-10 energy transfer sections is instantaneous.

[0110] Thus, the apparatus 100 is configured to receive a fluid medium flow (feed 21). Overall, the feed 21 may include or consist of any fluid, such as a liquid or gas, provided as a pure component or a mixture of components. Gaseous feeds include, but are not limited to, inert gases (e.g., air, nitrogen gas, etc.), reactive gases (e.g., oxygen, combustible gases, e.g., hydrocarbons), and any other gas, such as (water) steam, steam, carbon oxide gases (carbon monoxide, carbon dioxide), hydrogen, ammonia, etc. In an embodiment, it is preferred that the vaporous fluid medium enters the rotary rotary apparatus 100 in essentially gaseous form.

[0111] The feed can be any one of the following: inert gas, raw gas, process gas, make-up gas (so-called replacement / supplementary gas), etc. The choice of the feed depends on the process in which the apparatus 100 is used, and indeed on the particular industry / industry sector to which said process is assigned, since this process involves several requirements and / or limitations on the choice of the feed material.

[0112] Additionally, a number of cooling and / or thermal protection devices and / or apparatuses can be further incorporated into the apparatus 100 (and into an assembly / arrangement including a number of said apparatuses) to form a cooling and / or thermal protection arrangement. Efficient cooling is particularly essential when the apparatus 100 is used to heat fluids to temperatures above about 900° C. The cooling and / or thermal protection arrangement includes internal cooling means (e.g., means for directing a cooling fluid inside the apparatus), a number of thermal barrier coatings / films, and thermal protection materials.

[0113] Thus, the surfaces of the device 100 can be thermally protected by introducing coolant fluid into the internal cavities and / or conduits. This can also be implemented by delivering coolant fluid through the casing 20 (advantageously implemented as a double-walled casing) and / or through the fixed blade rows into the internal cavities and / or conduits containing the stationary and rotating components. Coolant fluid at a predetermined temperature and pressure level is delivered through specially formed channels and plenums inside the device 100 to provide internal cooling of the components. Cooling fluid can also be delivered in the form of films and cooling jets through a set of discrete surface holes or slits.

[0114] Coolant fluid at a predetermined temperature and pressure can be supplied into the rotor disk cavity to prevent ingress of work fluid into the rotor disk / shaft or bearing space. The cooling fluid is discharged into the main flow path through an axial and radial seal system. Additional coolant flow can be applied inside the seal arrangement (further described in connection with FIG. 9).

[0115] Depending on the device configuration, the feed fluid, and the particular technical application, the pressure within the device 100 can be maintained at a level below about 10 bar, including below atmospheric pressure (1.01325 bar / 101.325 kPa), or at a relatively high pressure level of about 10-50 bar (1-5 MPa). Adjustment of pressure levels using a pressure regulation section is described in further detail below.

[0116] Various high temperature thermal barrier coatings can be applied to all or selected internal surfaces of the device 100, particularly those surfaces in contact with the (work) fluid in the high temperature zone. For producing fluids heated to extremely high temperatures (greater than about 900° C.), thermal barrier materials such as ceramics and / or ceramic matrix composites can be used. High temperature ceramic and composite materials can be used to manufacture the rotor and stator blades, as well as to construct the internal liners inside the casing. Additionally or alternatively, low conductivity materials can be utilized.

[0117] It is believed that transpiration cooling for all blade rows (2, 3, 4) can be achieved through sintering techniques.

[0118] It is believed that similar methods can be utilized for thermal expansion control. It is believed that large temperature differences throughout the device 100 can cause large thermal stresses and differential thermal expansion between the various components. These could be controlled by applying various cooling methods and / or by providing mechanical protection, for example, by a corrugated outer casing, sliding casing segments, etc.

[0119] It should be emphasized that the cooling / thermal protection techniques described above have not previously been used in cooling common energy input turbomachinery, such as compressors.

[0120] In some cases, it is preferred that the rotor further includes a shroud 31 configured to cover one or more rows of rotor blades 3 (see FIG. 9). Implementations of shrouded rotor blades (a-d) and unshrouded / partially shrouded rotor blades (e-h) are summarized in FIG. 10. The shroud 31 protects the tips of the rotating blades 3. A fir-tree root connector for connecting the rotating blades to the disk / hub 3a is represented by reference numeral 32. The shroud can be provided as separate bands to cover the tips of the individual blades, or the bands can be machined to form a continuous shroud cover when assembled. The shroud can further have a single or multiple seals, such as radial or angled seals, installed or machined on the top. The single or multiple (radial or angled) seals can further be installed or machined in the associated casing segment to reduce leakage flow above the rotor blade row. A shroud blade with labyrinth seal and a shroud blade with jet seal are illustrated in Fig. 9(b,c), respectively. Any type of seal is indicated with reference number 33. Inside the casing, honeycombs 34 of different configurations can be installed (Fig. 9,d). Cooling jets can be used to stop leakage flows and cool the tips of the rotor blades (not shown).

[0121] Unshrouded rotors tend to be relatively inefficient due to high losses associated with leakage flow (flow that "leaks" across the uncovered rotating blades) and in some cases back leakage flow. A rotor cover such as a shroud effectively prevents or at least minimizes such leakage. Additionally, the shroud prevents backflow and harmful flow mixing of fluids that might otherwise occur between the sections. A simple tip without a shroud is shown in FIG. 9 as (f); a partially shrouded tip solution as (g), and a blade tip solution with a winglet / squealer geometry tip as (h).

[0122] In some cases, the apparatus 100 may include both shrouded and unshrouded rotor blade rows. Unshrouded rotors allow the rotor to operate at higher rotational speeds, and thus configurations with a number of unshrouded rotor blade rows followed by a number of shrouded rotor blade rows / separate rotor units may be beneficial in terms of adjusting flow conditions, particularly in multi-section configurations.

[0123] It is believed that large temperature differences across the device can cause differential radial and axial thermal expansion between stationary and rotating components. This can result in large axial movements and negative radial clearances between stationary and rotating components. Radial clearances can be controlled by introducing honeycomb and / or various abrasive structures and materials along with thermal management (cooling or heating) of the casing segments.

[0124] The row of fixed blades arranged upstream of the rotor includes a number of guide vanes, which are configured in terms of profile, size and arrangement around the rotor shaft to direct the fluid medium flow into the row of rotor blades in a predetermined direction with the aim of controlling and in some cases maximizing the rotor-specific work capacity. The guide vanes 2 are advantageously configured as nozzle guide vanes (NGVs). According to established nomenclature, the guide vanes arranged in front of the rotor blades in the section housing the inlet ports / lines 11 are called inlet guide vanes (IGVs) and those in the section housing the outlet ports / lines 12 are called outlet guide vanes (OGVs). For the sake of clarity, all the above mentioned categories of guide vanes are collectively called nozzle guide vanes.

[0125] The nozzle guide vanes 2, provided as static structures, do not add energy to the flow of the fluid medium. However, these stator vanes are configured in such a way that they add the necessary / desired directionality to the flow and allow the rotor to maximize the (mechanical) energy input into the fluid medium flow. This is achieved by dimensioning the guide vanes to force the fluid into the rotor at a predetermined and desired (e.g. by process parameters) flow angle and flow velocity. The angle at which the fluid flow enters the rotor blades (from the axial direction x) (see β2 in FIG. 1C) can be considered as the most important parameter here, since it determines how much energy the rotor blades 3 impart to the fluid.

[0126] The nozzle guide vane array 2 is thus configured as a flow conditioner device that directs the flow of fluid medium towards the rotor blade array in a circumferential direction opposite the rotation of the rotor blades in a manner that controls the level of energy input from the rotor and the velocity of the fluid. The flow conditioner device 2 manages the amount of energy input from the rotating blades and the velocity of the fluid entering the rotor.

[0127] In an embodiment, the nozzle guide vanes are configured to guide the fluid medium flow to enter the rotor blade row at a (relative) flow angle in the range of about 45-75 degrees from the axial direction x (see FIG. 1C, β2, the angle at which the relative fluid flow enters the rotor blade row from the axial direction x).

[0128] The stationary blade row, arranged downstream of the rotor blades and including a number of diffuser vanes 4, is thus configured as an energy converter device that converts the mechanical energy of the fluid medium into its thermal energy. Within the diffuser vanes, the (supersonic) fluid medium flow slows down through the formation of a shock train and dissipates its kinetic energy into the internal energy of the fluid medium, which increases the internal energy of said fluid medium and adds a certain amount of thermal energy to the fluid.

[0129] 1B and 1D illustrate the principles of energy transformation occurring inside the basic section 10. From a functional point of view, the flow conditioner (fixed guide vanes 2) manages (conditions) the flow upstream of the rotating blades. The impulse impeller blades 3 impart mechanical energy to the fluid, while the energy converter (fixed diffuser vanes 4) allows for the increase of internal energy in the fluid medium through a complex system of shock / shock (wave) trains and (energy) dissipation.

[0130] In the apparatus 100, the fixed vane rows 2, 4 are preferably arranged such that a three dimensional space 5 is formed between the exit from the at least one fixed diffuser vane row 4 and the entrance into the at least one fixed guide vane row 4.

[0131] In an embodiment, the space 5 is variable. The space 5 can be variable in terms of its dimensions, i.e. at least size and shape. By varying / adjusting the space 5 formed between the exit from the at least one fixed diffuser vane row 4 and the entrance to the at least one nozzle guide vane row 2 in the direction of the flow path formed inside the casing 20 between the inlet 11 and the outlet 12, the amount of thermal energy input to the fluid medium flow propagating through the device can be adjusted. Furthermore, by making the space 5 variable, it is possible to control the pressure distribution mechanism and the mixing level along the fluid flow path.

[0132] The terms "variable" and "adjustable" are used interchangeably in the present context and indicate the modifiability (adjustability) of an area or object.

[0133] The variable space 5 between the fixed blades 2, 4 can be achieved in a single section device implementation, or in an implementation including many (or at least two or more) sections.

[0134] In an embodiment, the device 100 includes a number of sections 10, where each section is formed of three consecutive blade rows, namely a fixed nozzle guide vane, a rotor blade and a fixed diffuser vane. In an embodiment, the device is configured with at least two sections. Multi-section configurations can be envisaged, including 2 to 10 rotor blade rows assembled on the same shaft. In such a multi-section configuration, the sections can be driven by the same or different (e.g. joined) rotor shafts.

[0135] In single and multiple sections, the fixed vanes 2, 4 as well as the rotor blades 3 can form fixed or variable blade channel geometries by varying the blade angle (blade mounting angle).

[0136] A required energy conversion duty may be achievable within a single section or within a certain number of sections (multi-section configuration). Linking a certain number of sections together may be beneficial if a more specific energy input is required.

[0137] Within the device 100, the sections 10 can be arranged in parallel and / or in series.

[0138] 2A and 2B. Fig. 2A shows an example multi-segment configuration including two segments 10 (10-1 and 10-2), each segment including a stator-rotor-stator / diffuser blade row (2, 3, 4). The space 5 between segments 10-1 and 10-2 can be defined as the distance L between, among other things, the fixed diffuser vane or fixed diffuser vane row of the upstream segment 10-1 and the fixed guide vane or fixed guide vane row of the downstream segment 10-2.

[0139] Like the space 5, the distance L can also be variable (adjustable). The distance L between adjacent sections 10-1, 10-2 is the span between the trailing edge of the fixed diffuser vane or row of fixed diffuser vanes of the upstream section 10-1 and the leading edge of the fixed guide vane or row of fixed guide vanes of the downstream section 10-2 along a path formed by a series of sections plotted on a common plane in successive order. In an embodiment, the distance L is defined along the horizontal (longitudinal) axis of the apparatus 100, optionally in the direction of fluid flow.

[0140] In some configurations, the variable space 5 (and thus the distance L) is disposed between at least one row of diffuser vanes and at least one row of nozzle guide vanes.

[0141] The space 5 and / or distance L between the diffuser vanes and the guide vanes, and optionally between the diffuser vanes of the upstream section and the guide vanes of the downstream stator, are made variable (adjustable) based on the desired flow conditions such as mixing levels and / or pressure levels. Along the distance between the upstream diffuser row and the downstream fixed guide row, the fluid flow velocity is at a minimum.

[0142] The distance L can be made variable in terms of modifying the span between the fixed blade rows, optionally between adjacent fixed blade rows, and optionally between adjacent sections. Adjusting / variable space 5, on the other hand, involves resizing and / or reshaping the interior of device 100 in a three-dimensional coordinate system. By modifying space 5, distance L can likewise be optionally modified, and vice versa. Thus, within the concept of a variable space 5 and / or distance L between adjacent fixed blade rows, various implementations of device 100 can be envisioned (see, for example, FIGS. 1A, 4 and 5).

[0143] In an embodiment, at least one fixed diffuser vane row of the upstream section 10-1 and at least one fixed guide vane row of the downstream section 10-2 are joined to form a single combined blade row 4-2 (FIG. 2B). The combined row 4-2 performs both diffuser vane and guide vane duties. In the blade configuration shown in FIG. 2B, the distance L between adjacent sections 10-1 and 10-2 is set to zero (L=0).

[0144] If necessary, the space between the upstream diffuser vanes and the downstream guide vanes could be increased as well to allow more space and time for mixing within the fluid medium. In such a case, the distance L could be increased arbitrarily as well (L>0).

[0145] Overall, the size / volume of space 5 (and thus distance L) depends at least on the velocity of the fluid flow through the apparatus 100. Thus, the propagation of the fluid medium exiting the rotor at supersonic speed through the fixed diffuser blades is accompanied by the creation of multiple shock systems, and therefore increasing the space gap 5 may be beneficial to minimize shock wave interactions.

[0146] Figures 3A and 3B illustrate in more detail the embodiment shown in Figures 2A and 2B, respectively. Figure 3C illustrates a "mixed" section solution, where the embodiments shown in Figures 3A and 3B (a three-blade and a two-blade section) are combined. Figure 3C illustrates an exemplary embodiment of the device 100 implemented with three (3) two-blade row sections and one (1) three-blade row section, with a space 5 between them.

[0147] In an embodiment, the final blade row within the apparatus 100 can be configured as a diffuser 4, integrated diffuser-stator 4-2 or turbo expander (not shown). A turbo expander is a turbo machine in which the fluid propagating through the apparatus expands to reduce the static pressure and temperature and output some shaft work to help drive the apparatus 100. A turbo expander device can be used where particularly rapid temperature changes are required. Thus, in an embodiment, the apparatus 100 includes a turbo expander device with single or multiple blade rows downstream of the final work (energy transfer / conversion) section 10.

[0148] The dimensions, alignment and spatial location of the fixed vanes 2 (upstream of the rotor), rotor blades 3 and / or fixed vanes 4 (downstream of the rotor) are preferably individually adjustable within each section, either by design (manufacturing) or by operation. Thus, the fixed vanes and / or rotor blades are variable within each section, at least in terms of their dimensions, alignment and spatial location, either pre-defined (set prior to and / or during operation) or manufactured. In addition to being variable from section to section, the fixed vanes and / or rotor blades may be configured in a fixed (non-adjustable) and individually adjustable during operation of the device.

[0149] In an embodiment, the rotor blades are configured the same in all sections. In an alternative embodiment, the rotor blades are variable from section to section. In an exemplary embodiment, the device includes a fixed number of sections with rotor blade radii that vary from section to section in a direction from inlet (11) to outlet (12) to meet energy input and flow capacity requirements. In an embodiment, the rotor blade height optionally varies longitudinally, and optionally axially, throughout the device 100.

[0150] The casing 20 is therefore modifiable to meet the requirements imposed by the variable rotor blade height. In some configurations, the casing is thus configured to essentially follow the shape of the elements that make up the individual sections. In some configurations, the casing has an essentially constant cross-section along its entire length. In other configurations, the device 100 has a casing in the shape of a cone (frustum of a cone) (see, for example, FIG. 1A).

[0151] In some configurations, the implementation of the rotary device 100 embodied as 100B generally follows the disclosure of U.S. Pat. No. 10,744,480 (Xu & Rosic), the entire contents of which are incorporated herein by reference (see FIG. 4). In the configuration 100B shown in FIG. 4, the casing 20 is provided as a confined space that contains (closely adjacent to) the fixed guide vanes, rotor blades and diffuser that form at least one energy transfer section 10. The internal and optionally external shape of the casing is configured to essentially follow the shape of the elements that make up said section. Thus, in some cases, the casing 20 has a variable cross-sectional area across its interior (FIG. 4). In the configuration 100B, the diffuser 4 is disposed in a space 5 (called the mixing space, established by a conduit that includes a bent section followed by a return channel). The mixing space can be configured to be variable in terms of its geometric shape and / or dimensional parameters.

[0152] The device 100B can be configured as a modular structure, where the casing 20 is established by a certain number of sequentially arranged modules 20A, 20B, 20C, 20D. The modular return channels and bend sections can be configured to be adjustable at least in terms of shape, length, cross section and their arrangement within the device 100, 100B.

[0153] In addition to the multi-segment configurations 100A, 100B that include a fixed number of segments arranged in series along the rotor shaft, the three-bladerow base segments can also be arranged in a regenerative multi-segment configuration, as illustrated in Figure 5. The configuration 100C shown in Figure 5 generally follows the disclosures of U.S. Patent Nos. 7,232,937 (Bushuev), 9,494,038 (Bushuev) and 9,234,140 (Seppala et al.).

[0154] Figure 5 shows a configuration with two inlets 11-1, 11-2 and two outlets (12-1, second outlet not shown) in plate A. Other configurations may be envisaged where appropriate.

[0155] The apparatus 100, embodied as 100C, includes a rotor unit mounted on a rotor shaft 1 positioned along a horizontal (longitudinal) axis X-X'. The rotor unit includes a plurality of rotor blades 3 arranged around the circumference of a rotor disk. The stationary components are represented by a plurality of fixed guide vanes 2 and fixed diffuser vanes 4 arranged in an essentially annular assembly or cascade on either side of the bladed rotor disk. The fixed guide vane row 2 is disposed upstream of the rotor blade cascade 3, and the fixed diffuser vane row 4 is disposed downstream of the rotor blade cascade in the direction of fluid flow through the apparatus between at least one inlet and at least one outlet.

[0156] In the implementation 20, the casing 20 is configured to substantially completely encase the periphery of the rotor disk with the rotor blades assembled thereon and the stationary vane rows 2, 4 adjacent thereto which form together with the rotor blades a stator-rotor-stator arrangement 2, 3, 4. The casing 20 has an essentially toroidal shape (a "doughnut" shape) in a three-dimensional configuration, such that the rotor unit with the associated bearing assembly can be considered as closing an aperture that defines an opening in a central portion of the toroidal shape. In its meridional cross section, the casing 20 is essentially ring-shaped.

[0157] Within the casing 20, the blade rows 2, 3, 4 are adjacent to one another such that a space 5 is created between the exit from the stator-rotor-stator arrangement (i.e. the exit from the fixed diffuser blade row 4) and the entrance into said arrangement (i.e. the entrance into the fixed guide vane row 2), as described herein above. In an embodiment, the space 5 is formed between an inner surface of the casing 20 and an outer surface of the flow shaping device 8. In an embodiment, the space 5 is configured to be vane-free. In additional or alternative embodiments, the space 5 may include a number of guide walls 7 (see FIG. 5, D).

[0158] The energy transfer / energy conversion section is established with three blade rows (2, 3, 4) as described herein above. In FIG. 5, the sections are labeled with Roman numerals i-x. In configuration 100C, the flow exiting the exit of the diffuser blade row 4 of one section (say section i) passes through the (vaneless) space 5 and follows a helical (helical toroidal) path into the fixed guide vane row 2 of the following section (section ii). The flow passes through successive blade rows 2, 3, 4 (section ii), exits the diffuser 4 (section ii) and continues towards the next section iii-x until the flow reaches the exit 12-1 (see plates B and C, where plate C shows sections i-x plotted on the same plane). The flow direction is labeled with arrows. The number of sections is determined by the process duty, the required temperature and / or pressure levels.

[0159] In configuration 100C, the spaces 5 are variable in terms of at least size and shape. Thus, at least the size and shape of the toroidal flow paths created by the spaces 5 between segments can be varied based on the required length (see plate C) and level of mixing. In some embodiments, the spaces 5 house a number of flow directing devices, such as guide walls 7 (see FIG. 5D). The guide walls 7 split the flow path and create additional individual paths.

[0160] See FIG. 6, which illustrates an example configuration for the inlet and outlet arrangements for the device 100. In embodiments, the device may include one section or multiple sections that include the inlet and outlet arrangements. In some configurations, such sections are not configured as work sections (i.e., adapted for energy transfer into the fluid), but merely for receiving and discharging the fluid, respectively. In some other configurations, the inlet and outlet sections may be configured entirely as work sections.

[0161] The inlets and outlets include associated openings / ports in the casing, as well as sleeves and / or manifolds associated with each of said ports. In an exemplary embodiment, the fluid can be delivered at at least one inlet 11 (11-1, 11-2) through a radial-axial transition duct (see FIG. 6A) or a certain number of circumferential sectors or pipes with different axial, radial or circumferential inlet velocity components (see FIG. 6, B, C). At least one outlet 12 (12-1, 12-2) or a section containing an outlet can itself be configured as a circumferential spiral structure with a single pipe or multiple pipes and / or with axial, radial or circumferential ducts.

[0162] FIG. 6 illustrates as A an apparatus 100 including at least one axial-radial inlet 11 (11-1, 11-2) and at least one axial outlet 12 (12-1, 12-2). Plate B shows an apparatus 100 with at least one axial-radial inlet 11 (11-1, 11-2) and at least one radial outlet 12 (12-1). Plate C shows an apparatus 100 with at least one radial inlet 11 (11-1) and at least one radial outlet 12 (12-1). Exemplary spiral structure configurations with single or multiple inlet and outlet ducts are shown in FIG. 6, C.

[0163] In some configurations, the apparatus 100 can further include an additional inlet port 13 within the inlet section (see FIG. 4). The additional inlet port 13, which is applicable to the configuration 100B shown in FIG. 4, is configured as a scroll inlet to generate a highly swirling flow relative to the rotor.

[0164] In an embodiment, the apparatus 100 (embodied herein as any one of 100A, 100B, 100C) further includes at least one section 14 configured to regulate (static) pressure changes across a corresponding row of rotor blades and / or control pressure levels through the apparatus 100. In particular, such pressure regulating (or pressure varying) section 14 is configured to increase the pressure within the apparatus 100. Furthermore, section 14 allows for more thermal energy (heat) to be added rapidly to the fluid. Such section 14 is required when the feed flow characteristics (pressure, temperature, mass flow rate, etc.) are not consistent with the requirements of the apparatus 100.

[0165] 7 shows apparatus 100 including a pressure regulating section 14 disposed at the inlet 11. In additional or alternative configurations, section 14 may be disposed at the outlet 12 of the apparatus and / or between the work (energy transfer / conversion) sections 10-1, 10-n (not shown). Work sections 10-1 through 10-n may be configured with three, two or mixed blade rows as described herein above.

[0166] Section 14 typically has a different (enhanced) load to provide a higher load input when compared to work sections 10-1 through 10-n. Section 14 can be considered to modify the thermal energy input pattern compared to the work sections.

[0167] The pressure regulation section 14 can have a variety of configurations depending on the design of the device. As an example, FIG. 7 shows section 14 configurations for radial flow (A), mixed flow (B) and axial flow (C). Other suitable configurations can be accommodated. Section 14 can be configured as a single section or multiple sections, and the configuration can further vary depending on its placement within the device 100.

[0168] In an embodiment, pressure varying section 14 can be configured differently from work sections 10-1-10-n in terms of the structure and arrangement of stationary and / or rotating components. Thus, section 14 can include a rotor with adjustable blade angles as well as, optionally, a stator with adjustable blade angles. The blade angles can be adjusted to meet process conditions (type of feedstock and its pressure, temperature, mass flow rate, etc.).

[0169] Additionally or alternatively, section 14 may be implemented structurally essentially identical to work section 10. In such a case, the pressure modification / pressure boost feature may be achieved through installation of section 14 on a separate rotor shaft capable of providing a higher rotor speed. Thus, for example, a two-spool engine configuration may be accommodated for apparatus 100 that couples work section 10 and pressure regulation section 14 to separate shafts that rotate at different speeds.

[0170] The equipment 100 implemented in single and multi-axis configurations is illustrated in Figure 8. The equipment units (100-1, 100-2, 100-3) implemented as single or multi-segment units can be arranged on multiple spools in parallel (Figure 8, B, parallel multi-spool arrangement) or in series (Figure 8, A, serial multi-spool arrangement). An assembly 100n including equipment units 100-1, 100-2 connected in series and parallel is shown in the corresponding dashed box.

[0171] Each spool can be driven by a separate prime mover 15 (15-1, 15-2, 15-3) configured as a drive unit selected from any of the following: an electric motor, a gas turbine, a steam turbine, or a combination thereof. It is believed that each spool can have the same or different rotational speeds depending on the particular use required. In some embodiments, the drive unit is preferably an electric motor.

[0172] Overall, each section (work 10 and pressure regulation section 14) can be configured with different workloads and / or capacities.

[0173] The apparatus 100 advantageously includes a rotor shaft sealing system (not shown). A sealing system, including but not limited to labyrinth seals, brush seals and / or leaf seals, is applied around the rotor shaft to prevent leakage of fluid outside the apparatus 100. A coolant flow at a specific pressure and temperature is used to pressurize the rotor cavity and prevent leakage of the working fluid.

[0174] The device 100 constructed according to the embodiments described hereinabove has a relatively wide range of tolerances for various design parameters. In particular, a multi-section solution can be constructed with a number of sections, each with a different volumetric flow rate / capacity. Thus, the work requirements and / or mixing levels can be adjusted / tuned separately within each section.

[0175] In all configurations 100, the flow rate can be optionally adjustable per section by changing the rotor size (diameter, quadruple increase) and / or blade height (linear increase). Variable height for the rotor blades may be achieved by adjusting the axial location of the rotor blade row on the rotor shaft, which allows for varying the volumetric flow rate through different sections with similar design. Depending on the device configuration, the blade root-tip radius ratio can be adjusted appropriately. The fixed blades (2, 4) can also be adjusted accordingly. By modifying the blade parameters in the manner shown above, it is possible to increase the volumetric flow capacity through the device (e.g., taking into account that both temperature and work requirements are highest at the end / outlet of the device).

[0176] In an embodiment, the device 100 further includes a number of catalytic surfaces or other catalytic elements (not shown). The catalytic surfaces can be formed by catalytic coatings of at least some of the individual blades or vanes of at least one blade / vane row (2, 3, 4), the rotor hub / disk, and / or the casing surface at predetermined locations within the device. The catalytic elements can be configured as (porous) ceramic or metal substrates or supports with an active coating. Alternatively, monolithic honeycomb catalysts can be used.

[0177] In an embodiment, the apparatus 100 (100A, 100B, 100C) further includes an apparatus for intermediate injection and / or extraction. The apparatus (not shown) includes a number of ports and conduits optionally arranged in a manifold configured to connect the apparatus 100 with intermediate facilities such as heat exchangers, heaters, chemical sources, etc. As an example, the apparatus 100 can be connected to at least one heat exchanger through an injection / extraction conduit system. In such an arrangement, a portion of the heated fluid is withdrawn from the apparatus 100 through an extraction conduit and directed into the heat exchanger, where thermal energy is extracted from the fluid. The heat exchanger can be configured to cool the extracted fluid, for example, from 1000-1500 degrees Celsius to less than about 1000 degrees Celsius. The cooled fluid can be injected (through the injection conduit / port) and returned to the process stream propagating through the apparatus 100 (i.e., for internal heating) or used in the cooling arrangement described herein above.

[0178] In additional or alternative configurations, similar arrangements can be employed to feed fluids cooled or heated elsewhere (e.g., steam) into the apparatus 100 and / or to inject chemicals (catalysts, additives, dopants, etc.). In such configurations, intermediate facilities are formed with a number of additional heat exchangers, heaters and / or associated chemical sources. The extraction / injection ports and associated manifolds are provided with valves, e.g., 3-way valves and associated detectors, to regulate the amount of fluid extracted / injected.

[0179] The extraction and / or injection ports can be located anywhere along the casing 20 between the inlet 11 and the outlet 12. In some cases, it is preferable to remove the fluid medium for heat extraction essentially at the midpoint of the heating process.

[0180] An assembly 100n can be established when at least two devices 100 are connected in parallel or in series (see FIG. 8). The connection between said devices can be mechanical and / or functional. A functional connection (e.g., in terms of processing similar raw materials) can be established when at least two physically integrated or non-integrated individual equipment units 100 (100-1, 100-2, 100-3) are connected. In the latter case, the connection between at least two devices 100 can be established through a certain number of auxiliary facilities (not shown). In some configurations, an assembly includes at least two devices at least functionally connected through their central shaft in a manner that mirrors each other. Such a mirror relationship can be further defined as having at least two devices 100 connected mechanically in series (sequence-like), while a functional connection (e.g., in terms of inputting heat into a fluid) can be considered as a parallel (array-like) connection. In some cases, the above-described "mirror image" assembly can be further modified to include at least two inlets and a common exhaust (discharge) section (not shown) located essentially at the center of the assembly.

[0181] Upon connecting at least one rotating device 100 or assembly 100n to at least one heat consumption unit / utility 101, an arrangement may be established (see dashed box in FIG. 11), which may further be part of a heat consumption system 1000.

[0182] The devices 100, 100n may be coupled directly or indirectly through a number of heat exchangers to a common heat consuming unit / utility 101. The heat consuming unit / utility 101 may include, but is not limited to, a furnace, oven, kiln, heater, burner, incinerator, boiler, dryer, conveyor device, reactor device, or combinations thereof.

[0183] The heat consuming process system 1000 is a facility configured to carry out a heat consuming industrial process implemented through a number of units / utilities 101 at a temperature essentially equal to or greater than about 500 degrees Celsius (°C). In an embodiment, the facility is configured to carry out a heat consuming industrial process essentially equal to or greater than about 1200°C, preferably essentially equal to or greater than about 1400°C, and more preferably essentially equal to or greater than about 1700°C. Upon application of the cooling techniques described hereinabove, temperatures of up to 2000-2500°C can be achieved. The system 1000 is not precluded from carrying out at least a portion of the industrial process at temperatures below 500°C.

[0184] The heat consuming unit / utility and the heat consuming process are represented by the same reference number 101. This is to emphasize that section 101 represents a process unit configured as an industrial plant, factory or any industrial system including equipment designed to perform an industrial process or a series of industrial processes aimed at producing an item essentially from raw materials or raw energy sources. In this disclosure, the expression "producing an item" includes, but is not limited to, the manufacturing, extraction and / or refining of materials (in this context, e.g., steel or chemical compounds) and / or power. In some embodiments, section 101 represents a heat consuming utility, such as, for example, a furnace or reactor device configured to perform a heat consuming process.

[0185] The mentioned processes typically have high thermal (heat) energy demands and consumption, which with conventional solutions (i.e. other than the heat integration scheme 1000 presented herein) constitute a large part of the industrial waste (gases and aerosols) into the atmosphere. The present disclosure provides an apparatus and method for inputting thermal energy into a fluid that can further be used within various conventional industrial processes (101) with high thermal energy demands, thus significantly improving the energy efficiency in said processes and reducing the amount of air pollutants emitted into the atmosphere. Thus, the apparatus 100 can be adopted for use as a heater.

[0186] A certain amount of input energy is directed into at least one rotating device 100 / assembly 100n coupled to a heat consuming unit and / or integrated into the system 1000. In an embodiment, the input energy comprises electrical energy. In an embodiment, the amount of electrical energy directed as input energy into at least one device 100 integrated into the heat consuming system / process facility 1000 is provided in the range of about 5 to about 100 percent, preferably in the range of about 50 to about 100 percent. Thus, the amount of electrical energy directed as input energy into at least one device 100 integrated into the system 1000 can constitute any one of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 100 percent (of the total energy input), or any intermediate value falling between the aforementioned points.

[0187] The apparatus 100 acts at least as a heater for a fluid medium (feed 21). The heated fluid enters the heat consuming process 101 as stream 22 and exits the process 101 / system 1000 as exhaust stream 24. At least a portion of the fluid can be recirculated within the system and returned to the feed pre-treatment (arrow 23: pre-treatment unit not shown).

[0188] The high temperature heat-heat consuming system 1000 is thus configured to perform at least one heat consuming process including, but not limited to: steel making; cement making; hydrogen and / or synthesis gas production, e.g., steam-methane reforming; conversion of methane to hydrogen, fuels and / or chemicals; thermal energy storage, e.g., high temperature heat storage; processes related to the oil and / or petrochemical industries; catalytic processes for endothermic reactions; processes for disposal of hazardous and / or harmful substances by incineration; and processes for producing high temperature materials such as glass wool, carbon fibers and carbon nanotubes, bricks, ceramic materials, porcelain and tiles.

[0189] In one aspect, a method for inputting thermal energy into a fluid medium is provided, the method comprising: (a) implemented in accordance with the embodiments described hereinabove; and - a casing with at least one inlet and at least one outlet; a rotor including at least one row of rotor blades configured as impulse impeller blades arranged around a periphery of a rotor hub mounted on a rotor shaft; at least one stationary nozzle guide vane disposed upstream of at least one row of rotor blades; at least one row of stationary diffuser vanes disposed downstream of at least one row of rotor blades; obtaining a rotating device (100) (100A, 100B, 100C) including: (b) adjusting the rotational speed of the rotor to a predetermined speed or range of speeds to achieve a fluid medium flow rate that meets the requirements imposed by the process; (c) adjusting the preheat level of the fluid medium; (d) directing the fluid medium flow along a flow passage formed inside the casing between the inlet and the outlet in a manner that imparts a quantity of thermal energy to the fluid medium flow by a series of energy transformations that occur as the fluid medium flow passes successively through the blade / vane rows formed by the nozzle guide vanes, the rotor blades and the diffuser vanes, respectively; At least

[0190] In the method, the amount of thermal energy input to a fluid medium flow propagating through the apparatus is adjusted by varying a space defined between an exit from at least one row of diffuser vanes and an entrance to at least one row of nozzle guide vanes in the direction of a flow path defined within the casing between an inlet and an outlet.

[0191] In an embodiment, the fluid medium comprises any one of a feed gas, a recycle gas, a make-up gas, and a process fluid. In an embodiment, the fluid medium enters the rotating device in essentially gaseous form. In an embodiment, the flow rate of the fluid medium flow is adjustable during operation of the rotating device. The flow rate adjustment step can be implemented through adjusting the rotational speed of the rotor shaft, optionally in sections.

[0192] It is obvious to a person skilled in the art that with the advancement of technology, the basic idea of ​​the present invention may be implemented in various forms. The present invention and its embodiments may generally vary within the scope of the attached claims.

Claims

1. A rotating device (100) for inputting thermal energy into a fluid medium, comprising: a casing (20) with at least one inlet (11) and at least one outlet (12), a rotor including at least one row of rotor blades (3) configured as impulse impeller blades arranged around a rotor hub (3a) mounted on a rotor shaft (1); at least one row of stationary nozzle guide vanes (2), each arranged upstream of said at least one row of rotor blades; and at least one row of stationary diffuser vanes (4), each arranged downstream of said at least one row of rotor blades; the device is configured to impart a quantity of thermal energy to a fluid medium flow guided along a flow path formed inside the casing (20) between the inlet (11) and the outlet (12) by a series of energy transformations that occur as the fluid medium flow passes successively through the blade / vane rows formed by the nozzle guide vanes (2), the rotor blades (3) and the diffuser vanes (4), respectively; and In said device, in the direction of the flow path formed inside said casing (20) between said inlet (11) and said outlet (12), a space (5) formed between an exit from said at least one diffuser vane row (4) and an entrance to said at least one nozzle guide vane row (2) is variable so as to adjust the thermal energy input to said fluid medium flow propagating through said device. A rotating device (100).

2. 2. The apparatus of claim 1, wherein the space (5) formed between the exit from the at least one diffuser vane row (4) and the entrance to the at least one nozzle guide vane row (2) in the direction of the flow path formed inside the casing (20) between the inlet (11) and the outlet (12) is variable at least in terms of size and shape.

3. 3. A device according to claim 1 or 2, wherein the space (5) is vane-free.

4. 3. Apparatus according to claim 1 or 2, wherein the space contains a flow shaping device and / or a flow guiding apparatus (7), such as a guide wall.

5. 3. The apparatus of claim 1, wherein the at least one stationary nozzle guide vane row, the at least one rotor blade row, and the at least one stationary diffuser vane row are configured to create a condition in which, when the fluid medium flow exits the at least one rotor blade row at supersonic speed and passes through the at least one diffuser vane row where it decelerates and dissipates kinetic energy into internal energy of the fluid medium, and when an amount of thermal energy is added to the fluid medium flow, the amount of kinetic energy added to the fluid medium flow by rotating the rotor blades is sufficient to raise the temperature of the fluid medium to a predetermined value.

6. 3. The apparatus according to claim 1 or 2, wherein the amount of thermal energy added to the fluid medium flow propagating through the apparatus is produced by the generation of a shock wave system during the successive propagation of the fluid medium flow through the at least one fixed nozzle guide vane row (2), the at least one rotor blade row (3) and the at least one fixed diffuser vane row (4) in a controlled manner.

7. 3. The apparatus of claim 1, wherein the at least one stationary nozzle guide vane (2) is configured as a flow conditioner device that directs the fluid medium flow toward the rotor blade row (3) in a circumferential direction opposite to rotor blade rotation to control the level of energy input from the rotor and the velocity of the fluid.

8. 3. The apparatus of claim 1, wherein the stationary nozzle guide vanes (2) are configured to direct the fluid medium flow to enter the rotor blade row (3) at a relative blade angle, as viewed axially, in a range of about 45 degrees to about 75 degrees.

9. 3. The apparatus of claim 1, wherein the rotor blades (3) are configured to receive the fluid medium flow from the stationary nozzle guide vanes (2) upon rotation of the rotor and impart mechanical energy to the process fluid by accelerating the flow to supersonic speeds and thus increasing its tangential velocity.

10. 3. The apparatus according to claim 1 or 2, wherein the rotor blade row (3) is configured to receive the fluid medium flow entering from any one of an axial, an oblique or a radial direction and to cause a change in flow velocity such that the fluid medium flow is accelerated by at least a factor of two.

11. 3. The apparatus of claim 1 or 2, wherein the rotor is configured in terms of the profile and dimensions of the rotor blades and their arrangement on a rotor hub to control mechanical energy to the fluid medium flow.

12. 3. The apparatus according to claim 1 or 2, wherein the at least one diffuser vane row (4) is configured as an energy converter device for converting mechanical energy of the fluid medium into thermal energy of the fluid medium.

13. The apparatus of claim 1 or 2, wherein the rotor includes a shroud (31) configured to cover the at least one row of rotor blades (3).

14. 3. The apparatus of claim 1, wherein the stationary nozzle guide vane array (2), the rotor blade array (3), and the stationary diffuser vane array (4) establish an energy transfer section (10) configured to mediate a complete energy conversion cycle.

15. 3. The device according to claim 1 or 2, wherein the distance (L) between the at least one fixed diffuser vane row (4) and the at least one fixed nozzle guide vane row (2) is variable.

16. 3. The device according to claim 1 or 2, comprising at least two rows of rotor blades (3) arranged successively on the rotor shaft (1).

17. 3. The device according to claim 1 or 2, comprising a number of energy transfer sections (10), said number of energy transfer sections being at least two.

18. 18. The device according to claim 17, comprising a number of energy transfer sections (10) arranged in parallel and / or in series.

19. 18. The apparatus of claim 17, wherein the distance (L) between the energy transfer sections (10), defined as the distance between the stationary diffuser vane row (4) of a first energy transfer section (10-1) and the stationary nozzle guide vane row (2) of a second energy transfer section (10-2) adjacent to the first energy transfer section, is variable.

20. 18. The device according to claim 17, wherein the distance (L) between the energy transfer sections (10) is made variable based on required flow conditions such as mixing level and / or pressure level.

21. 18. The apparatus of claim 17, wherein the at least one stationary diffuser vane row (4) of a first energy transfer section (10-1) and the at least one stationary nozzle guide vane row (2) of a second energy transfer section (10-2) consecutive to the first energy transfer section are joined to form a combined blade row (4-2), such that the distance between the first energy transfer section and the consecutive second energy transfer section is set to zero.

22. The apparatus of claim 17, further comprising at least one section (14) configured to regulate pressure across a corresponding row of the rotor blades.

23. 3. The device according to claim 1 or 2, wherein each energy transmission section (10) and each pressure regulation section (14) is established independently of the other sections in terms of controllability over its structure and / or its operation.

24. 3. The device according to claim 1 or 2, wherein the fixed vanes (2, 4) and / or the rotor blades (3) are individually adjustable within each section during operation of the device, at least in terms of their size, alignment and spatial location.

25. 3. The device according to claim 1 or 2, optionally comprising a rotor blade row (3) with blade radii configured section-by-section in the direction from the inlet (11) to the outlet (12).

26. 3. The apparatus according to claim 1 or 2, wherein the at least one inlet (11) or a section including said at least one inlet is configured to receive a fluid medium flow through a radial to axial transition duct or a certain number of circumferential sectors or pipes with different axial, radial or circumferential inlet velocity components.

27. 3. The device according to claim 1 or 2, wherein the at least one outlet (12) or the section including said at least one outlet is configured as a circumferential spiral structure with at least one pipe and / or axial, radial or circumferential duct.

28. The apparatus of claim 1 or 2, further comprising a turboexpander device disposed downstream of the last energy transfer section.

29. 3. The device according to claim 1 or 2, wherein the device is configured in an electrically operated state by being driven by at least one electric drive engine (15).

30. 3. The device according to claim 1 or 2, further comprising a cooling arrangement, optionally in conjunction with a heat-resistant coating and / or components made from heat-resistant materials.

31. 3. The apparatus of claim 1 or 2, further comprising a number of catalytic surfaces and / or catalytic elements.

32. 3. Use of the apparatus of claim 1 or 2 in producing said fluid medium heated to a temperature essentially of about 500 degrees Celsius (°C) or greater, preferably essentially of about 1000°C or greater, more preferably essentially of about 1400°C or greater, and even more preferably essentially of about 1700°C or greater.

33. Use according to claim 32, wherein the temperature increase achievable per energy transfer section (10) is in the range of 10 to 1000°C.

34. 3. An assembly (100n) comprising at least two rotating devices (100) according to claim 1 or 2, at least functionally coupled in parallel or in series.

35. 35. The assembly of claim 34, wherein the at least two devices are coupled in a mirror image relationship to one another such that their shafts are at least operatively coupled.

36. An arrangement comprising at least one rotating device (100) according to claim 1 or 2, coupled to at least one heat consumption unit (101).

37. 37. The arrangement of claim 36, wherein the heat consuming unit (101) is any one of a furnace, an oven, a kiln, a heater, a burner, an incinerator, a boiler, a dryer, a conveyor device, a reactor device, or a combination thereof.

38. A heat consuming system (1000) configured to implement an industrial heat consuming process and comprising at least one rotating device (100) according to claim 1 or 2.

39. 39. The heat consuming system of claim 38, wherein the industrial heat consuming process is selected from the group consisting of: steel making; cement production; hydrogen and / or synthesis gas production, e.g. steam-methane reforming; conversion of methane to hydrogen, fuels and / or chemicals; thermal energy storage, e.g. high temperature heat storage; processes related to the petroleum and / or petrochemical industries; catalytic processes for endothermic reactions; processes for the disposal of hazardous and / or toxic substances by incineration; and processes for the manufacture of high temperature materials, e.g. glass wool, carbon fibres and carbon nanotubes, bricks, ceramic materials, porcelain and tiles.

40. 1. A method for inputting thermal energy into a fluid medium, comprising: (a) obtaining a rotating device (100) having: a casing (20) with at least one inlet (11) and at least one outlet (12), a rotor including at least one row of rotor blades (3) configured as impulse impeller blades arranged around a rotor hub (3a) mounted on a rotor shaft (1); at least one row of stationary nozzle guide vanes (2), each arranged upstream of said at least one row of rotor blades; and at least one row of stationary diffuser vanes (4), each arranged downstream of said at least one row of rotor blades; (b) adjusting the rotational speed of the rotor to a predetermined speed or speed range to reach a fluid medium flow rate that meets the requirements imposed by the process; (c) adjusting the preheat level of the fluid medium; (d) directing a fluid medium flow along a flow path formed inside the casing (20) between the inlet (11) and the outlet (12) in a manner that imparts a quantity of heat energy to the fluid medium flow by a series of energy transformations that occur as the fluid medium flow passes successively through the blade / vane arrays formed by the nozzle guide vanes (2), the rotor blades (3) and the diffuser vanes (4), respectively; wherein the amount of heat energy input into the fluid medium flow propagating through the device is adjusted by varying a space (5) formed between an exit from the at least one diffuser vane row (4) and an entrance to the at least one nozzle guide vane row (2) in the direction of the flow path formed inside the casing (20) between the inlet (11) and the outlet (12). A method for inputting thermal energy into a fluid medium.

41. 41. The method of claim 40, wherein the fluid medium comprises any one of a feed gas, a recycle gas, a make-up gas, and a process fluid.

42. 42. The method of claim 40 or 41, wherein the fluid medium enters the device in essentially gaseous form.

43. 42. The method of claim 40 or 41, wherein the fluid medium flow rate is adjustable during operation of the device.

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