Integrated Power Production and Storage System

Abstract

To provide a combined cycle power plant to be integrated into manufacturing or production facilities in production and use, and storage of hydrogen and oxygen.SOLUTION: A power plant is configured to output power to a grid power system and comprises: a hydrogen generation system 106 configured to produce hydrogen; a gas turbine combined cycle power plant 104 comprising a gas turbine engine 114 configured to combust the produced hydrogen to generate a gas stream that can be used to rotate a turbine shaft and a heat recovery steam generator 116 configured to generate steam with the gas stream of the gas turbine engine to rotate a steam turbine 118; a storage system 110 configured to store the produced hydrogen; and a controller configured to operate the hydrogen generation system with electricity from the grid power system when the grid power system has excess energy and balance active and reactive loads on the grid power system using at least one of the hydrogen generation system and the gas turbine combined cycle power plant.SELECTED DRAWING: Figure 1B

Description

[Technical Field]

[0001] This specification relates generally, but not exclusively, to combined cycle power plants used to generate electrical power. More particularly, but not exclusively, this application relates to the production, use, and storage of hydrogen and oxygen in combined cycle power plants that may be integrated into manufacturing or production facilities. [Background technology]

[0002] The power grid is a mechanism for balancing the aggregate energy demands of consumers with the aggregate energy supply of electricity producers, which include renewable energy sources and traditional power plants, such as those that burn fossil fuels.

[0003] Renewable energy sources can include any source of energy that does not involve combustion or the emission of CO2. Typical renewable energy sources include hydroelectric power, solar power, and wind power. Solar and wind power, in particular, are intermittent and unpredictable.

[0004] A power plant may include a means for generating electricity on demand using fuels such as fossil fuels or hydrogen derived from various sources. Fossil fuels may include coal, natural gas, or fuel oil. A typical power plant includes a gas turbine and a generator, often including a steam turbine in a combined cycle configuration. The gas turbine and steam turbine may generate electrical power from mechanical energy converted from the combustion of fuel and the associated steam generation process.

[0005] An electricity consumer includes any user of electrical power. A consumer can be a residential consumer, a commercial consumer, or an industrial consumer. Consumers can use energy in a variety of ways, thereby placing different demands on the electrical grid.

[0006] Apparent, real and reactive power

[0007] Electric circuits consist of various types of power producers, or "generators," and power consumers, or "loads." Generators produce power that flows to the load and then returns to the generator to complete the circuit. Active loads are purely resistive loads that convert power entirely into other forms of energy without generating a magnetic field; examples include heaters and incandescent light bulbs. Reactive loads are loads that generate a magnetic field to convert power into other forms of energy, such as rotating mechanical power as in an induction motor or sound as in a speaker. When a reactive load is present in an electric circuit, more power appears to be supplied to the load by the generator ("apparent power") than is consumed by the load ("real power"). Due to the need to generate a magnetic field, there is a difference in the alignment between voltage and current, known as phase alignment. In AC circuits, apparent power (S) is the product of voltage (V) and current (I), given by the equation (S = VI). The amount of phase alignment between voltage and current is expressed as an angle (Φ), which ranges from negative (-) 90 degrees to positive (+) 90 degrees. A phase angle Φ = zero indicates that the voltage and current are in perfect phase alignment, and S = VI represents the real power (P) as well as the apparent power, S = P = VI. This corresponds to a circuit that contains a complete active load and no reactive load. In a circuit with a reactive load, the voltage and current are out of phase due to the need to generate a magnetic field, and more power appears to be supplied by the generator than is consumed by the load, Φ represents the amount of alignment or phase angle between the voltage and current, and real power is given by the equation P = VI cos(Φ). The difference between apparent power and real power is given by the relationship S = (P 2 +Q 2 ) 1 / 2where Q is defined as "reactive power." Consequently, reactive power is the difference between the apparent power and the real power produced in a circuit; reactive power is given by the relationship Q=VIsin(Φ) and is measured in units known as Volt-Amp-Reactive, or VAR. Reactive power can be generated in a generator by increasing or decreasing the voltage that creates the magnetic field (the "excitation voltage"), or by managing the amount of reactive load in the circuit, such as turning reactive loads on or off to manage VAR flow through the system. Failure to manage the balance of both real and reactive power flow can result in fluctuations in both voltage and frequency within the power system, potentially damaging electrical equipment.

[0008] An inverter is an electrical device that converts direct current power into alternating current power.

[0009] A rectifier is an electrical device that converts alternating current power into direct current power.

[0010] As mentioned above, various factors can have a significant impact on the stability of the power grid. Specifically, (1) when large industrial consumers start (or stop) using large amounts of electricity, or (2) when there are large fluctuations in electricity demand by residential and / or commercial consumers during a) peak periods such as morning and evening versus off-peak periods such as night and midday, or b) seasonal variations in demand such as cooling loads in summer, heating loads in winter, and relatively lower demand in spring and fall, or (3) when the type of load changes on a system, such as when large active loads are started or stopped, such as lights as daylight rises and falls, and electric heaters that are started or stopped as temperatures change during the winter, or (4) when the type of available power generation changes, such as wind, solar, nuclear, or fossil fuels, as weather patterns change a) in the short term as weather systems change, or b) on a seasonal basis as weather patterns change, both locally and at regional and national scales, such as with the transitions between spring, summer, fall, and winter, or 5) the way consumers use electricity can affect the availability of active and reactive power in addition to the voltage and frequency of the system. For example, the use of multiple large induction motors by one consumer can result in a need for large amounts of reactive power, which can effectively reduce the availability of real power to be used by other consumers or affect the voltage and frequency of the power grid, requiring adjustments to avoid damage to electrical components and devices. Such demands must be balanced against all of the aforementioned changes to apparent power, real power, and reactive power (hereinafter, together with other such similar changes in the power grid, collectively referred to as "real and reactive power changes").

[0011] In response to these real and reactive power changes, the grid must respond to maintain a balance between the supply and demand of real power, reactive power, system voltage, and frequency. The way the grid currently responds is by having at least some suppliers of electricity, both from power generating plants and renewable sources, increase or decrease their output of real power relative to the amount of watts supplied to maintain the balance, and change the nature of their operation to balance reactive power by supplying or consuming reactive power relative to the VARs consuming or supplying it. These various supplies and demands for real power, reactive power, system voltage, and frequency generally operate in isolation from one another, and only the grid operator manages the real and reactive power changes. Such external management is complex and may require many instances of power producers starting, stopping, and changing output levels, which introduces inefficiencies into the overall system. [Prior art documents] [Patent documents]

[0012] [Patent Document 1] U.S. Patent No. 5,266,024 Summary of the Invention [Means for solving the problem]

[0013] The inventors have recognized that, among other things, problems to be solved in power generation plants can include inefficient production, use, and storage of electricity, especially as consumers change their demand for electricity and electricity producers attempt to react to changes in demand.

[0014] The inventors recognized that ideally, it would be desirable for the power grid to consume as much renewable energy as possible because such energy is recognized as being supplied at a lower cost with reduced environmental impact relative to traditional power plants that utilize fossil fuels. However, the availability of such renewable energy is intermittent and unpredictable. Sun is available only during part of the day, wind is unpredictable, and the availability of both forms of energy varies with the seasons. Therefore, as the supply or demand for renewable energy fluctuates, the output and reactive power balance of the power plant are required to fluctuate. Additionally, as the demand and reactive power balance fluctuates, in some cases, measures can be taken to reduce the supply from renewable sources, such as reducing the blade pitch of a wind turbine. However, this is suboptimal because it represents a lost opportunity to utilize electricity at a lower cost and with reduced environmental impact. In some areas where solar energy supply is abundant, power plants may be required to be “off” (not producing power) during the day and “on” at night.

[0015] However, power plants represent complex systems with significant physical and thermal mass. These systems often require significant periods of time to start up or shut down to avoid damage that can result from severe thermal gradients associated with rapid transitions in power output. Furthermore, complex systems are typically designed to provide optimal performance at a particular design point, and operation at other points is often suboptimal. For example, gas turbines are often designed to provide optimal efficiency and emissions output at a particular base power output, and operation at other power outputs is less efficient and / or results in undesirable increased emissions. Therefore, it is desirable for gas turbine power plants to (1) operate near their base power design point and (2) avoid the severe thermal gradients associated with rapid power transitions.

[0016] In response to system active and reactive power changes and the desire to obtain maximum consumption of renewable energy, the power grid typically commands power generation plants to increase or decrease their power output to accommodate reduced demand, often at rates that are detrimental to the power generation plants.

[0017] The present subject matter can help provide solutions to these and other problems, such as by using novel thermal and electrical integration of various equipment, short-term and long-term storage systems and strategies, and novel operational concepts and controls. The various systems of the present disclosure can 1) stabilize the operating profile of gas turbines, 2) provide consistent real and reactive power within the power system grid across a range of scenarios, 3) provide rapid response to changes in demand for real and reactive power, 4) provide voltage and frequency support to the grid, 5) maximize utilization of available renewable energy, and 6) reduce carbon dioxide emissions of gas turbine power plants in either simple or combined cycle configurations during fluctuations in renewable energy supply and consumer demand.

[0018] For example, under normal conditions, electrolyzers take time to start operating, consuming large amounts of power due to the need to heat the water within the device. However, through novel integration of combustion turbine power plants with electrolyzers, the water can be maintained at operating temperature so that in response to a large industrial consumer ceasing its demand for electricity, the power grid can immediately command the electrolyzer to begin consuming power to convert water into hydrogen gas and oxygen gas. For example, the water feed to the electrolyzer can be conditioned by first passing through or flowing out of a heat recovery steam generator (HRSG), which captures thermal energy from a gas turbine to produce steam to drive a steam turbine. If the capacity of the electrolyzer is equal to or greater than the amount of power the consumer was using, the start of water conversion can maintain grid balance without having to change the operating profile of the gas turbine.

[0019] As the electrolyzer begins converting water (H2O) to H2 (H2) and O2 (O2), the gas turbine can simultaneously modify its operation to consume H2 and also begin reducing its fossil fuel (i.e., natural gas or fuel oil) consumption. In this way, the power grid can maximize its renewable energy use, avoid severe transitions in gas turbine loading, and maintain balance while reducing the consumption and corresponding purchasing and environmental costs associated with burning fossil fuels. H2 may be blended with other fuels or may be the only fuel consumed by the gas turbine. In either case, the consumption of H2 represents an improvement in gas turbine emissions, since the only combustion product of H2 is water vapor.

[0020] Additionally, the control system can use its intelligence to modify the operation of the gas turbine. For example, if the control system has reason to expect that consumer demand will not increase for some time, the control system can choose to shut down the gas turbine at a transition rate that avoids damaging development of thermal gradients and in the most efficient and environmentally emission-reducing manner. As the gas turbine output transitions, the electrolyzer consumption can also transition, thereby resulting in an inherently balanced transition.

[0021] Additionally, through the use of inverters and rectifiers, electrolyzers can be used to balance reactive power on the power grid.

[0022] Furthermore, the electrolyzer can be coupled with H storage, which can further increase the flexibility provided by the system. With sufficient H storage, during periods of peak supply (such as when supply dramatically exceeds demand and the power grid potentially requires gas turbines to be shut down or renewable resource production to be reduced), the system can enable the gas turbine to operate at its optimal design point and avoid such reductions. In such situations, excess power (i.e., the difference between supply and demand) can be used to power the electrolyzer to produce and store H gas.

[0023] Ideally, during such periods, the power generation capacity of the electrolyzer's H output exceeds that of the gas turbine, allowing the gas turbine to be operated at its design point for 100% H gas, and the hydrogen to be stored for future use. In such a scenario, the gas turbine would be operating at its most efficient point while emitting only water vapor.

[0024] The system can utilize different amounts of H2 storage as needed. As explained above, balancing benefits and emission reductions while avoiding severe thermal gradients in the grid can be achieved with minimal storage. However, with the addition of storage, these benefits can be enhanced by allowing maximum use of renewable energy while continuing to operate the gas turbine at its optimal design point (or with a transition point long enough to minimize damaging thermal gradients).

[0025] For those cases where optimizing storage is desirable, transmission pipelines can offer significant storage. For example, a gas turbine operating at a power output of 500 megawatts is known to consume approximately 27 tons of H2 per hour of operation when operating at 100% H2 content. Typical fuel pressures for gas turbine operation are approximately less than 800 pounds per square inch (psi). A 24-inch diameter pipe with a minimum wall thickness of 0.834 inches is strong enough to withstand 3000 psig of H2 gas. Each mile of such pipe can contain 4.6 tons of H2 gas when cycling between 3000 psig and 800 psig. That is, each 6-mile pipe can store 27.6 tons of H2, which can provide approximately one hour of operation of a gas turbine at 500 MW.

[0026] If the gas turbine is located a sufficient distance from the H2 source, the transmission pipeline may itself provide sufficient storage. Additionally, if the gas turbine and H2 source are installed together, one or more pipelines, each capped at one end or connected together to form a closed system, may extend from the site some distance to form an artificial underground storage vessel. However, if additional on-site storage is necessary or desirable, the pipe arrangements described herein may provide an improved storage arrangement. The pipe arrangements described herein may include pipes interleaved in an inverted pyramid shape, placed underground, with construction fill between the pipes. In effect, the construction fill is placed to create an inverted pyramid shape, with the pipes stacked one on top of the other. Due to the strength of the hoops and the inverted pyramid shape, no internal framing or structure is required.

[0027] In one example, a power plant may be configured to output electrical power to a grid power system and may include a hydrogen generation system configured to produce hydrogen, a gas turbine combined cycle power plant including a gas turbine engine configured to combust hydrogen from the hydrogen generation system to produce a gas stream that may be used to rotate a turbine shaft and a heat recovery steam generator (HRSG) configured to generate steam with the gas stream from the gas turbine engine to rotate the steam turbine, a storage system configured to store hydrogen produced by the hydrogen generation system, and a controller configured to operate the hydrogen generation system with electrical power from the grid power system when the grid power system has surplus energy and to balance active and reactive loads on the grid power system using at least one of the hydrogen generation system and the gas turbine combined cycle power plant.

[0028] In another example, a power plant may be configured to output electrical power to a grid power system and may include a gas turbine combined cycle power plant including an electrolyzer configured to produce hydrogen and oxygen, a gas turbine engine configured to combust hydrogen from the hydrogen production system to produce a gas stream that can be used to rotate a turbine shaft, and a heat recovery steam generator (HRSG) configured to generate steam with the gas stream from the gas turbine engine to rotate a steam turbine, a storage system configured to store the hydrogen produced by the hydrogen production system, and a nozzle configured to direct oxygen from the electrolyzer into the HRSG of the gas turbine combined cycle power plant.

[0029] In a further example, a method of burning fuel using a thermal nozzle includes the steps of: (A) supplying an oxidizer having an oxygen concentration of at least 30 volume percent at an initial velocity of less than 300 fps into an oxidizer supply duct communicating with a combustion zone; (B) supplying fuel, separate from the oxidizer, into the oxidizer supply duct at a velocity of at least 200 feet per second and at or above the initial velocity of the oxidizer to entrain the oxidizer within the high velocity fuel, wherein up to about 20% of the oxygen in the oxidizer supplied into the oxidizer supply duct is combusted with the fuel to generate heat and combustion in the combustion reaction. (C) mixing the combustion reaction products with the remaining oxygen in the oxidizer in the oxidizer supply duct to raise the temperature of the remaining oxidizer in the oxidizer supply duct; and (D) delivering the heated oxidizer from the oxidizer supply duct into the combustion zone at an exit velocity that exceeds the initial velocity by at least 300 feet per second, wherein the heated oxidizer is directed out of the oxidizer supply duct through a plurality of orifices arranged in different directions.

[0030] In one example, a power plant configured to output electrical power to a grid power system can include an electrolyzer configured to produce hydrogen and oxygen; a power converter electrically connecting the electrolyzer to the grid power system; a gas turbine combined cycle power plant including a gas turbine engine configured to combust hydrogen from the hydrogen production system to produce a gas stream that can be used to rotate a turbine shaft and a heat recovery steam generator (HRSG) configured to generate steam with the gas stream from the gas turbine engine to rotate the steam turbine; a storage system configured to store hydrogen produced by the hydrogen production system; and a controller configured to balance active and reactive loads on the grid power system using at least one of the power converter, the hydrogen production system, and the gas turbine combined cycle power plant.

[0031] In one example, a method of operating an integrated power plant connected to a grid power system includes operating a gas turbine engine to drive a first generator to supply electrical power to the grid power system, the gas turbine engine being operable with at least one of hydrogen and natural gas; operating an electrolyzer to produce hydrogen and oxygen with electrical power from the grid power system; storing hydrogen produced by the electrolyzer in a storage system; and coordinating operation of the gas turbine engine and the electrolyzer to supply demand on the grid power system.

[0032] This Abstract is intended to provide a summary of the subject matter of this patent application. It is not intended to provide an exclusive or comprehensive description of the invention. The Detailed Description is included to provide further information about this patent application. [Brief explanation of the drawings]

[0033] [Figure 1A] 1 is a schematic diagram illustrating an integrated power production system including a gas turbine combined cycle power plant (GTCC), a hydrogen production system, a hydrogen storage system, and a controller. [Figure 1B] 1 is a schematic diagram illustrating an integrated power production system including a gas turbine combined cycle power plant (GTCC), a hydrogen production system, a hydrogen storage system, and a controller. [Figure 2] FIG. 1B is a schematic diagram illustrating an exemplary master control system for the subsystems of FIGS. 3-10 suitable for use within the integrated power production system of FIGS. 1A and 1B. [Figure 3] FIG. 1 is a schematic diagram illustrating an exemplary combined cycle power plant having an electrolyzer connected to a hydrogen receiving tank and power conversion equipment. [Figure 4] FIG. 1 is a schematic diagram showing a heat recovery steam generator connected to an electrolyzer and also connected to a battery and a renewable energy source. [Figure 5] FIG. 1 is a schematic diagram showing a cooling loop for an electrolyzer bank. [Figure 6] FIG. 1 is a schematic diagram showing a heat recovery steam generator connected to an electrolyzer and a hydrogen surge system. [Figure 7] FIG. 1 is a schematic diagram showing a hydrogen storage system. [Figure 8] 1 is a schematic diagram illustrating a polygeneration facility including a combined cycle power plant, renewable energy producers, hydrogen and oxygen storage systems, and electrolyzers connected to industrial power consumers or plants. [Figure 9] FIG. 2 is a schematic diagram showing a nozzle for generating hot oxygen for injection into a heat recovery steam generator. [Figure 10] FIG. 1 is a schematic diagram showing a hybrid power converter connecting the power grid to an electrolyzer bank, a battery bank and a renewable energy source. [Figure 11] FIG. 1 is a schematic diagram illustrating a vertically arranged piping system suitable for use as a hydrogen storage system. [Figure 12] FIG. 1 is a schematic diagram showing multiple vertically arranged piping systems. [Figure 13A] FIG. 1 is a schematic diagram showing a perspective view of a multiple vertically arranged piping system including pipes with direction changes. [Figure 13B] FIG. 1 is a schematic diagram showing an end view of a multiple vertically arranged piping system including pipes with direction changes. [Figure 14A] FIG. 1 is a schematic diagram showing a side view of a multiple vertically arranged piping system including pipes arranged in a radial array. [Figure 14B] FIG. 1 is a schematic diagram showing a top view of a multiple vertically arranged piping system including pipes arranged in a radial array. [Figure 15] FIG. 1 is a schematic diagram showing a side view of multiple horizontally arranged piping systems arranged in multiple levels. [Figure 16A] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 16B] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 16C] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 16D] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 16E] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 16F] 1A-1C are schematic diagrams illustrating various arrangements of layering for the piping system of the present disclosure. [Figure 17] FIG. 1 is a schematic diagram showing a top view of an overhead support structure for fabricating and installing a piping system. [Figure 17A] FIG. 1 is a schematic diagram showing a side view of an overhead support structure for fabricating and installing a piping system. [Figure 17B] FIG. 1 is a schematic diagram showing a side view of an overhead support structure for fabricating and installing a piping system. [Figure 18] FIG. 1 is a schematic diagram showing a top view of an overhead welding gantry system for fabricating and installing a piping system. [Figure 18A] FIG. 1 is a schematic diagram showing a side view of an overhead welding gantry system for fabricating and installing a piping system. [Figure 18B] FIG. 1 is a schematic diagram showing a side view of an overhead welding gantry system for fabricating and installing a piping system. [Figure 19] FIG. 18C is a schematic diagram showing a top view of the overhead welding gantry system of FIGS. 18-18B with an additional section of pipe assembled. [Figure 19A] FIG. 18C is a schematic diagram showing a side view of the overhead welding gantry system of FIGS. 18-18B with an additional section of pipe assembled. [Figure 19B] FIG. 18C is a schematic diagram showing a side view of the overhead welding gantry system of FIGS. 18-18B with an additional section of pipe assembled. [Figure 20]10 is a schematic diagram showing the assembled pipe container being lowered into the groove. FIG. [Figure 20A] 10 is a schematic diagram showing the assembled pipe container being lowered into the groove. FIG. [Figure 20B] 10 is a schematic diagram showing the assembled pipe container being lowered into the groove. FIG. [Figure 21] FIG. 10 is a schematic diagram showing the second pipe container being assembled. [Figure 21A] FIG. 10 is a schematic diagram showing the second pipe container being assembled. [Figure 21B] FIG. 10 is a schematic diagram showing the second pipe container being assembled. [Figure 22] 10 is a schematic diagram showing a second pipe container being lowered into the trench and a third pipe container being assembled. FIG. [Figure 22A] 10 is a schematic diagram showing a second pipe container being lowered into the trench and a third pipe container being assembled. FIG. [Figure 22B] 10 is a schematic diagram showing a second pipe container being lowered into the trench and a third pipe container being assembled. FIG. [Figure 23A] FIG. 1 is a schematic diagram showing multiple elongated horizontal piping systems integrated into multiple layers without access passages. [Figure 23B] FIG. 1 is a schematic diagram showing multiple elongated horizontal piping systems integrated into multiple layers. [Figure 23C] FIG. 1 is a schematic diagram showing multiple elongated horizontal piping systems integrated into multiple layers with access passages. [Figure 24] 1 is a schematic diagram showing multiple vertically arranged piping systems connected to a power grid including consumers. [Figure 25] 1 is a schematic diagram showing multiple vertically arranged piping systems and underground storage caverns connected to a power grid including consumers. [Figure 26] FIG. 1 is a schematic diagram showing multiple vertically arranged piping system banks and underground storage caverns connected to a power grid including consumers. [Figure 27]FIG. 1 is a schematic diagram showing a plurality of interconnected vertically arranged piping system banks and underground storage caverns and a power grid including consumers. [Figure 28] FIG. 1 is a schematic diagram showing an underground storage cavern connected to a grid without a piping system. [Figure 29] FIG. 2 is a schematic diagram illustrating components of a controller for operating the integrated power production system of FIGS. 1A and 1B. DETAILED DESCRIPTION OF THE INVENTION

[0034] In the drawings, which are not necessarily drawn to scale, like numerals may describe like components in different drawings. Like numerals with different letter suffixes may represent different instances of like components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments described in the present document.

[0035] 1A and 1B are schematic diagrams illustrating an integrated power production system 100 that provides many advantages over baseline and prior art systems. The system 100 may include a gas turbine combined cycle power plant (GTCC) 104, a hydrogen production system 106, and a controller 108.

[0036] Control signals between various components and systems are designated by dashed / dotted lines, electrical connections through which electricity can flow are designated by dashed lines, and process lines through which gases or fluids can flow are designated by solid lines.

[0037] In an example, the hydrogen production system 106 can include an electrolyzer that also produces oxygen. The power production system 100 can also include one or both of a hydrogen storage system 110 and an oxygen storage system 112.

[0038] The GTCC 104 may include a gas turbine 114 , a heat recovery steam generator 116 , and a steam turbine 118 .

[0039] The controller 108 may be connected to the hydrogen production system 106 via controllers 120 and 122. The controller 108 may be connected to the GTCC 104 via controllers 124 and 126.

[0040] The power grid 128 provides electrical connections between various supplies of electricity, such as renewable wind power sources 130, renewable photovoltaic solar power sources 132, or combined cycle gas turbine power plants 104, and electricity consumers 152. Exemplary consumers 152 include residences, commercial buildings, and industrial facilities. The various consumers 152 may have available varying levels of real and reactive power.

[0041] Although only one consumer 152, one renewable wind power source 130, one renewable photovoltaic solar power source 132, one GTCC 104, one hydrogen production system 106, one hydrogen storage system 110, and one oxygen storage system 112 are shown in Figures 1A and 1B, the power production system 100 may include multiple instances of each in the same geographic location or distributed over a larger geographic area.

[0042] The main controller 108 provides command signals to various power supplies, including the wind power source 130, the solar power source 132, and the gas turbine 114, to ensure, among other things, the aggregate supply and demand for electricity remain balanced. The main controller 108 can coordinate with the electrolyzer production setpoint controller 122 and the electrolyzer VAR setpoint controller 120, respectively, and the GTCC output setpoint controller 124 and the GTCC VAR setpoint controller 126, respectively, to ensure a balance between supply and demand for active power, reactive power, system voltage, and frequency. The main controller 108 can also regulate when hydrogen is produced or consumed, and when electricity is delivered by using stored hydrogen or producing H for storage. As described with reference to FIGS. 4 and 10 , for example, the electricity production system 100 can additionally include various battery storage systems for short-term storage of electricity and reactive load regulation, as described herein. For example, as described with reference to FIG. 8, the integrated power production system 100 may be additionally integrated with an industrial plant that consumes power from the power grid 128 and may receive various inputs from the system 100.

[0043] The decisions of the main controller 108 may be made based on market conditions, the availability of renewable power, grid electricity costs, and other factors. In this way, the main controller 108 can manage power production from the renewable wind power sources 130, the renewable photovoltaic solar power sources 132, and the combined cycle gas turbine power plant 104 based on demand on the power grid 128, weather conditions, and other factors, while also managing hydrogen production in the hydrogen production system 106 using, for example, hydrogen and oxygen consumption in the GTCC 104 and the industrial facility 350 ( FIG. 8 ), and long-term and short-term storage of energy in the form of hydrogen and oxygen storage in the hydrogen storage system 110 and the oxygen storage system 112, respectively, and power in various batteries.

[0044] Power from the power grid 128 may first be provided to a transformer 133 to convert the voltage of the power grid 128 to a selected voltage that is optimized for operation of a power converter 134 to convert the AC power to DC power. In an example, the converter 134 may be a rectifier that can receive alternating current (AC) from the power grid 128 and produce direct current (DC), which may be optimal for operation of the electrolyzer in the hydrogen production system 106. Additionally, the converter 134 may be a hybrid converter as described herein. The GTCC 104, the steam turbine 118, the wind power source 130, and the solar power source 132 may each be provided with a transformer 135A-135D to convert the voltage of the generated power to a voltage compatible with the power grid 128.

[0045] The hydrogen production system 106 may be connected to a hydrogen purification system 136, which may use a hydrogen compressor 138 to supply hydrogen to the hydrogen storage system 110, and an oxygen purification system 140, which may supply oxygen to the oxygen storage system 112. The hydrogen purification system 136 may include a palladium membrane hydrogen purifier, a dense sheet metal membrane purifier, a pressure swing adsorption purifier, a catalytic recombination or deoxygenation purifier, or an electrochemical purifier, among others. The oxygen purification system 140 may utilize a cryogenic distillation process or a vacuum swing adsorption process. A valve 142 may be used to control the flow of stored hydrogen to the gas turbine 114. A valve 143 may be used to control the flow of stored oxygen to the HRSG 116. A valve 144 may be used to control the flow of natural gas to the gas turbine 114. Natural gas may be supplied via a natural gas source 146. The controller 108 can control the flow of hydrogen, oxygen, and natural gas to the GTCC 104 based on factors described herein (e.g., availability of renewable energy) to optimize the total output (e.g., electrical power and hydrogen) of the system 100.

[0046] The combined cycle gas turbine power plant 104 includes a gas turbine 114, a heat recovery steam generator (HRSG) 116, and a steam turbine 118. The function and operation of the combined cycle gas turbine power plant 104 will be understood by those skilled in the art, and many of the details will not be described herein for the sake of brevity. The gas turbine 114 includes a compressor 148, a combustor 150, and a turbine 152. The compressor 148, the turbine 152, and the generator 154 are physically connected via one or more shafts and may rotate together. Air is introduced into the compressor 148, which compresses the air, and fuel is introduced into the compressed air in the combustor 150. The fuel is ignited, and the combustion products have greatly increased temperature and pressure (and energy) relative to the compressed air. The high-energy combustion products expand in the turbine 152, which drives the compressor 148 and the generator 154.

[0047] After the high-energy combustion products exit the gas turbine 114, they are referred to as exhaust gases and are directed through the HRSG 116. The HRSG 116 can include one or more heat exchange assemblies that transfer heat from the exhaust gases to water. The water can be in the form of liquid water or steam. The HRSG 116 can have various stages to produce steam at specific temperature and pressure characteristics. Further, as described with reference to FIG. 3, the heat from the steam can be used to heat an electrolyzer in the hydrogen production system 106 using, for example, heat exchanger 158 or heat exchanger 162. The steam is then directed to the steam turbine 118, which can be physically connected to the generator 156 via a clutch 160. In some examples, the clutch 160 can be omitted. From the steam turbine 118, the steam can flow into a heat exchanger 162, such as a condenser, where the steam can be cooled. The heat from the steam and the water from the HRSG 116 can additionally be input into another system, such as that shown in FIG. 8. In some examples, the generator 156 may be the same generator connected to the gas turbine 114, or in other examples, it may be a separate generator (as shown in FIGS. 1A and 1B). The steam may expand in the steam turbine 118 and transfer torque to the generator 156 to generate power. The steam may then be condensed into liquid water and returned to the HRSG 116 to be reheated to specific properties. It will be appreciated that, as always, water may be circulated between the HRSG 116 and the steam turbine 118 in a loop.

[0048] In the example, the controller 108 is a main controller in signal communication with at least one of an electrolyzer VAR (volt-ampere reactive power) set point controller 120, an electrolyzer production set point controller 122, a GTCC plant output controller 124, and a GTCC plant VAR set point controller 126, each of which may respond to command signals provided by the main controller 108, as described in further detail below.

[0049] The hydrogen production system 106 can produce hydrogen using many different processes. Thermochemical processes use heat and chemical reactions to release hydrogen from organic materials such as fossil fuels and biomass, or from materials such as water. Water (H2O) can also be separated into hydrogen (H2) and oxygen (O2) using electrolysis or solar energy. Microorganisms such as bacteria and algae can produce hydrogen through biological processes.

[0050] In an example, the hydrogen production system 106 includes an electrolyzer. An electrolyzer may be an electrical device operable to consume electrical power and convert water into its constituent hydrogen and oxygen. Typically, the electrolyzer consumes direct current electrical power and utilizes a converter 134 to convert alternating current to direct current. The hydrogen may be stored in a hydrogen storage system 110, which may include a tank, pipeline, salt cavern, or other geological repository, as described with reference to Figures 11-16F. As will be appreciated by one skilled in the art, the electrolyzer of the hydrogen production system 106 generally receives an input of water and electricity to produce hydrogen gas and oxygen gas.

[0051] Electric power may be provided via an electrical grid 128. The electrical grid 128 may obtain power from one or more of a variety of power sources, such as a renewable wind power source 130 and a renewable photovoltaic solar power source 132. The electrical grid 128 may also obtain power from other sources, such as hydroelectric sources, nuclear sources, one or both of the generators 154 and 156 of the gas turbines 114 and steam turbines 118, respectively, of the combined cycle gas turbine plant 104, or from other gas turbine generators connected to the electrical grid 128.

[0052] The operation of the electrolyzer in the hydrogen production system 106 may be responsive to a production set point controller 122. The production set point controller 122 may control the amount of DC current to supply to the electrolyzer. The supply of DC current and water to the electrolyzer is directly related to the production of hydrogen gas and oxygen gas.

[0053] The operation of the electrolyzer of the hydrogen production system 106 may also be responsive to the electrolyzer VAR set point controller 120. The VAR set point controller 120 may control the amount of AC current that is converted to DC current to be supplied to the electrolyzer.

[0054] A power inverter converts DC power to AC power. A power inverter is a grid-connected device that allows power to be injected into the power grid 128. A typical use of a power inverter is unidirectional and may be, for example, in a photovoltaic solar power source 132 or a fuel cell.

[0055] In an example, converter 134 may include thyristor rectifier technology using transistor electronics that can convert single-phase, two-phase, or three-phase AC power to DC power. Such DC power output is generally unidirectional and not smooth, and is typically used for electroplating, DC processes, and electrolytic cell stacks.

[0056] In an example, converter 134 may include chopper rectifier technology using a combination of silicon-controlled rectifiers (SCRs) and insulated gate bipolar transistors (IGBTs) to convert single-phase, two-phase, or three-phase AC power to DC power. Such DC power output is generally unidirectional and not smooth, and is typically used for electroplating, DC processes, and electrolytic cell stacks.

[0057] In an example, converter 134 may be a power conversion system (PCS) that uses IGBTs and PWM (pulse wave modulation) to convert single-, two-, and three-phase AC power to DC, as well as to obtain DC power from sources such as electrochemical batteries, wind turbines, or solar generators and convert the DC power to AC power. Such a PCS is bidirectional, and both the AC and DC are "clean," near-pure waveforms free of harmonics or "ripple," a typical technology used to supply real and reactive power services to the power grid 128.

[0058] In an example, the converter 134 may be a “hybrid power conversion” system. The hybrid power conversion system may use a PCS topology on the AC (grid 128) connected side and a chopper / thyristor topology on the DC side connected to the electrolyzer of the hydrogen production system 106. This provides “clean” AC power whose phase angle can be adjusted to provide reactive power service to the grid 128, while producing “unclean” DC suitable for use by the electrolyzer to perform electrolysis at low cost. It will be appreciated that this hybrid power conversion can generally provide beneficial grid services, such as reactive power services provided by a full PCS topology, at a lower overall cost. Because the “hybrid power conversion” system can be connected to the grid 128 and provide reactive services, it is desirable that it be certified to UL standard UL 1741 or equivalent. An example hybrid power conversion system for the converter 134 is further described with reference to FIG. 10 .

[0059] It will be appreciated that the electrolyzer of the hydrogen production system 106 can receive water and DC power from the converter 134 to produce hydrogen gas and oxygen gas. Some examples of electrolyzers may also require an input of electrolyte, such as potassium hydroxide. The hydrogen gas can proceed to a hydrogen purification system 136, a hydrogen compressor 138, and then to the hydrogen storage system 110. Similarly, the oxygen gas can proceed to an oxygen purification system 140 and then to the oxygen storage system 112. A similar oxygen compressor (e.g., compressor 356 in FIG. 8 ) can optionally be used. It will be appreciated that while examples are described herein as hydroxide electrolysis electrolyzers, the scope of the present disclosure is not so limited and is intended to include other electrolyzer configurations, such as polymer electrolyte membrane (PEM) electrolysis units.

[0060] The hydrogen storage system 110 can include rock salt cavities for storing hydrogen gas. In some examples, the hydrogen storage system 110 can include one or more lengths of pipe or pressure vessels, such as "bullet" or spherical shapes, that are highly compressed to store hydrogen. Examples of hydrogen storage systems 110 are described in more detail with reference to Figures 11-16F.

[0061] The hydrogen gas in the hydrogen storage system 110 may be used as fuel and supplied to a combustor 150 of the gas turbine 114. Flow valves 142 and 144 may be responsive to the GTCC plant output controller 124 to supply the flow of hydrogen and natural gas fuels to the gas turbine 114. Under some conditions, the controller 124 may, for example, command the valves 142 and 144 to supply only one fuel (either natural gas or hydrogen) to the gas turbine 114. Under other conditions, the controller 124 may, for example, command the valves 142 and 144 to supply a mix of both natural gas and hydrogen to the gas turbine 114.

[0062] Relative to natural gas, combustion of hydrogen occurs at a higher temperature. Higher temperature combustion can be expected to result in increased production of nitrogen oxides (NOx). In an example, oxygen from oxygen storage system 112 can be supplied as "hot oxygen" to inlet duct 164 of HRSG 116 to reduce NOx production, for example, by using nozzle 300 of FIG. 9.

[0063] While examples of the present disclosure have been described with respect to using hydrogen as an energy storage medium, it will be appreciated that the scope of the present disclosure is not so limited and that other energy storage media may be produced using surplus renewable energy for subsequent use as a fuel, such as ammonia (or an energy carrier that can be decomposed to yield a fuel, including, for example, hydrogen).

[0064] As described below with reference to Table 1, the integrated power production system 100 can be operated to utilize available sources to produce energy for direct consumption or for storage through the production of hydrogen or electricity, which can be stored. Additionally, for example, the use of renewable energy and hydrogen fuel can be increased by either using renewable energy sources when available or using stored hydrogen produced during periods of low demand to reduce the emissions of the GTCC 104. Thus, for example, the overall operation of the GTCC 104 can be smoothed to eliminate or reduce periods of inefficient, high-machine-demand operation.

[0065] Figure 2 depicts another diagram of the control strategy for the system 100 shown in Figures 1A and 1B. The main controller 108 may be in communication with more specific setpoint controllers 120-126 (Figures 1A and 1B) via various plant controllers 154 for one or more instances of the GTCC 104 and electrolyzer of the hydrogen production system 106 in the system 100. Figure 2 illustrates different instances of power producers, such as the GTCC 104 and renewable wind power source 130, and the hydrogen production system 106 may be combined to provide the integrated power production system 100.

[0066] As described with reference to FIG. 3, the GTCC 104 may be combined with a hydrogen production system 106 to enable the HRSG 116 to heat the electrolyzer 201, which in turn supplies hydrogen to the gas turbine 114.

[0067] 4, the GTCC 104 may be combined with the hydrogen production system 106 and the renewable wind power source 130 to supply power to the battery 222 for use during intermittent downtime of the renewable wind power source 130 and for frequency support, and the oxygen may be expanded to allow cooling of the electrolyzer 201. In an example, the battery 222 may be replaced with another electrolyzer 201.

[0068] As will be described with reference to FIG. 5, multiple electrolyzers 201 may be connected to multiple converters 134 to heat or cool loop 230 to selectively heat or cool one or more of the electrolyzers 201 and converters 134.

[0069] As described with reference to FIG. 6 , the HRSG 116 may be combined with an electrolyzer 201 to provide heating, a steam turbine 118 to provide synchronous condensation, and hydrogen compressors 138 and 254 to provide hydrogen storage and surge capacity to coordinate the combustion of hydrogen and natural gas in the gas turbine 114.

[0070] As described with reference to FIG. 7, any or all of the hydrogen production systems 106 of FIGS. 1-6 may be connected to a hydrogen storage system 110, which may take the form of various underground storage facilities as described with reference to FIGS. 11-16F.

[0071] The various subsystems described with reference to Figures 3-7 may be combined into an integrated power production system 100 configuration operated in tandem by a main controller 108 to smooth periods of high and low demand on the power grid 128 by simultaneously reducing emissions through efficient use of available renewable energy sources and production of hydrogen for combustion in gas turbine engines, while producing power for short-term storage in batteries and hydrogen for long-term storage in reservoirs during periods of low grid demand for later use during periods of high grid demand.

[0072] FIG. 3 is a schematic diagram illustrating a system 200 including a combined cycle power plant 104 (FIG. 1B) having a gas turbine 114 (FIG. 1B), a HRSG 116, and a hydrogen production system 106. The hydrogen production system 106 may include an electrolyzer 201. The hydrogen production system 106 may be connected to power conversion equipment including a hydrogen receiving tank 110 and a converter 134. FIG. 3 depicts another diagram of several components suitable for use in the integrated power production system 100 of FIGS. 1A and 1B. FIG. 3 illustrates a system for utilizing heat from the exhaust gas of the turbine 114 as captured by the HRSG 116 using the integrated power production system 100. The system 200 may be connected to a main controller 108 (FIG. 1).

[0073] Power line 203 may be used to deliver power from the power grid 128 (FIGS. 1A and 1B) to the hydrogen production system 106, for example, to control the production of hydrogen using the electrolyzer 201 based on other parameters of the system 100. Hydrogen produced by the hydrogen production system 106 may be supplied to the hydrogen receiving tank 110 via hydrogen line 204. The hydrogen compressor 138 may be used to increase the pressure of the hydrogen and move the hydrogen to another location. The hydrogen compressor 138 may supply the gas turbine 114 via line 206A and to another process, such as an industrial or fuel use, via line 206B. Additionally, the compressed hydrogen may be sent back to the hydrogen receiving tank 110 via line 208 and valve 210. Furthermore, hydrogen may be supplied to the HRSG 116 via line 212, for example, to provide auxiliary combustion functions, etc.

[0074] 1A and 1B . However, a gas turbine configured to receive hydrogen from the hydrogen production system 106 may be located anywhere on the power grid 128, remote from the hydrogen production system 106. The gas turbine 114 may include a multi-shaft gas turbine engine and may be connected to the generator 154 via a clutch 214, such that the generator 154 may be configured to operate as a synchronous condenser. For example, the clutch 214 may be operated by the controller 108 to decouple the generator 154 from the gas turbine 114, and the generator 154 may be supplied with AC power from the power grid 128 to change or adjust the phase angle (Φ) of the power grid 128. The gas turbine 114 may be configured to operate as a simple-cycle power producer or in conjunction with a combined-cycle plant. The gas turbine 114 may be located remote from the electrolyzer 201. The gas turbine 114 may be configured to use hydrogen from the hydrogen production system 106 of Figures 1B, 3 and 7, hydrogen storage 110, and from other hydrogen sources or storage systems such as those shown in Figures 11-16F.

[0075] Advantageously, the heat from the HRSG 116 may be used by other industrial processes located with or near the system 100, such as for chemical production or for facility environmental temperature control, as shown in FIG.

[0076] In the illustrated example, the electrolyzer 201 of the hydrogen production system 106 can be heated by steam or water from the HRSG 116 using fluid line 202. As such, the electrolyzer 201 can be maintained in a warmed state or standby mode, allowing the electrolyzer 201 to quickly reach operational capability compared to startup from ambient temperature, thereby providing fast-reacting hydrogen production. Fluid can be circulated between the HRSG 116 and the hydrogen production system 106 using fluid line 202 to provide heating or cooling as desired. In an example, heat can be supplied to the hydrogen production system 106 from an industrial process or other heat source. In an additional example, cooling can be supplied to the hydrogen production system 106 by a source of cooling fluid other than the HRSG 116, such as expanded oxygen.

[0077] 4 is a schematic diagram illustrating a system 200 including a heat recovery steam generator 116 connected to a hydrogen production system 106, which in turn is connected to a battery 222 and a wind power source 130. The hydrogen production system 106 may be connected to a cooling system 224, which may include an expansion turbine 226, a generator 228, and a heat exchanger 229. The hydrogen production system 106 may be connected to a hydrogen receiving tank 110 and power conversion equipment, including a transformer 133 and a converter 134. The battery 222 may be connected to the wind power source 130 via power conversion equipment, including a transformer 133 and a converter 134. FIG. 4 depicts another diagram of several components suitable for use within the integrated power production system 100 of FIGS. 1A and 1B. 4 shows a system for using compressed O (or H) from the electrolyzer 201 to store power in a battery 222, for example to provide power load and frequency support functions, and to generate power to cool one or both of the converter 134 and the electrolyzer 201. The system 220 may be connected to the main controller 108 (FIG. 1), for example, to control the flow of fluid to the electrolyzer 201 and the operation of the battery 222 based on other parameters of the system 100. A power line 203 may be used to deliver power from the power grid 128 (FIGS. 1A and 1B) to the hydrogen production system 106 and the battery 222.

[0078] There are various ways in which oxygen from the hydrogen production system 106 may be advantageously integrated with other components within the integrated power production system 100. For example, oxygen from the oxygen storage system 112 ( FIGS. 1A and 1B ) or directly from the hydrogen production system 106 may be expanded, for example, through an orifice, an expansion valve, or an expansion turbine 226. It will be appreciated that the expansion of compressed oxygen results in a decrease in temperature. This reduced-temperature oxygen may be used as a fluid to cool the converter 134, which is connected to the hydrogen production system 106 via a heat exchanger 229. Similarly, the reduced-temperature oxygen may be used to cool the electrolyzer 201, which may be beneficial to facilitate a cool-down so that maintenance and other procedures can be performed. The fluid lines to the heat exchanger 229 may include various valves operable by the controller 108 to control the flow of reduced-temperature oxygen based on grid conditions. In an example, the expansion turbine 226 may be connected to a generator 228 to provide additional power to the grid 128. In an example, the expansion turbine 226 may be connected to the hydrogen compressor 138 (FIG. 3) to provide rotational power to the hydrogen compressor 138, thereby also recovering the energy expanded by the system 220 in cooling the electrolyzer 201. In such a configuration, the expansion turbine 226 can increase the total power output or reduce the auxiliary load to improve system efficiency.

[0079] As described herein, the electrolyzer 201 may be heated using heat from the HRSG 116, industrial process heat, district heating sources, commercial building heat, and the like.

[0080] The battery 222 may be used to store power generated by the wind power source 130. The battery 222 may additionally assist with both power load and frequency support functions, for example, when power from the wind power source 130 may be reduced. The controller 108 may provide regulation up / down, frequency up / down, or reactive power management. The oxygen cooling described above may also be used for temperature management of the battery 222. In an example, the battery 222 may be included at the location of the hydrogen production system 106.

[0081] FIG. 5 is a schematic diagram showing a fluid loop 230 for an electrolyzer bank 232 that may be connected to a rectifier bank 234. The fluid loop 230 may include a heat exchanger 229, a fluid line 236, and an electrolyzer line 238. The electrolyzer 201 may be connected to a power converter 134 via a power line 240. The fluid loop 230 may provide a temperature input (e.g., heat) or cooling to the electrolyzer 201, and the power converter 134 may provide an electrical input to the electrolyzer 201 so that the electrolyzer 201 can produce an output of hydrogen and oxygen (not shown in FIG. 5). FIG. 5 represents another diagram of components suitable for use with the integrated power production system 100 of FIGS. 1A and 1B. FIG. 5 shows how the electrolyzer 201 can be kept ready using heat from the loop 230 or can be quickly cooled down after using the loop 230. The loop 230 may be connected to the main controller 108 (FIG. 1) to control the flow of fluid through the loop 230, for example, based on other parameters of the system 100. The power line 203 may be used to deliver power from the power grid 128 (FIGS. 1A and 1B) separately through the converter 134 to the electrolyzer 201.

[0082] During times when one or more of the electrolyzers 201 are not operating to produce hydrogen and oxygen, it is desirable to supply heat to at least one of the electrolyzers 201 to keep such electrolyzers in a ready state to quickly and efficiently begin producing hydrogen. There are various ways in which thermal management of the electrolyzers 201 can be advantageously integrated with other components in the integrated system 100. In an example, heat is supplied via the HRSG 116 (see FIG. 3 ), which can supply steam or water to the loop 230 at a temperature sufficient to maintain the electrolyzers 201 in a standby mode. In an example, heat may be supplied by the converter 134 of the electrolyzer 201 operating to keep the currently inoperable electrolyzer in a ready state, thereby additionally cooling the converter 134 associated with the operating electrolyzer 201. In an additional example, heat may be supplied via a dedicated heating device 242. In an example, the heating device 242 can include a resistive heater, which can be powered from the power grid 128 ( FIGS. 1A and 1B ) or another source. In an example, the heating device 242 may include a burner that may be supplied with hydrogen fuel via the electrolyzer 201 for combustion.

[0083] The heat exchanger 229 or another heat exchanger may additionally be connected to a loop of cooling fluid, such as expanded oxygen from the turbine 226 of Figure 4. The expanded oxygen may be used to cool the electrolyzer 201, such as after it has been shut down, for example to allow for maintenance of the electrolyzer 201 quickly after shut down. In a further example, the converter 134 may be provided with cooling via the heat exchanger 229 of Figure 4.

[0084] Although not shown in FIG. 5, the loop 230 may be connected to the converter 134 via additional fluid lines to provide cooling for the converter 134, for example, to enable the converter 134 to operate at an efficient temperature.

[0085] Each of these examples, described with reference to FIG. 5, illustrates the synergistic use of heat exchange to facilitate one or more of cooling the converter 134 and heating the electrolyzer 201 in standby mode.

[0086] FIG. 6 is a schematic diagram showing the heat recovery steam generator 116 connected to the electrolyzer 201 and a hydrogen surge system 250. The hydrogen surge system 250 can include the hydrogen storage system 110, the hydrogen compressor 138, the hydrogen surge tank 252, the hydrogen surge compressor 254, the hydrogen purifier 136, and a mixing tank 258. FIG. 6 represents another diagram of components suitable for use with the integrated power production system 100 of FIGS. 1A and 1B. FIG. 6 shows how hydrogen produced using the electrolyzer 201 can be incorporated into the power generation of the integrated power production system 100. The system 250 can be connected to the main controller 108 (FIG. 1) to control the flow of hydrogen and natural gas, for example, to the gas turbine 114. A power line 203 can be used to deliver power to the electrolyzer 201 from the power grid 128 (FIGS. 1A and 1B).

[0087] The HRSG 116 may include low-temperature, medium-temperature, and high-temperature steam circuits within a steam circuit 260 configured to heat water and provide steam to the steam turbine 118. The electrolyzer 201 may output hydrogen at line 262 to supply hydrogen to the purifier 136. Hydrogen from the purifier 136 may be provided to the hydrogen storage system 110 via line 264. The hydrogen storage system 110 may include a tank or the like, as described with reference to FIGS. 7 and 11-16F. The hydrogen compressor 138 may provide compressed hydrogen to the surge tank 252 via lines 266A and 266B. The hydrogen in the surge tank 252 may be connected to the surge compressor 254 via line 268 and to a mixing tank 258 via line 270. The mixing tank 258 may be connected to a source of natural gas via line 272 and to the combustor of the gas turbine 114 via line 274. The hydrogen surge system 250 may additionally include valves 276 A, 276 B, and 276 C that may be operated by the controller 108 to control the flow of fuel through the system 250 .

[0088] There are various ways in which component thermal management can be advantageously integrated with other components in the integrated system 100. For example, the feedwater in the HRSG 116 in circuit 260 can be used to heat the electrolyzer 201. Additionally, the electrolyte in the electrolyzer 201 can be heated by the exhaust of the gas turbine 114 via an economizer coil in the HRSG 116. Alternatively, the electrolyzer 201 can be cooled via the feedwater of the HRSG 116, depending on where the feedwater is taken from the HRSG 116. In an additional example, a cooling circuit for the gas turbine 114 can be used to heat the electrolyzer 201.

[0089] The steam turbine 118 may be connected to the generator 156 via a clutch 160, allowing the generator 156 to rotate freely from the steam turbine 118 and act as a synchronous condenser for reactive power and / or voltage support. For example, the clutch 160 may be operated by the controller 108 to decouple the generator 156 from the steam turbine 118, which may be supplied with AC power from the power grid 128 to change or adjust the phase angle (Φ) of the power grid 128.

[0090] The hydrogen compressor 138 may be driven by various motive power sources or combinations of motive power sources. For example, the hydrogen compressor 138 may be driven by an electric motor. In other examples, the hydrogen compressor 138 may be driven by steam provided by another heat source, such as the HRSG 116 or the converter 134. Other examples include mechanical drive from the gas turbine 114 or the steam turbine 118 to the hydrogen compressor 138.

[0091] FIG. 7 is a schematic diagram illustrating a hydrogen storage system 110. The hydrogen storage system 110 can include a storage tank 280 and a pipeline 282. FIG. 7 depicts another diagram of components suitable for use with the integrated power production system 100 of FIGS. 1A and 1B. FIG. 7 illustrates that hydrogen can be stored in a variety of containers, including a tank 280 located remotely from the hydrogen production system 106 via a pipeline 282. Various approaches exist for providing hydrogen storage 110, such as those illustrated in FIGS. 11-16F. In the example of FIG. 7, the hydrogen storage 110 can include pipelines of various lengths, which are compressed above typical operating pressures to accommodate the storage of hydrogen. The system 110 can be connected to the main controller 108 (FIG. 1), for example, to control the flow of hydrogen to and from the tank 280.

[0092] FIG. 8 is a schematic diagram illustrating the integrated power production system 100 of FIGS. 1A and 1B operable in conjunction with an industrial facility 350. It will be appreciated that the industrial facility 350 can produce one or more of various fuels, chemicals, or material (e.g., steel, aluminum, etc.) products as output products 376. The industrial facility 350 can include a controller 352 and a transformer 354. As shown in FIGS. 1A and 1B, the integrated power production system 100 can include an oxygen storage system 112 and an oxygen purification system 140. The oxygen purification system 140 can be configured to supply purified oxygen to the oxygen storage system 112 via a compressor 356. The industrial facility 350 can have multiple inputs, including an oxygen input line 360 ​​or 362, a hydrogen input line 366, a saturated steam line 368, and a compressed steam line 370.

[0093] An oxygen input line 360 ​​may be connected to the system 100 at the output of the electrolyzer 201. The oxygen compressed by the compressor 356 may enter the oxygen storage system 112 after being purified by the purifier 140. The oxygen from the oxygen storage system 112 may proceed to the industrial facility 350 in line 362. The oxygen may further return to the system 100 from the oxygen storage system 112 at the HRSG 116 via an extension of line 364. A hydrogen input line 366 may be connected to the system 100 at the output of the hydrogen purification system 136. A saturated steam line 368 may be connected to the system 100 between the HRSG 116 and the heat exchanger 158. A compressed steam line 370 may be connected to the system 100 at the inlet of the steam turbine 118 or at any drum of the HRSG 116, as will be appreciated by those skilled in the art.

[0094] Industrial facility 350 can receive power from power grid 128 (FIGS. 1A and 1B) via power line 372, the voltage of which can be changed by transformer 354. Controller 352 can communicate with main controller 108 (FIGS. 1A and 1B) via control line 374. Industrial facility 350 can be operated using inputs 360-366 and other inputs to output product 376. Controller 352 can work in conjunction with controller 108 to produce output product 376 using sources from integrated power production system 100 based on the availability of hydrogen, oxygen, and steam due to conditions on power grid 128. To that end, lines 360-370 can include valves that can be operated by controller 108 and controller 352.

[0095] FIG. 9 is a schematic diagram of a thermal nozzle 300 that can be used to produce high-temperature oxygen. The thermal nozzle 300 can include a housing 302, an injector 304, an inlet port 306, and an outlet orifice 308. The housing 302 can include a chamber 310 that can be connected to an opening 312 into which the injector 304 can be inserted through a port 314. The port 314 can be configured to axially align the injector 304 with the outlet orifice 308. The injector 304 can include a tube having a lumen 316 and an outlet orifice 318. The thermal nozzle 300 can receive oxygen and fuel. In an example, the thermal nozzle 300 can be configured similarly to the thermal nozzle described in U.S. Patent No. 6,277,999 to Anderson, the entirety of which is incorporated herein by reference. However, the thermal nozzle 300 additionally includes an opening 312. As described in the '661 patent, the combination of fuel in an oxygen-rich environment can produce oxygen jets 320 of hot oxygen that create axial mixing 322. Additional openings 312 can provide further oxygen jets 324 of hot oxygen that create radial mixing 326.

[0096] Oxygen jets 320 and 324 can be discharged from thermal nozzle 300 with the following characteristics: high velocity, typically greater than 750 m / s, to create recirculation and mixing 322 and 326, and high radical concentration to support reaction kinetics. This promotes cooler "oxidation" reactions versus hotter "combustion" reactions. The reactivity and kinetics shown result from the injection of highly reactive gases. In the example, preheated oxygen destroys CO and NO precursors (NH3 and HCN) with little or no NOx production.

[0097] 1A and 1B , the thermal nozzle 300 may be disposed directly within the inlet duct 164 of the HRSG 116. In an example, the oxygen supplied to the thermal nozzle 300 may be supplied directly from the oxygen storage system 112. In an example, the oxygen supplied by the oxygen storage system 112 may be in thermal communication with one or more of: (i) the heated water of the HRSG 116; (ii) the heated steam of the HRSG 116; or (iii) the exhaust gas flowing through the HRSG 116. Any suitable heat exchanger may be used to transfer heat between the oxygen and the aforementioned streams.

[0098] The exemplary nozzle of the '666 patent can provide a high velocity output that may be suitable enough for injection into a generally laminar flow, such as in a pipe, intended to provide rapid mixing of the hot oxygen in the laminar flow. The openings 312 can function as output orifices located at multiple locations around the housing 302 of the nozzle 300. The openings 312 are intended to provide enhanced mixing of the hot oxygen in areas of high turbulence, such as in the inlet duct 164 of the HRSG 116.

[0099] 1B , in an example, oxygen supplied by oxygen storage system 112 may be supplied directly to the inlet of gas turbine 114. Introducing oxygen directly to the inlet of gas turbine 114 may reduce the percentage composition of nitrogen in the mass flow of the gas turbine, thereby reducing NOx production and emissions. Oxygen from oxygen storage system 112 may be supplied directly to the inlet of gas turbine 114 in the form of hot oxygen produced by thermal nozzle 300 described above. In an example, oxygen from oxygen storage system 112 may be supplied directly to inlet duct 164 in the state of oxygen storage system 112 (i.e., without the use of thermal nozzle 300). Other examples may include other equipment to change the state of the oxygen before being introduced into inlet duct 164. Examples of such equipment may include pumps for increasing the pressure (and / or temperature) of the oxygen from the oxygen storage system 112, expansion nozzles or valves for decreasing the pressure (and / or temperature) of the oxygen from the oxygen storage system 112, and heat exchangers that may be installed at various stages of the heat recovery steam generator 116 to heat or cool the oxygen supplied from the oxygen storage system 112. Other examples may include thermal communication between the oxygen from the storage system 112 and other electronic or process components that may benefit from the exchange of heat, such as the controllers 108, 120-126, the power conversion equipment 133, 134, the hydrogen production system 106, or the gas turbine 114.

[0100] [Table 1]

[0101] As summarized in Table 1, there are a variety of potential operating states that can be provided through coordination between the main controller 108 and the other controllers 120, 122, 124, 126 and various other controllers in the various subsystems shown with respect to Figures 3-7 and 10. Examples of such controllers are described with reference to Figure 29.

[0102] Case 1: The GTCC plant 104 is shut down when power demand by consumers 152 is relatively low, such as during the weekend. Excess power provided by the renewable power sources 130, 132 (beyond the amount required by consumers 152) is supplied via the power grid 128 to the transformer 133, converter 134, and electrolyzer of the hydrogen production system 106 to produce hydrogen, which is stored in the hydrogen storage system 110. Because the GTCC plant 104 is shut down, it is in a relatively “cold” thermal state. In such a “cold” thermal state, it is desirable to gradually ramp up the power output of the GTCC plant 104 to minimize thermal gradients and thermal stresses. However, as can happen from time to time, the power grid 128 may be called upon to prepare for a large demand for power, perhaps from a large industrial consumer starting up its plant. Typically, the GTCC plant 104 may be called upon to perform a “fast start-up,” which may impose high thermal gradients and thermal stresses within the gas turbine 114. The integration of the components of the system 100 provides an alternative solution that allows the gas turbine 114 to immediately supply high demand power while performing a desired slow start-up. In this case, the electrolyzer of the hydrogen production system 106 is shut down immediately or as soon as possible, and the energy previously consumed by the electrolyzer is then made available to the power grid 128 immediately or as soon as possible for distribution from renewable sources 130, 132 to consumers 152. At the same time, the GTCC plant 104 can begin process warm-up at a desired ramp-up rate while making the power previously consumed by the electrolyzer available to consumers 152. That is, the near-instant shutdown of the electrolyzer simulates a "fast start-up" by the GTCC plant 104 without imposing high temperature gradients and thermal stresses on the gas turbine 114 of the GTCC plant 104.

[0103] Case 2: The GTCC 104 is operating at minimal load (approximately 30%), running on natural gas, and is "parked." Because demand for electricity on the grid 128 is low, electricity is cheap, and the electrolyzer in the hydrogen production system 106 can operate at full load, with electricity from the grid 128 and / or the GTCC 104 being consumed to produce hydrogen gas that is stored in the hydrogen storage system 110. As in Case 1, an urgent increase in electricity may be requested by consumers 152. Again, the electrolyzer can be quickly shut down to provide an apparently near-instant supply of electricity to the grid 128. Because the GTCC 104 is operating at minimal load, its ability to produce electricity can be ramped up more quickly than in Case 1. Again, the rapid demand for electricity can be met by reducing the electrolyzer's consumption rather than by rapidly ramping up the GTCC 104. It will be appreciated that if the GTCC 104 is parked and operating on hydrogen instead of running on natural gas, the emissions may simply be water vapor with no carbon dioxide.

[0104] Case 3: Demand for Electricity is High but Drops Rapidly. Consider a situation where a large industrial consumer 152 suddenly trips off, causing a sudden drop in demand for electricity from the grid 128. Because demand is high, the GTCC 104 is operating at base (full) load, and the electrolyzer in the hydrogen production system 106 cannot produce much hydrogen (consume much energy from the grid 128). If the electrolyzer is kept warm (e.g., via heat from the HRSG 116 as described herein with reference to FIGS. 3-6 ), the electrolyzer can immediately increase hydrogen production to 100% and immediately begin consuming the electricity previously consumed by the large industrial consumer 152. That is, a rapid start-up of the electrolyzer can quickly replace the drop in demand from the industrial consumer 152. Therefore, the GTCC 104 can begin a slow ramp-down (while balancing with the electrolyzer in the hydrogen production system 106) to reduce the temperature gradient in the GTCC 104. Excess electricity consumed by the electrolyzer may be stored in the form of hydrogen in the hydrogen storage system 110 for later conversion into electricity by the GTCC 104.

[0105] Case 4: The GTCC 104 is off and the electrolyzer of the hydrogen production system 106 is operating at part load. As the availability of renewable power from sources 130, 132 decreases, the electrolyzer can reduce hydrogen production to maintain balance on the power grid 128.

[0106] Case 5: The GTCC 104 is operating at no load and at full speed (depending on temperature and speed, but not producing power) and is running on hydrogen from the hydrogen storage system 110. The power grid 128 recognizes and responds to an increased demand for power, and the GTCC 104 begins to scale up to the load while hydrogen production by the electrolyzer in the hydrogen production system 106 can be reduced. If there is insufficient hydrogen available to power the gas turbine 114, the GTCC 104 can begin opening the flow of natural gas via valve 144.

[0107] Case 6: The generator 154 of the gas turbine 114 is operating as a synchronous condenser, and the electrolyzer of the hydrogen production system 106 is consuming power from the power grid 128 while producing hydrogen gas to maintain balance on the power grid 128. If the power grid 128 begins to sense an increasing demand for power, the main controller 108 can direct the other controllers 120-126 and other controllers in the subsystems of Figures 3-7 and 10 to ramp the electrolyzer down and ramp the GTCC 104 up, first with natural gas fuel via valve 144, and then with hydrogen gas via the storage system 110 and valve 142.

[0108] While six separate cases are described above, it will be appreciated that the scope of the present disclosure is not so limited, but includes various combinations of each or all of the above cases, such as any intermediate operating conditions between those specific conditions described, and operating all on natural gas, all on hydrogen, or any combination of natural gas and hydrogen.

[0109] 10 is a schematic diagram of a hydrogen generation system 400 including an electrolysis pack 402, a battery pack 404, and a renewable energy producer 405 connected to a power grid 128 via a bidirectional inverter 406 and DC-DC inverters 408A and 408B. The system 400 may further include a first circuit breaker 410A, a second circuit breaker 410B, a third circuit breaker 410C, a fourth circuit breaker 410D, a fifth circuit breaker 410E, and a sixth circuit breaker 410F. Power from the power grid 128 may be transmitted to the system 400 through transformers 412A and 412B. The bidirectional inverter 406 may include an AC converter 414 and a DC converter 416. The DC-DC inverter 408A may include a first converter 418A and a second converter 420A. The DC-DC inverter 408B may include a first converter 418B and a second converter 420B. The electrolysis units 428 may be connected (via their hydrogen output) to the GTCC 422, which may be connected to the generator 424. The electrolysis units 428 may also be connected to an oxygen consumer 426.

[0110] Transformer 412A can transfer power from the power grid 128 to the hydrogen production system 400. Similarly, transformer 412B can transfer power from transformer 412A to converter 406. Bidirectional inverter 406 can convert alternating current from transformer 412A to direct current via AC converter 414. Electrolysis pack 402 can include multiple electrolysis units 428, which can be electrically connected together, such as in series or parallel, to receive current from inverter 406. Each electrolysis unit 428 can be configured to convert an input of water (HO) into hydrogen (H) gas and oxygen (O) gas using electricity, such as via DC.

[0111] The inverter 408A can convert the DC from the inverter 406 from one voltage to another voltage suitable for use with the battery pack 404. The battery pack 404 can include multiple battery units 430 that can be electrically connected together, such as in series or parallel, to receive current from or supply current to the inverter 408A.

[0112] Renewable energy producer 405 may include multiple instances 432 of one or both solar panels and wind turbines, which may be connected together in series or parallel to provide electrical input to inverter 408B. Inverter 408B may convert DC from one voltage to another, such as converting DC from renewable energy producer 405 to a voltage suitable for use with inverter 406.

[0113] [Table 2]

[0114] In a first state, circuit breakers 410A-410D may be closed. In such a state, electrolysis unit 428 may actively convert electricity and water into hydrogen and oxygen, and battery unit 430 may be simultaneously charged. The first state may be used when the hydrogen and oxygen products are stored, such as in hydrogen storage system 110 and oxygen storage system 112 (FIG. 1) for long-term storage, and when energy is stored in battery unit 430 for short-term storage. The first state may occur when there is excess energy available on power grid 128, such as when renewable energy sources, e.g., wind power source 130 and solar power source 132 (FIG. 1), are operating at high capacity.

[0115] In a first state, circuit breakers 410E and 410F can be open or closed. With circuit breaker 410E open, renewable energy source 405 can be in a non-producing state. With circuit breaker 410E closed, renewable energy source 405 can produce and supply power, for example, to produce hydrogen using electrolysis unit 428 and store the power in battery unit 430. With circuit breaker 410F open, GTCC 422 can be shut down. With circuit breaker 410F closed, GTCC 422 can operate for standby service, such as at minimum load.

[0116] In a second state, circuit breakers 410A, 410B, and 410D may be closed and circuit breaker 410C may be open. In such a state, excess power from the power grid 128 may be stored in the battery unit 430. Thus, excess power from the power grid 128 during periods when it is desired to not operate the electrolysis pack 402 may be stored for later use by the electrolysis pack 402.

[0117] In a second state, circuit breakers 410E and 410F may be open or closed. With circuit breaker 410E open, renewable energy source 405 may be in a non-producing state. With circuit breaker 410E closed, renewable energy source 405 may be producing, for example, to store power in battery unit 430. With circuit breaker 410F open, GTCC 422 may be shut down. With circuit breaker 410F closed, GTCC 422 may be operating for standby service, such as at minimum load.

[0118] In a third state, circuit breakers 410A, 410B, and 410D may be closed, and circuit breaker 410C may be open. In such a state, battery unit 430 may be discharging to grid 128 or connected to grid 128 in a standby mode. Thus, battery unit 430 may be used for energy storage services. Benefits of operating in the third state include peak power (e.g., providing additional power from battery unit 430 to grid 128), frequency regulation (e.g., using battery unit 430 to adjust the frequency of grid 128), voltage, and reactive power, including traditional battery energy storage system (BESS) services.

[0119] In a third state, the circuit breaker 410E may be open, with the renewable energy source 405 not supplying power. With the circuit breaker 410F open, the GTCC 422 may be shut down and the battery unit 430 can provide traditional service or act as a spinning reserve. With the circuit breaker 410F closed, the GTCC 422 and the battery unit 430 may be adding power to the power grid 128.

[0120] In a fourth state, breaker 410A may be closed and breakers 410B, 410C, and 410D may be open. In such a state, bidirectional inverter 406 may be connected to power grid 128 to provide power conversion system services and reactive power services.

[0121] In a fourth state, breaker 410E may be open such that renewable energy source 405 is not providing power. With breaker 410F open, GTCC 422 may be shut down. With breaker 410F closed, GTCC 422 may be providing power, reactive service, and inertia.

[0122] In the fifth state, breakers 410A and 410D may be closed and breakers 410B and 410C may be open. The fifth state may be useful for providing power conversion system services to the power grid 128, for providing reactive power services, and for connecting the renewable energy source 405 to the battery unit 430.

[0123] In a fifth state, the circuit breaker 410E is closed, allowing the renewable energy source 405 to charge the battery unit 430. With the circuit breaker 410F open, the GTCC 422 may be shut down. With the circuit breaker 410F closed, the GTCC 422 may be providing power, reactive service, and inertia.

[0124] In a sixth state, breakers 410A, 410B, and 410C may be closed and breaker 410D may be open. In such a state, system 400 may be electrolysis grid-connected. The sixth state may be useful for production of hydrogen and oxygen for long-term storage (e.g., via storage of hydrogen in system 110 and oxygen in system 112).

[0125] In a sixth state, circuit breakers 410E and 410F may be open or closed. With circuit breaker 410E open, renewable energy source 405 may be non-producing. With circuit breaker 410E closed, renewable energy source 405 may be producing, for example, to supply power to electrolysis unit 428 to produce hydrogen. With circuit breaker 410F open, GTCC 422 may be shut down. With circuit breaker 410F closed, GTCC 422 may be operating for standby service, such as at minimum load.

[0126] In the seventh state, circuit breakers 410C and 410D may be closed and circuit breakers 410A and 410B may be open. In such a state, electrolysis pack 402 may be connected to battery pack 404. The seventh state may be useful for recovering excess power stored in battery unit 430 for use with electrolysis unit 428 to produce hydrogen and oxygen, thereby shifting short-term storage to long-term storage (e.g., via storage of hydrogen in system 110 and oxygen in system 112).

[0127] In the seventh state, circuit breakers 410E and 410F may be open or closed. With circuit breaker 410E open, renewable energy source 405 may be in a non-producing state. With circuit breaker 410E closed, renewable energy source 405 may be producing, for example, to supply power to electrolysis unit 428 to produce hydrogen. With circuit breaker 410F open, GTCC 422 may be shut down. With circuit breaker 410F closed, GTCC 422 may be operating for standby service, such as at minimum load.

[0128] FIG. 10 illustrates a system in which an electrolysis unit 428 may be integrated into the system 100. To enable the system 400 to operate independently of the power grid 128, the system 400 may include a DC subsystem within the circuit breaker 410A that is not connected to the power grid 128. Thus, energy from the renewable energy generator 405 may be stored in a battery or used directly by the electrolysis unit 428. The inclusion of the battery unit 430 may additionally be used to reduce the number of electrolysis units 428 or damage to the electrolysis units 428. For example, the battery unit 430 may be used to keep the electrolysis units 428 operational or warmed up when power from the renewable energy generator 405 or the power grid 128 is not available, thereby reducing cycling of the electrolysis units 428. In an example, the components of the system 400 may include components from FIGS. 1A-9 with similar names but different reference numbers. For example, the electrolysis unit 428 may include the electrolyzer 201 and the battery unit 430 may include the battery 222 .

[0129] Storage System

[0130] The present application additionally discloses a number of storage systems that may be used for hydrogen storage, means and methods for incorporating the storage systems, and methods for connecting such storage systems to an integrated power production facility.

[0131] It is known to store hydrogen, as well as other gases, in a variety of storage vessels. A common storage vessel configuration includes a forged tube that may be certified to ASME and / or DOT standards that incorporate transportation safety requirements, particularly for vessels that may be transportable. These storage vessels may incorporate specific design features, such as flanges and / or hemispherical ends, to meet such standards. Vessels with such safety and certification margins are expensive to produce.

[0132] The present disclosure provides multiple configurations for stationary pipelines that can be safe, easy to install, and inexpensive. Stationary pipelines can be used as storage vessels for hydrogen via pressurization above standard pressure. Additionally, standard pipes can be deployed as storage vessels both above and / or below ground when pipelines are not readily available or in service.

[0133] 11 illustrates a vertically arranged piping system 500 that may be utilized as a gas storage system, such as for storing hydrogen. Piping system 500 may include various subsystems for providing and maintaining an acceptable quantity and pressure of hydrogen, including a compressor 505, one or more venting subsystems 510, vents 512, valves 514A-514G, appropriate sensors 515, such as pressure transducers, storage pipes 520, and connecting lines 522A-522F. In an example, storage pipes 520 may be buried below ground 525. In an example, system 500 may be connected to an adjacent storage system 530, which may be similar to system 500 or other systems described herein, to increase the storage capacity of system 500.

[0134] FIG. 12 illustrates a storage system 550 including multiple storage pipes 520 interconnected in clusters 554. System 550 may be connected to one or more producers 552 that generate or produce hydrogen, such as electrolysis units. Clusters 554 may include packs of pipes 520 connected to a common header pipe 556, such as line 522A, that connects to the above-ground portion of system 550. In the illustrated example, each of clusters 554 includes six pipes 520. It will be appreciated that system 550 is contemplated to include pipes 520 that may be buried up to two miles below ground level 525 using current drilling technology. For comparison, pipes 520 may be stacked end-to-end to a length equivalent to nine Empire State Buildings as a comparable reference. In the example of system 500 of FIG. 11 or system 550 of FIG. 12, it is expected that the depth utilized will be directly related to the amount of hydrogen needed to be stored. That is, longer pipes can be extended deeper underground to store larger amounts (eg, volumes) of hydrogen.

[0135] In examples, pipe 520 may be a steel pipe inserted into a wellbore. In examples, pipe 520 may be made of other materials, such as fiber-reinforced composites and other metals and alloys. In examples, pipe 520 may include standard well casing or multiple well casings joined together sufficiently to contain hydrogen. In examples, other storage arrangements may be used, such as to treat the well to make it suitable for containing hydrogen, or to make the geology surrounding the well impermeable to hydrogen.

[0136] The vertical cylindrical tank or vessel in pipe 520 is connected to a high pressure P high The gas is stored at a lower pressure P low Therefore, the storage capacity of hydrogen in any such pipe is P high From the amount of hydrogen that can be stored in the volume of the pipe 520 at lowThe amount of hydrogen stored in the volume of the pipe 520 may be less than the amount of hydrogen that can be stored within the volume of the pipe 520 at the grade of the ground 525. Installation techniques for installing the pipe 520 below the ground surface 525 may include open-cutting or drilling. Additionally, the pipe 520 may be installed within an existing (such as an abandoned) oil and / or gas production well. Various support subsystems, such as valves, converters, headers, and / or manifolds, may be installed either above or below the grade of the ground surface 525.

[0137] Compressor 505 converts hydrogen into P high It will be appreciated that compressor 505 consumes energy to compress the hydrogen to the required storage pressure, etc. During times of low demand for hydrogen (and / or electricity), which may coincide with times of peak renewable electricity production and availability, it is anticipated that compressor 505 may be operated to compress the hydrogen to the required storage pressure. Similarly, during periods of high demand for hydrogen (and / or electricity), compressor 505 may be turned off to conserve power, and hydrogen may be drawn from pipe 520 to provide energy, such as electricity, via thermal combustion and / or one or more fuel cells.

[0138] The pressure of hydrogen in pipe 520 is P low Approaching (or P low Since the pressure can be lower than the pressure in the pipe 520, the compressor 505 can be used to draw hydrogen from the pipe 520 and provide hydrogen at any particular desired pressure, which can be greater than the pressure in the pipe 520.

[0139] FIG. 13A illustrates a storage system 560. The storage system 560 may be similar to the storage system 500 (FIG. 1). However, the storage system 560 may include a vessel 562 (such as a pipe) that includes a change in direction. The vessel 562 may include a vertical portion 564 and a horizontal portion 566. It is contemplated that directional drilling techniques utilized in other industries (oil, gas, and / or water exploration) may be utilized to increase the storage capacity of the system 500 without the need to drill to the required depth, or when obstacles prevent or block drilling to the required depth. As described above, multiple systems 560 may be arranged in fluid communication together in a cluster 568 to provide increased storage capacity. As shown in FIG. 13B, each cluster 568 may include a matrix of one to six vessels 562 of the systems 560. The clusters 568 may be stacked vertically.

[0140] 14A and 14B show top and side views of a cluster arrangement 570. The cluster arrangement 570 includes a radial geometry that can allow for efficient use of ground space, such that all of the associated subsystems can be located near a common connection point for many storage vessels. The cluster arrangement 570 can include vessels 572 arranged where a first end of the vessel 572 is located near a center 574 where the ends of the vessels are close together, and the vessels 572 can extend radially away from the center 574 to outer portions 576 where the ends of the vessels 572 are farther apart. The vessels 572 can include pipes as described herein and can be arranged in a straight configuration or in a configuration with curved or angled changes in direction.

[0141] FIG. 15 is a schematic diagram of a storage system 580. System 580 shows an arrangement having three layers 582, 584, and 586 of vessels 588. Layers 582-586 can be connected to line 522A in a variety of ways. Vessels 588 in each layer 582, 584, and 586 can be individually plumbed above grade using lines 590, as shown for layer 582 in layer 1, at header pipe 592. Individual vessels 588 can be connected to a common header 592 via lines 594 before piping above grade, as shown for layer 584 in layer 2. Individual layers can be independent, as shown for layer 1, or can be in fluid communication with the layers above or below, as shown using line 596 connecting layer 584 in layer 2 and layer 586 in layer 3.

[0142] 16A-16C show various cross-sectional views of layers 582-586. FIG. 16A shows layers 582-586 arranged symmetrically. FIGS. 16B and 16C show layers 582-586 arranged asymmetrically. Layers 582-586 may be arranged with the goal of minimizing the cost of mechanical support between individual containers 588 as well as reducing the total space required. In examples, containers 588 may be held in place by soil or by artificial supports.

[0143] 16D and 16E show an alternative layer arrangement in which a reservoir 588 is disposed within a groove 590. FIG.

[0144] Vessel 588 in any configuration may be installed completely below ground level, or may be installed with access passages 596 at the ends or at various subsystem locations for maintenance and inspection, as shown in Figure 16F. In this way, valves connected to the ends of vessel 588 may be accessible.

[0145] 17, 17A and 17B show diagrams of a gantry system 600. The gantry system 600 may be used for fabricating and erecting the various vessels described herein.

[0146] Figure 17 shows a top view of a gantry system 600 including a support structure 602 having vertical portions 604 and horizontal portions 606. Figure 17A is a side view of the gantry system 600 showing the spaced apart vertical portions 604. Figure 17B is a side view of the gantry system 600 showing the vertical portions 604 connected by a horizontal portion 606.

[0147] The gantry system 600 may be installed above the trench 608. The vertical portions 604 may be installed in the ground above the grade 525 along either side of the trench 608. The horizontal portions 606 may connect the vertical portions 604 on either side of the trench 608. The vertical portions 604 and the horizontal portions 606 may form a temporary support structure.

[0148] Figure 18 shows a top view of the welding gantry 620 relative to the support structure 602 of the gantry system 600. Figure 18A is a side view of the welding gantry 620, omitting the gantry system 600 for clarity and showing the vessel 622 and welding unit 621. Figure 18B is a side view of the gantry system 600 showing the welding gantry 620 positioned on wheels 624 within the support structure 602.

[0149] The welding gantry 620 can include a lower frame 626 on which wheels 624 can be mounted. The lower frame 626 can be connected to an upper frame 628 via supports 630. The vessel 622 can be suspended from the upper frame 628 using cables 632 and hoists 634. The welding gantry 620 can include a welding unit 621 that can weld the individual sections 636 together to form a vessel 622 that is longer than the length of the individual sections 636 alone. The welding unit 621 can be fully enclosed to manage pre- and post-weld heat treatments, radiography, environmental control, etc. In examples, the welding unit 621 can also be open to the atmosphere or partially protected to provide a lower-cost alternative for potentially less demanding applications. The welding gantry 620 can be robotically controlled to move along the gantry system 600 and perform welding operations with the welding unit 621.

[0150] In an example, the first step may be to excavate and remove soil at grade 525 to provide a location for trench 608 for vessel 622. Following site excavation, a temporary support structure 602 may be installed. Temporary support structure 602 may include a vertical portion 604 and a horizontal portion 606. After installing support structure 602, a welding gantry 620 having a welding unit 621 may be installed, and various sections of pipe 636 may be joined to obtain the desired vessel length. Welding gantry 620 may include a hoist 634 having a trolley for moving pipe sections 636 into position on a work platform. Gantry 620 may include a hoist 634 on both sides of temporary support structure 602, such that sections of pipe 636 may be installed on both sides of the structure to optimize the efficiency of construction, such as the welding process.

[0151] Figure 19 shows a top view of the gantry system 600 showing the location of the welding gantry 620 relative to the groove 608. Figure 19A is a side view of the gantry system 600 showing the temporary support structure 602 supporting the section 636 of fabricated pipe that will form the vessel 622, and the welding gantry 620 supporting another section 636 of pipe. Figure 19B is a side view of the gantry system 600 showing the temporary support structure 602 and the welding gantry 620 holding the section 636 of pipe at the same horizontal level.

[0152] 20-20B show further construction details and assembly steps for use of system 600. Temporary support structure 602 may include wire ropes 640 connected to synchronized hoists 638 for evenly lowering vessel 622 into trench 608. A welding gantry 620 may be supported by structure 602 beneath sections 636 of pipe and can move from section to section to weld the ends of the sections together to form vessel 622 of the desired length.

[0153] 21-22B illustrate further assembly steps using system 600. Once each vessel 622 is welded together to the desired length, it can be lowered into trench 608 via hoist 638 and positioned as desired. Once one layer of vessels 622 is completed, soil 642 can be backfilled in trench 608 on top of the first layer of vessels 622 to support the next layer of vessels 622. If aisle access is employed (see FIG. 16F), the soil 642 does not cover the ends to the aisle. As shown in FIGS. 23A-23C, this continues until the complete placement of the vessel 622 layer is provided and backfilled with soil, or until other support structures are in place. FIG. 23A shows the vessels 622 fully buried, with only the header pipes 644 extending above the grade 525 of the soil 642.

[0154] The gantry system 600, including the temporary support structure 602 and the welding gantry 620, may allow for the assembly of long lengths of assembled pipe on-site and the lowering of the assembled pipe to the fabricated location. The hoist 638 may move longitudinally from side to side along the support structure 602 to provide access to all of the trenches 608. The wire ropes 640 may move sections of pipe perpendicular to the trenches 608, thereby allowing the sections of pipe to be moved to various three-dimensional positions within the trenches 608. The welding gantry 620 may move longitudinally within the support structure 602 above the trenches 608. The hoist 634 may move left and right on the gantry 620 to provide access to all of the trenches 608. The cables 632 may move sections of pipe perpendicular to the trenches 608, thereby allowing the sections of pipe to be moved to various three-dimensional positions within the trenches 608. In this manner, the welding gantry 620 can be used to load sections of pipe into the support structure 602 and assemble additional sections of pipe onto the sections of pipe supported by the support structure 602. The welding gantry 620 can move out of the way of the support structure 602 or work in conjunction with the support structure 602 to move assembled lengths of pipe sections into the trench 608.

[0155] 24-27 show storage system 700 through a sequence of steps in which pipe storage systems 702, 704, 706, and 708 are added sequentially to accommodate the need for increased hydrogen storage capacity. Storage system 700 can include a storage controller 710 in communication with main controller 108, which in turn communicates with power grid 128 (FIGS. 1A and 1B).

[0156] FIG. 24 shows a first system 702 including a hydrogen production unit 712 and a consumer 714 that consumes hydrogen. The hydrogen production unit 712 and the consumer 714 may be connected by piping 716. Additionally, the system 702 may include appropriate sensors 718 and actuators and communicate signals and controls with a storage controller 710 that may operate the system 700 and associated subsystems (described above with reference to other figures herein, particularly FIGS. 11-23C ) to store and supply hydrogen in response to appropriate conditions, as may be defined or directed by the grid controller 108. A compressor 722 may be provided within the piping 716 to compress and move the hydrogen through the system 702. In an example, the first system 702 may be configured similarly to system 550 of FIG. 12 .

[0157] FIG. 25 illustrates the addition of a second storage system 704 having a salt cavern 730 as the storage system rather than the vessels described above. System 704 may have a hydrogen production unit 732 and a consumer 734. Additionally, system 704 may include appropriate sensors 736 and actuators and communicate signals and controls with a storage controller 710, which may operate system 704 and associated subsystems (described above with reference to other figures herein, particularly FIGS. 11-23C) to store and supply hydrogen in response to appropriate conditions, as may be defined or directed by grid controller 108. A compressor 738 may be provided in piping 740 to compress and move hydrogen through system 704. As shown in FIG. 25, systems 702 and 704 may each communicate signals and controls with controller 710, but are separate with respect to their respective capabilities for distributing hydrogen. That is, storage in system 702 cannot receive hydrogen from producers 732 in system 704 and cannot supply hydrogen to consumers 734 in system 704. Similarly, hydrogen stored within system 704 cannot be exchanged with producers 712 or consumers 714 in system 702.

[0158] FIG. 26 illustrates the addition of a third storage system 706. As will be appreciated, storage system 706 includes the same components as system 702 described with reference to FIG. 24 and will not be described here for clarity. As shown in FIG. 26, systems 702, 704, and 706 can all communicate signals and controls with a storage controller 710, respectively. Systems 702 and 706 are connected in terms of their ability to distribute hydrogen. That is, the storage of system 700 can receive hydrogen from a producer 712 of system 706 and can supply hydrogen to a consumer 714 of system 706. Similarly, hydrogen stored within system 706 can be exchanged with the producer 712 or consumer 714 of system 700. However, as shown in FIG. 26, systems 700 and 706 are separate from system 704 in terms of their respective capabilities to distribute hydrogen to system 704.

[0159] Figure 27 illustrates the addition of a fourth storage system 708. As will be appreciated, storage system 708 includes the same components as system 702 described with reference to Figure 24 and, for clarity, will not be labeled or described here. As shown in Figure 27, systems 702, 704, 706, and 708 can each communicate signals and controls with storage controller 710. Figure 27 illustrates that the introduction of system 708 "bridges together" systems 702 and 706 with system 704, thereby connecting systems 702, 704, 706, and 708 in terms of their respective capabilities for distributing hydrogen among one another. That is, the storage of each of systems 702, 704, 706, and 708 can receive hydrogen from producers 712 and 732 of any of the other systems 702, 704, 706, and 708, and can supply hydrogen to consumers 714 and 734 of any of the other systems 702, 704, 706, and 708. In such a situation, the large storage of hydrogen associated with salt cavern 704 can be utilized by the other systems. Additionally, if any hydrogen producer from any of systems 702, 704, 706, or 708 becomes inoperable or unavailable due to maintenance or repair, hydrogen produced or stored by any of the other systems may be available for use by consumers associated with the potentially unavailable system.

[0160] Storage system 700 can include an example of hydrogen storage system 110 of Figures 1A and 1B. In an additional example, hydrogen storage system 110 of Figures 1A and 1B can include one of systems 702, 704, 706, and 708.

[0161] 29 is a schematic diagram illustrating components of the controller 108 for operating the integrated power production system 100 and the controllers 120-126 for operating the hydrogen production system 106 and the GTCC 104. The controller 108 may include circuitry 80, a power supply 82, memory 84, a processor 86, input devices 88, output devices 90, and a communication interface 92. The controller 108 may be in communication with an electrical grid 128, which may provide electrical power to an end user or consumer 152. The controller 108 may also be in communication with the controllers 120 and 122 for the hydrogen production system 106 and the controllers 124 and 126 for the GTCC 104, which may be in communication with one or more subsystem controllers, such as the storage controller 24A and the battery and generator controller 24B. Controller 24A can communicate with hydrogen storage system 110 and oxygen storage system 112 as well as their various components, such as valves 142-144, compressor 138, turbine 226 and compressor 254, and purification units 136 and 140. Controller 24B can communicate with batteries 222 and 430 as well as various other components, such as circuit breakers 410A-410F and clutches 160 and 214.

[0162] Controllers 120-126 and controllers 24A and 24B may also include various computer system components that facilitate receiving and issuing electronic instructions, storing instructions, data and information, communicating with other devices, e.g., display devices, input devices, output devices, etc. For example, power controllers 120-126 may each include a power supply 50, a memory 52, a processor 54, control circuitry 56, etc.

[0163] Circuit 80 may include any suitable computer architecture, such as a microprocessor, chips, etc., that enable memory 84, processor 86, input devices 88, output devices 90, and communication interface 92 to operate together. Power supply 82 and power supply 50 may include any suitable method for providing power to controller 108 and controllers 120-126, respectively, such as an AC or DC power supply. Memory 84 and memory 52 may include any suitable memory devices, such as random access memory, read-only memory, flash memory, magnetic memory, and optical memory. Input device 88 may include a keyboard, mouse, pointer, touch screen, and other suitable devices for providing user input or other input to circuit 80 or memory 84. Output device 90 may include a display monitor, viewing screen, touch screen, printer, projector, audio speakers, etc. Communication interface 92 may include devices that enable circuit 80 and controller 108 to receive information from and send information to other computing devices, such as a modem, router, I / O interface, bus, local area network, wide area network, the Internet, etc.

[0164] The controller 108 may be configured to operate a power grid 128, and as such may be referred to as the "home office" for the system 100. The power grid 128 may include the hydrogen production system 106, the GTCC 104, the renewable energy sources 130 and 132, high-voltage transmission lines that carry power from remote sources to demand centers, and distribution lines that connect to consumers 152. The power grid 128 may be configured to operate at a control frequency where all power input to the power grid from disparate sources is input at the same frequency to facilitate power integration. In one example, the power grid 128 may operate at a control frequency of 60 Hertz (Hz).

[0165] The controller 108 can determine the demand placed on the power grid 128, for example, by monitoring the consumption of the consumers 152. The controller 108 can coordinate the generation of power from the GTCC 104 and the renewable energy sources 130 and 132. The controller 108 can allocate or instruct the GTCC 104 how much power output the GTCC 104 should contribute to the power grid 128, and such allocation can respond dynamically based on the capabilities and availability of either the GTCC 104 or the renewable energy sources 130 and 132. The controller 108 can ensure that the total power generated by the GTCC 104 and the renewable energy sources 130 and 132 meets the power demands of the consumers 152. If the power demands of the consumers 152 exceed or are lower than the power supplied by the GTCC 104 and the renewable energy sources 130 and 132, the controller 108 can instruct a response strategy to the GTCC 104. In this manner, the controller 108 can interact with the controllers 124 and 126 for the GTCC 104 .

[0166] The circuitry 80 communicates with, i.e., can read from and write to, a memory device, such as a memory 84. The memory 84 may include various computer-readable instructions for implementing the operation of the power grid 128. As such, the memory 84 may include instructions for monitoring the demand on the power grid 128 and the power being supplied to the power grid 128. The circuitry 80 may be connected to various sensors to perform such functions. The memory 84 may also include information that can assist the controller 108 in providing instructions to the controllers 120-126. For example, the memory 84 may include the type, size (capacity), age, maintenance history, location, location within the geography covered by the power grid 128, and proximity of each of the GTCCs 104 to the consumers 152. The memory 84 may also include instructions for determining the percentage and contribution of the GTCCs 104 and other power plants to the total power supply.

[0167] The controllers 120-126 may be configured to operate the GTCC 104 and the hydrogen production system 106. The memory 52 may include various computer-readable instructions for implementing the operation of the GTCC 104 and the hydrogen production system 106. As such, the memory 52 may include instructions for monitoring the power generation allocation from the controller 108, instructions for power generation for each generator 156 and 154, etc. The memory 52 may additionally include instructions for operating the electrolyzer 201 and the electrolysis unit 428.

[0168] Additionally, memory 52 may include operational efficiency information, such as production efficiency and economic efficiency information, for each of the generator units 156 and 154, including the gas turbines 114. For example, memory 52 may include the power generation efficiency of each of the turbines 114. Memory 52 may include economic information, such as the maintenance and economic history for the gas turbines 114, and the time since the last service, repair, overhaul, refurbishment status, etc. Memory 52 may also include information regarding the operational efficiency of the GTCC 104, including the financial efficiency of each of the gas turbines 114, such as various contractual obligations with various power plant operators and manufacturers of the gas turbines 114 and service providers for the gas turbines 114.

[0169] Controllers 120-126 may operate or communicate with controllers 24A and 24B to operate compressor 138, turbine 226, compressor 254, valves 142-144, purification units 136 and 140, circuit breakers 410A-410F, and clutches 160 and 214, as well as other components of system 100.

[0170] Controller 108 can work in conjunction with controllers 120-126 to operate controllers 24A and 24B to maximize or most efficiently operate system 100, for example, by controlling the operation of hydrogen production system 106 to produce hydrogen when conditions on power grid 128 permit. In this manner, memory 52 and memory 84 can include instructions for operating or performing any of the methods described herein, such as those described with reference to Table 1 and Cases 1-6, as well as the seven operating states described with reference to FIG.

[0171] Various notes and examples Integrated Power Generation System

[0172] Example 1 is a power plant configured to output electrical power to a grid power system, the power plant including: a hydrogen generation system configured to produce hydrogen; a gas turbine combined cycle power plant including a gas turbine engine configured to combust hydrogen from the hydrogen generation system to produce a gas stream that can be used to rotate a turbine shaft and a heat recovery steam generator (HRSG) configured to generate steam with the gas stream from the gas turbine engine to rotate the steam turbine; a storage system configured to store hydrogen produced by the hydrogen generation system; and a controller configured to operate the hydrogen generation system with electrical power from the grid power system when the grid power system has surplus energy and to balance active and reactive loads on the grid power system using at least one of the hydrogen generation system and the gas turbine combined cycle power plant.

[0173] In Example 2, the subject matter of Example 1 optionally includes a power conversion device connecting the hydrogen production system to a grid power system, the power conversion device including a DC converter for converting DC power from the hydrogen production system into clean AC power for the grid power system, and an AC converter for converting AC power from the grid power system into DC power for the hydrogen production system.

[0174] In Example 3, the subject matter of any one or more of Examples 1-2 optionally includes the DC converter including a chopper converter or a thyristor converter, and the AC converter including a power conversion system.

[0175] In Example 4, the subject matter of any one or more of Examples 1-3 optionally includes: the gas turbine engine being connected to the gas turbine generator via a first clutch; and the controller being configured to selectively actuate the first clutch to allow the gas turbine generator to rotate freely and absorb a reactive load.

[0176] In Example 5, the subject matter of any one or more of Examples 1-4 optionally includes: the steam turbine being connected to the steam turbine generator via a second clutch; and the controller being configured to selectively actuate the second clutch to allow the steam turbine generator to rotate freely and absorb the reactive load.

[0177] In Example 6, the subject matter of any one or more of Examples 1-5 optionally includes a battery connected to the grid power system to provide load and frequency support.

[0178] In Example 7, the subject matter of Example 6 optionally includes a renewable energy producer connected to a grid power system, wherein the battery can be charged from the renewable energy producer without the grid power system.

[0179] In Example 8, the subject matter of any one or more of Examples 1-7 optionally includes an auxiliary burner configured to combust hydrogen from the hydrogen production system to heat the hydrogen production system.

[0180] In Example 9, the subject matter of any one or more of Examples 1-8 optionally includes the hydrogen production system including an electrolyzer.

[0181] In Example 10, the subject matter of Example 9 optionally includes a heat source for heating the electrolytic cell, the heat source including a resistive heater or a power conversion device.

[0182] In Example 11, the subject matter of any one or more of Examples 9-10 optionally includes a heat exchange circuit connected to the electrolytic cell for cooling or heating the electrolytic cell.

[0183] In Example 12, the subject matter of Example 11 optionally includes the heat exchange circuit being connected to a gas turbine combined cycle power plant to provide steam.

[0184] In Example 13, the subject matter of any one or more of Examples 11-12 optionally includes wherein the electrolyzer is further configured to produce oxygen, and wherein the power plant further includes an oxygen storage system.

[0185] In Example 14, the subject matter of Example 13 optionally includes that the heat exchange circuit is supplied with cooled oxygen from the electrolyzer.

[0186] In Example 15, the subject matter of any one or more of Examples 13-14 optionally includes an oxygen turbine driven by oxygen from the electrolyzer, and an electrical generator driven by the oxygen turbine.

[0187] In Example 16, the subject matter of any one or more of Examples 9-15 optionally includes a conduit connecting the oxygen output of the electrolyzer to an HRSG of a gas turbine combined cycle power plant.

[0188] In Example 17, the subject matter of Example 16 optionally includes a nozzle connected to the inlet of the HRSG for injecting oxygen from the electrolyzer at a velocity of 750 m / s or greater.

[0189] In Example 18, the subject matter of any one or more of Examples 1-17 optionally includes burning hydrogen in the HRSG using an auxiliary combustion burner.

[0190] In Example 19, the subject matter of any one or more of Examples 1-18 optionally includes a natural gas source connected to a gas turbine engine, the gas turbine engine configured to combust natural gas, hydrogen, and combinations thereof.

[0191] In Example 20, the subject matter of any one or more of Examples 1-19 optionally includes wherein the hydrogen storage system includes an underground storage system.

[0192] In Example 21, the subject matter of Example 20 optionally includes wherein the hydrogen storage system includes rock salt cavities.

[0193] In Example 22, the subject matter of any one or more of Examples 20-21 optionally includes the hydrogen storage system including a plurality of pipes.

[0194] In Example 23, the subject matter of Example 22 optionally includes a temporary support structure including a hoist configured to install the pipe in the trench, and a welding gantry operable with the temporary support structure to assemble the sections of pipe.

[0195] syringe

[0196] Example 1 is a power plant configured to output electrical power to a grid power system, the power plant including: an electrolyzer configured to produce hydrogen and oxygen; a gas turbine combined cycle power plant including a gas turbine engine configured to combust hydrogen from the hydrogen production system to produce a gas stream that can be used to rotate a turbine shaft; and a heat recovery steam generator (HRSG) configured to generate steam with the gas stream from the gas turbine engine to rotate a steam turbine; a storage system configured to store the hydrogen produced by the hydrogen production system; and a nozzle configured to direct oxygen from the electrolyzer into the HRSG of the gas turbine combined cycle power plant.

[0197] In Example 2, the subject matter of Example 1 optionally includes the nozzle including an injector configured to receive fuel and a housing into which the injector extends and into which oxygen enters, and the housing including a plurality of mixing ports in the injector arranged radially to allow the fuel and oxygen to mix outside the nozzle.

[0198] In Example 3, the subject matter of Example 2 optionally includes the plurality of radial mixing ports configured to create mixing vortices to reduce the formation of NOx in the gas stream.

[0199] Example 4 is a method for burning fuel using a thermal nozzle, the method comprising the steps of: (A) supplying an oxidizer having an oxygen concentration of at least 30 volume percent at an initial velocity of less than 300 fps into an oxidizer supply duct communicating with a combustion zone; and (B) supplying fuel, separate from the oxidizer, into the oxidizer supply duct at a velocity of at least 200 feet per second and at or above the initial velocity of the oxidizer to mix the oxidizer with the high-velocity fuel, wherein up to about 20% of the oxygen in the oxidizer supplied into the oxidizer supply duct is combusted with the fuel to generate heat and combustion reactions. (C) mixing the combustion reaction products with the remaining oxygen in the oxidizer in the oxidizer supply duct to raise the temperature of the remaining oxidizer in the oxidizer supply duct; and (D) delivering the heated oxidizer from the oxidizer supply duct into the combustion zone at an exit velocity that exceeds the initial velocity by at least 300 feet per second, wherein the heated oxidizer is directed out of the oxidizer supply duct through a plurality of orifices arranged in different directions.

[0200] Hybrid Power Converter

[0201] In Example 1, the indefinite example subject matter optionally includes the power converter being configured to convert AC power from the grid power system to DC power for the electrolyzer, and DC power from the electrolyzer to AC power for the grid power system.

[0202] In Example 2, the indefinite example subject matter optionally includes that the power converter includes a DC converter including a chopper converter or a thyristor converter and an AC converter including a power conversion system.

[0203] In Example 3, the indeterminate example subject matter optionally includes further including a battery configured to absorb active and reactive loads on the grid power system.

[0204] In Example 4, the subject matter of Example 3 optionally includes a renewable energy producer configured to power the battery without a grid power system.

[0205] Operating Status Method

[0206] Example 1 is a method of operating an integrated power plant connected to a grid power system, the method including: operating a gas turbine engine to drive a first generator to supply electrical power to the grid power system, the gas turbine engine being operable with at least one of hydrogen and natural gas; operating an electrolyzer to produce hydrogen and oxygen with electrical power from the grid power system; storing hydrogen produced by the electrolyzer in a storage system; and coordinating operation of the gas turbine engine and the electrolyzer to supply demand on the grid power system.

[0207] In Example 2, the subject matter of Example 1 optionally includes coordinating operation of the gas turbine engine and the electrolyzer to a power demand of the grid power system includes starting the gas turbine engine from shutdown until it is operating at maximum power and shutting down operation of the electrolyzer, and the demand of the grid power system is a request for maximum power.

[0208] In Example 3, the subject matter of Example 2 optionally includes the gas turbine engine starting from 0% load and the electrolyzer starting from 100% load and operating from renewable energy connected to the grid power system.

[0209] In Example 4, the subject matter of any one or more of Examples 1-3 optionally includes coordinating operation of the gas turbine engine and the electrolyzer to a power demand of the grid power system includes ramping up operation of the gas turbine engine from a part load at a maximum ramp rate and shutting down operation of the electrolyzer, and wherein the demand of the grid power system is a request for maximum power.

[0210] In Example 5, the subject matter of Example 4 optionally includes the gas turbine engine starting from 30% load and running on natural gas, and the electrolyzer starting from 100% load.

[0211] In Example 6, the subject matter of any one or more of Examples 1-5 optionally includes coordinating operation of the gas turbine engine and the electrolyzer to a power demand of the grid power system includes ramping down operation of the gas turbine engine from a maximum load condition and activating operation of the electrolyzer, and changing the demand of the grid power system from a maximum power demand to the reduced power demand.

[0212] In Example 7, the subject matter of Example 6 optionally includes the gas turbine engine starting from 100% load and operating on natural gas and hydrogen from the electrolyzer, and the electrolyzer starting from 0% load.

[0213] In Example 8, the subject matter of any one or more of Examples 1-7 optionally includes coordinating operation of the gas turbine engine and the electrolyzer to power demands of the grid power system includes operating the gas turbine engine in a standby mode and ceasing operation of the electrolyzer, and the demands of the grid power system are constant.

[0214] In Example 9, the subject matter of Example 8 optionally includes: the gas turbine engine starting up from shutdown; the electrolyzer being one of a plurality of electrolyzers, 50% of the plurality of electrolyzers starting up from 0% load and 50% of the electrolyzers starting up from 100% load; and power being supplied to the grid power system by renewable energy curtailment.

[0215] In Example 10, the subject matter of any one or more of Examples 1-9 optionally includes coordinating operation of the gas turbine engine and the electrolyzer to power demands on the grid power system includes ramping up operation of the gas turbine engine to a maximum speed and reducing output of the electrolyzer, and the demand on the grid power system is increased.

[0216] In Example 11, the subject matter of Example 10 optionally includes the gas turbine engine being ramped up to no-load speed and operating on natural gas and hydrogen from the electrolyzer, and the electrolyzer being started from 100% load and operating from renewable energy connected to the grid power system.

[0217] In Example 12, the subject matter of any one or more of Examples 1-11 optionally includes wherein coordinating operation of the gas turbine engine and the electrolyzer to electrical power demands of the grid power system includes ramping up operation of the gas turbine engine from a non-operating state and shutting down operation of the electrolyzer, and wherein demands on the grid power system are increasing.

[0218] In Example 13, the subject matter of Example 12 optionally includes the gas turbine engine starting from performing grid condensing operation to begin operation first on natural gas and then on hydrogen, and the electrolyzer starting from 100% load.

[0219] In Example 14, the subject matter of any one or more of Examples 1-13 optionally includes operating a heat recovery steam generator (HRSG) using exhaust gases from the gas turbine engine to rotate a steam turbine to drive a second generator.

[0220] In Example 15, the subject matter of any one or more of Examples 1-14 optionally includes heating the electrolyzer with steam from the HRSG.

[0221] The above detailed description includes references to the accompanying figures, which form a part of the detailed description. By way of illustration, the figures show specific embodiments in which the invention may be practiced. These embodiments are also referred to herein as "examples." Such examples may include elements in addition to those shown or described. However, the inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the inventors also contemplate examples using any combination or permutation of those elements (or one or more aspects thereof) shown or described with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

[0222] In the event of a conflicting usage between this specification and any document incorporated by reference, the usage in this specification will control.

[0223] As used herein, the terms “a” and “an” are used, as is common in patent documents, to include one or more, regardless of any other instance or usage of “at least one” or “one or more.” The term “or” is used herein to refer non-exclusively, or unless otherwise indicated, “A or B” includes “A but not B,” “B but not A,” and “A and B.” The terms “including” and “in which” are used herein as the plain English equivalents of the respective terms “comprising” and “wherein.” Similarly, in the following claims, the terms “including” and “comprising” are open-ended, i.e., a system, device, item, composition, phrase, or process that includes elements in addition to the elements recited after such term in a claim is still deemed to be within the scope of that claim. Moreover, in the following claims, terms such as "first," "second," and "third" are used merely as labels and are not intended to impose numerical requirements on their objects.

[0224] The above description is intended to be illustrative, not limiting. For example, the above-described examples (or one or more aspects thereof) could be used in combination with each other. Other embodiments could be used, for example, by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 CFR §1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to describe or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may be present in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as an example or embodiment, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. [Explanation of symbols]

[0225] 100 Integrated Power Production System 104 Gas Turbine Combined Cycle Power Plant (GTCC) 106 Hydrogen Production System 108 Controller 110 Hydrogen storage system, hydrogen receiving tank 112 Oxygen Storage System 114 Gas Turbine 116 Heat Recovery Steam Generator (HRSG) 118 Steam Turbine 120 Electrolyzer VAR Set Point Controller 122 Electrolyzer Production Set Point Controller 124 GTCC Plant Output Set Point Controller 126 GTCC Plant VAR Set Point Controller 128 Power Grid 130 Renewable wind power sources 132 Renewable Photovoltaic Solar Power Source 134 Converter 135A~D Transformer 136 Hydrogen Purification System 138 Hydrogen Compressor 140 Oxygen Purification System 142,143,144 Valve 146 Natural Gas Sources 148 Compressor 150 Combustor 152 Turbine 154,156 generators 158 Heat exchanger 160 clutch 162 Heat exchanger 164 Inlet Duct 200 systems 201 Electrolytic cell 214 Clutch 220 System 222 Battery 224 Cooling System 226 Expansion Turbine 228 Generator 229 Heat exchanger 230 Fluid Loop 232 Electrolyzer Bank 234 Rectifier Bank 236 Fluid Line 238 Electrolyzer line 240 Power Lines 242 Heating Devices 250 Hydrogen Surge System 252 Hydrogen surge tank 254 Hydrogen surge compressor 258 Mixing Tank 260 Steam Circuit 276A~C Valve 280 Storage Tank 282 Pipeline

Claims

1. 1. A power generation plant configured to output electrical power to a grid power system, comprising: an electrolyzer system configured to produce hydrogen; 1. A gas turbine combined cycle power plant, comprising: a gas turbine engine configured to combust hydrogen from the electrolyzer system to produce a gas stream that can be used to rotate a turbine shaft; and a heat recovery steam generator (HRSG) configured to generate steam from the gas stream of the gas turbine engine to rotate a steam turbine; a gas turbine combined cycle power plant including: a storage system configured to store hydrogen produced by the electrolyzer system; and a heat exchange circuit connecting the electrolyzer system and the HRSG, the heat exchange circuit being configured to circulate at least one of steam and water between the HRSG and the electrolyzer system to heat the electrolyzer system; The power plant, wherein the heat exchange circuits extend between the individual electrolyzers of the electrolyzer system.

2. The power plant described in claim 1, wherein the heat exchange circuit is configured to circulate water between the HRSG and the electrolyzer system.

3. The power plant of claim 1, wherein the heat exchange circuit is configured to circulate steam between the HRSG and the electrolyzer system.

4. A power generation plant as described in claim 1, wherein the heat exchange circuit is further configured to circulate at least one of steam and water between individual electrolytic cells of the electrolytic cell system to exchange heat between electrolytic cells in different operating states.

5. A power plant as described in claim 4, wherein at least one of the steam and water is from the HRSG.

6. The power plant described in claim 1, wherein the heat exchange circuit is configured to cool the electrolyzer system.

7. The electrolyzer system further configured to produce oxygen; the power plant further comprising an oxygen storage system and an oxygen expansion device; 2. The power plant of claim 1, wherein the heat exchange circuit is configured to receive from the electrolyzer system expanded oxygen after passing through the oxygen expansion device, the expanded oxygen serving as a cooling fluid.

8. A power plant as described in claim 6, further comprising a power converter connecting at least one electrolytic cell of the electrolytic cell system to a grid power system, wherein the heat exchange circuit can be utilized to cool the power converter.

9. A power generation plant configured to output electrical power to a grid power system, comprising: an electrolyzer system configured to produce hydrogen; 1. A gas turbine combined cycle power plant, comprising: a gas turbine engine configured to combust hydrogen from the electrolyzer system to produce a gas stream that can be used to rotate a turbine shaft; and a heat recovery steam generator (HRSG) configured to generate steam from the gas stream of the gas turbine engine to rotate a steam turbine; a gas turbine combined cycle power plant including: a storage system configured to store hydrogen produced by the electrolyzer system; and a heat exchange circuit connecting the electrolyzer system to a cooling source and a heating source, the heating source comprising an industrial process, a district heating source, or a commercial building heating system; power generation plants, including

10. The power plant described in claim 9, wherein the heating source includes the HRSG.

11. The electrolytic cell system includes a plurality of electrodes, including an active electrolytic cell and an inactive electrolytic cell; 10. The power plant of claim 9, wherein the heat source comprises water from the operating electrolyzer of the electrolyzer system for heating the inactive electrolyzer.

12. The power plant of claim 9, wherein the heat source includes heat from a power converter or resistance heater connecting at least one electrolytic cell of the electrolytic cell system to the grid power system.

13. The electrolytic cell system comprising a plurality of electrodes including an active electrolytic cell and an inactive electrolytic cell; 10. The power plant of claim 9, wherein the cooling source comprises water from the inactive electrolyzer of the electrolyzer system for cooling the active electrolyzer.

14. The electrolyzer system according to claim 1, further comprising an oxygen turbine for receiving oxygen from the electrolyzer system. The power plant of claim 9 , wherein the cooling source comprises oxygen expanded by the oxygen turbine.

15. A power generation plant configured to output electrical power to a grid power system, comprising: an electrolyzer system configured to produce hydrogen; 1. A gas turbine combined cycle power plant, comprising: a gas turbine engine configured to combust hydrogen from the electrolyzer system to produce a gas stream that can be used to rotate a turbine shaft; and a heat recovery steam generator (HRSG) configured to generate steam from the gas stream of the gas turbine engine to rotate a steam turbine; a gas turbine combined cycle power plant including: a storage system configured to store hydrogen produced by the electrolyzer system; and a heat exchange circuit connecting the electrolyzer system to a cooling source and a heating source, the heat exchange circuit extending between the individual electrolyzers of the electrolyzer system; power generation plants, including 16. A power generation plant configured to output electrical power to a grid power system, comprising: an electrolyzer system configured to produce hydrogen; 1. A gas turbine combined cycle power plant, comprising: a gas turbine engine configured to combust hydrogen from the electrolyzer system to produce a gas stream that can be used to rotate a turbine shaft; and a heat recovery steam generator (HRSG) configured to generate steam from the gas stream of the gas turbine engine to rotate a steam turbine; a gas turbine combined cycle power plant including: a storage system configured to store hydrogen produced by the electrolyzer system; and a heat exchange circuit connecting the electrolyzer system to a cooling source and a heating source; a power converter connecting at least one electrolyzer of the electrolyzer system to a grid power system; Including, The heat exchange circuit may be utilized to cool the power converter.

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