System and method for energy generation and energy conversion

Abstract

The invention relates to a system (100) for energy generation and energy conversion. The system (100) comprises a generator (200) or an electric motor (210) having a shaft (220), the two ends of the shaft (220) being connected to one planetary gear mechanism (500, 550) each; a first extension package (300) which is connected to the shaft (220) by means of the first planetary gear mechanism (500); a second extension package (400) which is connected to the shaft (220) by means of the second planetary gear mechanism (550); wherein the generator (200) converts mechanical energy into electrical energy or the electric motor (210) converts electrical energy into mechanical energy, and wherein the first planetary gear mechanism (500) adapts the rotational speed of the first extension package (300) and the second planetary gear mechanism (500) adapts the rotational speed of the second extension package (400).

Description

[0001] System and process for energy generation and energy conversion

[0002] The invention relates to a system, a method and a computer program product for energy conversion.

[0003] In industrial gearbox systems, an E-Pack is a term used for "Extension Package" and is a unit or assembly that typically contains several mechanical and / or electrical components. Depending on the application, it can have different functions. In particular, an E-Pack can be configured as an electric drive system, compressor, or generator.

[0004] A planetary gear set is a transmission consisting of several gears arranged in a specific configuration. It comprises a sun gear, the central gear, and the planet gears, which rotate around the sun gear. The ring gear is an outer gear that surrounds the planet gears. The planet carriers support the planet gears and coordinate their movement. This type of transmission offers high torque transmission in a compact design. The planet gears allow for even load distribution across multiple gears. Planetary gear sets can achieve high gear ratios, both high and low.

[0005] A generator converts mechanical energy into electrical energy. This occurs according to the principle of electromagnetic induction, where movement in a magnetic field generates an electrical voltage. Generators are used in many applications, from power plants to vehicles, to produce electricity.

[0006] It is known to combine an E-Pack with a planetary gearbox and flange it to a generator or motor, i.e., to mechanically connect it rigidly to the generator. Since the planetary gearbox does not have its own shaft bearings, it is not supported separately but utilizes the generator's bearings. This provides a compact, efficient, and reliable solution for converting mechanical energy into electrical energy.

[0007] Hydrogen technology is gaining increasing importance, particularly in light of the energy transition and the search for emission-free energy carriers. Existing systems, such as the combination of e-packs with planetary gearboxes and generators, offer compact and reliable solutions, but are limited in their flexibility and range of applications. For many applications, such as the compression of hydrogen gas, the production of hydrogen through electrolysis, the storage of hydrogen, or the conversion of hydrogen into electrical energy in fuel cells, flexible, efficient, and compact electric compressors, drive, and generator systems are needed.

[0008] The object of the invention is the development of a compressor system, a drive system, or a generator system characterized by greater compactness in limited installation space, greater speed flexibility, and higher energy efficiency. These systems are to be designed for use in a wide variety of applications in the energy, transport, and industrial sectors, with a particular focus on their use in hydrogen technology, including integration with fuel cells, in order to provide tailored solutions for the requirements of emerging hydrogen-based technology.

[0009] This problem is solved according to the invention with respect to a system by the features of claim 1, with respect to a method by the features of claim 11, and with respect to a computer program product by the features of claim 15. The further claims relate to preferred embodiments of the invention.

[0010] The present invention relates to a flexible and adaptable system for energy generation or for driving industrial processes. The system comprises a generator or an electric motor, a shaft, and two planetary gearboxes arranged at the respective ends of the shaft. A first E-pack and a second E-pack are connected to the shaft via these planetary gearboxes. The E-packs can be compressors, turbines, generators, or other machines requiring different speeds and power outputs.

[0011] The system can be flexibly adapted to different industrial requirements. It can be used in both energy generation and the process industry. The use of frequency converters allows for precise control of the E-Packs' speed, enabling optimal adaptation to current operating conditions and thus increasing energy efficiency. Precise speed control and optimized operation also result in reduced machine wear and tear, leading to a longer system lifespan.

[0012] The possibility of operating the turbines with hydrogen and using the compressors for hydrogen production makes the system particularly attractive for sustainable energy generation and storage, especially in the field of hydrogen technology.

[0013] According to a first aspect, the invention provides a system for energy generation and energy conversion. The system comprises a generator or an electric motor with a shaft, the shaft being connected at both ends to a planetary gear; a first E-pack connected to the shaft via the first planetary gear; a second E-pack connected to the shaft via the second planetary gear; wherein the generator converts mechanical energy into electrical energy or the electric motor converts electrical energy into mechanical energy, and wherein the first planetary gear adjusts the speed of the first E-pack and the second planetary gear adjusts the speed of the second E-pack.In a further training course, it is stipulated that the first E-pack is designed as a low-pressure turbine, low-pressure compressor, generator, electric motor or other machine; and that the second E-pack is designed as a high-pressure turbine, high-pressure compressor, generator, electric motor or other machine.

[0014] In an advantageous embodiment, the planetary gears are designed to offer different over- or under-reduction ratios in order to optimally match the speeds of the E-packs to the speed of the shaft.

[0015] In another embodiment, the generator or electric motor is connected to a variable frequency drive (VFD) to precisely control the speed of the E-Packs and adapt it to the operating conditions; and the variable frequency drive is connected to a control unit that adjusts the speed of the E-Packs based on the requirements of the process or the load requirements.

[0016] In particular, it is intended that the generator is designed as a 4-pole generator with a rated speed of 1,500 revolutions per minute and is operated at a mains frequency of 50 Hz.

[0017] In particular, it is intended that the electric motor is designed as a 4-pole electric motor with a rated speed of 1,500 revolutions per minute and is operated at a mains frequency of 50 Hz.

[0018] Advantageously, the low-pressure turbine operates at a speed of 7,500 revolutions per minute and delivers a power output of 15 MW, and the high-pressure turbine operates at a speed of 14,000 revolutions per minute and delivers a power output of 15 MW. Advantageously, the low-pressure turbine and / or the high-pressure turbine is a hydrogen-powered gas turbine, and the generator converts the mechanical energy produced by at least one gas turbine into electrical energy.

[0019] In a further training course, it is stipulated that the low-pressure compressor operates at a speed of 7,500 revolutions per minute and delivers a power of 15 MW, and that the high-pressure compressor operates at a speed of 14,000 revolutions per minute and also delivers a power of 15 MW.

[0020] In particular, it is provided that the low-pressure compressor can be speed-controlled via a first frequency converter and the high-pressure compressor via a second frequency converter, in order to flexibly adapt the speed of the low-pressure compressor and the high-pressure compressor to the current operating conditions.

[0021] Advantageously, the system according to the invention is designed for use in hydrogen technology, in particular for hydrogen electrolysis, hydrogen compression or hydrogen utilization.

[0022] According to a second aspect, the invention provides a method for energy generation and energy conversion. The method comprises the following process steps:

[0023] - Operating an electric motor with a shaft at a constant speed, wherein the shaft is connected to a first E-pack via a first planetary gear and to a second E-pack via a second planetary gear;

[0024] - Adjusting the speed of the first E-pack by a central variable frequency drive (VFD) or a first frequency converter;

[0025] - Adjusting the speed of a second E-pack using a central variable frequency drive (VFD) or a first frequency converter. In a further development, the frequency converter is connected to a control unit that adjusts the speed of the low-pressure compressor and the high-pressure compressor based on the process or load requirements.

[0026] In a further development, it is provided that the first E-Pack is configured as a low-pressure compressor, the speed of which is adjusted by the first frequency converter (VFD) to achieve a specific speed for a low-pressure application; and wherein the second E-Pack is configured as a high-pressure compressor, the speed of which is adjusted by the second frequency converter (VFD) to achieve a specific speed for a high-pressure application.

[0027] In an advantageous embodiment, the electric motor is designed as a 4-pole generator with a rated speed of 1,500 revolutions per minute and is operated at a mains frequency of 50 Hz.

[0028] According to a third aspect, the invention provides a computer program product comprising executable program code that performs the method according to the second aspect.

[0029] A further advantage is a system that includes a common lubrication supply, providing lubricant to at least the electric motor or generator and the two planetary gearboxes. The compact arrangement of the system enables particularly effective central oil lubrication.

[0030] A further advantage is a system that includes central cooling, designed to cool the lubricant, the electric motor, the planetary gears, and / or the gas to be compressed between the two low-pressure and high-pressure compressors. This cooling can be particularly effective, utilizing a central heat exchanger or multiple heat exchangers, a cooling water flow, and / or a heat pump to facilitate compression and lubricant cooling.

[0031] A further advantage is a system in which the E-Packs are designed for the compression of gas, in particular for the compression of hydrogen gas, methane, propane, butane, or chlorine gas. This system is characterized by its ability to efficiently compress large quantities of gas on an industrial scale.

[0032] The invention will now be explained in more detail with reference to exemplary embodiments shown in the drawing.

[0033] This shows:

[0034] Figure 1 shows a sectional view of a connection between an electric motor and a generator according to the prior art;

[0035] Figure 2 shows a sectional view of a system according to the invention;

[0036] Figure 3 shows a schematic representation of a first embodiment;

[0037] Figure 4 shows a schematic representation of a second embodiment;

[0038] Figure 5 is a flowchart to explain the individual process steps of a process according to the invention;

[0039] Figure 6 is a schematic representation of a computer program product.

[0040] Figure 7 is a schematic representation of the invention.

[0041] Additional features, aspects, and advantages of the invention or its embodiments will become apparent from the detailed description in conjunction with the claims. Fig. 1 shows an electric motor 10 combined with a planetary gear 20 and coupled to a generator 30. The electric motor 10 is thus mechanically rigidly connected to the generator 30 via the planetary gear 20. The electric motor 10 drives the planetary gear 20, which increases the speed of the electric motor 10 and drives the generator 30. The generator 30 then converts the mechanical energy into electrical energy, which can be used for other machines 40 or systems.

[0042] The generator 30 can also be operated as an electric motor when electrical energy is supplied. In reverse operation, the generator 30 then supplies mechanical energy, which is transmitted via the planetary gear 20 to a shaft to drive a machine. In this case, the generator 30 is designed as a synchronous or asynchronous machine, so that it can also be operated in reverse. The planetary gear 20 is typically a symmetrical gear and therefore also designed for reverse operation.

[0043] Fig. 2 shows a system 100 according to the invention, consisting of a generator 200, a first E-Pack 300, and a second E-Pack 400. The generator 200 comprises a shaft 220, at each of whose two ends an E-Pack 300, 400 is arranged. The first E-Pack 300 is connected to the shaft 220 via a first planetary gear 500. The second E-Pack 400 is connected to the shaft 220 via a second planetary gear 550. The generator 200 can alternatively also be operated as an electric motor 210 or be configured as an electric motor 210.

[0044] The generator 200 can be designed as a synchronous machine, an asynchronous machine or a variable speed machine.

[0045] A synchronous machine is an electric motor or generator in which the rotor rotates at the same frequency as the rotating magnetic field of the stator. This means that the rotor rotates synchronously with the rotating magnetic field. The rotor speed is exactly proportional to the frequency of the applied alternating voltage and remains constant regardless of the load. The rotor typically contains permanent magnets or is driven by direct current via slip rings, thus generating a constant magnetic field.

[0046] Synchronous machines are frequently used where a constant speed is required, e.g. in generators of power plants, in precision drives and in some industrial applications.

[0047] An asynchronous machine, also called a three-phase induction machine, is an electric motor or generator in which the rotor rotates at a slightly lower speed than the rotating magnetic field of the stator. Particularly under load, the rotor speed is somewhat lower than the synchronous speed of the stator field. This difference is called slip and is necessary for the motor's operation. The rotor is usually a wound rotor that generates a magnetic field through induction, which opposes the stator field. Asynchronous machines are robust, require little maintenance, and are cost-effective. They are frequently used in industrial drives, pumps, and many other machines where variable speed and high reliability are required.

[0048] Both machine types have their specific areas of application, and the choice between synchronous and asynchronous machines depends on the requirements of the respective application.

[0049] A variable-speed machine is an electric motor or generator whose speed can be flexibly and precisely controlled by an electronic controller, such as a variable frequency drive (VFD). This allows the electric motor or generator to operate at different speeds, independent of the fixed grid frequency, which normally dictates a fixed speed. This enables optimal adaptation to varying load conditions, increases energy efficiency, and offers diverse application possibilities in various industrial processes. The variable frequency drive modulates the frequency and voltage of the current supplied to the electric motor or generator. This allows the speed and torque of the electric motor or generator to be adjusted to specific requirements.The frequency converter can both increase and decrease the speed, allowing for flexible adaptation to different loads or operating conditions.

[0050] Unlike conventional electric motors, which have a fixed speed (e.g., unregulated synchronous or asynchronous machines), the speed of variable-speed machines can be continuously varied from very low to very high values. This is particularly advantageous in applications requiring precise speed control. Because variable-speed machines can optimally adjust speed and torque to the load requirements, energy consumption is reduced. This leads to higher energy efficiency, especially in applications with fluctuating load demands. For example, the speed of a compressor can be reduced when lower gas pressure is required, resulting in significant energy savings.

[0051] Variable-speed motors are used extensively in the transportation sector. In electric drive systems of vehicles such as electric cars, rail vehicles, and ships, they enable precise control of motor power and torque, thereby optimizing energy consumption and increasing range. Particularly in urban traffic, where frequent acceleration and braking are necessary, variable-speed drives can significantly reduce energy consumption by adjusting power output as needed.

[0052] Depending on the application, the E-Packs 300 and 400 can be configured as electric motors, generators, brakes, or specific machines such as turbines, pumps, or compressors. When configured as electric motors, the E-Packs 300 and 400 can be synchronous or asynchronous (induction) motors. The E-Packs 300 and 400 can also be configured as small generators that convert mechanical energy into electrical energy, which is particularly advantageous when the system according to the invention is intended to generate 100 kWh of energy.

[0053] When the E-Packs 300 and 400 are configured as braking or recuperation units, they can convert kinetic energy into electrical energy (recuperation). This is particularly useful in vehicle applications or industrial processes where energy can be saved and recovered.

[0054] The E-Packs 300, 400 can also be designed as special machines such as pumps or compressors, which are used, for example, to generate pressure in hydraulic or pneumatic systems.

[0055] In addition, the E-Packs 300 and 400 can also contain power converters that convert direct current to alternating current or adjust voltages.

[0056] The shaft 220 of the generator 200 plays a central role in the system 100 according to the invention, which connects two E-Packs 300, 400 to the two ends of the shaft 220 via a planetary gear unit 500, 550, respectively. The shaft 220 serves as the main transmission element for mechanical energy and, through its connection with the planetary gear units 500, 550, enables flexible adjustment of the speed as well as efficient load distribution between the two E-Packs 300, 400, which is particularly advantageous in applications with high demands on compactness and energy efficiency.

[0057] The shaft 220 transmits the mechanical energy generated by at least one E-Pack 300, 400 to the rotor of the generator 200 and converts it into electrical energy (or vice versa if the generator 200 is operated as an electric motor 210). The rotor, which is set in rotation by the shaft 220, is the moving component of the generator 200. As the rotor rotates in the magnetic field of the stator, the conversion of mechanical energy into electrical energy (or vice versa) occurs through electromagnetic induction.

[0058] Planetary gearboxes are mechanical systems that transmit and convert speeds and torques. They are particularly compact and enable high power density while maintaining stability and efficiency. In the system 100 according to the invention, the planetary gearboxes 500 and 550 can increase or decrease the speed of the shaft 220 depending on the requirements of the connected E-packs 300 and 400.

[0059] The E-Packs 300 and 400 are attached to the ends of the shaft 220 and operate in conjunction with the generator 200 via the planetary gear sets 500 and 550. The generator 200 can be operated as a load (in generator mode) and as a power source (in motor mode). The shaft 220 transmits the mechanical power between the generator 200 and the E-Packs 300 and 400, while the planetary gear sets 500 and 550 enable speed adjustment.

[0060] When the E-Packs 300, 400 serve as drives, the mechanical energy is transferred via the planetary gears 500, 550 to the shaft 220, which drives the generator 200 to generate electrical energy.

[0061] When generator 200 serves as the energy source, the mechanical energy is transferred via shaft 220 and planetary gears 500 and 550 to the E-Packs 300 and 400. These can then either pass the mechanical energy on to other systems or use the energy for further conversions.

[0062] The arrangement of one E-Pack 300 and one E-Pack 400 at each end of the shaft 220 of the generator 200 is very space-saving and characterized by its high compactness. This is advantageous in confined spaces, e.g., in industrial plants or vehicles. Furthermore, different speeds of the E-Packs 300 and 400 can be set as drive or output via a variable frequency drive (VFD) 700.

[0063] A VFD is an electronic device that can vary the frequency and voltage of the electrical energy supplied to an electric motor. This allows for stepless and precise control of the motor's speed and torque. The VFP 700 thus offers the possibility of precisely controlling different speeds of the E-Packs 300 and 400 as either drive or output units. Therefore, the first E-Pack 300 can operate at a different speed than the second E-Pack. This offers significant advantages for process control in various applications.

[0064] By adjusting the motor speed to the actual demand, the VFD 700 can significantly reduce the energy consumption of the system 100 according to the invention. Furthermore, the VFD 700 enables smooth starting and stopping of the E-Packs 300 and 400, thereby reducing the mechanical stress and wear of the E-Packs 300 and 400.

[0065] The symmetrical arrangement of the E-Packs 300 and 400 at both ends of the shaft 220 distributes the load evenly. This symmetrical arrangement ensures a uniform and stable power transmission. Uneven loading, which can lead to uneven wear of the shaft 220 or other components, is avoided. Vibrations of the shaft 220 are minimized, ensuring smooth operation.

[0066] The symmetrical arrangement of the E-Packs 300, 400 thus extends the service life of the system 100 according to the invention and maximizes its efficiency.

[0067] Furthermore, the system 100 according to the invention is more economical than an arrangement with two generators 30, each connected to a single electric motor 10 via a planetary gearbox 20. For example, a single generator 200 with a power output of 30 megawatts is generally less expensive than two generators, each with a power output of 15 megawatts. This is due to savings in manufacturing, maintenance, and installation costs. A larger generator generally requires less material and labor per unit of power than two smaller generators. Maintaining a single generator can also be less expensive than maintaining two separate generators, thus reducing operating costs. In addition, a single generator 200 requires less space, connections, and infrastructure, which can reduce installation costs.

[0068] The system 100 according to the invention can be used in various application scenarios in which a powerful generator 200 or electric motor 210 is used in combination with various machines.

[0069] Fig. 3 shows a first embodiment in which the two E-Packs 300 and 400 are configured as turbines driving a generator 200 with a power output of 30 MW. The first E-Pack 300 is configured as a low-pressure turbine 320, and the second E-Pack 400 as a high-pressure turbine 420. The low-pressure turbine 320 operates, for example, at a speed of 7,500 revolutions per minute and delivers a power output of 15 MW. It is suitable for applications requiring moderate speed and power. The high-pressure turbine 420 operates, for example, at a higher speed of 14,000 revolutions per minute and also delivers a power output of 15 MW. The high-pressure turbine 420 is designed for applications requiring high power and speed.

[0070] The low-pressure turbine 320 and the high-pressure turbine 420 together drive the generator 200 with a total output of 30 MW. The generator 200 converts the mechanical energy of the low-pressure turbine 320 and the high-pressure turbine 420 into electrical energy. Depending on the application, the generator 200 can be configured as a 2-pole, 4-pole, or 8-pole generator to meet specific speed and power requirements.

[0071] Two-pole generators are designed for applications requiring high rotational speeds. At a grid frequency of 50 Hz, the rated speed of a two-pole generator is typically 3,000 revolutions per minute. This design is ideal for compact and powerful machines such as gas turbines. However, the high speed can lead to increased vibrations, requiring careful design and balancing.

[0072] Four-pole generators have a rated speed of approximately 1,500 revolutions per minute at a grid frequency of 50 Hz. These generators are frequently used in applications where a balance between speed and torque is required. They are particularly common in large machines and industrial plants where consistent power output and stable operation are essential.

[0073] 8-pole generators have a rated speed of approximately 750 rpm at a grid frequency of 50 Hz. This design is ideal for applications requiring high torque at low speeds. Examples include large industrial machines, generators for hydroelectric power plants, and wind turbines. The low speed ensures smooth and stable operation, which is particularly advantageous in high-torque applications.

[0074] Since the low-pressure turbine 320 and the high-pressure turbine 420 have different rotational speeds (14,000 rpm and 7,500 rpm, respectively), and the generator 200 operates at a constant speed of 1,500 rpm, the reduction ratios of the planetary gearboxes 500 and 550 must be different to match the different rotational speeds of the low-pressure turbine 320 and the high-pressure turbine 420 to the desired speed of the generator 200. For the low-pressure turbine 320, the reduction ratio is: 7,500 rpm / 1,500 rpm = 5:1

[0075] The reduction ratio for the high-pressure turbine 420 is:

[0076] 14,000 rpm / 1,500 rpm = 9.33:1

[0077] These different gear ratios ensure that both turbines 320 and 420, with their specific rotational speeds, can work efficiently with the generator 200.

[0078] The different gear ratios are achieved by using differently designed planetary gear sets 500 and 550. The gear ratio or...

[0079] The gear ratio of a planetary gearbox is determined by its dimensions and the number of gears (sun gear, planet gears, and ring gear). To adapt different turbine speeds to the same generator speed, the gear systems in the two planetary gearboxes, 500 and 550, are designed differently. Each planetary gearbox, 500 and 550, is designed to optimally transmit the specific turbine speed to the desired generator speed.

[0080] The use of specially adapted 500 and 550 planetary gearboxes maximizes efficiency and optimizes installation space. Each 500 and 550 planetary gearbox thus operates under optimal conditions for the specific load, minimizing wear and energy losses.

[0081] Within the scope of the invention, it may also be possible to use multi-stage planetary gears or other gear types in addition to simple planetary gears.

[0082] The low-pressure turbine 320 and the high-pressure turbine 420 each have their own control systems to optimize efficiency and operation independently. Fig. 4 shows a second embodiment in which a powerful electric motor 210 with a power output of 30 megawatts (MW) drives two compressors. The electric motor 210 is typically a 4-pole machine with a rated speed of 1,500 rpm at a frequency of 50 Hz. 4-pole electric motors are frequently used in large machines and industrial processes.

[0083] The first E-Pack 300 is configured as a low-pressure compressor 350, and the second E-Pack 400 as a high-pressure compressor 450. The low-pressure compressor 350 operates at a speed of 7,500 revolutions per minute and requires a power output of 15 MW. The low-pressure compressor 350 is designed for applications requiring low pressure.

[0084] The 450 high-pressure compressor operates at a higher speed of 14,000 rpm and also requires a power output of 15 MW. The 450 high-pressure compressor is designed for applications where higher pressure needs to be generated.

[0085] Since the speed of the electric motor 210 is lower than that of the compressors 350 and 450, the planetary gear sets 500 and 550 are used to provide the higher speed for the compressors 350 and 450. To adapt the lower speed of the electric motor 210 to the different speeds of the low-pressure compressor 350 and the high-pressure compressor 450, the respective planetary gear sets 500 and 550 are designed differently. The planetary gear set 500, which connects the low-pressure compressor 350 to the shaft 220 of the electric motor 210, is designed to provide a gear reduction from the lower speed of the electric motor 210 to the higher speed of the low-pressure compressor 350. The planetary gear 550, which connects the high-pressure compressor 450 to the shaft 220 of the electric motor 210, is designed to achieve the higher speed of the high-pressure compressor 450 by means of a gear reduction.The low-pressure compressor 350 and the high-pressure compressor 450 can be speed-controlled via the variable frequency drive (VFD) 700 if required. This means that the speed of both the low-pressure compressor 350 and the high-pressure compressor 450 can be flexibly adapted to the current operating conditions, which increases energy efficiency and optimizes operation.

[0086] In the low-pressure compressor 350, the planetary gearbox 500 converts the constant speed of the electric motor (1,500 rpm) into the speed required for the low-pressure compressor (7,500 rpm). The variable frequency drive (VFD) 700 regulates the speed of the low-pressure compressor 350 within the range of 7,500 rpm to adjust efficiency and performance according to requirements.

[0087] In the high-pressure compressor 450, the planetary gearbox 550 converts the constant speed of the electric motor (1500 rpm) into the speed required for the high-pressure compressor (14,000 rpm). The variable frequency drive (VFD) 700 regulates the speed of the high-pressure compressor 450 within the range of 14,000 rpm to achieve the desired pressure.

[0088] It can be provided that the low-pressure compressor 350 has its own frequency converter 720 and the high-pressure compressor 450 has its own frequency converter 750, or that a central frequency converter 700 is used. The choice depends on the specific requirements of the system 100 and operational considerations. If flexibility and individual control are particularly important, using a separate frequency converter 720, 750 for each compressor 350, 450 is often the preferred option. The respective frequency converter 700, 720, 750 is connected to a control unit 800, which adjusts the speed of the low-pressure compressor 350 and the high-pressure compressor 450 based on the requirements of the respective process or load requirements. The two exemplary embodiments show how the system 100 according to the invention can be flexibly adapted to different industrial requirements.In both cases, a combination of machines is used that require different speeds and power outputs to achieve high overall efficiency. The use of 700, 720, and 750 frequency converters allows for precise control of the speed of the 300 and 400 E-Packs, which is particularly advantageous in processes with variable loads. This results in higher energy efficiency and a longer machine lifespan.

[0089] The ability to power multiple E-Packs 300 and 400 with a single powerful Generator 200 or Electric Motor 210 saves space and reduces installation complexity. This is particularly advantageous in environments with limited installation space.

[0090] The system 100 according to the invention can be used in various industrial applications such as energy generation or the process industry, where high performance combined with compactness and flexibility is required. This is particularly relevant in hydrogen technology, from hydrogen electrolysis and storage to energy generation in fuel cells.

[0091] In this way, the System 100, consisting of a powerful electric motor 210, a low-pressure compressor 350, and a high-pressure compressor 450, can be used in a hydrogen production plant for the efficient production and processing of hydrogen. The electric motor 210 drives the two compressors 350 and 450, which each perform different tasks in the hydrogen production process.

[0092] The 350 low-pressure compressor generates the pressure necessary for electrolysis. In the electrolysis cell, water (H₂O) is split into hydrogen (H₂) and oxygen (O₂) by an electric current. The 350 low-pressure compressor ensures that the water is fed into the electrolysis cell at the correct pressure to guarantee a constant electrolysis process. At higher pressures, electrolysis cells can operate more efficiently because the reaction rate between the water and the electrodes increases. This leads to a higher production rate of hydrogen and oxygen. Optimal pressure ensures that the electrolysis cell achieves its maximum efficiency.

[0093] In specialized high-pressure electrolysis systems, the pressure can be set to 30 to 100 bar or even higher. This is particularly useful for applications where the hydrogen produced under these high pressures is directly processed for storage or transport.

[0094] After electrolysis, the produced hydrogen (H2) is compressed by the high-pressure compressor 450. The high-pressure compressor 450 operates at a higher speed to compress the hydrogen (H2) to the high pressures of 350 to 700 bar required for storage or further transport. This is essential for the efficient storage or further use of the hydrogen in cylinders or tanks.

[0095] The 700, 720, and 750 frequency converters enable precise speed control of the two compressors, 350 and 450. The low-pressure compressor 350 and the high-pressure compressor 450 can be independently adjusted to the specific requirements of the electrolysis and compression processes. This flexibility is particularly important for maximizing energy efficiency and adapting operation to changing load requirements, such as fluctuating hydrogen demand or varying operating conditions.

[0096] By selectively adjusting the rotational speeds, energy distribution is optimized and the overall efficiency of the hydrogen production plant is increased. System 100 thus integrates electrolysis and compression into a compact and flexible solution that enables efficient hydrogen production and further processing. The first embodiment of System 100, consisting of a generator 200 that absorbs the mechanical energy of a low-pressure turbine 320 and a high-pressure turbine 420 and converts it into electrical energy, can be used, for example, in a vehicle, particularly in heavy-duty transporters and trucks. These vehicles require significant power and energy to transport heavy loads over long distances. The use of hydrogen gas turbines can offer advantages here, as they can efficiently convert large amounts of energy.

[0097] In this application example, the low-pressure turbine 320 and the high-pressure turbine 420 are designed as gas turbines and can be operated with hydrogen. The hydrogen is used as fuel and is burned in the combustion chamber of the gas turbine to produce hot gases that drive the turbine. The main advantage of hydrogen is that its combustion produces no CO2, making it more environmentally friendly than fossil fuels.

[0098] In a vehicle, the mechanical energy of the two hydrogen-powered turbines 320, 420 is transferred to a generator 200, which produces electricity. This electricity can then be stored in batteries or accumulators or supplied directly to the vehicle's electric motor. The generated electricity then powers the vehicle's electric drive trains and systems. The system 100 according to the invention can thus contribute to sustainable energy generation and environmentally friendly vehicle technologies.

[0099] Another application of the system 100 according to the invention is power plants in which hydrogen-powered gas turbines are used for electricity generation.

[0100] The system 100 according to the invention thus contributes to the energy transition by increasing the efficiency and flexibility of energy use. Using a single generator 200 or electric motor 210 with a power output of 30 MW instead of two separate units with 15 MW reduces energy losses and increases efficiency. Fewer machines mean less energy loss due to friction and heat. The variable frequency drives (VFDs) 700, 720, and 750 enable precise speed control, resulting in more efficient operation of the connected E-Packs 300 and 400. In this way, only the energy actually required is consumed, leading to a reduction in overall energy consumption.

[0101] The System 100's ability to adapt to varying load and operating conditions results in greater efficiency and sustainability. This allows for the optimized integration of renewable energy sources, which are subject to natural fluctuations. The more compact design requires less space and materials for System 100 installation, leading to resource savings. Reducing the number of machines results in lower maintenance and operating costs, which in turn saves energy and resources.

[0102] Fig. 5 illustrates the process steps of a process for energy generation and energy conversion.

[0103] In step S10, an electric motor 210 with a shaft 220 is operated at a constant speed, the shaft 220 being connected via a first planetary gear 500 to a first E-Pack 300 and via a second planetary gear 550 to a second E-Pack 40).

[0104] In step S20, the speed of the first E-Pack 300 is adjusted by a central frequency converter (VFD) 700 or a first frequency converter 720.

[0105] In step S30, the rotational speed of a second E-Pack 400 is adjusted by a central frequency converter (VFD) 700 or a second frequency converter 750. Fig. 6 schematically represents a computer program product 900 comprising an executable program code 950 that performs the method according to the first aspect of the present invention.

[0106] The system 100 according to the invention can be flexibly adapted to different industrial requirements. Furthermore, it can be used in both energy generation and the process industry. The use of frequency converters 700, 720, and 750 enables precise control of the speed of the E-Packs 300 and 400, thus ensuring optimal adaptation to the current operating conditions. This leads to an increase in energy efficiency. The precise speed control and optimized operation result in reduced wear on the machines, which in turn extends the service life of the system 100.

[0107] The possibility of operating the turbines 320, 420 with hydrogen and using the compressors 350, 450 for hydrogen production makes the System 100 a particularly attractive option for sustainable energy generation and storage, especially in the field of hydrogen technology.

[0108] Fig. 7 shows a schematic, non-scale representation of the system 100 according to the invention. The system 100 is designed to enable the conversion of electrical energy into mechanical energy and to compress a gas using this mechanical energy. The system 100 comprises an electric motor 210 with a shaft 220, the shaft 220 being connected at both ends to a planetary gear 500, 550; a first E-pack 300, which is connected to the shaft 220 via the first planetary gear 500; and a second E-pack 400, which is connected to the shaft 220 via the second planetary gear 550.The first planetary gear (500) adjusts the rotational speed of the first E-pack 300, and the second planetary gear (500) adjusts the rotational speed of the second E-pack 400, wherein the first E-pack 300 is configured as a low-pressure compressor 350 or another machine; and wherein the second E-pack 400 is configured as a high-pressure compressor 450 or another machine. The arrangement in Figure 1 is advantageous for compressing gas in large-scale industrial plants, particularly hydrogen gas. The compressed gas enables improved transport and more compact storage in gas tanks. The electric motor 210 can also be advantageously operated as a generator 200 (not shown in the figure), for example, when the system 100 is decelerated before coming to a standstill, or when the compressor 350, 450 is configured as a turbine in reverse operation.The compact arrangement of System 100 is particularly advantageous because it allows transport in its assembled state and / or the system can be positioned on a common foundation. Furthermore, the compact arrangement of the planetary gearboxes 500 and 550 on the electric motor 210 advantageously enables the shared use of ancillary systems such as control, cooling, lubrication supply, and / or central oil lubrication.

[0109] Reference sign

[0110] electric motor

[0111] planetary gear

[0112] generator

[0113] system

[0114] generator

[0115] electric motor

[0116] Wave

[0117] First e-pack

[0118] Low-pressure turbine

[0119] Low-pressure compressor

[0120] Second e-pack

[0121] High-pressure turbine

[0122] High-pressure compressor

[0123] First planetary gear

[0124] Second planetary gear

[0125] Variable Frequency Drive (VFD)

[0126] First frequency converter

[0127] Second frequency converter

[0128] Control unit

[0129] Computer program product

[0130] Program code

Claims

Patent claims 1. Energy conversion system (100) comprising an electric motor (210) with a shaft (220), wherein the shaft (220) is connected at both ends to a planetary gear (500, 550); a first E-pack (300) connected to the shaft (220) via the first planetary gear (500); a second E-pack (400) connected to the shaft (220) via the second planetary gear (550); wherein the electric motor (210) converts electrical energy into mechanical energy, and wherein the first planetary gear (500) adjusts the speed of the first E-pack (300) and the second planetary gear (500) adjusts the speed of the second E-pack (400), wherein the first E-pack (300) is configured as a low-pressure compressor (350) or another machine; and wherein the second E-Pack (400) is designed as a high-pressure compressor (450) or another machine.

2. System (100) according to claim 1 or 2, wherein the planetary gear units (500, 550) are designed to provide different over- or under-reduction ratios to optimally match the speeds of the E-packs (300, 400) to the speed of the shaft (220); and wherein a frequency converter (700) is connected to a control unit (800) which adjusts the speed of the E-packs (300, 400) based on the requirements of the process or the load requirements.

3. System (100) according to one of the preceding claims, wherein the generator (200) or electric motor (210) is connected to a frequency converter (VFD) (700) to precisely control the speed of the E-Packs (300, 400) and adapt it to the operating conditions.

4. System (100) according to one of claims 1 to 3, wherein the generator (200) is designed as a 2- or 4-pole generator with a rated speed of 1,500 revolutions per minute and operates at a grid frequency of 26 50 Hz, or wherein the electric motor (210) is designed as a 4-pole electric motor with a rated speed of 1,500 revolutions per minute and is operated at a mains frequency of 50 Hz.

5. System (100) according to one of the preceding claims, wherein the low-pressure compressor (350) operates at a speed of 4,500 - 40,000 revolutions per minute, in particular at a speed of 5,000 - 8,000 revolutions per minute, and delivers a power of 0.5 - 40 MW, in particular a power of 12 - 18 MW, and wherein the high-pressure compressor (450) operates at a speed of 4,000 - 40,000 revolutions per minute, in particular at a speed of 10,000 - 15,000 revolutions per minute and also delivers a power of 0.5 - 40 MW, in particular 12 - 18 MW.

6. System (100) according to claim 5, wherein the low-pressure compressor (350) can be speed-controlled via a first frequency converter (720) and the high-pressure compressor (450) can be speed-controlled via a second frequency converter (750) in order to flexibly adapt the speed of the low-pressure compressor (350) and the high-pressure compressor (450) to the current operating conditions.

7. System (100) according to one of the preceding claims, wherein the system (100) is designed for use in hydrogen technology, in particular for hydrogen electrolysis, hydrogen compression or hydrogen utilization.

8. System (100) according to one of the preceding claims, wherein the system (100) comprises a common lubricant supply which supplies at least the drive (200, 210) and the two planetary gear units (500, 550) with lubricant.

9. System (100) according to one of the preceding claims, wherein the system (100) comprises a central cooling system designed to cool the lubricant, the electric motor (210), the planetary gears (500, 550) and / or the gas to be compressed between the two low-pressure compressor (350) and high-pressure compressor (450).

10. System (100) according to one of the preceding claims, wherein the E-Packs (300, 400) are designed for the compression of gas, in particular for the compression of hydrogen gas, methane, propane, butane or chlorine gas.

11. Processes for energy generation and energy conversion, comprising the process steps: - Operating (S10) an electric motor (210) with a shaft (220) at a constant speed, wherein the shaft (220) is connected via a first planetary gear (500) to a first E-pack (300) and via a second planetary gear (550) to a second E-pack (400); - Adjusting (S20) the speed of the first E-pack (300) by a central variable frequency drive (VFD) (700) - Adjusting (S30) the speed of a second E-pack (400) by the single central frequency converter (VFD) (700) 12. Method according to claim 11, wherein the frequency converter (700, 720, 750) is connected to a control unit (800) which adjusts the speed of the low-pressure compressor (350) and the high-pressure compressor (450) based on the requirements of the process or the load requirements.

13. Method according to claim 12, wherein the first E-Pack (300) is configured as a low-pressure compressor (320) whose speed is adjusted by the first frequency converter (VFD) (720) to achieve a specific speed for a low-pressure application; and wherein the second E-Pack (400) is configured as a high-pressure compressor (450) whose speed is adjusted by the second frequency converter (VFD) (750) to achieve a specific speed for a high-pressure application.

14. Method according to claim 12 or 13, wherein the electric motor (210) is designed as a 2- or 4-pole generator with a rated speed of 1,500 revolutions per minute and is operated at a mains frequency of 50 Hz. 29

Images