Heat exchanger system

Abstract

To provide a heat exchanger system.SOLUTION: In one aspect, the disclosed embodiments relate to a system. The system may include a turbine and a regenerative heat exchanger system. The regenerative heat exchanger system is configured to receive the exhaust gas from the turbine. The regenerative heat exchanger system may include a pre-cooling section for cooling the exhaust gas, a primary heating section for receiving the cooled exhaust gas, and a secondary heating section for receiving the cooled exhaust gas.SELECTED DRAWING: None

Description

[Background technology]

[0001] Heat-to-power cycles typically use either an air-breathing gas turbine direct-fired Brayton cycle or an indirectly heated closed Rankine cycle using steam as the working fluid. High efficiency can be achieved by combining a Brayton cycle with a bottoming Rankine cycle to form a combined cycle. While combined-cycle power generation can achieve high efficiency, it is not suitable for CO2 capture, and installation can have high capital costs due to the large amount of equipment and piping required. In some cases, a supercritical CO2 (scCO2) Brayton heat-to-power cycle can be used in preference to a heat-to-power cycle. Advantageously, a supercritical CO2 (scCO2) Brayton heat-to-power cycle can have reduced greenhouse gas (GHG) emissions, improved carbon capture, higher efficiency, a reduced footprint, and lower water consumption. However, there are several technical challenges that must be overcome before the benefits of a supercritical CO2 (scCO2) Brayton heat-to-power cycle can be realized. In particular, the design and operation of regenerative heat exchangers for these supercritical CO2 (scCO2) Brayton heat and power cycles is an area of ​​ongoing research and development.

[0002] The semi-closed direct-ignition oxy-fuel Brayton cycle may be referred to as the Allam power cycle or Allam cycle. The Allam cycle is a process for converting fossil fuels into mechanical power while capturing the carbon dioxide and water generated. Traditionally, the Allam cycle requires an economizer heat exchanger and an additional low-grade external heat source to achieve high efficiencies comparable to existing combined-cycle-based technologies, with the significant added benefit of capturing CO2 for use or storage. The efficiency of the Allam cycle is increased when the turbine is operated at higher temperatures, typically above 600°C, and at high pressures of 120 to 400 bar. These conditions lead to the simultaneous requirements of high pressure, high temperature, and high efficiency for the heat exchange system. Typically, multiple individual heat exchange units must be arranged in a network to achieve the required regenerative heat exchange while simultaneously recovering heat from an external low-grade heat source. Examples of conventional heat exchanger systems and methods can be found in U.S. Pat. No. 8,272,429, U.S. Pat. No. 8,596,075, U.S. Pat. No. 8,959,887, U.S. Pat. No. 10,018,115, U.S. Pat. No. 10,422,252, and U.S. Patent Publication No. 2019 / 0063319, all of which are incorporated herein by reference.

[0003] Conventionally, heat exchanger systems may be divided into high, medium, and low temperature sections. While it is desirable to cool the exhaust gas in the high temperature section to a minimum temperature (e.g., a temperature consistent with the low heat source temperature), this conflicts with mechanical requirements that drive the layout, cost, and reliability of such systems. Typically, the design temperature and pressure of the high temperature section are set by the maximum temperature and pressure, which in turn drives the mechanical requirements. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 8,272,429 [Patent Document 2] U.S. Patent No. 8,596,075 [Patent Document 3] U.S. Patent No. 8,959,887 [Patent Document 4] U.S. Patent No. 10,018,115 [Patent Document 5] U.S. Patent No. 10,422,252 [Patent Document 6] US Patent Application Publication No. 2019 / 0063319 Summary of the Invention [Means for solving the problem]

[0005] This description is provided to introduce a selection of concepts that are further described below in the Detailed Description. This description is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0006] In one aspect, embodiments disclosed herein relate to a system. The system may include a turbine and a regenerative heat exchanger system configured to receive exhaust gas from the turbine. The regenerative heat exchanger system may include a pre-cooling section for cooling the exhaust gas, a main heating section for receiving the cooled exhaust gas, and a sub-heating section for receiving the cooled exhaust gas.

[0007] In another aspect, embodiments disclosed herein relate to a method that may include producing an exhaust gas through a turbine, feeding the exhaust gas into a pre-cooling section of a regenerative heat exchanger system to cool the exhaust gas, splitting the cooled exhaust gas into a main flow path feeding the main heating section of the regenerative heat exchanger system and a secondary flow path feeding the cooled exhaust gas into a secondary heating section of the regenerative heat exchanger system, flowing the cooled exhaust gas in the secondary flow path through a first secondary heat exchanger of the secondary heating section and a second secondary heat exchanger of the secondary heating section, flowing the cooled exhaust gas in the main flow path through a first main heat exchanger of the main heating section, a second main heat exchanger of the main heating section, and a third main heat exchanger of the main heating section, and providing a fluid flow from the main flow path and the secondary flow path to a combustor coupled to the turbine.

[0008] In yet another aspect, embodiments disclosed herein relate to a pre-cooling heat exchanger. The pre-cooling heat exchanger may include a first annular shell forming a pressure boundary. The first annular shell may have an exhaust gas inlet configured to receive exhaust gas from the turbine and one or more exhaust outlets configured to exhaust the exhaust gas. The pre-cooling heat exchanger may also include a second annular shell provided within the first annular shell. The pre-cooling heat exchanger may further include a tube bundle provided within the second annular shell. Additionally, an annular distribution device may be provided within the second annular shell, the annular distribution device configured to control the exhaust gas flow rate into the tube bundle.

[0009] In one aspect, embodiments disclosed herein relate to a regenerative heat exchanger system. The regenerative heat exchanger system may include a pre-cooling section with a first rigid framework, a sub-section within a third rigid framework, and a first main section within a second rigid framework. The pre-cooling section may include one or more heat exchangers to receive and cool the exhaust gas. The sub-section may include a first secondary heat exchanger and a second secondary heat exchanger. The first main section may include a first main heat exchanger, a second main heat exchanger, and a third main heat exchanger.

[0010] In another aspect, embodiments disclosed herein relate to a method including cooling exhaust gas using a pre-cooling section with a first rigid framework, splitting the exhaust gas using a manifold positioned outside the first rigid framework to flow into a first main section within a second rigid framework, a second main section within a third rigid framework, and a sub-section within the third rigid framework, flowing the exhaust gas through one or more curved flow loops within the sub-sections, through a first secondary heat exchanger of the sub-sections, and to a second secondary heat exchanger of the sub-sections, and flowing the exhaust gas through one or more curved flow loops within the first main section. The method may include flowing the exhaust gas via a loop through a first main heat exchanger of the first main section to a second main heat exchanger of the first main section and then to a third main heat exchanger of the first main section; flowing the exhaust gas within the second main section through one or more curved flow loops through the first main heat exchanger of the second main section to the second main heat exchanger of the second main section and then to the third main heat exchanger of the second main section; and flowing the exhaust gas via a secondary curved flow loop from the second secondary heat exchanger, the third main heat exchanger of the first main section, and the third main heat exchanger of the second main section to an exhaust gas manifold.

[0011] In one aspect, embodiments disclosed herein relate to a heat exchanger system including a rigid framework. A first heat exchanger may be coupled to a first support structure on top of the rigid framework. A second heat exchanger may be positioned below the first heat exchanger. The second heat exchanger may be coupled to a second support structure, the second support structure suspended from the rigid framework via a first set of tethers, the first set of tethers configured to move the second support structure vertically and horizontally. A second set of tethers may be connected to the second support structure and extend downward to suspend a support beam. A third set of tethers may be connected to the support beam and extend downward to suspend a third support structure, the third set of tethers configured to move the third support structure vertically and horizontally. A third heat exchanger may be coupled to the third support structure. The vertical and horizontal movement of the second support structure may be based on thermal expansion of the second heat exchanger. The vertical and horizontal movement of the third support structure may be based on thermal expansion of the third heat exchanger.

[0012] In another aspect, embodiments disclosed herein relate to a heat exchanger system including a rigid framework. A first heat exchanger may be coupled to a first support structure on top of the rigid framework. A second heat exchanger may be positioned below the first heat exchanger. The second heat exchanger may be coupled to a second support structure. The second support structure may be suspended from the rigid framework via a first set of tethers. The first set of tethers may be configured to move the second support structure vertically and horizontally. The vertical and horizontal movement of the second support structure may be based on thermal expansion of the second heat exchanger.

[0013] In yet another aspect, embodiments disclosed herein relate to a heat exchanger system including a rigid framework. A first support structure may be suspended from the rigid framework via a first set of tethers having one end coupled to the rigid framework and another end coupled to the first support structure. The first set of tethers may be configured to move the first support structure vertically and horizontally. A first heat exchanger may be coupled to the first support structure. A second set of tethers may be connected to the first support structure and extend downward to suspend a support beam. A third set of tethers may be connected to the support beam and extend downward to suspend a second support structure. The third set of tethers may be configured to move the second support structure vertically and horizontally. A second heat exchanger may be coupled to the second support structure. The vertical and horizontal movement of the first support structure may be based on thermal expansion of the first heat exchanger. The vertical and horizontal movement of the second support structure may be based on the thermal expansion of the second heat exchanger.

[0014] Other aspects and advantages of the present invention will become apparent from the following description and appended claims. The present invention provides, for example, the following. (Item 1) 1. A system comprising: The turbine and a regenerative heat exchanger system configured to receive exhaust gas from the turbine, the regenerative heat exchanger system comprising: a pre-cooling section for cooling the exhaust gas; a main heating section for receiving the cooled exhaust gas; a sub-heating section for receiving the cooled exhaust gas; a regenerative heat exchanger system comprising: A system comprising: (Item 2) Item 1. The system of item 1, wherein the pre-cooling section further comprises one or more shells and a tube heat exchanger with an annular distributor, and the system is configured such that fluid exiting an end of the sub-heating section flows into the pre-cooling section. (Item 3) Item 10. The system of item 1, wherein the main heating section operates at a higher temperature than the secondary heating section. (Item 4) Item 10. The system of claim 1, wherein the main heating section further comprises at least two heat exchangers in series, the at least two heat exchangers being printed circuit type heat exchangers and vertically arrayed. (Item 5) Item 1, wherein the sub-heating section further comprises at least two heat exchangers in series, the at least two heat exchangers being printed circuit type heat exchangers and vertically stacked and arrayed. (Item 6) Item 1. The system of claim 1, wherein the regenerative heat exchanger system further comprises a heat recovery section configured to add heat to the recycle heating section. (Item 7) Item 1. The system of item 1, wherein the primary heating section is a recycle heating section and the secondary heating section is an oxidant heating section. (Item 8) Item 10. The system of item 1, further comprising one or more valves configured to balance flow between the main heating section and the secondary heating section. (Item 9) Item 10. The system of item 1, further comprising a manifold configured to split flow from the pre-cooling section to the main heating section and the secondary heating section. (Item 10) 1. A method comprising: producing exhaust gases via a turbine; feeding the exhaust gas into a pre-cooling section of a regenerative heat exchanger system to cool the exhaust gas; splitting the cooled exhaust gas into a primary flow path that feeds a primary heating section of the regenerative heat exchanger system and a secondary flow path that feeds a secondary heating section of the regenerative heat exchanger system; flowing the cooled exhaust gas through a first auxiliary heat exchanger of the sub-heating section and a second auxiliary heat exchanger of the sub-heating section in the sub-flow path; flowing the cooled exhaust gas in the main flow path through a first main heat exchanger of the main heating section, a second main heat exchanger of the main heating section, and a third main heat exchanger of the main heating section; providing fluid flow from the primary flow path and the secondary flow path to a combustor coupled to the turbine; A method comprising: (Item 11) 11. The method of claim 10, further comprising cooling the exhaust gas in the pre-cooling section to a temperature of 575°C. (Item 12) Item 11. The method according to item 10, further comprising heating the secondary flow path to a temperature of 350 to 500°C. (Item 13) Item 11. The method of item 10, further comprising heating the main flow path to a temperature of 520 to 650°C. (Item 14) Item 11. The method of claim 10, further comprising adding heat to the primary flow path via a heat source. (Item 15) 11. The method of claim 10, further comprising balancing the split of the cooled exhaust gas into the primary and secondary flow paths with one or more valves. (Item 16) A pre-cooling heat exchanger, a first annular shell forming a pressure boundary, said first annular shell comprising: an exhaust gas inlet configured to receive exhaust gas from the turbine; one or more exhaust outlets configured to exhaust the exhaust gas; a first annular shell comprising: a second annular shell provided within the first annular shell; a tube bundle provided within the second annular shell; and an annular dispersion device provided within the second annular shell, the annular dispersion device configured to control exhaust gas flow rate into the tube bundle; A pre-cooling heat exchanger comprising: (Item 17) Item 17. The pre-cooling heat exchanger according to item 16, wherein the tube bundle is a U-tube bundle. (Item 18) Item 18. The pre-cooling heat exchanger of item 17, further comprising a support plate within the first annular shell configured to support the weight of the U-tube bundle. (Item 19) Item 17. The pre-cooling heat exchanger of item 16, further comprising a stationary head channel at an end of the first annular shell, the stationary head channel comprising an inlet configured to receive oxidant from the sub-heating section and an outlet configured to allow the oxidant to flow out. (Item 20) 20. The pre-cooling heat exchanger of claim 19, wherein the stationary head channel further comprises a passage partition configured to split the flow between the inlet and the outlet. (Item 21) 1. A regenerative heat exchanger system comprising: a pre-cooling section within a first rigid framework, said pre-cooling section comprising one or more heat exchangers for receiving and cooling exhaust gases; a subsection within a third rigid framework, the subsection comprising a first secondary heat exchanger and a second secondary heat exchanger; a first main section within a second rigid framework, said first main section comprising a first main heat exchanger, a second main heat exchanger, and a third main heat exchanger; A regenerative heat exchanger system comprising: (Item 22) Item 22. The regenerative heat exchanger system of item 21, further comprising a manifold configured to split the cooled exhaust gas stream from the pre-cooling section into the first main section and the sub-section. (Item 23) Item 23. The regenerative heat exchanger system of item 22, wherein the manifold is positioned within a space between the first rigid framework, the second rigid framework, and the third rigid framework. (Item 24) Item 22. The regenerative heat exchanger system of item 21, further comprising a second main section within a fourth rigid framework, the second main section comprising a fourth main heat exchanger, a fifth main heat exchanger, and a sixth main heat exchanger. (Item 25) 25. The regenerative heat exchanger system of claim 24, further comprising one or more valves to balance the split of the cooled exhaust gas stream into the first main section, the second main section, and the sub-section. (Item 26) Item 25. The regenerative heat exchanger system of item 24, further comprising a heat recovery section connected to the first main section and the second main section. (Item 27) Item 25. The regenerative heat exchanger system of item 24, wherein the first rigid framework, the second rigid framework, the third rigid framework, and the fourth rigid framework are each formed by a plurality of vertically oriented structural members and a plurality of horizontally oriented structural members interconnected together. (Item 28) 22. The regenerative heat exchanger system of claim 21, wherein the one or more shell-and-tube heat exchangers include a precooler inlet on the shell side to receive the exhaust gas. (Item 29) 22. The regenerative heat exchanger system of claim 21, further comprising a first recycled CO2 manifold for providing recycled CO2 into the regenerative heat exchanger system. (Item 30) 30. The regenerative heat exchanger system of claim 29, further comprising a second recycled CO2 manifold for allowing the recycled CO2 to flow out of the regenerative heat exchanger system. (Item 31) 22. The regenerative heat exchanger system of claim 21, wherein the one or more shell-and-tube heat exchangers include an oxidant inlet on the tube side to receive oxidant from the subsection. (Item 32) 22. The regenerative heat exchanger system of claim 21, wherein the one or more shell-and-tube heat exchangers include an oxidant inlet on the tube side to receive oxidant from the subsection. (Item 33) 1. A method comprising: cooling the exhaust gas using a pre-cooling section within a first rigid framework; splitting the exhaust gas into a first main section within a second rigid framework, a second main section within a third rigid framework, and a sub-section within a third rigid framework using a manifold positioned outside the first rigid framework; flowing the exhaust gas within the subsection through one or more tortuous flow loops, through a first secondary heat exchanger of the subsection, to a second secondary heat exchanger of the subsection; flowing the exhaust gas through one or more tortuous flow loops within the first main section, through a first main heat exchanger of the first main section, to a second main heat exchanger of the first main section, and then to a third main heat exchanger of the first main section; flowing the exhaust gas through one or more tortuous flow loops within the second main section, through a first main heat exchanger of the second main section, to a second main heat exchanger of the second main section, and then to a third main heat exchanger of the second main section; flowing the exhaust gas from the second auxiliary heat exchanger, the third main heat exchanger of the first main section, and the third main heat exchanger of the second main section through a secondary curved flow loop to an exhaust gas manifold; A method comprising: (Item 34) 34. The method of claim 33, further comprising operating the first secondary heat exchanger at a higher temperature than the second secondary heat exchanger. (Item 35) Item 34. The method of item 33, further comprising operating a first main heat exchanger of the first main section at a higher temperature than a second main heat exchanger of the first main section, and operating a second main heat exchanger of the first main section at a higher temperature than a third main heat exchanger of the first main section. (Item 36) Item 34. The method of item 33, further comprising operating a first main heat exchanger of the second main section at a higher temperature than a second main heat exchanger of the second main section, and operating a second main heat exchanger of the second main section at a higher temperature than a third main heat exchanger of the second main section. (Item 37) 34. The method of claim 33, further comprising distributing recycled CO2 to the first main section and the second main section via a first recycled CO2 manifold. (Item 38) 38. The method of claim 37, further comprising heating the recycled CO2 using the first main section and the second main section, and flowing the heated recycled CO2 out through a second recycled CO2 manifold. (Item 39) 34. The method of claim 33, further comprising providing an oxidant to the pre-cooling section via an oxidant manifold. (Item 40) 34. The method of claim 33, further comprising providing heat to the first main section and the second main section via a heat recovery section. (Item 41) 1. A heat exchanger system comprising: A rigid framework; a first heat exchanger coupled to a first support structure on top of the rigid framework; a second heat exchanger positioned below the first heat exchanger, the second heat exchanger coupled to a second support structure, the second support structure suspended from the rigid framework via a first set of tethers configured to move the second support structure vertically and horizontally; and a second set of tethers connected to the second support structure and extending downward to suspend the support beam; a third set of tethers connected to the support beams and extending downward to suspend a third support structure, the third set of tethers being configured to move the third support structure vertically and horizontally; a third heat exchanger coupled to the third support structure; Equipped with the vertical and horizontal movement of the second support structure is based on thermal expansion of the second heat exchanger; the vertical and horizontal movement of the third support structure is based on thermal expansion of the third heat exchanger; Heat exchanger system. (Item 42) Item 42. The heat exchanger system of item 41, wherein the first heat exchanger is configured to operate at a higher temperature than the second heat exchanger, and the second heat exchanger is configured to operate at a higher temperature than the third heat exchanger. (Item 43) Item 42. The heat exchanger system of item 41, wherein the first set of tethers, the second set of tethers, and the third set of tethers are selected from structural tension members, steel rods, chain links, or wire ropes. (Item 44) Item 42. The heat exchanger system of item 41, wherein the first set of tethers and the third set of tethers are angled. (Item 45) Item 42. The heat exchanger system of item 41, wherein the rigid framework comprises two pillars spaced a distance from each other. (Item 46) Item 46. The heat exchanger system of item 45, wherein the first heat exchanger, the second heat exchanger, and the third heat exchanger are located between the two columns. (Item 47) Item 46. The heat exchanger system of item 45, wherein a first end of each of the two pillars is removably secured to the floor. (Item 48) Item 48. The heat exchanger system of item 47, wherein the first support structure is movably coupled to a second end of each of the two pillars distal to the first end. (Item 49) Item 42. The heat exchanger system of item 41, further comprising one or more protrusions extending from the rigid framework, wherein ends of the first set of tethers are connected to the one or more protrusions. (Item 50) Item 42. The heat exchanger system of item 41, wherein the first heat exchanger is thermally decoupled from the second heat exchanger, and the second heat exchanger is thermally decoupled from the third heat exchanger. (Item 51) 1. A heat exchanger system comprising: A rigid framework; a first heat exchanger coupled to a first support structure on top of the rigid framework; a second heat exchanger positioned below the first heat exchanger, the second heat exchanger coupled to a second support structure, the second support structure suspended from the rigid framework via a first set of tethers configured to move the second support structure vertically and horizontally; and Equipped with A heat exchanger system, wherein the vertical and horizontal movement of the second support structure is based on thermal expansion of the second heat exchanger. (Item 52) Item 52. The heat exchanger system of item 51, wherein the first heat exchanger is thermally decoupled from the second heat exchanger. (Item 53) Item 52. The heat exchanger system of item 51, wherein the first set of tethers is angled. (Item 54) Item 54. The heat exchanger system of item 53, wherein the ends of the first set of tethers are connected to the rigid framework and the second support structure via a rack and pinion or gear-driven cam. (Item 55) Item 54. The heat exchanger system of item 53, wherein the angle of the first set of tethers is selected based on a predetermined thermal expansion or contraction. (Item 56) Item 52. The heat exchanger system of item 51, wherein the first heat exchanger is configured to operate at a higher temperature than the second heat exchanger. (Item 57) 1. A heat exchanger system comprising: A rigid framework; a first support structure suspended from the rigid framework via a set of first tethers having one end coupled to the rigid framework and another end coupled to the first support structure, the set of first tethers configured to move the first support structure vertically and horizontally; and a first heat exchanger coupled to the first support structure; a second set of tethers connected to the first support structure and extending downward to suspend a support beam; a third set of tethers connected to the support beams and extending downward to suspend a second support structure, the third set of tethers being configured to move the second support structure vertically and horizontally; and a second heat exchanger coupled to the second support structure; Equipped with the vertical and horizontal movement of the first support structure is based on thermal expansion of the first heat exchanger; the vertical and horizontal movement of the second support structure is based on thermal expansion of the second heat exchanger; Heat exchanger system. (Item 58) Item 58. The heat exchanger system of item 57, wherein the first heat exchanger is thermally decoupled from the second heat exchanger. (Item 59) Item 58. The heat exchanger system of item 57, wherein the first set of tethers and the third set of tethers are angled. (Item 60) Item 58. The heat exchanger system of item 57, wherein the first heat exchanger is configured to operate at a higher temperature than the second heat exchanger. [Brief explanation of the drawings]

[0015] [Figure 1A] 1A and 1B illustrate schematic diagrams of a power generation system according to one or more embodiments of the present disclosure. [Figure 1B] 1A and 1B illustrate schematic diagrams of a power generation system according to one or more embodiments of the present disclosure.

[0016] [Figure 2] FIG. 2 illustrates a schematic diagram of a regenerative heat exchanger according to one or more embodiments of the system of the present disclosure.

[0017] [Figure 3] FIG. 3 is a cross-sectional view of a pre-cooling heat exchanger according to one or more embodiments of the present disclosure.

[0018] [Figure 4A] 4A and 4B illustrate perspective views of a regenerative heat exchanger according to one or more embodiments of the system of the present disclosure. [Figure 4B] 4A and 4B illustrate perspective views of a regenerative heat exchanger according to one or more embodiments of the system of the present disclosure.

[0019] [Figure 4C] FIG. 4C is a side view of the regenerative heat exchanger system of FIGS. 4A and 4B according to one or more embodiments of the present disclosure.

[0020] [Figure 4D] FIG. 4D is a top view of the regenerative heat exchanger system of FIGS. 4A and 4B according to one or more embodiments of the present disclosure.

[0021] [Figure 5A]FIG. 5A is a side view of a heat exchanger according to one or more embodiments of the system of the present disclosure.

[0022] [Figure 5B] FIG. 5B is a side view of the heat exchanger suspension system of FIG. 5A according to one or more embodiments of the present disclosure.

[0023] [Figure 6] 6-9 are side views of heat exchanger systems according to one or more alternative embodiments of FIG. 5A. [Figure 7] 6-9 are side views of heat exchanger systems according to one or more alternative embodiments of FIG. 5A. [Figure 8] 6-9 are side views of heat exchanger systems according to one or more alternative embodiments of FIG. 5A. [Figure 9] 6-9 are side views of heat exchanger systems according to one or more alternative embodiments of FIG. 5A. DETAILED DESCRIPTION OF THE INVENTION

[0024] Detailed Description Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. Like elements in various figures may be designated by like reference numerals for consistency. Moreover, in the following detailed description, numerous specific details are set forth to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to those skilled in the art that the described embodiments may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. As used herein, the terms "coupled" or "coupled to" or "connected" or "connected to" may indicate establishing either a direct or indirect connection and are not limited to either unless expressly stated as such. As used herein, fluid may refer to a slurry, liquid, gas, and / or mixtures thereof. Wherever possible, similar or identical reference numbers are used in the figures to identify common or identical elements. The figures are not necessarily to scale, and certain features and perspectives of the figures may be shown exaggerated in size for purposes of illustration.

[0025] In one aspect, embodiments disclosed herein relate to power generation systems for power generation, petrochemical plants, waste heat recovery, and other industrial applications. Power generation systems may also be referred to in this disclosure as regenerative heat exchanger systems, synonymously with a heat exchanger network or assembly. In addition, regenerative heat exchanger systems may incorporate a pre-cooling section to reduce turbine exhaust gas temperatures. Regenerative heat exchanger systems may minimize heat exchanger life cycle costs, which are essential for efficient regenerative thermal energy exchange at high pressures and with high thermal effectiveness. In some embodiments, regenerative heat exchanger systems may be used for supercritical carbon dioxide (scCO2) power cycles, such as the Allam cycle.

[0026] In another aspect, embodiments disclosed herein relate to regenerative heat exchanger systems for power generation, petrochemical plants, waste heat recovery, and other industrial applications. A regenerative heat exchanger system may also be synonymously referred to as a heat exchanger network or assembly in this disclosure. Additionally, a regenerative heat exchanger system may incorporate a pre-cooling section to reduce turbine exhaust gas temperatures. A regenerative heat exchanger system may minimize heat exchanger life cycle costs, which are essential for efficient regenerative thermal energy exchange at high pressures and with high thermal effectiveness. In some embodiments, a regenerative heat exchanger system may be used for supercritical carbon dioxide (scCO2) power cycles, such as the Allam cycle.

[0027] In yet another aspect, embodiments disclosed herein relate to heat exchanger systems for power generation, petrochemical plants, waste heat recovery, and other industrial applications. A heat exchanger system may also be synonymously referred to as a heat exchanger network or assembly in this disclosure. Additionally, a heat exchanger system may incorporate a heat exchanger suspension system to minimize expansion stresses resulting from thermal expansion of the heat exchanger and interconnecting piping. The heat exchanger suspension system may minimize the life cycle costs of the heat exchanger, which is essential for efficient regenerative thermal energy exchange at high pressures and with high thermal effectiveness. In some embodiments, the heat exchanger suspension system may be used for supercritical carbon dioxide (scCO2) power cycles, such as the Allam cycle.

[0028] A regenerative heat exchanger system according to embodiments herein may include a combination of printed circuit type (PCHE) and shell and tube type (STHE) heat exchangers. For example, a regenerative heat exchanger system may include a pre-cooling section, a main heating section (recycle heating), and a secondary heating section (oxidant heating). In some embodiments, a heat recovery section may optionally be connected to the main heating section and / or the secondary heating section.

[0029] In one or more embodiments, the regenerative heat exchanger system may use a heat exchanger network incorporating parallel sections for heating a secondary portion of the high-pressure gas and a primary portion of the high-pressure gas. The secondary portion may consist of oxygen containing CO (oxidant), and the primary portion may consist of the remainder of the recycled CO (recycled CO). The two parallel sections may have substantially different temperature profiles. In a non-limiting example, the primary portion (approximately 75% of the total flow, in the range of 51-90%) may be heated to a lower temperature than the secondary portion. The secondary portion may first be heated to an intermediate temperature of approximately 440°C (in the range of 350-550°C) before being used to pre-cool the entire hot exhaust stream from a high temperature of approximately 600°C (in the range of 550-850°C) to a temperature low enough to avoid significant mechanical design constraints, particularly below 575°C. The 575°C limit may represent a mechanical design constraint when a diffusion-bonded PCHE is employed and fabricated from austenitic stainless steels, particularly alloy 316 / 316L. The PCHE alloy 316 block may require allowable stresses determined from time-dependent (creep) properties at temperatures above 575°C. Additionally, a heat recovery section may be provided within the regenerative heat exchanger system. The heat recovery section may add heat, e.g., low-grade heat, at temperatures below the combustion temperature.

[0030] Conventional power generation systems in industrial applications are typically significantly larger and heavier. They require a large amount of space and can include extensive layouts and arrangements of piping, each weighing tens of tons. In some cases, large heat exchangers connected in series can include complex bends or changes in orientation. In addition, large manifolds are required to introduce fluid into the heat exchange and when the fluid exits the heat exchange. Such power generation systems can be both heavier in weight and more expensive to manufacture due to the greater number of parts and components. For example, stress loops are used in the system to accommodate piping expansion. This additional piping of the stress loops required to connect the various manifolds and heat exchangers together adds to the weight, installation costs, and overall cost of the power generation system.

[0031] Thus, one or more embodiments of the present disclosure may be used to overcome such challenges and provide additional advantages over conventional power generation systems, as will be apparent to those skilled in the art. In one or more embodiments, the regenerative heat exchanger system may be lighter in weight and lower in cost compared to conventional power generation systems, due in part to minimized creep fatigue / damage, independent oxidant and recycle sections such that exhaust fluid flow splitting can be controlled using one or more cryogenic valves, and exhaust fluid exiting the turbine not requiring an equalization vessel to be installed between the turbine and the regenerative heat exchanger. Additionally, the regenerative heat exchanger system may increase reliability and performance over thousands of hours, even though some components of the regenerative heat exchanger system are subjected to high pressures, high temperatures, and high operating cycles. Overall, the regenerative heat exchanger system may minimize risks associated with product engineering, flow loop manufacturing, shorten assembly time, reduce hardware costs, and reduce weight and envelope.

[0032] Turning to FIG. 1A , FIG. 1A illustrates a schematic diagram of a power generation system 100 according to one or more embodiments of the present disclosure. In one or more embodiments, a turbine 101 may be powered by a fuel source 102 via a combustor 103. As known in the art, a turbine, such as turbine 101, may be a structure useful for extracting energy from a fluid flow and converting the fluid flow into useful work, such as to drive a generator and produce electricity, and is often a rotating device with other components (i.e., a rotor, a stator, and / or turbine blades) having various functions related to producing or converting mechanical energy. Note that turbine 101, in one or more embodiments, may be configured as a gas or steam turbine. Combustor 103 may be the component of turbine 101 where combustion occurs, such as a chamber. Additionally, an oxygen source 112 may be provided to feed oxygen into combustor 103. As known to those skilled in the art, turbine 101 may produce exhaust gases 104. The exhaust gas 104 may be fed into a regenerative heat exchanger system 105 (see dotted square) to form the turbine exhaust gas stream.

[0033] In one or more embodiments, the regenerative heat exchanger system 105 may include a pre-cooling section 200, a main heating section 301, and a secondary heating section 302. In some embodiments, the main heating section 301 may be a recycle heating section, and the secondary heating section 302 may be an oxidant heating section. The pre-cooling section 200 may be a high-temperature pre-cooler having a shell and tube type structure, and the shell may be combined with an annular distributor. Both the main section 301 and the secondary section 302 may include at least two heat exchangers stacked vertically on top of each other to form a vertical modular heat exchanger stack.

[0034] Still referring to FIG. 1A , all of the exhaust gas 104 exiting the turbine may be fed into the pre-cooling section 200. The pre-cooling section 200 may cool the exhaust gas 104 relative to a subportion of the high-pressure gas to be heated, preferably relative to the oxidant stream, before redistribution to the independent parallel trains (e.g., the main section 301 and the sub-section 302). In this manner, the exhaust gas 104 may be cooled directly upon entering the main section 301 and the sub-section 302, significantly reducing costs and increasing reliability. Additionally, a manifold 205 may optionally be used to split the cooled exhaust gas 104 into flows entering the main section 301 and the sub-section 302. The cooled exhaust gas 104 may be split into a main flow path 131 feeding into the main section 301 and a sub-flow path 130 feeding into the sub-section 302. Additionally, one or more valves 106 may be used to balance the split of exhaust gas flow 104 flowing from main section 301 into sub-section 302. Additionally, flow resistance may be provided in both main section 301 and sub-section 302 to balance the flow of exhaust gas 104. Additionally, flow may exit main section 301 via flow line 133, while flow may exit sub-section 302 via flow line 132. In some embodiments, one or more valves 106 may be provided on flow line 132.

[0035] In some embodiments, a heat recovery system may be operatively coupled to the regenerative heat exchanger system 105. The heat recovery system may add heat at temperatures below the combustion temperature. Further examples of heat recovery systems include, but are not limited to, adding heat directly or indirectly to the turbine exhaust gas stream (via low-grade heat source 108), recovering heat from an air separation unit (ASU) coupled to the compressor (not shown), or recovering heat from a recycle gas compressor discharge from the compressor (not shown). In non-limiting examples, flow line 134 from pump 111 may feed into subsection 302, while flow line 135 from pump 111 may feed into main section 301. Additionally, separator 109 may separate liquid condensate from the exhaust gas so that liquid condensate 109a may be collected. Furthermore, compressor 110 may be coupled to separator 109. Additionally, a discharge flow line 138 may be provided from pump 111 for product carbon dioxide (CO2) to exit power generation system 100. In some embodiments, a heat recovery system may be incorporated into main section 301. It is further contemplated that a series of manifolds within the recycle and heat recovery sections may be used to redistribute the recycled high-pressure carbon dioxide and provide dew points for various turbine cooling streams, as may be required. Additionally, a first flow return line 136 from main section 301 and a second flow return line 137 from sub-section 302 may be used to provide fluid flows from main section 301 and sub-section 302 to combustor 103.

[0036] Referring now to FIG. 1B , another embodiment of the power generation system 100 according to embodiments herein is illustrated, with like numbers representing like parts. The embodiment of FIG. 1B is similar to that of FIG. 1A . However, instead of only one heat exchanger, both the main section 301 and the sub-section 302 may include two or more vertical modular heat exchangers stacked in series. The PCHE block may have a maximum size based on the plate size that can be accommodated within the diffusion-bonded furnace, and therefore, it may be beneficial to have more than one vertical modular heat exchanger stack. In some embodiments, there may be a need to redistribute high-pressure flow between the main section 301 and the heat recovery section, and therefore, it may be beneficial to have more than one vertical modular heat exchanger stack.

[0037] 2 illustrates an expanded schematic view of the regenerative heat exchanger system 105, where like numbers represent like parts, according to embodiments herein. As indicated by arrow 104, exhaust gases exiting the turbine may enter the pre-cooling section 200 via one or more transport pipes. In a non-limiting example, four nominally identical transport pipes may be used to transport the exhaust gases (arrows 104) to the pre-cooling section 200. It should be noted that any number of transport pipes may be used without departing from the scope of the present disclosure.

[0038] In one or more embodiments, the pre-cooling section 200 may include one or more shell-and-tube heat exchangers (“STHEs”) 201. The STHEs ​​201 of the pre-cooling section 200 may be made from a material selected from Inconel materials (e.g., alloy 625 or alloy 617) or similar materials that do not undergo time-dependent properties at their highest temperatures. One or more transport piping may be connected to the shell-side 202 of the STHE 201. In a non-limiting example, each STHE 201 may have one transport piping connected to it. On the tube-side 203 of the STHE 201, the STHE 201 may receive a fluid flow (e.g., oxidant fluid) from the sub-sections (302a, 302b). In some embodiments, the mass heat capacity (e.g., mass flow × specific heat capacity) of the tube-side fluid of the STHE 201 may be lower than the mass heat capacity of the exhaust gas (arrow 104) entering the STHE 201 on the shell-side 202. Due to the lower mass heat capacity of the oxidant fluid on the tube side, the temperature change of the exhaust gas may be small (e.g., 15-50°C), while the temperature change of the oxidant stream may be large (e.g., 100-200°C). It is further contemplated that STHE 201 may include a heated oxidant outlet 204 through which the oxidant stream exits. From STHE 201, the exhaust gas may enter a manifold 205, splitting the exhaust gas stream.

[0039] In some embodiments, manifold 205 may split the exhaust gas along various flow paths. In a non-limiting example, manifold 205 splits the exhaust gas into two flow paths, such as a secondary exhaust gas flow 206 and a primary exhaust gas flow 207.

[0040] In the exhaust gas substream 206, the exhaust gas flows through a subsection having a first secondary heat exchanger 302a and a second secondary heat exchanger 302b. Both the first secondary heat exchanger 302a and the second secondary heat exchanger 302b may be a printed circuit type heat exchanger ("PCHE"), a coil-wound type heat exchanger, a microtube heat exchanger, an etched plate with stamped fins, a diffusion-bonded exchanger, or any other type of heat exchanger. Additionally, both the first secondary heat exchanger 302a and the second secondary heat exchanger 302b may be constructed from a suitable material, such as dual-certified stainless steel 316 / 316L. Additionally, the first secondary heat exchanger 302a may be operated at a higher temperature than the second secondary heat exchanger 302b. Furthermore, the exhaust gas may be used to preheat the substream 134 to 350-500°C. In some embodiments, both the first secondary heat exchanger 302a and the second secondary heat exchanger 302b may be used for oxidant heating.

[0041] In the mainstream exhaust gas flow 207, the exhaust gas flows through a main section having a first main heat exchanger 301a, a second main heat exchanger 301b, and a third main heat exchanger 301c. Each of the main heat exchangers 301a, 301b, and 301c may be a printed circuit type heat exchanger ("PCHE"), a coil-wound type heat exchanger, a microtube heat exchanger, a diffusion-bonded exchanger using etched plates and stamped fins, or any other type of heat exchanger. Additionally, the first main heat exchanger 301a may operate at the highest temperature within the main section, while the third main heat exchanger 301c may operate at the lowest temperature within the main section. The second main heat exchanger 301b may operate at a temperature between the first main heat exchanger 301a and the third main heat exchanger 301c. Additionally, each of the main heat exchangers 301a, 301b, and 301c may be constructed from dual-certified stainless steel 316 / 316L material. Furthermore, the main exhaust gas flow 207 may be used to preheat the main exhaust gas flow 135 to 520-650°C. In some embodiments, each of the main heat exchangers 301a, 301b, and 301c may be used to heat recycled CO2. Additionally, a second flow line 304 may be used to provide a cooling stream to the turbine. In a non-limiting example, the cooling stream may be recycled gas exiting 107a or 301b. In some cases, the temperature of the cooling stream may not match the required turbine coolant temperature. To meet the required turbine coolant temperature, hot or cold gas may be added to the cooling stream to raise or lower its temperature to match the required turbine coolant temperature. In some embodiments, the cooling stream may be a blended mixture of a recycle stream exiting 107a or 301b and a higher temperature recycle stream exiting 301a.

[0042] In some embodiments, flow balancing of gas exhaust between the sub-sections (302a, 302b) and the main sections (301a, 301b, 301c) may be controlled by flow resistance within the sub-sections (302a, 302b) and the main sections (301a, 301b, 301c). In a non-limiting example, one or more valves at the outlets (i.e., cold ends) of the sub-sections (302a, 302b) may be used for flow balancing.

[0043] In the heat recovery stream 208, recycled exhaust gas or a separate low-grade heat stream may be used to add heat at temperatures below the combustion temperature via the first and second recuperator heat exchangers 107a and 107b. In some embodiments, the recycled exhaust gas may be reheated and recycled back through the heat recovery sections 107a and 107b. Both the first and second recuperator heat exchangers 107a and 107b may be printed circuit type heat exchangers ("PCHEs"), coil-wound type heat exchangers, microtube heat exchangers, diffusion-bonded exchangers using etched plates and stamped fins, or any other type of heat exchanger. Additionally, both the first and second recuperator heat exchangers 107a and 107b may be constructed from suitable materials, such as dual-certified stainless steel 316 / 316L. Additionally, the first recuperator heat exchanger 107a may be at a higher temperature than the second recuperator heat exchanger 107b. In some embodiments, the first recuperator heat exchanger 107a and the second recuperator heat exchanger 107b may be integrated into the second main heat exchanger 301b and the third main heat exchanger 301c, respectively.

[0044] In one or more embodiments, the pre-cooling section 200 may cool the exhaust gas. In a non-limiting example, the exhaust gas 104 may be pre-cooled to a temperature of 575°C. By pre-cooling the exhaust gas 104 to 575°C, the available temperature difference for the first main heat exchanger 301a may be reduced. This may be compensated for by using additional heat transfer surface area or by increasing the overall heat transfer coefficient. The product of the overall heat transfer coefficient and the heat transfer surface area may be referred to as UA, which is equivalent to the required amount of heat divided by the average temperature difference LMTD, which may be calculated from the inlet and outlet temperatures of the hot and cold streams. The UA value of a heat exchanger may be related to the cost of the heat exchanger. By including the pre-cooling section 200 in the regenerative heat exchanger system 105, the required UA may increase overall by approximately 15%. However, the difference in cost (e.g., cost / UA value) between the high temperature and low temperature sections may reduce the overall cost of the regenerative heat exchanger system 105. In a non-limiting example, the cost / UA value for a system above 575°C may be more than 30% higher than the cost / UA value for a system below 575°C. The regenerative heat exchanger system 105 may offer a lower cost / UA value due to the extended expected life of the equipment and reduced material usage due to the higher allowable stresses for heat exchangers below 575°C. While the Inconel material of the pre-cooling section 200 may be a more expensive material, the amount of material required is relatively small due to the higher LMTD in the pre-cooling section 200, which reduces the required UA.

[0045] Embodiments herein for operating the regenerative heat exchanger system 105 may be implemented on a computing system. Any combination of mobile, desktop, server, router, switch, embedded device, or other types of hardware may be used in conjunction with the regenerative heat exchanger system 105. For example, the computing system may include one or more computer processors, non-persistent storage (e.g., volatile memory, e.g., random access memory (RAM), cache memory), persistent storage (e.g., hard disk, optical drive, e.g., compact disc (CD) drive or digital versatile disc (DVD) drive, flash memory, etc.), communications interfaces (e.g., Bluetooth interface, infrared interface, network interface, optical interface, etc.), and numerous other elements and functionality. Furthermore, it is contemplated that software instructions in the form of computer-readable program code for implementing embodiments of the present disclosure may be stored, in whole or in part, temporarily or permanently, on a non-transitory computer-readable medium, e.g., a CD, DVD, storage device, diskette, tape, flash memory, physical memory, or any other computer-readable storage medium. For example, software instructions may correspond to computer-readable program code that, when executed by a processor, is configured to implement one or more embodiments of the present disclosure.

[0046] In one or more embodiments, a pre-cooling heat exchanger may be used in a regenerative heat exchanger system. The pre-cooling heat exchanger may be a shell-and-tube heat exchanger ("STHE") to distribute exhaust gases from the turbine. In some embodiments, instead of an STHE, the pre-cooling heat exchanger may be a printed circuit-type heat exchanger ("PCHE"), a coil-wound-type heat exchanger, a microtube heat exchanger, a diffusion-bonded exchanger using etched plates plus stamped fins, or any other type of heat exchanger. The pre-cooling heat exchanger may then feed the exhaust gases directly into the heat exchanger, thereby eliminating the need for a large, high-temperature exhaust manifold. In a non-limiting example, the STHE may replace the large, high-temperature exhaust manifold so that the turbine exhaust gases can be cooled directly as they enter the secondary (oxidant stream) and primary (recycled stream) sections of the regenerative heat exchanger system. In some embodiments, the pressure components of the pre-cooling heat exchanger may be made from a material selected from Inconel materials (e.g., alloy 625 or alloy 617) or similar materials that do not undergo time-dependent properties at the highest temperatures. The internal components of the pre-cooling heat exchanger 500, which are non-pressure parts, may be made from stainless steel or similar materials.

[0047] In one or more embodiments, fluids may enter the center and split into two streams (one flowing to the right and the other flowing to the left). The fluids may exit the heat exchanger through two or more separate outlets. The streams may again be combined outside the heat exchanger through a piping system. In some embodiments, fluids may enter at two or more points, combine, and ultimately exit through a single outlet nozzle. Large pressure drops can cause tube vibration, which can damage the tubes and shell. Thus, splitting the flow within a heat exchanger can be useful to reduce the risk of damage due to vibration and can reduce the pressure drop associated with the heat exchange system.

[0048] In some embodiments, the heat exchanger may be a double split-flow exchanger. This means that the heat exchanger may have two areas where the flow is split and then recombined, and two support plates. When pressure drop needs to be kept low, a split-shell design may be employed. Furthermore, baffle plates may not be present in a split-shell design exchanger; a single support plate is disposed in the center of the shell.

[0049] Referring to FIG. 3 , in one or more embodiments, FIG. 3 illustrates that a pre-cooling heat exchanger 500 can have two annular shells 501, 502 and a distribution section 513. The first annular shell 501 can be an outer shell that forms a pressure boundary. Additionally, the first annular shell 501 can include an exhaust gas inlet 503 provided on a shell side 504 that can receive exhaust gas from the turbine. Transport piping can be connected to the exhaust gas inlet 503 from the turbine. Further, at the end of the pre-cooling heat exchanger 500, a stationary head channel 505 with an inlet 506 and an outlet 507 can be provided. A passage partition 508 can be provided within the stationary head channel 505 to split the flow between the inlet 506 and the outlet 507. The inlet 506 can be used to receive oxidant from the sub-section. It is further envisioned that one or more exhaust outlets 515 can be provided on the shell side 504 for the exhaust flow to exit.

[0050] Still referring to FIG. 3 , the second annular shell 502 may be an inner shell or shroud around the tube bundle 509, with two or more tube-side passages. The tube bundle 509 may be a U-tube bundle. A support plate 511 is provided to support the weight of the tube bundle 509 and prevent tube overloading of the tubes into the tube sheet and channel 505 assembly connections. In some embodiments, the large difference in flow rates between the shell side 504 and the tube side 509 means that multiple passages can be used to maintain reasonable tube-side 509 velocities and heat transfer coefficients. Additionally, the annular dispersion device 513 may replace the function of an exhaust manifold by gradually slowing down the exhaust gas flow and providing a controlled inflow to the tube bundle 509. The annular dispersion device may comprise slots, rectangular or oval, with an open area that decreases with distance from the inlet 503. Furthermore, the tube bundle 509 may have rod or grid-type baffles that support the tubes and are arranged on a baffle ring 514, rather than traditional section plate-type baffles. Additionally, it is envisioned that insulation 517 may be provided within the pre-cooling heat exchanger 500 between various internal components.

[0051] 4A , in one or more embodiments, FIG. 4A illustrates a perspective view of a regenerative heat exchanger system 105. The various components of the regenerative heat exchanger system 105 may be arranged in a top-down configuration within one or more rigid frameworks (120, 121, 122, 123). The top-down configuration may have an arrangement such that the components of the regenerative heat exchanger system 105 operating at the highest temperature are positioned in the vertically uppermost position, while the components of the regenerative heat exchanger system 105 operating at the lowest temperature are positioned in the vertically lowermost position. In a non-limiting example, the pre-cooling section 200 may be within the first rigid framework 120, the first main section 301 may be within the second rigid framework 121, the second main section 305 may be within the third rigid framework 122, and the sub-section 302 may be within the fourth rigid framework 123. Each of the rigid frameworks 120, 121, 122, 123 may be made from a plurality of vertically oriented structural members 124 and a plurality of horizontally oriented structural members 125. In a non-limiting example, the plurality of vertically oriented structural members 124 and the plurality of horizontally oriented structural members 125 may be interconnected together to form a rectangular frame around the various components of the regenerative heat exchanger system 105. It is further envisioned that the plurality of vertically oriented structural members 124 and the plurality of horizontally oriented structural members 125 may be angled at any angle without departing from the scope of the present disclosure. The plurality of vertically oriented structural members 124 and the plurality of horizontally oriented structural members 125 may be made from a metallic material, such as steel, stainless steel, iron, or any other type of metal.

[0052] In some embodiments, pre-cooling section 200 may include one or more shell-and-tube heat exchangers (“STHEs”) 201 a, 201 b, 201 c, 201 d inside first rigid framework 120. In a non-limiting example, first STHE 201 a, second STHE 201 b, third STHE 201 c, and fourth STHE 201 d may be positioned in parallel. Additionally, all four STHEs ​​201 a, 201 b, 201 c, 201 d may operate at approximately the same temperature. Furthermore, while four STHEs ​​201 a, 201 b, 201 c, 201 d are shown in FIG. 4A , it should be noted that this is merely for illustrative purposes and that any number of STHEs ​​may be used without departing from the scope of the present disclosure. All four STHEs ​​201a, 201b, 201c, and 201d may be fabricated from a material selected from Inconel materials (e.g., Alloy 625 or Alloy 617) or similar materials that do not undergo time-dependent properties at the maximum design operating temperature. Additionally, a precooler inlet 209 may be provided on each STHE 201a, 201b, 201c, and 201d to receive exhaust gas from the turbine. Each precooler inlet 209 may have a transport line connected thereto from the turbine so that the number of transport lines can be proportionally matched to the number of STHEs. Furthermore, an outlet 204 may be provided on each STHE 201a, 201b, 201c, and 201d to allow heated oxidant to exit the precooling section 200.

[0053] On each STHE 201a, 201b, 201c, 201d, an inlet 212 may be provided to allow heated oxidant to enter the pre-cooling section 200 from the sub-section 302. In a non-limiting example, an oxidant manifold 211 may be provided between the sub-section 301 and the pre-cooling section 200. An oxidant flow line 212 may be connected to the inlet 210 of each STHE 201a, 201b, 201c, 201d from the oxidant manifold 211 and the sub-section 302. Additionally, an oxidant inlet 306 may be provided within the fourth rigid framework 123 to allow oxidant flow to connect to the sub-section 302. Additionally, on the tube side, exhaust gas exits each STHE 201a, 201b, 201c, 201d and enters the manifold 205 via flow tubes 213. The manifold 205 may be positioned outside the one or more rigid frameworks (120, 121, 122, 123) and downstream of the pre-cooling section 200 relative to the exhaust flow.

[0054] In some embodiments, manifold 205 may be used to split the exhaust gas flow into sub-section 302, first main section 301, and second main section 305. Flow loop 214 may be used as a conduit for the exhaust gas to flow from manifold 205 to sub-section 302, first main section 301, and second main section 305. In a non-limiting example, flow loop 214 may extend from manifold 205 to individual heat exchangers (301 a, 302 a, 305 a) with each of sub-section 302, first main section 301, and second main section 305.

[0055] In subsection 302, exhaust gas flows through flow loop 214 to first heat exchanger 302a and then to second heat exchanger 302b. In a non-limiting example, one or more meander flow loops 215 may be used as a conduit for exhaust gas to flow from first heat exchanger 302a to second heat exchanger 302b. Additionally, a secondary meander flow loop 216 may be used to flow exhaust gas from second heat exchanger 302b to exhaust gas manifold 217 of regenerative heat exchanger system 105. Furthermore, secondary meander flow loop 216 may include one or more flow balancing valves 218. Using a top-down configuration, first heat exchanger 302a may be operated at a higher temperature than second heat exchanger 302b. In one or more embodiments, the top exchanger may experience higher temperatures and therefore it is essential that the top exchanger be accessible for maintenance and inspection. Additionally, the top heat exchanger is not constrained by connections to other heat exchangers and can expand as freely as possible.

[0056] 4B, in one or more embodiments, a perspective view of the regenerative heat exchanger system 105 is illustrated, rotated 90 degrees counterclockwise from FIG. 2A. In the first main section 301, exhaust gas flows through the flow loop 214 to the first heat exchanger 301a, then to the second heat exchanger 301b, and then to the third recycle heat exchanger 301c. In a non-limiting example, one or more curved flow loops 306 may be used as a conduit for the exhaust gas to flow from the first heat exchanger 301a to the second heat exchanger 301b. In addition, a secondary curved flow loop may be used to flow the exhaust gas from the second heat exchanger 301b to the third heat exchanger 301c. Furthermore, a flow conduit 308 may be used to flow the exhaust gas from the third recycle heat exchanger 302c to the exhaust gas manifold 217. Using a top-down configuration, the first heat exchanger 301a may operate at the highest temperature while the third heat exchanger 301c may operate at the lowest temperature, and the second heat exchanger 301b may operate at a temperature between the first and third heat exchangers 301a and 301c.

[0057] In one or more embodiments, the second main section 305 may have the same arrangement as the first main section 302. For example, exhaust gas flows through the flow loop 214 to the first heat exchanger 305a, then to the second heat exchanger 305b, and then to the third heat exchanger 305c. In addition, one or more curved flow loops 309 may be used as a conduit for the exhaust gas to flow from the first heat exchanger 305a to the second heat exchanger 305b. In addition, a secondary curved flow loop (see 310 in FIG. 4C ) may be used to flow the exhaust gas from the second heat exchanger 305b to the third heat exchanger 305c. Furthermore, a flow conduit 311 may be used to flow the exhaust gas from the third heat exchanger 305c to the exhaust gas manifold 217. Using a top-down configuration, the first heat exchanger 305a may operate at the highest temperature, while the third heat exchanger 305c may operate at the lowest temperature, and the second heat exchanger 305b may operate at a temperature between the first and third heat exchangers 305a and 305c.

[0058] 4B, the heat recovery section 107 may be connected to the first main section 301 and the second main section 305 via heat recovery pipes 312. The heat recovery pipes 312 may be provided between the first heat exchangers 301 a, 305 a and the second heat exchangers 301 b, 305 b of the first main section 301 and the second main section 305, and between the second heat exchangers 301 b, 305 b and the third heat exchangers 301 c, 305 c. It is further envisioned that a recycled CO2 inlet 313 may be provided at the bottom of the first main section 301 and the second main section 305. From the recycled CO2 inlet 313, the recycled CO2 may proceed through the recycled CO2 manifold (see 315 in Figure 2C), be distributed to the third heat exchanger 301c, 305c, the second heat exchanger 301b, 305b, and the first heat exchanger 301a, 305a, be heated, and then exit through the hot recycled CO2 manifold 314.

[0059] Referring now to Figure 4C, a side view of the regenerative heat exchanger system 105 from Figures 4A and 4B is illustrated, according to one or more embodiments of the present disclosure. As shown by Figure 4C, the first rigid framework 120 for the pre-cooling section 200 may be spaced a distance D from the second rigid framework (see 121 in Figures 4A and 4B) for the first main section (see 301 in Figures 4A and 4B), the third rigid framework (see 122 in Figures 4A and 4B) for the second main section 305, and the fourth rigid framework 123 for the sub-section 302. In a non-limiting example, the manifold 205 may be positioned within the space created by the distance D between the first rigid framework 120 and the other rigid frameworks (121, 122, 123). Furthermore, the height H of the first rigid framework 120 may be less than the height H' of the other rigid frameworks (121, 122, 123).

[0060] In one or more embodiments, the curved flow loops 215, 309 and secondary curved flow loops 216, 310 in each of the sub-section 302, first main section (301), and second main section 305 may have portions that extend outward from the corresponding rigid frameworks (121, 122, 123). In this configuration, the curved flow loops and secondary curved flow loops are more flexible than linear connections and can expand with minimal constraint.

[0061] Referring now to FIG. 4D , a top view of the regenerative heat exchanger system 105 from FIGS. 4A and 4B is illustrated, according to one or more embodiments of the present disclosure. As shown by FIG. 4D , the width W of the first rigid framework 120 may be equal to the width W′ of the second rigid framework 121, the third rigid framework 122, and the fourth rigid framework 123. The second rigid framework 121 may be spaced apart from the third rigid framework 122 by a distance D′. The third rigid framework 122 may be spaced apart from the fourth rigid framework 123 by a distance D″. In a non-limiting example, the distance D′ may be greater than the distance D″. FIGS. 4C and 4D illustrate examples of how each of the rigid frameworks (120, 121, 122, 123) may have different dimensions (height and width) so that the components of the regenerative heat exchanger system 105 can be easily positioned adjacent to one another and enable fluid connection.

[0062] As shown in FIGS. 4A-4D , in one or more embodiments, the various components of the regenerative heat exchanger system 105 (pre-cooling section 200, sub-section 302, first main section 301, and second main section 305) having a top-down configuration may enable a modular and compact system. By having a top-down configuration, the footprint for the regenerative heat exchanger system 105 may be much smaller than a conventional linear system arranged on the same plane. In a non-limiting example, the footprint for the entire regenerative heat exchanger system 105 may be approximately 11 feet by 14 feet. It is further contemplated that the footprint may be any dimensional size without departing from this disclosure. Additionally, the footprint may be based on operational and transportation requirements, such as special considerations on the route due to bridge heights and size limitations based on truck, rail, and ship lengths.

[0063] Additionally, the regenerative heat exchanger system 105 may allow the high-temperature piping to and from the turbine to not have to run flush. Further, the pre-cooling section 200, the sub-section 302, the first main section 301, and the second main section 305 may each be constructed in a modular and compact design, allowing for easy manufacturing and shipping to the site with a minimal number of field connections. In one or more embodiments, the pre-cooling section 200, the sub-section 302, the first main section 301, and the second main section 305 are each supported within a corresponding rigid framework (120, 121, 122, 123) allowing for independent expansion within the corresponding rigid framework (120, 121, 122, 123). Because the corresponding rigid framework (120, 121, 122, 123) does not constrain the expansion of the pre-cooling section 200, sub-section 302, first main section 301, and second main section 305 under thermal loads, routing of connecting piping to provide sufficient flexibility can be greatly simplified. This is especially important for heat exchangers that transition from rigid blocks to flexible header and nozzle assemblies. Furthermore, it is envisioned that the high-temperature heat exchanger, which experiences the highest thermal expansion loads, may be located at the top, where the module will be most flexible, and therefore may be most accessible for inspection or repair. Furthermore, condensate from the high-temperature heat exchanger or other sections may necessarily be drained downward from the regenerative heat exchanger system 105.

[0064] A control system may be provided for operating the regenerative heat exchanger system 105 locally or remotely. Embodiments herein for operating the regenerative heat exchanger system 105 may be implemented on a computing system. Any combination of mobile, desktop, server, router, switch, embedded device, or other type of hardware may be used in conjunction with the regenerative heat exchanger system 105. For example, the computing system may include one or more computer processors, non-persistent storage (e.g., volatile memory, e.g., random access memory (RAM), cache memory), persistent storage (e.g., hard disk, optical drive, e.g., compact disc (CD) drive or digital versatile disc (DVD) drive, flash memory, etc.), communication interfaces (e.g., Bluetooth interface, infrared interface, network interface, optical interface, etc.), and numerous other elements and functionalities. Furthermore, it is contemplated that software instructions in the form of computer-readable program code for implementing embodiments of the present disclosure may be stored, in whole or in part, temporarily or permanently, on a non-transitory computer-readable medium, such as a CD, DVD, storage device, diskette, tape, flash memory, physical memory, or any other computer-readable storage medium. For example, the software instructions may correspond to computer-readable program code that, when executed by a processor, is configured to implement one or more embodiments of the present disclosure.

[0065] Turning to FIG. 5A, FIG. 5A shows an example of a suspended heat exchanger system, according to one or more embodiments. The following example is for illustrative purposes only and is not intended to limit the scope of the present invention. The heat exchanger system 400, as shown in FIG. 5A, may be used in any industrial application, such as power generation. In some embodiments, the heat exchanger system 400 may be used in any industrial application requiring a heat exchanger.

[0066] In one or more embodiments, the heat exchanger system 400 may have a top-down configuration, allowing for easier installation on-site. A rigid frame may include two columns 401, 402 spaced a distance D''' from each other. The two columns 401, 402 may be made of a metal material and extend upward to a height H''. A first end 401 a, 402 a of each column 401, 402 may be removably secured to the floor at the work site. Additionally, the two columns 401, 402 may be rigid to allow a crane, trailer, or forklift to raise and lower the heat exchanger system 400 using the two columns 401, 402 as anchor points. One or more heat exchangers 403, 404, 405 may be provided within the heat exchanger system 400 between the two columns 401, 402. While three heat exchangers 403, 404, and 405 are shown in FIG. 5A, it should be noted that this is for illustrative purposes only, and any number of heat exchangers may be used without departing from the scope of the present disclosure. For example, the secondary (oxidant flow) section may have two heat exchangers, while the primary (recycled flow) section may have three heat exchangers. Heat exchangers 403, 404, and 405 may be printed circuit-type heat exchangers ("PCHEs"), coil-wound-type heat exchangers, microtube heat exchangers, diffusion-bonded exchangers using stamped fins in addition to etched plates, plate-thin exchangers, or any other type of heat exchanger. Furthermore, it is envisioned that heat exchangers 403, 404, and 405 may be replaced with cryogenic or boiler-type heat exchangers.

[0067] In the configuration of FIG. 5A , in one or more embodiments, the heat exchangers 403, 404, 405 may be arranged in series and vertically arrayed. The first heat exchanger 403 may be at a vertically uppermost position within the heat exchanger system 400. In a non-limiting example, the first heat exchanger 403 may be coupled to a first support structure 406. The first support structure 406 may be a rigid metal plate coupled to the second ends 401 b, 402 b of each pillar 401, 402. Additionally, a plate or cap 407 may be provided on the second ends 401 b, 402 b of each pillar 401, 402 to which the first support structure 406 may be movably connected. Additionally, a portion of the first heat exchanger 403 may extend beyond the height H″ of the two pillars 401, 402.

[0068] The second heat exchanger 404 may be positioned below the first heat exchanger 403. The second heat exchanger 404 may be coupled to a second support structure 408. The second support structure 408 may be a rigid metal plate to which the second heat exchanger 404 is coupled. A first set of tethers 409 may suspend the second support structure 408 from the two posts 401, 402. The first set of tethers 409 may include two or more tethers. In a non-limiting example, the first set of tethers 409 may be angled at an angle to center the second support structure 408 between the two posts 401, 402. The first set of tethers 409 may be tension members, steel rods, chain links, wire rope, or any type of rod or bar to support the weight and movement of the second heat exchanger 404. Additionally, the ends 410 of the first set of tethers 409 may be connection points for the first set of tethers 409 on the two rods 401, 402 and the second support structure 408. In some embodiments, the connection points may be variable positions using a rack and pinion or gear-driven cam to allow the first set of tethers 409 to be repositioned. Using a rack and pinion or gear-driven cam, the connection points may be adjusted to allow active control and directly move the second heat exchanger 404 and the third heat exchanger 405.

[0069] A second set of tethers 411 may extend vertically downward from the second support structure 408, suspending the support beam 412. The second set of tethers 411 may include two or more tethers. Ends 413 of the second set of tethers 411 may be connection points for the second set of tethers 411 on the second support structure 408 and the support beam 412. In some embodiments, the connection points may be variable using a rack and pinion or gear-driven cam to allow the second set of tethers 411 to be repositioned. Using a rack and pinion or gear-driven cam, the connection points may be adjusted to allow active control and directly move the third heat exchanger 405. The second set of tethers 411 may be tension members, steel rods, chain links, wire rope, or any type of rod or bar to support the weight and movement of the support beam 412.

[0070] In one or more embodiments, a third heat exchanger 405 may be positioned near the first ends 401 a, 402 a of the two pillars 401, 402 and below the second heat exchanger 404. The third heat exchanger 405 may be coupled to a third support structure 415. The third support structure 415 may be a rigid metal plate to which the third heat exchanger 405 is coupled.

[0071] A third set of tethers 414 may extend downward from the support beams 412, suspending a third support structure 415. The third set of tethers 414 may include two or more tethers. In a non-limiting example, the third set of tethers 414 may be angled to center the third support structure 415 between the two posts 401, 402. In some embodiments, the ends 416 of the third set of tethers 414 may be connection points for the third set of tethers 414 on the support beams 412 and the third support structure 415. In a non-limiting example, the connection points may be variable positions using a rack and pinion or gear-driven cam to allow the third set of tethers 414 to be repositioned. Using a rack and pinion or gear-driven cam, the connection points may be adjusted to allow active control and directly move the third heat exchanger 405. The third set of tethers 414 may be tension members, steel rods, chain links, wire rope, or any type of rod or bar to support the weight and movement of the third heat exchanger 405 .

[0072] 5A , the first heat exchanger 403 may operate at the highest temperature of the three heat exchangers 403, 404, 405 in the heat exchanger system 403. The third heat exchanger 405 may operate at the lowest temperature of the three heat exchangers 403, 404, 405 in the heat exchanger system 400. The second heat exchanger 404 may operate at a temperature between the temperatures of the first heat exchanger 403 and the third heat exchanger 405. With the first heat exchanger 403 positioned at the top level in the heat exchanger system 400, the first heat exchanger 403 may expand without any movement restrictions so that the second heat exchanger 404 and the third heat exchanger 405 may also move. Additionally, because the second heat exchanger 404 and the third heat exchanger 405 operate at a lower temperature than the first heat exchanger 403, the second heat exchanger 404 and the third heat exchanger 405 may have a higher allowable stress than the first heat exchanger 403. Therefore, movement of the second heat exchanger 404 and the third heat exchanger 405 may be more easily accommodated than movement of the first heat exchanger 403. Additionally, any thermal expansion of the tubing 417 interconnected between the three heat exchangers 403, 405, 405 may be compensated for by the sets of tethers 409, 411, 414.

[0073] In one or more embodiments, the three heat exchangers 403, 405, 405 are thermally decoupled within the heat exchanger system 400. By having the first heat exchanger 403 coupled to the first support structure 406 in a vertically uppermost position, the first heat exchanger 403 can thermally expand independently without affecting the second heat exchanger 404 and the third heat exchanger 405. Additionally, the first set of tethers 409 can allow the second heat exchanger 404 to be thermally decoupled from the first heat exchanger 403. As the second heat exchanger 404 thermally expands, the first set of tethers 409 can move the second support structure 408 vertically such that the second heat exchanger 404 is thermally independent from the first heat exchanger 403 and the third heat exchanger 405. Additionally, by having support beams 412 hanging from the second set of tethers 411, the support beams 412 may thermally decouple the second heat exchanger 404 and the third heat exchanger 405 from one another.

[0074] 5B, which illustrates an example of a heat exchanger suspension system 420 for the heat exchanger system (see 400) of FIG. 1A, according to one or more embodiments. The following example is for illustrative purposes only and is not intended to limit the scope of the present invention. The heat exchanger suspension system 420 may include a first set of tethers 409, a second set of tethers 411, and a third set of tethers 414 connected to a second support structure 408, a support beam 412, and a third support structure 415.

[0075] In one or more embodiments, the first heat exchanger (see 403) may be vertically coupled, while the second heat exchanger (see 404) and the third heat exchanger (see 405) may be supported by a second support structure 408 and a third support structure 415, respectively. Thus, the second heat exchanger (see 404) and the third heat exchanger (see 405) may undergo vertical displacement as a result of the thermal expansion of 403 as well as their own thermal expansion during operation.

[0076] As shown in FIG. 5B , arrow 421 represents the vertical displacement of the second heat exchanger (see 404) and the third heat exchanger (see 405). Additionally, arrows 422a and 422b represent the horizontal thermal expansion of the second heat exchanger (see 404) and the third heat exchanger (see 405). In a non-limiting example, when the second heat exchanger (see 404) thermally expands in the horizontal direction (arrow 422a), the first set of tethers 409 may move a distance Th in the horizontal plane. This movement distance Th may also change the angle of the first set of tethers 409, which in turn causes the second heat exchanger (see 404) to drop a distance Tv due to the angle change. As the second heat exchanger (see 404) drops a distance Tv, the third heat exchanger (see 405) may also drop a distance Tv. However, when the third heat exchanger (see 405) thermally expands in the horizontal direction (arrow 422b), the second set of tethers 411 may move a distance Th′ in the horizontal plane, changing the angle of the second set of tethers 411. With the change in angle of the second set of tethers 411, the third heat exchanger (see 405) may move downward by an additional amount such that the distance Tv′ moved vertically by the third heat exchanger (see 405) may be the sum of the distance Tv and the additional amount lowered.

[0077] Using the heat exchanger suspension system 420, both horizontal and vertical thermal expansion of various components within the heat exchanger system (see 400) can be accommodated by changing or adjusting the angles of the tether sets 409, 411, 414 to compensate for the thermal expansion. By compensating for thermal expansion, thermal imbalances from various components cooling and heating at different rates can be managed by the heat exchanger suspension system 420. The heat exchanger suspension system 420 also minimizes expansion stresses resulting from thermal expansion of the heat exchangers and interconnecting piping within the heat exchanger system (see 400). Additionally, it is envisioned that insulation can be used in conjunction with the heat exchanger suspension system 420 to further assist in managing thermal imbalances. Insulation may be used to prevent heat loss and improve system efficiency, which may also have the benefit of helping to manage thermal balance and providing more accurate prediction of displacement from thermal expansion.

[0078] Referring now to Figure 6, another embodiment of a heat exchanger system according to embodiments herein is illustrated, where like numbers represent like parts. The embodiment of Figure 6 is similar to that of Figure 5A. However, heat exchanger system 400 may have only first heat exchanger 403 and second heat exchanger 404, without the third heat exchanger (see 405 in Figure 5A).

[0079] Referring now to FIG. 7, another embodiment of a heat exchanger system according to embodiments herein is illustrated, with like numbers representing like parts. The embodiment of FIG. 7 is similar to that of FIG. 5A. However, heat exchanger system 400 may have only two heat exchangers, both suspended from a heat exchanger suspension system (see 420 in FIG. 5B). In a non-limiting example, first heat exchanger 403 may be removed, leaving second heat exchanger 404 and third heat exchanger 405 suspended from their respective sets of tethers (409, 414).

[0080] Referring now to FIG. 8 , another embodiment of a heat exchanger system according to embodiments herein is illustrated, with like numbers representing like parts. The embodiment of FIG. 8 is similar to that of FIG. 5A . However, instead of the first set of tethers 409 and the third set of tethers 414 (see FIG. 5A ) being angled outward, the first set of tethers 409 may be angled inward. In a non-limiting example, one or more protrusions 430 may extend inward from the rigid frame (two posts 401, 402) such that one end 410 of the first set of tethers 409 can be a connection point on the one or more protrusions 430. By angling the first set of tethers 409 inward, thermal expansion of the second heat exchanger 404 can cause the second support structure 408 to rise vertically upward. Additionally, the third set of tethers 414 may also be angled inward to raise the third support structure 415 vertically upward based on the thermal expansion of the third heat exchanger 405 .

[0081] Referring now to FIG. 9 , another embodiment of a heat exchanger system according to embodiments herein is illustrated, with like numbers representing like parts. The embodiment of FIG. 9 is similar to that of FIG. 5A . However, the two posts 401, 402 of the rigid frame may be moved closer together such that the distance D″″ between the two posts 401, 402 is less than the distance D′″. By moving the two posts 401, 402 closer together, the first set of tethers 409 may be angled inward. By angled the first set of tethers 409 inward, thermal expansion of the second heat exchanger 404 may cause the second support structure 408 to rise vertically upward. Additionally, the third set of tethers 414 may also be angled inward, causing the third support structure 415 to rise vertically upward based on the thermal expansion of the third heat exchanger 405.

[0082] As illustrated in Figures 5A-9, the heat exchanger system 400 connects a series of independently moving components. The heat exchanger system 400 described herein allows for a series of independently moving components to be connected while providing benefits in the overall system, including, for example, lower stress on the heat exchangers (404, 405) to the piping nozzle (417). With respect to the heat exchanger system 400 in Figures 5A-9, the heat exchanger suspension system (420) may have a system of tethers 409, 411, 414 that may be configured to adjust the position (i.e., neutral, raised, lowered) of the lower heat exchangers (404, 405). In one or more embodiments, the configuration of this system of tethers 409, 411, 414 may be based on the expected thermal expansion or contraction of the components during startup, operation, and shutdown of the heat exchanger system 400. Additionally, the angle of the tethers may be selected based on the expected thermal expansion or contraction. Additionally, each angle of the tether may be adjusted independently.

[0083] In the heat exchanger system 400, the support bar 412 can enhance the independent movement of the heat exchangers (404, 405). With the inclusion of the support bar 412, the second heat exchanger 404 does not affect the ability of the third heat exchanger 405 to move independently. Thus, the support bar 412 provides various degrees of freedom to accommodate piping movement and expansion within the heat exchanger system 400. The support bar 412 advantageously decouples the thermal expansion of each heat exchanger, allowing for isolation and use of expansion methods that minimize loads on the nozzles and may allow for shorter expansion piping lengths. By minimizing loads and allowing for shorter piping, the overall weight of the unit can be reduced. Additionally, the stresses associated with the heat exchanger suspension system (420) allow the lengths of various piping to be reduced, allowing the overall system to be more compact.

[0084] While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate that other embodiments may be devised that do not depart from the scope of the present disclosure as described herein. Accordingly, the scope of the present disclosure should be limited only by the appended claims.

Claims

[Claim 1] Systems, methods, etc.

Images