Control devices for steam generators

Abstract

The steam generator (1) comprises a pressure vessel (2), a gas inlet (3) to the pressure vessel (2) configured to receive pressurized hydrogen (4) and oxygen (5), ignition means (6) within the pressure vessel (2) configured to ignite the hydrogen (4) and oxygen (5) received at the gas inlet (3), a water jacket (7) within or on the pressure vessel (2), a water inlet (8) configured to receive and supply pressurized water (9) into the water jacket (7), jets (10) within the pressure vessel (2), and a steam outlet (11) for the exit of steam (12) from the pressure vessel (2). During use, the water (9) received at the water inlet (8) passes through the water jacket (7) to provide cooling for the pressure vessel (2) and is output at the jets (10) to provide a water spray (and / or water film) (13) that mixes with the ignited hydrogen and oxygen (14) and evaporates.

Description

Technical Field

[0001] The present invention generally relates to the field of steam generators, and more particularly to a steam generator that mixes hydrogen and oxygen with feed water to produce a stable supply of steam. The present invention also generally relates to the field of control devices for steam generators.

Background Art

[0002] Reducing energy consumption and finding renewable energy sources have always been in demand. Fossil fuels are being phased out gradually before they run out, and reducing carbon emissions is the goal, but the global energy demand continues to increase. Energy is required for power generation, heating and cooling of air and water, transportation, and other energy services in industries and various manufacturing plants. Exploring sustainable renewable energy resources that are naturally replenished is the solution. These resources generally utilize wind, sunlight, tidal currents, waves, and geothermal energy. However, although these resources provide abundant supplies, they are intermittent, and their production is not always sufficient when energy demand is high. The energy supply they provide does not always match demand. In addition, there are also numerous problems with existing renewable energy solutions.

[0003] In power supply, the utilization of wind power by wind turbines has been proven to meet demand well, but the efficiency of these wind turbines is low, and their locations are restricted by topography. Hydroelectric generators exhibit similar geographical problems, and the scale of such power plants is very large. The usable power generated as a product of these renewable generators cannot be stored, so additional devices are required for this purpose.

[0004] The idea of ​​using fuel cells or rechargeable batteries, while not renewable, offers an alternative energy source. Lithium is a common metal used in such batteries; its supply is finite and will eventually be depleted, but it offers a highly renewable resource. The situation is similar for other chemical batteries, with energy storage and global deployment being the current challenges. However, these battery systems require toxic chemicals and large amounts of energy for production. Furthermore, disposal after use presents problems due to the toxicity of the materials and the highly reactive nature of metals such as lithium. Costs are high, and the supply chain is unsustainable.

[0005] An additional energy resource that is gaining wider use is the fuel cell, often a hydrogen fuel cell. These fuel cells can continuously supply electricity as long as a fuel source and oxygen are available. However, the manufacture of these fuel cells generally requires a large amount of energy, and processing costs can be very high. While they offer clean technology, these fuel cells exhibit numerous problems throughout their lifespan. Hydrogen fuel cells, in particular, require extremely high-purity hydrogen to operate, presenting manufacturing and storage challenges. These fuel cells also suffer from slow start-up times, are susceptible to changes in environmental conditions and motion, and tend to supply fluctuating voltages. Furthermore, they require temperature control, such as the addition of a cooling system.

[0006] Climate change and concerns about global warming are driving research into the use of renewable energy resources. However, finding truly renewable, sustainable, and consistent solutions requires addressing the shortcomings of existing renewable energy sources. There is a demand for sustainable energy generators that are zero-emission, have no performance loss with each charging cycle, and do not degrade over time. They must utilize readily available, non-specialized materials and employ standard manufacturing processes. Energy consumption at the beginning of the product's lifecycle must be addressed. The number of moving parts must be minimized where possible to reduce the risk of failure. Components must be easily repairable. Energy generators must be available that provide an abundant supply of renewable energy, are low-noise, and are not geographically limited. To address these demands, sustainable energy generators are currently being developed. The goal of these generators is to be zero-emission generators that maximize cycle efficiency and resist degradation over time. These sustainable energy generators, such as steam generators, utilize readily available, non-specialized materials, and many employ standard manufacturing processes. There is a need to provide energy generators that offer abundant renewable energy sources, are low-noise, and are not geographically limited.

[0007] Control is crucial for these sustainable energy generators. An effective control system is needed to control energy generators, such as steam generators, to ensure that energy supply demands are met while monitoring and preventing generator failures. Any control system is necessary to eliminate risks associated with energy generators, such as ignition or explosion. Operating conventional turbines with steam generators has historically been considered inefficient and rejected as an impractical approach. Generally, the heat of combustion from the reaction has been seen as an undesirable byproduct that must be dissipated to prevent damage and generator failure. The system as a whole needs to be finely tuned to prevent large energy losses, such as the amount of energy lost to dissipate excess heat, which generally result in unacceptably low efficiency. It is necessary to control and regulate pressure, temperature, and gas flow within any steam generator system, and the system must respond directly to any abnormal conditions reported within the system.

[0008] Conventional technologies exhibit a number of devices that attempt to address these needs in various ways.

[0009] EP2912374 (Thyssenkrupp Marine Systems) discloses an apparatus and method for generating steam by combustion of hydrogen and oxygen in a combustion chamber while adding water. This document aims to address the problems of existing steam generators, which include the fact that internal temperatures reach extreme levels, require specialized components and materials, and the outer walls of the chamber become too hot for practical use in various environments. The adiabatic flame temperature can be relatively high during the stoichiometric combustion of hydrogen and oxygen, causing the steam to dissociate into hydrogen and oxygen. The resulting steam requires a post-combustion catalytic process to purify and remove the dissociated oxygen and hydrogen. A solution is to provide at least one cooling water channel in the outer wall of the combustion chamber. Liquid water is also introduced into the combustion zone of the chamber along with the oxygen supply, either in addition to or instead of the post-combustion zone. This lowers the reaction temperature, prevents the dissociation of steam, and generates steam of the highest purity. However, adding water along with the oxygen supply reduces the efficiency of the process because the steam temperature drops before it can be ignited and mixed with the hydrogen and oxygen. The cooling water channels do cool the outer wall of the combustion chamber to some extent, but only in the areas where they are located.

[0010] US Patent No. 9617840 (World Energy Systems, Inc.) discloses a steam generation system for oil recovery and proposes a water-cooled liner for a combustion sleeve. This liner may incorporate a fluid injection strut for injecting fluid spray droplets into the combustion chamber to generate heated steam. However, this steam generation system is intended for use as a downhole steam generator, not as a renewable energy source.

[0011] US Patent No. 5644911 (Westinghouse Electric) discloses a steam turbine power system and a method of operation for injecting and burning hydrogen and oxygen in stoichiometric ratios. This semi-closed steam turbine produces very few by-products other than water associated with superheated steam. A portion of the high-pressure steam generated by a steam compressor can be received by the steam turbine and used to cool the steam turbine.

[0012] US Patent No. 2010314878 (Dewitt) discloses a hydrogen and oxygen combustion system for generating steam, incorporating means for regulating and controlling temperature and pressure conditions within the system. Steam is generated directly by a combustion reaction of hydrogen and oxygen, and the temperature is regulated by injecting water into the superheated steam body generated by such reaction. The system temperature is regulated. The system pressure is regulated by controlling the total flow rates of hydrogen, oxygen, and water into the combustion chamber of the steam generation engine. Data is transmitted to a central control system, with temperature data acquired by a thermocouple sensor array and pressure data transmitted from a pressure transducer sensor array. These sensor arrays are located immediately adjacent to the steam intake of a turbine or other application device and are coupled to fluidly communicate with the steam generation engine. A computerized central control system regulates the flow rates of individual hydrogen and oxygen gases, the water injection flow rate, and the overall system efficiency of one or more steam generation engine systems to bring the steam-driven device under optimal conditions.

[0013] US Patent No. 4074708 (Combustion Eng) discloses a device for rapidly superheating steam flowing to a turbine so that the unit can be quickly brought back into operation after a short shutdown, such as a hot restart. The device includes a steam generator that burns hydrogen and oxygen directly in the steam line to the turbine. During operation, hydrogen and oxygen are supplied from a storage tank to a superheater, including a burner, via a supply line. During normal operation of the generator, a small amount of power may be rectified to operate an electrolyzer, generating the hydrogen and oxygen necessary to ignite the superheater, for example, during a hot restart. To maintain the temperature at the outlet point, a control valve in the supply line supplies appropriate amounts of hydrogen and oxygen to the burner in the superheater. The valve is controlled by a controller that receives temperature signals from a temperature sensing device. A flow meter is used to measure the amount of hydrogen and oxygen flowing to the burner, and these signals are supplied to the controller to position the valve to maintain a stoichiometric ratio. The device proposes a control system that interacts with various sensors, but the disclosed device does not generate steam. Rather, the steam is produced elsewhere and its temperature is simply raised by a hydrogen-oxygen burner for superheating. There is no control over the steam generation at its source.

[0014] While proposals in the prior art appear to address the efficiency of existing steam generators and the problem of controlling the temperature of the combustion chamber, they do not address the problem of efficiently capturing and utilizing the heat of combustion. Controlling and containing the heat of combustion allows for the use of standard materials through standard manufacturing methods. Furthermore, they do not address the problem of requiring high purity of the supply gas, particularly the purity of the hydrogen supply. The requirement for high purity involves pre- or post-combustion processes. Proposals in the prior art also address the problems of system efficiency and controlling the temperature and pressure within the system to prevent failures and resulting shutdowns, but they do not provide a means to fine-tune the system to maximize energy output while adjusting pressure conditions to prevent ignition and / or explosion. [Overview of the Initiative]

[0015] A preferred embodiment of the present invention aims to provide a steam generator constructed from standard materials by a common manufacturing process, made possible by efficient temperature control and heat transfer. It also aims to provide a constant energy supply from a renewable source, independent of special processing and conditions of the renewable source. Furthermore, it aims to provide a steam generation module that can be configured in various sizes depending on the application and is not limited by terrain or specific environmental conditions. A preferred embodiment of the present invention aims to provide a steam generation system with controls for significantly improving system efficiency, monitoring and regulating heat transfer by monitoring and regulating temperature, and also monitoring pressure to eliminate the risk of generator failure.

[0016] According to one aspect of the present invention, pressure vessel and A gas inlet to a pressure vessel, configured to receive pressurized hydrogen and oxygen, An ignition means within a pressure vessel, configured to ignite hydrogen and oxygen received at the gas inlet, A steam outlet for the steam outlet from the pressure vessel, A water jacket inside or on top of a pressure vessel, A water inlet configured to receive pressurized water and supply it to the water jacket, A water outlet is located between the gas inlet and the steam outlet inside the pressure vessel. A steam generator is provided, wherein during use, water received at the water inlet passes through the water jacket to cool the pressure vessel and is output from the water outlet to supply a water atom and / or water film that mixes with ignited hydrogen and oxygen and evaporates, and the water outlet comprises a body through which gas passes when it flows from the gas inlet to the steam outlet.

[0017] Preferably, the pressure vessel has a double-wall structure with a water jacket in between.

[0018] Preferably, the pressure vessel includes a combustion zone, an ignition means is attached inside thereof, and the combustion zone is configured to receive hydrogen and oxygen from a gas inlet and mix the gases during the combustion process.

[0019] Preferably, the pressure vessel includes a water injection zone, and a water outlet is attached inside thereof.

[0020] Preferably, the water outlet is disposed at the tip of a bullet-shaped portion, and the bullet-shaped portion is concentrically attached inside the pressure vessel along the central axis of the pressure vessel with its tip facing the combustion zone.

[0021] Preferably, the water outlet includes a nozzle.

[0022] Preferably, the water outlet includes a plurality of channels for generating an array of water.

[0023] Preferably, the array is a radial fan extending substantially in the radial direction of the main axis of the pressure vessel.

[0024] Preferably, the water outlet includes molybdenum.

[0025] Preferably, the ignition means includes a glow plug.

[0026] Preferably, the steam outlet is at the end of the pressure vessel opposite to the gas inlet.

[0027] Preferably, the steam outlet incorporates valve control means.

[0028] Preferably, the valve control means is a Laval nozzle.

[0029] The gas inlet may include a gas mixing nozzle for mixing the gas as the gas passes through.

[0030] Preferably, the gas mixing nozzle includes a plurality of longitudinal grooves for mixing the gas.

[0031] The gas inlet may have two independent paths, one for hydrogen and one for oxygen, which are configured to mix within the pressure vessel as the hydrogen and oxygen are output from the gas inlet.

[0032] Preferably, the pressure vessel is approximately cylindrical in shape.

[0033] Preferably, the pressure vessel incorporates a mixing zone that provides a space in which the gases inside the vessel are mixed during use.

[0034] Preferably, the water outlet is located between the combustion zone and the mixing zone.

[0035] According to an additional aspect of the present invention, a steam generation system is provided comprising a steam generator, a gas supply system for the generator, a water supply system for the generator, and a controller for the steam generation system. The steam generator is Inlets for hydrogen gas, oxygen gas, purge gas, and water, An igniter configured to ignite hydrogen and oxygen within the generator, Output for pressurized steam generated by ignition of hydrogen and oxygen in the generator and Equipped with, The gas supply system comprises a first high-pressure stage and a second low-pressure stage. The first high-pressure stage is configured to receive pressurized hydrogen, oxygen, and purge gases and to supply these gases to the second low-pressure stage under reduced pressure. The second low-pressure stage is configured to receive gas from the first high-pressure stage under reduced pressure and supply these gases to the steam generator. The water supply system is configured to supply pressurized water to the steam generator. The controller is configured to control the operation of the steam generation system during the prime phase, run phase, and shutdown phase. In the prime phase, hydrogen gas and oxygen gas are introduced into the first high-pressure stage, and the pressures of hydrogen and oxygen can be increased in the first high-pressure stage. During the run phase, hydrogen and oxygen gases are introduced into the second low-pressure stage at a lower pressure than that used in the first high-pressure stage, and then the hydrogen and oxygen gases are supplied into the steam generator where they are ignited by an igniter, and water is supplied into the steam generator to mix with the ignited gases. During the shutdown phase, the supply of hydrogen and oxygen to the steam generator is stopped, the supply of water to the steam generator is stopped, and purge gas is supplied to the gas supply system and steam generator to expel hydrogen and oxygen gas from the gas supply system and steam generator.

[0036] In the context of this specification, for ease of reference, the terms “high pressure” and “low pressure” are used to represent pressures that are higher and lower relative to each other, when obtained in the first and second stages of a gas supply system.

[0037] Preferably, in the prime phase, the respective low-flow valves are opened first to allow the hydrogen and oxygen pressures to increase in stages, and then the respective high-flow valves are opened to allow the hydrogen and oxygen pressures to increase rapidly.

[0038] Preferably, during the run phase, the controller calculates the stoichiometric mass ratio of oxygen to hydrogen from measured values ​​of hydrogen and oxygen temperature, pressure, and mass flow rate, and controls valves in the system to maintain the stoichiometric mass ratio at a desired level.

[0039] Preferably, during the run phase, the controller monitors the water mass flow rate and the hydrogen or oxygen mass flow rate and adjusts these mass flow rates to achieve a desired overall mass flow rate through the steam generator.

[0040] Preferably, the operation of the steam generation system is controlled by user operation of start and shutdown buttons.

[0041] Preferably, during use, the prime phase is initiated by the initial activation of the start button.

[0042] Preferably, during use, the run phase is started by pressing the start button after the prime phase is completed.

[0043] Preferably, during use, the steam generation system enters a standby state when the start button is activated during the run phase.

[0044] Preferably, a steam generation system according to any of the above embodiments of the present invention includes at least one indicator that shows at least one of the proper completion of the prime phase, the proper operation of the run phase, and a fault condition.

[0045] Preferably, the controller operates at a predetermined time or within a predetermined time. The pressure within the system is outside the specified range. The flow rate within the system is outside the specified range. The temperature within the system is outside the specified range, and The ignition current supplied to the steam generator is outside the specified range. It is operable to detect one or more fault conditions comprising the following:

[0046] Preferably, the controller is operable to initiate a shutdown phase when a fault condition is detected.

[0047] A steam generation system according to any of the above embodiments of the present invention may incorporate at least one steam generator according to any of the above embodiments of the present invention.

[0048] The present invention also extends to a turbine generator incorporating at least one steam generator or steam generation system according to any of the above embodiments of the present invention.

[0049] For a proper understanding of the present invention and to illustrate how embodiments of the present invention may be carried out, the accompanying drawings are referenced below as examples. [Brief explanation of the drawing]

[0050] [Figure 1] One embodiment of the steam generator is shown in a cross-sectional view, illustrating a double-walled pressure vessel. [Figure 2] This diagram is similar to Figure 1, but rotated 90 degrees with respect to the main axis, and shows the gas flow path through the steam generator and gas mixing zone. [Figure 3] This diagram is similar to Figure 1 and shows the flow of water through the steam generator. [Figure 4] One embodiment of the gas inlet is shown. [Figure 5A] One embodiment of the nozzle is shown in an isometric view. [Figure 5B] The nozzle in Figure 5A is shown in an exploded view. [Figure 6] This shows a pair of steam generators mounted side-by-side and operably connected to a turbine. [Figure 7] This diagram illustrates a method for generating steam using a steam generator. [Figure 8] This is a schematic diagram of one embodiment of a steam generation system, showing the first high-pressure stage of the gas supply system. [Figure 9] Figure 8 is a schematic diagram showing the second low-pressure stage and control panel of the gas supply system, where the second low-pressure stage is connected to the first high-pressure stage in Figure 8 at AA. [Figure 10] Figures 8 and 9 show the control panel of the steam generation system controller. [Modes for carrying out the invention]

[0051] In drawings, similar reference numerals indicate similar or corresponding parts.

[0052] It should be understood that the various features described below and illustrated in the drawings are preferred but not required. The combinations of features described and / or illustrated are not considered to be the only possible combinations. Unless otherwise specified, individual features may be omitted, modified, or combined in different ways in practice.

[0053] Figures 1-3 show one embodiment of a steam generator 1 comprising a substantially cylindrical pressure vessel 2. The pressure vessel 2 incorporates at least one gas inlet 3 at one end. The gas inlet 3 supplies hydrogen 4 and oxygen 5 as gaseous fuels into the pressure vessel 2. These gaseous fuels can be of varying purities. These gases may be pressurized before entering the pressure vessel 2. Thus, in this example, the pressure vessel 2 is supplied with pressurized hydrogen 4 and pressurized oxygen 5. The pressurized hydrogen 4 and pressurized oxygen 5 are configured to enter the combustion zone 14 through one or more gas inlets 3 and begin mixing when they enter the pressure vessel 2. Ignition means 6 are arranged to generate a flame and ignite the mixture of hydrogen 4 and oxygen 5 to produce steam 12. Generally, steam 12 is known to be produced by burning hydrogen 4 and oxygen 5.

[0054] The ignition means 6 may include a glow plug. Typically, a glow plug is a pencil-shaped metal piece with a heating element at its tip. When power is supplied, this heating element generates heat due to its electrical resistance and begins to emit light of the visible spectrum. The filament constituting the glow plug is preferably made of platinum or iridium, which are materials with oxidation resistance at high temperatures. The ignition means 6 may include alternative heating elements that are suitable for the conditions, such as a spark plug, a laser, or other alternative ignition means.

[0055] It is also known that water 9 needs to be introduced into the pressure vessel 2 to generate additional steam 12. The water 9 is injected through the water jacket 7, through the outlet 10, into a water injection zone 13, which is generally located behind the combustion zone 14. The water may also be injected into the mixing zone 15. As an alternative to or addition to injection, the water may exit the outlet 10 as a membrane.

[0056] Pressurized hydrogen 4 can be introduced into the pressure vessel 2, spatially separated from pressurized oxygen 5. As a result of introducing water 9 into the pressure vessel 2, the adiabatic flame temperature inside the pressure vessel 2 decreases locally. The inner walls of the pressure vessel 2 and the other components constituting the steam generator 1 experience a significantly lower heat load due to the injection of water 9.

[0057] To further reduce the heat load on the outer wall of the pressure vessel 2, the water jacket 7 surrounds at least the casing of the combustion zone 14 and the casing of the mixing zone 15. This water path through the water jacket 7 cools the pressure vessel 2. While the reaction temperature is certainly likely to be relatively low due to the water 9 injected into the pressure vessel 2, the cooling of the outer wall of the pressure vessel 2 retains thermal energy within the system. The inside of the outer wall can be insulated to further retain heat within the system. The water 9 injected into the pressure vessel 2 is supplied from the water jacket 7 surrounding the casing. This water 9 surrounding the pressure vessel 2 of the steam generator 1 is introduced into the pressure vessel 2 in a common flow as a spray and / or film. Thus, this water spray and / or film is advantageously preheated.

[0058] The water 9 added to the water injection zone 13 adjusts the volume and temperature of the resulting steam 12 supplied through the steam outlet 11. Therefore, in order to control the temperature of the steam 12, the volume of water 9 added to the steam generator 1 in this post-combustion stage also needs to be controlled. This water 9 is evaporated (flashed) by the temperature of the generated steam 12 present in the mixing zone 15. The steam 12 is discharged from the pressure vessel 2 at the steam outlet 11. In this embodiment, the steam outlet 11 is configured to be at the end of the pressure vessel 2 opposite to the gas inlet 3. The steam outlet 11 may incorporate a valve control means. This valve control means may include a Laval nozzle with an hourglass shape or a tube that narrows in the middle. This shape accelerates the steam 12 as it passes through.

[0059] Figure 2 shows the passages for pressurized hydrogen gas 4, pressurized oxygen gas 5, and generated steam 12 through the steam generator 1. The combustion zone 14 shows the gas mixing during the combustion process. The superheated steam resulting from the combustion process is shown in the mixing zone 15, and the resulting steam 12 is shown passing through the steam outlet 11. Figure 2 shows one configuration of the gas mixing zones throughout the pressurized vessel 2.

[0060] As may be shown in the figure, the water outlet 10 has a body through which the gas flows from the gas inlet 3 to the steam outlet 11.

[0061] Figure 3 shows the passage of water 9 through the steam generator 1. The water 9 enters the steam generator 1 through at least one water inlet 8, where it fills the water jacket 7 between the walls of the double-walled pressure vessel 2, thereby forming a water jacket 7 that surrounds the pressure vessel 2. This water 9 is heated by the inner wall of the pressure vessel 2 as a result of the combustion process. The preheated water 17 passes through the water supply pipe 16 to supply water 9 to the nozzle 10, where it is injected near the hydrogen-oxygen flame. This water spray is configured not to hit the ignition means 6. The nozzle 10 is configured to atomize the supplied water 9. Thus, the nozzle 10 is advantageously a nozzle, and by being configured at the tip of a bullet-shaped portion, the bullet-shaped portion is mounted concentrically with the nozzle within the pressure vessel 2, and the nozzle 10 faces the combustion zone 14 of the pressure vessel 2. As described above, as an addition or alternative, water 9 may be discharged from the outlet 10 as a film.

[0062] The nozzle 10 can be made of a material that can withstand considerably high temperatures. One example of a suitable material for this nozzle 10 is molybdenum.

[0063] Figure 4 shows one embodiment of the gas inlet 3, where hydrogen 4 enters from one inlet and oxygen 5 enters from another, passing through a central gas nozzle, the diameter of which gradually decreases until the oxygen 5 enters the pressure vessel 2 adjacent to the glow plug 6. The hydrogen 4 enters longitudinal holes concentrically arranged around the central gas nozzle and passes through the holes until it enters the pressure vessel 2 adjacent to the glow plug 6. Thus, in this example, the hydrogen 4 and oxygen 5 are mixed by surface mixing as both enter the pressure vessel 2 from the inlet 3 through their respective channels. The diameters of the central gas nozzle and the longitudinal holes determine the gas velocity. The glow plug 6 ignites the gas as described above.

[0064] In an alternative configuration, inlet 3 may be configured as a premixed gas mixing nozzle that receives both hydrogen 4 and oxygen 5 and mixes them simultaneously as they pass through. Longitudinal grooves within the nozzle facilitate gas mixing. The nozzle diameter determines the velocity of the gas mixture.

[0065] Figures 5A and 5B show one embodiment of the nozzle 10, which has multiple channels that convert water 9 into a water spray array. The resulting single water spray pattern may be a radial fan (i.e., extending radially along the overall axis of the pressure vessel 2) so that the water spray does not come into direct contact with the ignition means 6. The nozzle 10 is generally bullet-shaped and is mounted in a bracket so that the nozzle 10 is aligned with the axis of the pressure vessel 2. This bullet-shaped component creates a partition between the combustion zone 14 at the front of the pressure vessel 2 and the mixing zone 15 at the rear of the pressure vessel 2. The outlet 10 may be configured to output water as a membrane as an additional or alternative spray.

[0066] The purpose of the mixing zone 15 is to provide a uniform mixture in the pressure vessel 2. The mixture of hydrogen 4 and oxygen 5 passing through the gas inlet 3 is ignited by the ignition means 6 and combusted. The combustion of this hydrogen-oxygen mixture forms a hydrogen-oxygen flame, resulting in a product gas having pure water vapor or steam 12. During the combustion of hydrogen 4 with oxygen 5, the combustion zone 14 is cooled by water 9 surrounding the outer wall of the pressure vessel 2. This water 9 is also supplied through the injection port 10 and forms a water spray that is injected into the water injection zone 13. This water 9 evaporates, forming additional water vapor or steam 12. The steam 12 is released from the steam generator 1 through the steam outlet 11, where it is made available for a wide variety of applications.

[0067] Figure 6 shows a pair of steam generators 1 mounted side by side and configured to discharge steam 12 through a steam outlet 11 to drive a turbine 18. Additional configurations may include those for supplying hydraulic or mechanical power, or for supplying electricity in other configurations. In Figure 6, the pipe 16 has a different configuration than those shown in Figures 1 and 3.

[0068] Figure 7 is a diagram of the steam generation process using steam generator 1, which largely requires no explanation. Steam generator 1 is configured to generate steam 12 by controlled combustion of pressurized hydrogen 4 and oxygen 5 and controlled addition of pressurized water 9. A water jacket 7 surrounding the pressure vessel 2 regulates the temperature inside the pressure vessel 2, at least partially. This temperature regulation allows for the use of standard materials and standard manufacturing techniques. This also ensures that maintenance of steam generator 1 is non-specialized to a certain extent. In the example in Figure 7, the generated steam 12 is used to drive a turbine that drives a generator to produce electricity. Nitrogen may be introduced as a purge gas.

[0069] The steam generator 1 ensures efficient capture of combustion heat and utilizes this heat as part of the process. Combustion of hydrogen 4 and oxygen 5 occurs at a temperature of approximately 2500 degrees Celsius. This temperature is lowered by pressurized preheated water 17, which is preheated in the water jacket 7 and injected into the mixing zone 14.

[0070] By adding water 9 as a spray to a 2500°C combustion hydrogen-oxygen mixture, the added water is converted into superheated steam, and in this way, thermal energy is converted into mass flow rate and pressure. The system's effectiveness is improved by dividing the water 9 into small droplets, which provides a large surface area and makes the flash-off process more effective. The water 9 is heated by the combustion gas to generate a larger volume of steam 12, and the advantage of this is that even more steam 12 is generated as the combustion gas releases heat for this purpose and becomes useful steam 12 itself. This occurs because the spray is introduced at the nozzle 10 to the steam outlet 11 of the steam generator 1.

[0071] Therefore, by adding more water 9 and mixing this water 9 with the pressurized water spray, the mass flow rate of the steam is increased and the temperature of the large amount of steam is reduced. An output temperature of 400°C and an output pressure of 40 bar are selected as a preferred example because they provide an energy density steam that can be handled by standard materials.

[0072] Figures 8 and 9 show a steam generation system comprising a steam generator, a gas supply system for the generator, a feedwater system for the generator, and a controller for the steam generation system. The steam generator may be, for example, one of the steam generators exemplified and described above. The names of the components of the steam generation system can be seen in Figures 8 and 9. The control panel is shown in Figure 10.

[0073] The system described herein is designed so that the steam generator can be operated by two buttons on the control panel: a start button and a shutdown button. For user discretion, the system includes optional throttle mode and standby mode. The buttons may be physical buttons or touch-sensitive elements.

[0074] The controller operates in three phases, titled Prime, Run, and Shutdown, as described below. Upon startup, pressing the Start button initiates system priming. Subsequent presses of the Start button will start the system if it was stopped, or shut it down if it was running. The system remains in the priming state until the Shutdown button is pressed.

[0075] As can be seen in Figures 8 and 9, the system is divided into two stages, separated by a vertical dashed line and connected by arrow AA, which runs from Figure 8 to Figure 9. Figure 8 shows the relatively high-pressure stage, where pressures exceeding 100 bar may be used. Figure 9 shows the relatively low-pressure stage, where pressures of 55 bar or less may be used.

[0076] Figures 8 and 9 show several solenoid-operated valves and sensors. For ease of reference, each solenoid-operated valve will be referred to as a solenoid below. All solenoids are normally closed, with the exception of the normally open vent solenoid. Normally closed means that the solenoid opens only when energized, and normally open means that the solenoid closes only when energized. When the control system is first switched on, all solenoids are not yet energized.

[0077] Preferably, all or most of the sensors are distributed to various other locations within the steam generation system. This provides design flexibility. Prime

[0078] When the start button is pressed during startup, the following step sequence begins.

[0079] 1. Pressure sensors #3 to #8 are checked for pressure within the system. If any of these exceed the required pressure level, the system will display a fault on the LCD display screen of the control panel, and the system will not proceed.

[0080] 2. Pressure sensors #1, #2, and #5 are checked. If any of these are below the required range, the system opens the manual shut-off valve and displays a prompt on the LCD screen requesting that the start button be pressed again when the valve is open. If the start button is pressed a second time and any of pressure sensors #1, #2, and #5 are still below the required range, the system displays a fault on the LCD screen and does not proceed.

[0081] 3. If the conditions in steps 1 and 2 are met, the system biases the vent solenoids to close them. The system opens both solenoids (low flow) and the piping between the solenoids (low flow), and the pressure reducing valve begins pressurizing. The pressurizing rate is determined by the flow limiter located upstream of the solenoid (low flow). This results in a gradual pressurization that eliminates the risk of adiabatic heating, which could cause faults or fires in the piping.

[0082] 4. As the system pressurizes, the system monitors pressure sensors #3 and #4 and compares them to pressure sensors #1 and #2, respectively. If the difference between #1 and #2 and #3 and #4 is less than 3 bar, the system closes the low-flow solenoid and opens the high-flow solenoids #1 and #2. Throughout this process, the system monitors flow sensors #1 and #2. Once flow is detected, the process stops, the low-flow solenoid and high-flow solenoids #1 and #2 are closed, the vent solenoid is opened, and solenoid #3 is opened for 2 seconds. The system then displays a fault on the LCD display and does not proceed further. The purpose of opening solenoid #3 for 2 seconds is to expel potentially hazardous gases from the system. The system then prompts the user to press the shutdown button via the LCD display.

[0083] 5. Once steps 1-4 have been properly performed, the priming process is complete, the "Priming Complete LED" lights up, and the steam generator is ready to start. At this point, the system can be set to start immediately or to enter standby mode and wait until the start button is additionally pressed for startup. If any of the pressure sensors #1-#4 exceed the specified range with respect to high or low pressure, the system will report a fault on the LCD screen, proceed to shutdown, and the "Priming Complete LED" will turn off. run

[0084] When the start button is pressed immediately after priming, the run process begins, and the system attempts to achieve and maintain the target steam temperature, steam pressure, and steam mass flow rate during the run mode.

[0085] 1. Whenever the system exhibits any type of fault, the system will enter a shutdown state, which means all solenoid valves will close, vents will open, and the "priming complete LED" will turn off. In this way, the system will return to a safe state.

[0086] 2. The system checks pressure sensors #3 and #4. If either is outside the starting pressure range, the system will indicate a fault on the LCD screen and then proceed to shutdown, with the "priming complete LED" turning off. The system then checks valve position sensors #1 and #2 to ensure that each pressure reducing valve is in the correct position for burner starting. This position ensures that the initial gas delivery pressure provides the appropriate gas mass flow rate to start the steam generator burner. The ratio and magnitude of the gas mass flow rate for starting are variable depending on the initial conditions in the steam generator, which vary with respect to hot starts and cold starts. A cold start is when the generator is started for the first time and all components of the generator are at ambient temperature. A hot start is when the generator is restarted a short time after a shutdown and the components of the generator are retaining a large amount of heat.

[0087] 3. If the conditions in step 2 are met, the system switches on the glow plug igniter in the steam generator and monitors its current. If the initial current of the glow plug does not reach the required value, the system reports a fault on the LCD screen, proceeds to shut down, and the "priming complete" LED turns off.

[0088] 4. If the conditions in step 3 are met, the system continues to monitor the glow plug current, and as the glow plug heats up, the current decreases due to the increase in resistance caused by the heating process. At the desired current level, the controller determines that the glow plug is hot enough to initiate gas ignition.

[0089] 5. If the conditions in step 4 are met, the controller starts the water pump. The controller compares the output from flow sensor #3 with a predetermined required flow rate. The difference between these two values ​​represents the error between the required flow rate and the actual flow rate. If the predetermined required flow rate is greater than the flow rate measured by flow sensor #3, the error is positive, and the controller increases the pump speed. If the predetermined required flow rate is less than the flow rate measured by flow sensor #3, the error is negative, and the controller decreases the pump speed. In a loop within the system's software, the flow sensor output is measured approximately every 1 / 10th of a second, and the pump speed is adjusted; this is known as the error loop. If, after a predetermined time, the output of flow sensor #3 cannot match the predetermined required flow rate, the controller proceeds to shut down, indicating a fault on the LCD screen, and the "priming complete LED" turns off.

[0090] 6. When the predetermined required flow rate matches the output from flow sensor #3, the controller opens solenoids (high flow rate) #4 and #5. The gas enters the steam generator and is ignited by the glow plug, thereby initiating steam generation. If, after a predetermined time, temperature sensor #3 does not detect a temperature rise above a predetermined level, the controller proceeds to shut down, indicating a fault on the LCD screen, and the "priming complete" LED turns off. If the temperature does not rise, this indicates that the gas has not been ignited.

[0091] 7. If there are no problems, the controller then monitors temperature sensor #3 and pressure sensor #8. If the temperature and pressure reach the predetermined values ​​within a predetermined time, the steam generator is considered to have ignited and "heated up". If the predetermined pressure and temperature are not achieved for a predetermined time, the controller will indicate a fault on the LCD screen and proceed to shut down, and the "priming complete LED" will turn off.

[0092] 8. If the conditions in step 7 are met, the system is in run mode at this point, and the running LED lights up. The system then attempts to achieve the target temperature, pressure, and mass flow rate. During this time, the system also needs to maintain a stoichiometric mass ratio of 8 for oxygen to hydrogen. Using temperature sensor #1, pressure sensor #6, and flow sensor #1, the controller calculates the hydrogen mass flow rate. Similarly, using temperature sensor #2, pressure sensor #7, and flow sensor #2, the controller calculates the oxygen mass flow rate. From these values, the software determines the actual mass ratio of oxygen to hydrogen. The controller then determines the error in the ratio by subtracting the actual mass ratio from the stoichiometric ratio. If this error is positive, there is an excess of oxygen, and the oxygen pressure reducing valve is closed. If the error is negative, the oxygen pressure reducing valve is opened. This process continues throughout the run phase as a gas mixing error loop.

[0093] 9. Since the mass flow rates of oxygen and hydrogen are linked, at this point the system only needs to consider two control elements: the hydrogen mass flow rate and the water mass flow rate. The target hydrogen mass flow rate and water mass flow rate are both set by the controller software or by the user. The target water mass flow rate and hydrogen mass flow rate can be adjusted to control the overall mass flow rate, and can therefore be used to adjust the generator with a throttle, i.e., to adjust the overall steam mass flow rate output from the generator. When used for throttle adjustment, the overall mass flow rate and hydrogen mass flow rate are mapped in the past, and the throttle position is mapped to the target water mass flow rate and hydrogen mass flow rate. Therefore, when a change in throttle occurs, a new target value is adopted from the mapped value. These target mass flow rates are adjusted by checking temperature sensor #3 and pressure sensor #8. An error control loop very similar to the one generated for the oxygen mass flow rate is generated for the hydrogen mass flow rate and water mass flow rate. The error is formed from the target hydrogen mass flow rate and the actual hydrogen mass flow rate, and the target water mass flow rate and the actual water mass flow rate. The target is the total mass flow rate, but changes in the oxygen and hydrogen mass flow rates have only a slight effect on the total mass flow rate. However, when deciding whether to change the hydrogen or water mass flow rate, the current state of the total mass flow rate is taken into consideration. For example, if the temperature is higher than the required temperature and the mass flow rate is lower than the required mass flow rate, the water flow will be increased, thereby lowering the temperature and increasing the mass flow rate. However, if the temperature is higher than the required temperature and the mass flow rate is also higher than the required mass flow rate, the hydrogen flow will be reduced, thereby lowering the temperature and reducing the mass flow rate.

[0094] 10. Because the system tends to have a very low frequency response, the direction in which temperature and pressure change must also be considered. For example, if the temperature and pressure are higher than the required temperature and pressure but decreasing, the controller will not change the target values. Similarly, if the temperature and pressure are higher than the required temperature and pressure and increasing, the magnitude of the response will also increase. As a result of all these factors, a lookup table is generated that determines the system target values ​​for hydrogen mass flow rate and water mass flow rate. This table also ensures that only one error loop is always running, and the controller runs only the error loop for the changed target values, while other error loops are suspended. If the option is "do nothing", no loops are executed. In this way, the system self-corrects only when necessary. The system maintains this state until a shutdown is requested. The lookup table is as follows: [Table 1]

[0095] 11. If the start button is pressed again, the system will stop steam generation by closing solenoids (high flow) #4 and #5, the glow plug will be switched off, and the running LED will turn off.

[0096] 12. Temperature sensor #3 and pressure sensor #8 are monitored, and if the pressure is less than 1 bar and the temperature is less than 100°C, the water pump is switched off.

[0097] 13. If the start button is pressed again, the controller restarts the run process in step 1 of the run. shutdown

[0098] The shutdown ensures that all piping is depressurized, hydrogen and oxygen are cleared, the water pump is switched off, the glow plug igniter is switched off, manual valves are closed, and the system is deactivated and safe.

[0099] 1. If the system is generating steam, the system will stop steam generation by closing solenoids (high flow) #4 and #5, the glow plug will be switched off, and the running LED will turn off.

[0100] 2. Temperature sensor #3 and pressure sensor #8 are monitored, and if the pressure is less than 1 bar and the temperature is less than 100°C, the water pump is switched off.

[0101] 3. If the criteria in step 2 are met, solenoids (high flow) #1 and #2 are closed and the vent solenoid is opened.

[0102] 4. If pressure sensors #3 and #4 drop below 1 bar, the vent solenoid closes, solenoids (high flow) #4 and #5 open, and solenoid (high flow) #3 opens for 3-5 seconds.

[0103] 5. If pressure sensors #3, #4, #5, #6, and #7 indicate a pressure of less than 1 bar, the vent solenoids open and solenoids (high flow) #4 and #5 close. The system is then considered to have been purged and released from pressure downstream of solenoids (high flow) #1 and #2.

[0104] 6. At this point, the controller will prompt the user via the LCD screen to close the manual shut-off valves and press the shutdown button when they are closed.

[0105] 7. If the criteria in step 6 are met and the shutdown button is pressed as requested, solenoids (high flow) #1 and #2 are opened.

[0106] If pressure sensors #1 and #2 still detect a pressure exceeding 1 bar after 8.5 seconds, solenoids (high flow) #1 and #2 will be closed, and the controller will report via the LCD screen that the hydrogen or oxygen manual valve is not properly closed or is defective and requires inspection.

[0107] If pressure sensors #1 and #2 detect a pressure of less than 1 bar within 9.5 seconds, solenoid (high flow) #3 will open, resulting in a final nitrogen purge.

[0108] If pressure sensor #5 still detects a pressure exceeding 1 bar after 10.5 seconds, solenoid (high flow) #3 will be closed, and the controller will report via the LCD screen that the nitrogen manual valve is not properly closed or is defective and requires inspection.

[0109] If pressure sensor #5 detects a pressure of less than 1 bar within 11.5 seconds, solenoid (high flow) valve #3 closes and the priming complete LED turns off. At this point, the system is considered to be completely purged and completely inactive.

[0110] In this specification, the verb “to prepare” has its general dictionary meaning of non-exclusive inclusion. That is, using “to prepare” (or any of its derivatives) to include one or more features does not exclude the possibility of including additional features. The word “suitable” (or any of its derivatives) indicates one or more features that are suitable but not essential.

[0111] Any or all of the features disclosed herein (including the attached claims, abstract, and drawings) and / or any or all of the steps of any method or process disclosed may be combined in any combination, except in any combination in which at least some of the features and / or steps are inconsistent with each other.

[0112] Each feature disclosed herein (including the attached claims, abstract, and drawings) may be replaced by alternative features that serve the same, equivalent, or similar purpose unless otherwise specified. Thus, unless otherwise specified, each disclosed feature is merely an example of a whole set of equivalent or similar features.

[0113] The present invention is not limited to the details of the above-described embodiments (which may be more than one). The present invention also extends to any novel features or combinations of features disclosed herein (including the appended claims, abstract, and drawings), or any novel methods or steps of processes disclosed herein, or any novel combinations of such methods or processes.

Claims

1. A steam generator, A pressure vessel comprising a combustion zone, a water outlet zone downstream of the combustion zone, and a mixing zone downstream of the combustion zone within the pressure vessel, A gas inlet to the pressure vessel, wherein the gas inlet is configured to receive pressurized hydrogen and oxygen, An ignition means in the combustion zone of the pressure vessel, wherein the ignition means is configured to ignite hydrogen and oxygen received at the gas inlet, A steam outlet for the steam outlet from the pressure vessel, A water jacket surrounding the pressure vessel provides cooling for the pressure vessel, A water inlet configured to receive pressurized water and supply the water to the water jacket, A water outlet is located between the gas inlet and the steam outlet within the water outlet zone of the pressure vessel, A steam generator equipped with, A steam generator in which, during use, water received at the water inlet passes through the water jacket to cool the pressure vessel and is output from the water outlet to supply a water spray and / or water film that evaporates when mixed with ignited hydrogen and oxygen, the water outlet comprises a body through which gas flows when it flows from the gas inlet to the steam outlet, the body being elongated and aligned with the direction of gas flow from the gas inlet to the steam outlet, the water being discharged to the side of the body at the front end of the body during use, and the mixing zone providing a space downstream of the body from which the gas in the pressure vessel is mixed during use.

2. The steam generator according to claim 1, wherein the pressure vessel has a double-wall structure that forms a water jacket between the walls.

3. The steam generator according to claim 1 or 2, wherein the combustion zone is configured to receive the hydrogen and oxygen from the gas inlet and to mix the gases during the combustion process.

4. The steam generator according to claim 1, 2, or 3, wherein the body of the water outlet is bullet-shaped, the tip of the body faces the combustion zone, and the body is mounted concentrically inside the pressure vessel along the central axis of the pressure vessel, with water being discharged from the tip during use.

5. The steam generator according to any one of claims 1 to 4, wherein the water outlet is provided with a nozzle.

6. The steam generator according to claim 5, wherein the water outlet comprises a plurality of channels for generating a water array.

7. The steam generator according to claim 6, wherein the array is a radial spray extending radially along the main axis of the pressure vessel.

8. The steam generator according to any one of claims 1 to 7, wherein the water outlet is equipped with molybdenum.

9. The steam generator according to any one of claims 1 to 8, wherein the ignition means comprises a glow plug.

10. The steam generator according to any one of claims 1 to 9, wherein the steam outlet is located at the end of the pressure vessel opposite to the gas inlet.

11. The steam generator according to any one of claims 1 to 10, wherein the steam outlet incorporates a valve control means.

12. The steam generator according to claim 11, wherein the valve control means is a Laval nozzle.

13. The steam generator according to any one of claims 1 to 12, wherein the gas inlet is equipped with a gas mixing nozzle for mixing the gas as it passes through.

14. The steam generator according to claim 13, wherein the gas mixing nozzle comprises a plurality of longitudinal grooves for mixing the gas.

15. The steam generator according to any one of claims 1 to 12, wherein the gas inlet comprises two independent paths, one for hydrogen and one for oxygen, and these are configured to mix in the pressure vessel when the hydrogen and oxygen are output from the gas inlet.

16. The steam generator according to any one of claims 1 to 15, wherein the pressure vessel is substantially cylindrical.

17. A steam generating system comprising a steam generator according to any one of claims 1 to 16, a gas supply system for the steam generator, a water supply system for the steam generator, and a controller for the steam generating system. The steam generator is, Inlet for hydrogen gas, oxygen gas, purge gas, and water. Equipped with, The gas supply system comprises a first high-pressure stage and a second low-pressure stage. The first high-pressure stage is configured to receive pressurized hydrogen, oxygen, and purge gas, and to supply these gases to the second low-pressure stage under reduced pressure. The second low-pressure stage is configured to receive the gas from the first high-pressure stage under reduced pressure and to supply these gases to the steam generator. The water supply system is configured to supply pressurized water to the steam generator. The controller is configured to control the operation of the steam generation system during the prime phase, run phase, and shutdown phase. In the prime phase, hydrogen gas and oxygen gas are introduced separately into the first high-pressure stage, and the pressures of the hydrogen and oxygen can be increased in the first high-pressure stage. In the run phase, hydrogen gas and oxygen gas are separately introduced into the second low-pressure stage at a lower pressure than that used in the first high-pressure stage, and thereafter the hydrogen and oxygen gases are supplied into the steam generator where they are ignited by the ignition means, and water is separately supplied into the steam generator so as to be mixed with the ignited gases at a point downstream of the ignition means. A steam generation system in which, during the shutdown phase, the supply of hydrogen and oxygen to the steam generator is stopped, the supply of water to the steam generator is stopped, and purge gas is supplied to the gas supply system and the steam generator to expel hydrogen and oxygen gas from the gas supply system and the steam generator.

18. The steam generation system according to claim 17, wherein in the prime phase, the respective low flow valves are opened first to allow the hydrogen and oxygen pressures to increase in stages, and then the respective high flow valves are opened to allow the hydrogen and oxygen pressures to increase rapidly.

19. The steam generation system according to claim 17 or 18, wherein in the run phase, the controller calculates the stoichiometric mass ratio of oxygen to hydrogen from measured values ​​of temperature, pressure, and mass flow rate of hydrogen and oxygen, and controls valves in the system to maintain the stoichiometric mass ratio at a desired level.

20. The steam generation system according to claim 19, wherein in the run phase, the controller monitors the mass flow rate of water and the mass flow rate of hydrogen or oxygen, and adjusts these mass flow rates to achieve a desired overall mass flow rate through the steam generator.

21. The steam generation system according to any one of claims 17 to 20, wherein the operation of the steam generation system is controlled by user operation of a start button and a shutdown button.

22. The steam generating system according to claim 21, wherein during use, the prime phase is initiated by the first activation of the start button.

23. The steam generation system according to claim 21 or 22, wherein during use, the run phase is started by the activation of the start button after the completion of the prime phase.

24. The steam generation system according to claim 21, 22, or 23, wherein during use, the steam generation system enters a standby state when the start button is activated during the run phase.

25. A steam generation system according to any one of claims 17 to 24, comprising at least one indicator indicating the proper completion of the prime phase, the proper operation of the run phase, and at least one fault condition.

26. The controller, at a predetermined time, or within a predetermined time, The pressure within the aforementioned system is outside a predetermined range. The flow rate within the aforementioned system is outside a predetermined range. The temperature within the system is outside a predetermined range, and The ignition current supplied to the steam generator is outside a predetermined range. A steam generating system according to any one of claims 17 to 25, which is operable to detect a fault condition comprising one or more of the following:

27. The steam generation system according to any one of claims 17 to 26, wherein the controller is operable to initiate the shutdown phase when a fault condition is detected.

28. A turbine generator incorporating at least one steam generator as described in any one of claims 1 to 16.

29. A turbine generator incorporating at least one steam generation system according to any one of claims 17 to 27.

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