Hybrid integrally geared centrifugal compressor pump

Abstract

Systems and methods are described for a hybrid centrifugal compressor pump with an integrally geared drive system such that multiple pump and compressor stages can share the same drive system. This helps lower the number of parts in an overall fluid treatment system. As a result, embodiments of a hybrid compressor pump can achieve longer life resulting in efficiency gains and cost savings.

Description

HYBRID INTEGRALLY GEARED CENTRIFUGAL COMPRESSOR PUMPBACKGROUNDTechnical Field

[0001] This disclosure generally relates to compressors and pumps for fluid treatment systems.Related Technology

[0002] The liquefaction of numerous fluids needs the gas phase to be compressed first, then liquefied in a cooling machine and finally the outlet liquid shall be pumped for its storage or its processing. The gas compressor and liquid pump are usually two different rotating machines manufactured by two different companies. The use of these components can lead to complications and inefficiencies because the components have different designs, individual driving systems, operate with different tolerances, and require different knowledge bases for maintenance.BRIEF SUMMARY

[0003] One embodiment of the present disclosure comprises a hybrid compressor-pump. The hybrid compressor-pump comprises a housing and a central gear within the housing and configured to be driven by a power supply. It further comprises one or more pumps configured to attach to the housing and be driven by the central gear; and one or more compressors configured to attach to the housing and be driven by the central gear; wherein each of the one or more pumps and one or more compressors comprise one or more connection points such that the one or more pumps and one or more compressors can be arranged in a variety of orders of operations for treating a fluid under process.

[0004] Another embodiment under the present disclosure comprises a drive system for a fluid treatment system. The system comprises a central gear configured to be driven by a power supply; and one or more stages configured to treat a fluid under process and each comprising one or more connection lines. It further comprises one or more shafts configured to be driven by the central gear, each of the one or more shafts configured to drive a first of the one or more stages at one end and a second of the one or more stages at a second end; the system characterized in that wherein the one or more connections lines allow the one or more stages to be configured in a variety of orders of operation to treat the fluid under process.

[0005] A further embodiment under the present disclosure comprises a method of manufacturing a hybrid-compressor pump. The method can comprise providing a central gear configured to be driven by a power supply; and coupling one or more shafts to an outer edge of the central gear, the one or more shafts configured to be driven by the central gear and to drive one of one or more stages of the fluid treatment system at a first end and to drive another of the one or more stages at a second end; wherein the one or more stages can be coupled in a variety of orders of operation for treating a fluid under process.

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an indication of the scope of the claimed subject matter.

[0007] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description of the embodiments that follows may be better understood. Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present disclosure will become more fully apparent from the following description and appended claims or may be learned by the practice of the disclosure as set forth hereinafter. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In order to describe the manner in which the above recited and other advantages and features of the disclosure can be obtained, a more particular description of the disclosure briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the disclosure and are not therefore to be considered to be limiting of its scope. The disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0009] FIG. 1 illustrates the thermodynamic path of a fluid in a liquefied gas process;

[0010] FIG. 2 shows a schematic of a possible fluid treatment process;

[0011] FIG. 3 shows a possible hybrid compressor-pump embodiment under the present disclosure;

[0012] FIG. 4 shows a possible hybrid compressor-pump embodiment under the present disclosure;

[0013] FIGS. 5A-5B show a possible hybrid compressor-pump embodiment under the present disclosure;

[0014] FIG. 6 shows a possible hybrid compressor-pump embodiment under the present disclosure; and

[0015] FIG. 7 shows a possible method embodiment under the present disclosure.DETAIEED DESCRIPTION

[0016] Before describing various embodiments of the present disclosure in detail, it is to be understood that this disclosure is not limited to the parameters of the particularly exemplified systems, methods, apparatus, products, processes, and / or kits, which may, of course, vary. Thus, while certain embodiments of the present disclosure will be described in detail, with reference to specific configurations, parameters, components, elements, etc., the descriptions are illustrative and are not to be construed as limiting the scope of the claimed invention. In addition, the terminology used herein is for the purpose of describing the embodiments and is not necessarily intended to limit the scope of the claimed invention.

[0017] Embodiments under the present disclosure include integrally-geared centrifugal compressor-pumps. Such embodiments can solve problems in the prior art that result from multiplemanufacturers or machines being used for separate compressors and pump stages in a single fluid treatment system or process. Embodiments hereunder can comprise a single machine, with both compressor stages and pump stages, driven by a single motor. This offers a more compact solution with fewer components and a single driving system. Increased life span, increased reliability, and greater efficiency are just a few of the advantages.

[0018] In certain fluid treatment systems, the liquefaction of numerous fluids needs the gas phase to be compressed first, then liquefied in a cooling machine, after which the outlet liquid can be pumped for its storage or its processing. This can be shown in graph form in Figure 1. As can be seen, vapor can be compressed below the saturation line. Then the vapor / gas can be cooled and condensed into a liquid and then pumped away above the saturation line.

[0019] A schematic of a possible fluid treatment system, embodying aspects of Figure 1, is shown in Figure 2. A fluid mix of gas CO2 and water H2O can enter first separator 20. Some water is separated out, and the rest of the process fluid proceeds to a first compressor 22 and then a first cooler 25. The process fluid then enters a second separator 30 and some water is separated out. The process fluid enters a first mixer 32 and is mixed with an output of a first heat exchanger 55. The process fluid then enters a second compressor 34 and a second cooler 36. The process fluid then enters a third separator 40 and some water is separated out. The process fluid then enters a second mixer 42 and is mixed with an output of first heat exchanger 55. The process fluid then passes through a third compressor 44 and third cooler 46 before entering a fourth separator 50 where some water is separated out. The process fluid then enters first exchanger 55. The process fluid then enters splitter 60. One outlet 62 of splitter 60 enters a second heat exchanger 70, where it is cooled. The second outlet 64 passes through an expansion valve 66 and returns to heat exchanger 55 before mixing with the process fluid at second mixer 42. The process fluid, from second heat exchanger 70 enters second expansion valve 72, is expanded and enters separator 80. Eiquid CO2 from separator 80 is pumped away by pump 85. Separated fluid from separator 80 at outlet 86 is directed back through second heat exchanger 70 and then first heat exchanger 55 before being mixed with the process fluid at first mixer 32. Each point R is a point where a specific pressure and temperature are needed. In system 100 the process fluid is generally undergoing a continual increase in pressure and temperature, such as shown in Figure 1. The second heat exchanger 70 cools the pressurized CO2 into a liquid. The liquid CO2 can then be pumped away by pump 85.

[0020] System 100 of Figure 2 could comprise separate components for each compressor 20, 34, 44, and each pump 85. However, advantages could be achieved by combining these components into a single apparatus.

[0021] One embodiment of the current disclosure is shown in Figure 3. Figure 3 shows a hybrid compressor-pump 300. A gas, as a process fluid, can enter inlet 310 (similar to the first stage of Figure 2). The process fluid can pass through multiple compressors 320, 330, before passing through a heat exchanger 340 (in this embodiment a cooling box), and passing through two pump stages 350, 360, and leaving outlet 370 as a liquid. Driving system 380 can be any kind of driver, such as an electrical motor, a steam turbine, a gas turbine or a gas engine. Hybrid compressor-pump 300 can comprise a single drive unit to drive pumps 350, 360 and compressors 320, 330. With a single drive unit there is less chance of failure at any given moment. Furthermore, each pump 350, 360 and compressor 320, 330 can be isolated in any given embodiment. For instance, in certain embodiments maybe only compressors 320, 330 and one pump 350 is utilized, and pump 360 can be left unused. Or, in other embodiments, hybrid compressor-pump 300 could replace one pump 360 with an additional compressor stage.

[0022] The hybrid compressor-pump 300 of Figure 3 can also be represented by hybrid compressor-pump 400 of Figure 4. An inlet (not shown) can lead to compressor 420. Line 425 connects compressor 420 to compressor 430. Other lines (not shown) can connect an outlet of compressor 430 to an inlet of pump 450. Line 455 can connect pump 450 to pump 460, which can lead to an outlet or other components.

[0023] Another embodiment of a hybrid compressor-pump 500 is shown in Figures 5A and 5B. Hybrid compressor-pump 500 preferably comprises four stages 515, 525, 535, 545 all driven by a common drive system coupled on shaft-end 560. In this embodiment, stages 515, 525, 535 are compressors and stage 545 is a pump. As described above, other embodiments could comprise other numbers of compressors / pumps. First compressor stage 515 can comprise a process suction inlet 510, inlet guide vanes 505 and a process discharge outlet 518. First compressor stage 515 can be connected to second compressor stage 525. Second compressor stage 525 comprises a process suction inlet 520, process discharge outlet 528. Third compressor stage 535 can similarly comprise a process suction inlet 530 and process discharge outlet 538. Pump stage 545 can comprise a process suction inlet 540 and process discharge outlet 548. The various process discharge outlets518, 528, 538, 548, and / or process suction inlets 510, 520, 530, 540 can allow for coupling of the stages 515, 525, 535, 545 in a variety of orders of operation.

[0024] Gearbox 565 can comprise gearing that drives each stage 515, 525, 535, 545 at the same time. Lube pump 570 can supply oil or other lubricant to the gearing of the gearbox 565.

[0025] Figure 6 displays a cut-away view of a hybrid compressor-pump 600 under the present disclosure. Housing 610 contains a central gear 620 that can be driven by input shaft 630. Input shaft 630 can be coupled to a driving system, such as a gas-powered or electric motor. Hybrid compressor-pump 600, in this embodiment, comprises four stages: three compressor stages 665, 670, 675 and pump stage 680. Each stage 665, 670, 675, 680 comprises a suction inlet 667, 671, 676, 681, that can be connected to an outlet of another stage or to receive a process fluid from another component. Each compressor stage 665, 670, 675 comprises an impeller 690 used to create an increased pressure on a fluid. Impellers 690 are assembled on pinion 695 and run into housing 610. A variety of attachment points 602 can be used to attach housing 610 to other components or to a floor or other surface. Bolts, nuts, welding, and / or other attachment means and methods can be used. Each stage 665, 670, 675, 680 can comprise a variety of connection lines 622 that allow for injection and / or removal of one or more fluids. The order of operation of the stages 665, 670, 675, 680 can be varied and chosen by a user depending on the given embodiment. For example, in one situation, hybrid compressor-pump 600 can be set up so that a process fluid passes through the three compressor stages 665, 670, 675 and then pump stage 680 as a final stage. Pump stage 680 can also comprise an impeller 683, or other pumping means.

[0026] Figure 7 displays a possible method embodiment 700 under the present disclosure. Step 710 is providing a central gear configured to be driven by a driving system. Step 720 is coupling one or more shafts to an outer edge of the central gear, the one or more shafts configured to be driven by the central gear and to drive one of one or more stages of the fluid treatment system at a first end and to drive another of the one or more stages at a second end; wherein the one or more stages can be coupled in a variety of orders of operation for treating a process fluid.

[0027] As described above, hybrid compressor-pump embodiments under the present disclosure can comprise a variety of pumps and compressors driven by a single central gear. Preferred embodiments comprise four stages on two parallel shafts. The stages on a single axis can be driven by a single shaft, though separate shafts or other gearing could be coupled to the centralgear for power. But it could be possible in some situations to have more than six stages coupled to the central gear.

[0028] The housings, gears, impellers and other components in the fluid treatment systems described hereunder preferably comprise metals and alloys (e.g., steel, aluminum, copper, etc.). Fittings, bushings, gaskets, connection lines, and other components may comprise rubber, plastic, or other materials. However, the embodiments described herein are not limited to any specific materials embodiment and a variety of materials can be used for a variety of components.Abbreviated List of Defined Terms

[0029] To assist in understanding the scope and content of this written description and the appended claims, a select few terms are defined directly below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains.

[0030] The terms “approximately,” “about,” and “substantially,” as used herein, represent an amount or condition close to the specific stated amount or condition that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount or condition that deviates by less than 10%, or by less than 5%, or by less than 1%, or by less than 0.1%, or by less than 0.01% from a specifically stated amount or condition.

[0031] Various aspects of the present disclosure, including devices, systems, and methods may be illustrated with reference to one or more embodiments or implementations, which are exemplary in nature. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments disclosed herein. In addition, reference to an “implementation” of the present disclosure or invention includes a specific reference to one or more embodiments thereof, and vice versa, and is intended to provide illustrative examples without limiting the scope of the invention, which is indicated by the appended claims rather than by the following description.

[0032] As used in the specification, a word appearing in the singular encompasses its plural counterpart, and a word appearing in the plural encompasses its singular counterpart, unless implicitly or explicitly understood or stated otherwise. Thus, it will be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. For example, reference to a singular referent (e.g., “a widget”) includes one, two, or more referents unless implicitly or explicitly understood or stated otherwise. Similarly, reference to a plurality of referents should be interpreted as comprising a single referent and / or a plurality of referents unless the content and / or context clearly dictate otherwise. For example, reference to referents in the plural form (e.g., “widgets”) does not necessarily require a plurality of such referents. Instead, it will be appreciated that independent of the inferred number of referents, one or more referents are contemplated herein unless stated otherwise.

[0033] As used herein, directional terms, such as “top,” “bottom,” “left,” “right,” “up,” “down,” “upper,” “lower,” “proximal,” “distal,” “adjacent,” and the like are used herein solely to indicate relative directions and are not otherwise intended to limit the scope of the disclosure and / or claimed invention.Conclusion

[0034] It is understood that for any given component or embodiment described herein, any of the possible candidates or alternatives listed for that component may generally be used individually or in combination with one another, unless implicitly or explicitly understood or stated otherwise. Additionally, it will be understood that any list of such candidates or alternatives is merely illustrative, not limiting, unless implicitly or explicitly understood or stated otherwise.

[0035] In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as being modified by the term “about,” as that term is defined herein. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the subject matter presented herein. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherentlycontain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0036] Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims.

[0037] The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention itemed. Thus, it should be understood that although the present invention has been specifically disclosed in part by preferred embodiments, exemplary embodiments, and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and such modifications and variations are considered to be within the scope of this invention as defined by the appended items. The specific embodiments provided herein are examples of useful embodiments of the present invention and various alterations and / or modifications of the inventive features illustrated herein, and additional applications of the principles illustrated herein that would occur to one skilled in the relevant art and having possession of this disclosure, can be made to the illustrated embodiments without departing from the spirit and scope of the invention as defined by the items and are to be considered within the scope of this disclosure.

[0038] It will also be appreciated that systems, devices, products, kits, methods, and / or processes, according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and / or portions) described in other embodiments disclosed and / or described herein. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and / or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and / or portions without necessarily departing from the scope of the present disclosure.

[0039] Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems,methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein.

[0040] All references cited in this application are hereby incorporated in their entireties by reference to the extent that they are not inconsistent with the disclosure in this application. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques specifically described herein are intended to be encompassed by this invention.

[0041] When a group of materials, compositions, components, or compounds is disclosed herein, it is understood that all individual members of those groups and all subgroups thereof are disclosed separately. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and sub-combinations possible of the group are intended to be individually included in the disclosure. Every formulation or combination of components described or exemplified herein can be used to practice the invention, unless otherwise stated. Whenever a range is given in the specification, for example, a temperature range, a time range, or a composition range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure. All changes which come within the meaning and range of equivalency of the items are to be embraced within their scope.

[0042] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appendedclaims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

CLAIMSWhat is claimed is:

1. A hybrid compressor-pump, comprising: a gearbox; a central gear within the gearbox and configured to be driven by a driving system; one or more pumps configured to attach to the gearbox and be driven by the central gear; and one or more compressors configured to attach to the gearbox and be driven by the central gear; wherein each of the one or more pumps and one or more compressors each comprise one or more connection points such that the one or more pumps and one or more compressors can be arranged in a variety of orders of operations for treating a process fluid.

2. The hybrid compressor-pump of claim 1, wherein the central gear comprises a connection to a driving system.

3. The hybrid compressor-pump of claim 1, wherein at least one of the one or more compressors comprises an impeller configured to be driven by the central gear.

4. The hybrid compressor-pump of claim 1, wherein at least one of the one or more compressors comprises one or more variable inlet guide vanes.

5. The hybrid compressor-pump of claim 1, wherein at least one of the one or more compressors comprises one or more diffuser guide vanes.

6. The hybrid compressor-pump of claim 1, wherein the one or more pumps comprises one pump and the one or more compressors comprises three compressors.

7. The hybrid compressor-pump of claim 1, wherein the one or more pumps comprises two pump and the one or more compressors comprises two compressors.

8. A gearbox for a hybrid compressor-pump, comprising: a central gear configured to be driven by a driving system; one or more shafts configured to be driven by the central gear, each of the one or more shafts configured to drive a first of the one or more stages at one end and a second of the one or more stages at a second end; wherein the one or more connections lines allow the one or more stages to be configured in a variety of orders of operation to treat the process fluid.

9. The gearbox of claim 8, wherein the one or more stages comprises one or more pump stages and one or more compression stages.

10. The gearbox of claim 8, wherein a first of the one or more shafts is configured to drive the one pump stage at one end and one of the compression stages at the other end; and wherein a second of the one or more shafts is configured to drive a second of the compression stages at one end and the third compression stage at the other end.

11. The gearbox of claim 8, wherein the one or more stages comprises six or more stages and the one or more shafts comprises three or more shafts.

12. The gearbox of claim 8, wherein the one or more stages comprises less than six stages.

13. The gearbox of claim 8, wherein any compressor stage comprising the one or more stages comprises an impeller driven by one of the one or more shafts.

14. The gearbox of claim 8, further comprising a lubricant pump configured to supply lubricant to the central gear.

15. The gearbox of claim 8, wherein each compressor stage comprising the one or more stages comprises a suction inlet.16 The gearbox of claim 8, wherein the one or more stages comprises two pump stages and two compression stages.

17. A method of manufacturing a hybrid compressor-pump for a fluid treatment system, comprising: providing a central gear configured to be driven by a driving system; coupling one or more shafts to an outer edge of the central gear, the one or more shafts configured to be driven by the central gear and to drive one of one or more stages of the fluid treatment system at a first end and to drive another of the one or more stages at a second end; wherein the one or more stages can be coupled in a variety of orders of operation for treating a process fluid.

18. The method of claim 17, wherein the one or more stages comprise three compressor stages and one pump stage, and wherein the method further comprises coupling two compressor stages to one of the one or more shafts and coupling a third compressor stage and the pump stage to another of the one or more shafts.

19. The method of claim 17, further comprising coupling the one or more stages to the one or more shafts.

20. The method of claim 17, further comprising coupling an impeller to the one or more shafts for each compressor stage comprising the one or more stages.

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