A thermal energy harnessing system

Abstract

A thermal energy harnessing system 100 includes a circulating boiler 104 comprising a turbine having a stator and rotor 200 of predetermined dimensions. The rotor 200 is adapted to rotate at a predetermined speed within the boiler 104 by a driving unit, comprising an electric motor 108 coupled with the circulation boiler 104 to rotate the rotor 200 for circulating fluid flowing in boiler 104 through multiple recesses of the rotor 200 to generate cavitation heat. The generated heat is transferred to a heat-exchanging unit flow connected with the boiler 104 in a closed loop. The heat exchanging unit comprising heat exchangers configured to receive generated heat from the circulating boiler 104 to heat a heating liquid flowing through a buffer tank 110 of the heat exchangers and an electronic control unit 114 configured to control an operation of the boiler 104, the heat exchanging unit, and the driving unit.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to the field of energy-harnessing turbines. More specifically, the present invention relates to a thermal energy harnessing system that helps produce thermal energy by utilizing the physical phenomenon of cavitation in synergy with the connection to a heating system.BACKGROUND OF THE INVENTION

[0002] The phenomenon of cavitation occurs in turbines when there is a rapid change in pressure, causing the formation and subsequent collapse of bubbles trapped with heat within a liquid. In the context of a thermal cavitation turbine, this process is induced by subjecting a liquid (such as water) to rapidly change its pressure and temperature, typically through the use of specialized chambers and nozzles. During the thermal cavitation phenomenon, these turbines have the potential to efficiently convert thermal energy into mechanical work.

[0003] While converting such energy, they come with several notable disadvantages. One major limitation is the erosion and damage that can occur to the turbine components due to the intense heat formation resulting from the rapid collapse of vapor bubbles. The repeated formation and collapse of cavitation bubbles can lead to erosion of the turbine blades and other components, reducing the efficiency and lifespan of the turbine. Furthermore, when the cavitation bubbles collapse, they force energetic liquid into very small volumes, thereby creating spots of high temperature and emitting shock waves, sometimes becoming a source of noise and eroding the turbine components.

[0004] Thus, there is an unmet need to obviate said problems by providing a system that could significantly manage and mitigate this erosion in the development and operation of thermal cavitation turbines. Also, controlling the optimal cavitation conditions and ensuring consistent performance of the turbine is complex. This also requires the precise design and materials for manufacturing and maintaining the turbine, and it can lead to cost increments.OBJECTIVES OF THE INVENTION

[0005] The subject of this patent application pertains to a high-performance heat turbine designed to generate thermal energy by harnessing the heat produced due to the physical phenomenon of cavitation in conjunction with a heating system. It is capable of solving the above-stated limitations of thermal turbines.

[0006] An objective of the present invention is to develop a high-performance heat turbine that maximizes the efficiency of thermal energy generation by harnessing cavitation heat through the utilization of a heating source in synergy with the turbine.

[0007] Another objective of the present invention is to implement a controlled cavitation process to minimize detrimental effects on the turbine and associated components, ensuring a prolonged operational lifespan and reduced maintenance requirements.

[0008] Another objective of the present invention is to design a system that maintains precise control over fluid circulation in the heat turbine, promoting stable cavitation conditions for sustained thermal energy production.

[0009] Another objective of the present invention is to determine and maintain an optimal balance between cavitation energy release, turbine output, and engine load, thereby maximizing overall system efficiency.

[0010] A further objective of the present invention is to seamlessly integrate the heat turbine with heating systems and provide a reliable source of thermal energy for diverse applications.

[0011] Another objective of the present invention is to develop and implement a specialized program for the automatic execution of the cavitation and thermal energy generation process, ensuring user-friendly operation and reducing the need for constant manual monitoring.

[0012] Yet another objective of the present invention is to design a heat turbine with scalability and adaptability in mind, allowing for customization to various heating system sizes and applications while maintaining consistent performance and efficiency.SUMMARY OF THE INVENTION

[0013] The present invention relates to a thermal energy harnessing system that maximizes the efficiency of thermal energy generation by harnessing cavitation heat via a heating source in synergy with the turbine and maintains precise control over fluid circulation, promoting stable cavitation conditions for sustained thermal energy production with scalability, adaptability allows customization to various sized heating system while maintaining consistent efficiency.

[0014] In an embodiment, a thermal energy harnessing system, comprising a circulating boiler having a turbine including a stator and a rotor of predetermined dimensions. The turbine is connected to a driving unit that drives the rotor at a predetermined speed to generate cavitation heat due to the circulation of fluid in the turbine, a heat-exchanging unit flow connected with the turbine in a primary circuit forming a closed loop, i.e., the heat-exchanging unit is configured to receive the cavitation heat generated in the circulating boiler via the primary circuit for heating a liquid flowing in a secondary circuit of the heat-exchanging unit. An electronic control unit is configured to control the operation of the turbine, the heat-exchanging unit, and the driving unit.

[0015] In an embodiment, the circulating boiler is in a vertical configuration, wherein the circulating boiler is installed at the bottom and a circulation pump is installed at the top over the circulating boiler, the circulation pump supplies torsional energy to the circulating boiler via a direct drive.

[0016] In an embodiment, the heat-exchanging unit includes a buffer tank having a first heat exchanger wherein an outlet of the circulating boiler is flow connected to an inlet of the buffer tank, wherein between an outlet of the buffer tank and an inlet of the circulating boiler, the circulation pump is connected.

[0017] In an embodiment, the circulating boiler is adapted to receive a fresh supply of fluid to maintain the cavitation process within the turbine.

[0018] In an embodiment, the driving unit is an electric motor having a predetermined speed.

[0019] In an embodiment, the motor is controlled by at least one of a soft starter or a frequency inverter.

[0020] In another embodiment, the rotor includes recesses on the outer surface of the rotor.

[0021] In another embodiment, the output of the turbine and the load associated with the system is determined by the number of recesses on the outer surface of the rotor.

[0022] In another embodiment, each of the recesses on the rotor is of different circular diameters and depths.

[0023] In an embodiment, a measurement and regulation unit is installed between the circulating boiler and the buffer tank to measure temperature and / or pressure, to generate cavitation at a desired pressure in the circulating boiler.

[0024] According to a further embodiment of the present invention the control unit is configured to control the opening and closing of a plurality of motorized valves between two circuits, and switch on and off one or more circulation pumps connected to an outlet of the primary circuit, when a predetermined temperature is reached in the secondary circuit.

[0025] In an embodiment, a refilling unit refills the circulating boiler with the fluid, at a pressure range of 0.2 bar to 1 bar.

[0026] In an embodiment, each circuit of the primary circuit includes a separate buffer tank having one chamber.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1, illustrates a front view of a thermal energy harnessing device. Figure 2, illustrates a perspective view of the rotor associated with the thermal energy harnessing device. Figure 3, illustrates a block diagram explaining the working operation of the thermal energy harnessing device. DETAIL DESCRIPTION OF THE INVENTION

[0028] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and the following description. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the present disclosure herein may be employed.

[0029] At the outset, for ease of reference, certain terms used in this application and their meanings as used in this context are set forth. To the extent a term used herein is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Further, the present techniques are not limited by the usage of the terms used in the application, as all equivalents, synonyms, new developments, and terms or techniques that serve the same or a similar purpose are considered to be within the scope of the present claims.

[0030] The articles "a" and "an" as used herein mean one or more when applied to any feature in embodiments of the present invention described in the specification and claims. The use of "a" and "an" does not limit the meaning to a single feature unless such a limit is specifically stated. The article "the" preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective "any" means one, some, or all indiscriminately of whatever quantity.

[0031] The present invention relates to a thermal energy harnessing system that works in combination with a heating source to utilize the heat energy dissipated due to the phenomenon of cavitation in the turbines.

[0032] Referring to Fig 1, a front view of a thermal energy harnessing system 100 is illustrated, wherein system 100 comprises a housing 102 developed in a cuboidal-shaped structure that possesses an orientation of a box-like entity. The housing 102 encompasses all the components associated with the thermal energy harnessing system 100. The housing 102 is further attached with multiple wheels 106 that provide easy and convenient handling / maneuvering to the housing 102. The thermal energy harnessing system 100 includes a circulating boiler 104 installed within the housing 102 , wherein the circulating boiler 104 comprises a turbine. The turbine disclosed here includes a stator and a rotor (as shown in Fig. 2) of predetermined dimensions. The stator of the turbine is fixed while the rotor rotates via a driving unit connected to the turbine.

[0033] The driving unit disclosed above comprises an electric motor 108 having a predetermined speed, wherein the electric motor 108 is controlled by at least one of a soft starter or a frequency inverter. The soft starter or the frequency inverter is electrically coupled with the electric motor 108 to provide a soft start to the motor 108. The soft starter / frequency inverter is a solid-state device that protects the AC electric motor 108 from damage caused by sudden influxes of power by limiting the large initial inrush of current during the start-up of the motor 108.

[0034] These soft-starters provide a gentle ramp up to full speed and are used only at the start-up of the motor 108 for providing a soft-start to the electric motor 108. The motor provides torsional energy to the circulating boiler 104 , wherein the rotor of the circulating boiler 104 starts rotating and gradually reaches a predetermined rotor speed of the turbine to circulate a fluid flowing in a primary circuit of the thermal energy harnessing system 100. In an embodiment, a specially designed flange of a certain dimension is provided between the motor 108 and the circulating boiler 104 , wherein a string seal is fitted therein to prevent water from leaking out of the turbine of the circulating boiler 104. During the circulation of fluid, the fluid passes through a plurality of recesses (not shown here) formed on the rotor, due to which the region between the stator and the rotor, at a certain distance, a process of cavitation and frictional force is generated which leads to the development of bubbles within the fluid with a certain amount of generation of heat. This generated heat gets trapped into said bubbles and is carried and this phenomenon of cavitation further results in the generation of cavitation heat due to the bursting of these bubbles during discharge from the circulating boiler 104.

[0035] In an embodiment, the circulating boiler 104 can either be installed horizontally or vertically. The vertical configuration is shown in Fig.1. The vertical installation can be realized by utilizing rubber feet or by alternatively using a separate stand or by using a bracket (not shown here) attached to the wall of the housing 102. As shown in Fig. 1, the circulating boiler 104 is installed at the bottom, while a dimensioned circulation pump 112 is positioned at the top of the circulating boiler 104.

[0036] Further, in Fig. 1, the cavitation heat so produced due to the circulation of liquid through the recesses 202 of the rotor 200 (shown in Fig. 2) is then supplied to a heat exchanging unit which is flow connected to the turbine in a closed loop of the primary circuit, to receive the cavitation heat. The heat-exchanging unit disclosed here comprises a buffer tank 110 having an inlet, an outlet, and a first heat exchanger installed therein. The buffer tank 110 here, includes a chamber tank whose inlet is flow connected to the outlet of the circulating boiler 104. A secondary circuit also passes through the buffer tank 110 , and the buffer tank 110 is configured to receive the cavitation heat from the primary circuit for heating the liquid flowing through the secondary circuit in the heat-exchanging unit.

[0037] The buffer tank 110 , from the outlet, is connected with a circulation pump 112 , which is further connected to the inlet of the circulating boiler 104. The circulation pump 112 is adapted to receive fluid from the buffer tank 110 and supply fresh fluid to the circulating boiler 104 , for maintaining the cavitation process inside the boiler. This whole process forms a primary cycle of the primary circuit. In an embodiment, a refilling unit (not shown here) can be provided within the system 100 and can be connected to the inlet of the circulating boiler 104 for refilling the fluid within the circulating boiler 104 at a maintained pressure range from 0.2 bar to 1 bar.

[0038] Further, the thermal energy harnessing system 100 is installed with an electronic control unit 11 configured to control the operation of the circulating boiler 104 , the heat-exchanging unit, and the driving unit. The control unit 114 further includes a control panel 116 for example, a control panel 116 manufactured under a trademark of Siemens, Further, the control panel 116 can be password-protected to prevent unwanted manipulation of the control unit 114 , for example, the control panel 116 may be accessed by 3 authorized users only. In an embodiment, the control panel 116 is attached to the top of the thermal energy harnessing system 100.

[0039] The control unit 114 is integrated with a processor to determine the parameters of fluid flowing in through the inlet of boiler 104 and the fluid flowing inside the heat-exchanging unit. These fluid parameters such as temperature, pressure, and alike are detected by the control unit 114 , based on an output generated through an additional unit installed in the system 100. The additional unit is electrically paired with the control unit 114 and is in connection with temperature indicators, pressure sensors, and temperature sensors, which work in coordination to determine the above-mentioned fluid parameters. These parameters are then sent to the processor module via electrical signals.

[0040] The processor module of the control unit 114 detects the electrical signals received from the additional unit via a built-in / integrated measurement and regulation method and analyses them for further processing. Upon processing, the processor of the control unit 114 automatically controls the opening and closing of a plurality of motorized valves installed between the two circuits. As well as switching ON and OFF one or more circulation pumps 112 connected on the primary circuit, when a predetermined temperature of the fluid in the secondary circuit is reached, to ensure a regulated and controlled cavitation process and continuous generation of thermal energy. At the same time, the harmful effects of cavitation and overheating of the circulating boiler 104 are prevented from reaching their critical limits, thereby preventing damage to the boiler's components.

[0041] In an embodiment, the control unit 114 can be installed with a switching unit that is built within the control unit 114 and is suitable for displaying operating states, the amount of power consumption, and the temperature of the thermal energy via a display screen.

[0042] Fig. 2 illustrates a perspective view of a rotor 200. The rotor 200 disclosed here is a cylindrical shaped entity developed with a plurality of recesses 202 on the outer surface. The recesses 202 here refer to multiple holes of various diametric and depth dimensions drilled on the outer surface of the rotor 200 which enables the fluid to flow therethrough for the generation of the bubbles within the fluid with a certain amount generation of heat. This heat gets trapped in the bubbles, which on bursting produce cavitation heat into the environment. This phenomenon of cavitation takes place due to the recesses 202 drilled on the outer surface of the rotor 200 and having variable diametric dimensions and depths.

[0043] The size and the number of the recesses 202 on the rotor 200 determine the output of the turbine and the load on the system 100. The recesses 202 developed on rotor 200 are developed by a matrix calculation, with a circular diameter of 13-19 > 7-11 mm and with a depth (h) = 12-16 > 7-11 mm, measured to the center point, closing at a 90° angle, 11-15 mm row spacing, 17-25 mm column spacing, so that a 90° degree angle is closed with axis rotations. The matrix calculation for holes is done by taking into account the required heat output.

[0044] Referring to Fig. 3 a block diagram explaining the working of the present invention is illustrated including two primary circuits in a closed loop cycle and one secondary open loop circuit. Each of the primary circuits includes a buffer tank 110, and a circulating boiler 104 comprising a turbine (W) provided with an inlet and an outlet. The inlet of the circulating boiler 104 is connected with a T-shaped de-aerator connected with a source of liquid to flow within the circulating boiler 104. The turbine (W) after receiving the fluid from the inlet starts operating via an electric motor 108 (not shown here) coupled to the turbine. The motor 108 upon actuation starts rotating the rotor 200 of the turbine (W) at a gradual increment of speed and until it reaches a pre-determined set speed. The high speed here ranges from 1200 to 3600 RPM.

[0045] Further, as the rotor 200 rotates at a higher speed, due to the development of recesses 202, it starts generating a plurality of bubbles along with the generation of heat, wherein a certain amount of heat gets trapped within the bubbles and is carried along with the flowing fluid. The fluid with the bubbles on discharging from the turbine's (W) outlet bursts and dissipates a huge amount of the heat within the liquid, which in turn results in the heating of the flowing liquid. The heated liquid, when reaches a pre-set temperature, as detected by the additional unit provided in the system 100 , is then passed towards a circulating pump (U1) by the actuation of a motorized valve (D1) attached at the boiler's 104 outlet.

[0046] The circulating pump U1 upon receiving the hot liquid via the motorized valve (D1), further supplies the hot liquid to an upper tank (O). The heated liquid from the upper tank (O) is then supplied to the heat-exchanging unit (W1) through a second motorized valve (D2). The heated liquid after entering the heat-exchanging unit enters within the first heat-changer of the buffer tank 110 via the inlet of the first heat-exchanger. The heated liquid starts flowing within the heat-exchanging unit and circulates within the tubes of the heat-exchanger and dissipates the heat within the environment of the first chamber of the buffer tank 110. For example, the temperature of this heat may reach up to 65 °C degrees in the primary circuit.

[0047] The heat after entering the buffer tank 110 comes in contact with normal cool water supplied through the buffer tank 110 for exchanging heat with cool liquid flowing in the secondary circuit to make the cool liquid warm. The warm liquid is then further supplied to another buffer tank 110 for further heating of the warm water. This further heating of warm liquid is achieved by again heating the warm water by following a similar process of heat exchange, by actuation of motorized valves (D1) and (D3) along with the circulating pump (U2). This further heating of the warm liquid coming from the buffer tank 110 and coming to the other second buffer tank forms the secondary circuit.

[0048] After, the exchange of heat the hot liquid circulating in the tubes of the heat exchanger flows back to the circulating boiler 104 via outlets of the heat exchangers, by actuation of circulating pump (U1) and U2 along with the motorized valve D4 and D5 for again repeating the whole process of heating the liquid in the secondary circuit for the use which substantially reaches a range of 30 to 36 °C degrees.

[0049] In operation, the proposed invention relates to a thermal energy harnessing system 100 which works on the principle that at a high speed of the rotor 200 the turbine generates vacuum bubbles in the circulated fluid. These bubbles, upon mutual impingement, dissipate heat within the precisely defined gap between the stator and rotor 200 of the turbine. The heat produced in the primary circuit is utilized to warm fluid in a secondary circuit through the heat exchanger. Further, a fresh fluid is introduced into the primary circuit to sustain the cavitation process, which is facilitated by a control valve. To achieve this, an electric motor 108 and a specialized turbine, interconnected with a heating system designed to attain a temperature of up to 95 °C when coupled to the motor 108.

[0050] The motor 108 operates the coupled circulated boiler 104 to rotate the rotor 200 at a predetermined speed, ensuring a specific speed on the rotor's 200 circumference. The maintained speed of rotor 200 ensures that the physical process of cavitation which generates the induction of vacuum bubbles, does not reach the limit of destructive effect. The amount of generated thermal energy and temperature of the generated thermal energy can be adjusted by changing the speed of the rotor 200. The speed of the rotor 200 can be increased between 3000 - 3,600 rpm for 1-5 minutes if rapid heating is required during operation.

[0051] Here, the speed of motor 108 is controlled, which is facilitated through a soft starter or frequency inverter. Additionally, the stator and rotor 200 possess prescribed dimensions, with recesses 202 strategically drilled into the rotor 200 surface. The precise number of recesses 202 dictates the output of the circulating boiler 104 and the load on the system 100. The entire process is overseen by a program specifically developed and pre-fed within the processor of the control unit 114 for the automatic execution of this sequence via a measurement and regulation method that governs the entire operation of heat generation.

[0052] This method ensures a regulated and controlled cavitation process. As well as ensures the continuous generation of thermal energy while preventing the adverse effects of cavitation and device overheating from reaching critical limits. This in turn prevents the components of the circulating boiler 104 from damaging due to these critical limits of the above disclosed parameters.

[0053] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within understood that the phraseology or the terminology employed herein is for description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

Claims

1. A thermal energy harnessing system, comprising: a circulating boiler having a turbine comprising a stator and a rotor of predetermined dimensions, wherein the rotor of the turbine is driven by a driving unit at a predetermined speed, enabling circulation of a fluid in the turbine to generate cavitation heat; a heat-exchanging unit flow connected to said turbine in a primary circuit forming a closed loop, the heat-exchanging unit is configured to receive the cavitation heat generated in the circulating boiler via the primary circuit, for heating a liquid flowing in a secondary circuit of said heat-exchanging unit; an electronic control unit configured to control the operation of the turbine, the heat-exchanging unit, and the driving unit.

2. The thermal energy harnessing system as claimed in claim 1, wherein in a vertical configuration, the circulating boiler is installed at an operational bottom and a circulation pump at an operational top of the circulating boiler, the circulation pump supplying torsional energy to the circulating boiler via a direct drive.

3. The thermal energy harnessing system as claimed in claim 1, wherein the heat-exchanging unit includes a buffer tank having a first heat exchanger, wherein an outlet of the circulating boiler is flow connected to an inlet of the buffer tank, wherein the circulation pump is connected to an outlet of the buffer tank and an inlet of the circulation boiler.

4. The thermal energy harnessing system as claimed in claim 1, wherein the circulating boiler is adapted to receive a fresh supply of the fluid to maintain the cavitation process within the turbine.

5. The thermal energy harnessing system as claimed in claim 1, wherein the driving unit is an electric motor having a predetermined speed.

6. The thermal energy harnessing system as claimed in claim 5, wherein the motor is controlled by at least one of a soft starter or a frequency inverter.

7. The thermal energy harnessing system as claimed in claim 1, wherein the rotor includes recesses on an outer surface of the rotor.

8. The thermal energy harnessing system as claimed in claim 7, wherein a number of the recesses on the rotor determine an output of the turbine and an associated load to the system, wherein the recesses are of different circular diameters and depths.

9. The thermal energy harnessing system as claimed in claim 1 comprises a measurement and regulation unit installed between the circulation boiler and the buffer tank to measure at least one of a temperature and a pressure and to generate cavitation at a desired pressure in the circulation boiler.

10. The thermal energy harnessing system as claimed in claim 1, wherein the control unit is configured to control at least one of: opening and closing of a plurality of motorized valves between the two circuits; and switching on and off one or more circulation pumps connected to an outlet of the secondary circuit, when a predetermined temperature is reached in the secondary circuit.

11. The thermal energy harnessing system as claimed in claim 1, wherein a refilling unit refills the circulation boiler with the fluid, at a pressure of from 0.2 to 1 bar.

12. The thermal energy harnessing system as claimed in claim 1, wherein each circuit of the primary circuit includes a separate buffer tank having one chamber.

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