Sustainable heat to power generation system

Abstract

A power generation system includes a heat source operable to heat a heating fluid, a compressor operable to compress a working fluid and to discharge a compressed working fluid, and a center casing connected to the compressor to receive the compressed working fluid. The center casing includes a warm fluid outlet and a hot fluid inlet. A warm fluid collector connects to the center casing to receive the compressed working fluid via the warm fluid outlet. A heat exchanger includes a hot fluid path through which the heating fluid flows and a cool fluid path through which the compressed working fluid flows to transfer heat from the heating fluid to the compressed working fluid to produce a hot working fluid. A hot fluid collector connects to the center casing to direct the hot working fluid into the center casing via the hot fluid inlet. A generator operates to produce a flow of electrical power, and a turbine is connected to the center casing to receive the hot working fluid, the turbine operable in response to the hot working fluid to drive the compressor and the generator.

Description

Docket No. 2024PF00443SUSTAINABLE HEAT TO POWER GENERATION SYSTEMBACKGROUND

[0001] Heat recovery, from any source, for electricity generation is a significant field within the broader scope of energy efficiency and sustainability technologies. The fundamental principle involves capturing excess thermal energy that is typically released as a byproduct of industrial processes, power generation, or even from mechanical equipment, and converting it into electrical energy. This process not only enhances overall energy efficiency but also contributes to reducing greenhouse gas emissions by lowering the demand for additional fuel consumption.

[0002] However, power generation systems must often be built into or integrated into the industrial system or take years to build after the industrial process is established. An easily deployable system capable of working with virtually any heat source would be welcome in the industry.SUMMARY

[0003] In one aspect, a power generation system includes a heat source operable to heat a heating fluid, a compressor operable to compress a working fluid and to discharge a compressed working fluid, and a center casing connected to the compressor to receive the compressed working fluid. The center casing includes a warm fluid outlet and a hot fluid inlet. A warm fluid collector connects to the center casing to receive the compressed working fluid via the warm fluid outlet. A heat exchanger includes a hot fluid path through which the heating fluid flows and a cool fluid path through which the compressed working fluid flows to transfer heat from the heating fluid to the compressed working fluid to produce a hot working fluid. A hot fluid collector connects to the center casing to direct the hot working fluid into the center casing via the hot fluid inlet. A generator operates to produce a flow of electrical power, and aDocket No. 2024PF00443 turbine is connected to the center casing to receive the hot working fluid, the turbine operable in response to the hot working fluid to drive the compressor and the generator.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0005] FIG. 1 is a longitudinal cross-sectional view of a gas turbine engine taken along a plane that contains a longitudinal axis or central axis.

[0006] FIG. 2 schematically illustrates a power generation system that includes a gas turbine engine similar to the one illustrated in FIG. 1.

[0007] FIG. 3 schematically illustrates another power generation system that includes a gas turbine engine similar to the one illustrated in FIG. 1.

[0008] FIG. 4 schematically illustrates another power generation system that includes a gas turbine engine having two shafts.

[0009] FIG. 5 is a perspective view of a portion of the compressor connected to a center casing.

[0010] FIG. 6 is a side section view of the center casing of FIG. 5 better illustrating the internal features.

[0011] FIG. 7 is a side view of a portion of the compressor, the center casing, and a portion of the turbine and illustrating one arrangement of a warm fluid collector and a hot fluid collector.

[0012] FIG. 8 is a side view of a portion of the compressor, the center casing, and a portion of the turbine and illustrating another arrangement of a warm fluid collector and a hot fluid collector.Docket No. 2024PF00443

[0013] FIG. 9 is a perspective view of a portion of the compressor, the center casing, and a portion of the turbine and illustrating another arrangement of a warm fluid collector and a hot fluid collector.

[0014] FIG. 10 is a side view of the power generation system of FIG. 2, FIG. 3, or FIG. 4 positioned on a trailer for transportation.

[0015] FIG. 11 is a side view of the power generation system of FIG. 2, FIG. 3, or FIG. 4 positioned on another trailer for transportation.DETAILED DESCRIPTION

[0016] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0017] Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0018] It should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “including,”Docket No. 2024PF00443“having,” and “comprising,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an” and “the” are intended to include the plural forms (i.e., one or more) as well, unless the context clearly indicates otherwise. Further, the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0019] Also, terms such as “first”, “second”, “third” and so forth may be used herein to refer to various elements, information, functions, or acts, but should not be considered as limiting in any way. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0020] In addition, the term “adjacent to” may mean that an element is relatively near to but not in contact with a further element or that the element is in contact with the further portion unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

[0021] FIG. 1 illustrates an example of a gas turbine engine 100 including a compressor section 102, a combustion section 104, and a turbine section 106 arranged along a central axis 108. The compressor section 102 includes a plurality of compressor stages 110 with eachDocket No. 2024PF00443 compressor stage 110 including a set of rotating blades 112 and a set of stationary vanes 114 or adjustable guide vanes. A rotor 116 supports the rotating blades 112 for rotation about the central axis 108 during operation. In some constructions, a single one-piece rotor 1 16 extends the length of the gas turbine engine 100 and is supported for rotation by a bearing at either end. In other constructions, the rotor 116 is assembled from several separate spools that are attached to one another or may include multiple disk sections that are attached via a bolt or plurality of bolts.

[0022] The compressor section 102 is in fluid communication with an inlet section 118 to allow the gas turbine engine 100 to draw atmospheric air into the compressor section 102. During operation of the gas turbine engine 100, the compressor section 102 draws in atmospheric air and compresses that air for delivery to the combustion section 104. The illustrated compressor section 102 is an example of one compressor section 102 with other arrangements and designs being possible.

[0023] In the illustrated construction, the combustion section 104 includes a plurality of separate combustors 120 that each operate to mix a flow of fuel with the compressed air from the compressor section 102 and to combust that air-fuel mixture to produce a flow of high temperature, high pressure combustion gases or exhaust gas 122. Of course, many other arrangements of the combustion section 104 are possible.

[0024] The turbine section 106 includes a plurality of turbine stages 124 with each turbine stage 124 including a number of rotating blades and a number of stationary blades or vanes. The turbine stages 124 are arranged to receive the exhaust gas 122 from the combustion section 104 at a turbine inlet 126 and expand that gas to convert thermal and pressure energy into rotating or mechanical work. The turbine section 106 is connected to the compressor section 102 to drive the compressor section 102. For gas turbine engines 100 used for power generation or as prime movers, the turbine section 106 is also connected to a generator, pump, or other device to be driven. As with the compressor section 102, other designs and arrangements of the turbine section 106 are possible.

[0025] A control system 128 is coupled to the gas turbine engine 100 and operates to monitor various operating parameters and to control various operations of the gas turbine engine 100. In preferred constructions the control system 128 is typically micro-processor based andDocket No. 2024PF00443 includes memory devices and data storage devices for collecting, analyzing, and storing data. In addition, the control system 128 provides output data to various devices including monitors, printers, indicators, and the like that allow users to interface with the control system 128 to provide inputs or adjustments. In the example of a power generation system, a user may input a power output set point and the control system 128 may adjust the various control inputs to achieve that power output in an efficient manner.

[0026] The control system 128 can control various operating parameters including, but not limited to variable inlet guide vane positions, fuel flow rates and pressures, engine speed, valve positions, generator load, and generator excitation. Of course, other applications may have fewer or more controllable devices. The control system 128 also monitors various parameters to assure that the gas turbine engine 100 is operating properly. Some parameters that are monitored may include inlet air temperature, compressor outlet temperature and pressure, combustor outlet temperature, fuel flow rate, generator power output, bearing temperature, and the like. Many of these measurements are displayed for the user and are logged for later review should such a review be necessary.

[0027] FIG. 2 schematically illustrates a power generation system 200 that includes a gas turbine similar to that of FIG. 1, and more specifically an industrial gas turbine but that replaces the combustor 120 with an external heat source 202 and a heat exchanger 204. The heat source 202 can include any heat source but preferably includes a non-carbon generating heat source. Some examples of heat sources 202 include waste heat from various processes, concentrated solar, modular nuclear reactors, and the like.

[0028] The heat exchanger 204 is illustrated as a counterflow heat exchanger that includes a hot fluid path and a cool fluid path. Of course, many different heat exchanger arrangements and designs could be employed as may be required by the process and / or the fluids used.

[0029] The heat source 202 generates a flow of heating fluid 206 that is directed through the hot fluid path of the heat exchanger 204. After passing through the heat exchanger 204, the heating fluid 206 flows to a return 208. The return 208 could simply be a discharge into the atmosphere or a body of water if the fluids is clean air or water of the return 208 could include a fluid connection that returns the fluid to the heat source 202 for reheating. For example, one construction uses a heat source 202 such as a small modular reactor to heat the heating fluidDocket No. 2024PF00443 206. In this arrangement, helium may be used as the heating fluid 206 such that the return 208 operates to return the heating fluid to the heat source 202 for reheating.

[0030] As noted, the power generation system 200 of FIG. 2 includes a gas turbine that includes a compressor 210 and a turbine 212. The compressor 210 includes a multi-stage axial flow compressor that includes a rotating element that, when rotated operates to draw in a working fluid 214 from a working fluid source 216, compress that working fluid 214, and discharge a compressed working fluid 218. In most constructions, the working fluid 214 is atmospheric air, and specifically filtered atmospheric air and the working fluid source 216 is the atmosphere. However, a closed cycle could be employed in which a different fluid (e.g., helium) is used and is not discharged from the system.

[0031] The turbine 212 includes a multi-stage axial flow turbine that receives a flow of hot working fluid 220, expands the hot working fluid 220, and discharges an exhaust gas 222. The turbine 212 includes one or more rotating elements that are driven by the expansion of the hot working fluid 220 to rotate the rotating element of the compressor 210 and to rotate a rotating element of a generator 224 that operates to generate a flow of electrical power. In the illustrated construction, the generator 224 operates to produce between 2 MW and 30 MW or electrical power with systems commonly operating between 4 MW and 10 MW with other sizes being possible.

[0032] It is desirable for the power generation system 200 to be as compact as possible. To facilitate this, the compressor 210 and the turbine 212 are connected to one another via a center casing 500 illustrated in FIG. 5. This results in a compact arrangement and allows the turbine 212 to directly drive the compressor 210 via a shaft.

[0033] To improve the efficiency of the power generation system 200, a recuperator 226 may be used in addition to the heat exchanger 204. In the arrangement of FIG. 2, the compressed working fluid 218 exits the compressor and flows into the recuperator 226. The recuperator 226 is illustrated as a counterflow heat exchanger having a hot fluid path and a cool fluid path. Of course, many different heat exchanger arrangements and designs could be employed as may be required by the process and / or the fluids used.

[0034] The compressed working fluid 218 flows through the cool fluid path of the recuperator 226 and is preheated by the exhaust gas 222 (sometimes referred to as the spent working fluid)Docket No. 2024PF00443 which flows from the turbine 212, through the hot fluid path of the recuperator 226, to an exhaust 228. As discussed with regard to the return 208, the exhaust could be an outlet to the atmosphere if the working fluid 214 is air or the exhaust 228 could include piping that redirects the exhaust gas 222 top the working fluid source 216 where it completes a closed cycle.

[0035] After the compressed working fluid 218 is preheated in the recuperator 226 it flows to the cold fluid path of the heat exchanger 204 where it is heated by the heating fluid 206. After heating, the compressed working fluid 218 exits the heat exchanger 204 as the hot working fluid 220.

[0036] To aid in maintaining a desired temperature at the inlet of the turbine 212, some constructions may include a bypass flow 230 and a bypass valve 232. The bypass flow 230 extends from a point between the compressor 210 and the recuperator 226 or the heat exchanger 204 to a point upstream of the turbine 212. When the bypass valve 232 is open, a portion of the compressed working fluid 218 is directed to the inlet of the turbine 212 and bypasses the heat exchanger 204 and the recuperator 226 such that it is substantially cooler than he hot working fluid 220. Generally, the bypass valve 232 is controllable to allow for a variable bypass flow 230 and better control of the temperature of the hot working fluid 220 as it enters the turbine 212.

[0037] While many different operating parameters are possible, in one construction, the power generation system 200 uses air as the working fluid 214. The compressor 210 operates at a pressure ratio of between 10 to 1 and 20 to 1 and a maximum turbine inlet temperature between 600 and 900 degrees C. The power generation system 200 further includes helium as the heating fluid 206 with the helium delivered to the heat exchanger 204 at a maximum temperature between 600 and 900 degrees C.

[0038] FIG. 3 illustrates another power generation system 300 that is similar to the power generation system 200 of FIG. 2. The power generation system 300 of FIG. 3 includes a heat source 202, a return 208, and a heat exchanger 204 similar to those described with regard to FIG. 2. In addition, the power generation system 300 includes a compressor 210, a turbine 212, a generator 224, a working fluid source 216, and an exhaust 228 that are each similar to that described with regard to the power generation system 200 of FIG. 2.Docket No. 2024PF00443

[0039] The power generation system 300 differs from the power generation system 200 of FIG. 2 in that it does not include a recuperator 226 and includes a different arrangement for the bypass flow 230 and the bypass valve 232. In the power generation system 300, the bypass flow 230 extends from a point upstream of the turbine 212 but downstream of the heat exchanger 204 to the exhaust 228. Thus, rather than delivering cool working fluid 214 to the turbine inlet, the bypass flow 230 directs hot working fluid 220 directly to the exhaust 228 and bypasses the turbine 212.

[0040] FIG. 3 also illustrates a warm fluid collector 302 and a hot fluid collector 304 positioned in the power generation system 300. The warm fluid collector 302 is arranged to collect the compressed working fluid 218 as it is discharged from the compressor 210 and direct that compressed working fluid 218 to the heat exchanger 204. Similarly, the hot fluid collector 304 receives the hot working fluid 220 from the heat exchanger 204 and evenly distributes the hot working fluid 220 to the turbine 212. Each of the warm fluid collector 302 and the hot fluid collector 304 are discussed in greater detail with regard to FIG. 7 and FIG. 8.

[0041] FIG. 4 illustrates yet another power generation system 400 that is similar to the power generation system 300 of FIG. 3 with some additional features. The power generation system 400 includes a heat source 202, a heat exchanger 204, and a return 208 that are each similar to the corresponding components described with regard to the power generation system 200 and the power generation system 300. However, in addition to these components, the power generation system 400 includes a pump 402 that operates to pressurize the heating fluid 206 within the heating cycle. The pump 402 may operate to pump a liquid or compress a gas or vapor for return to the heat source 202 for reheating. Any suitable pump or compressor design may be employed as the pump 402.

[0042] The turbine of the power generation system 400 includes a multi-shaft turbine that allows the turbine to be divided into a drive turbine 404 and a power turbine 406. The drive turbine 404 is connected to the compressor 210 via a shaft 408 to define a first rotor. Operation and rotation of the drive turbine 404 drives the operation of the compressor 210. The power turbine 406 is connected to the generator 224 via a second shaft 408 to define a second rotor. Operation and rotation of the power turbine 406 drives the generator 224 and the generator 224 produces a flow of electrical power in response. The drive turbine 404 and the power turbine 406 may be positioned within a single casing or may be separated from one another as may beDocket No. 2024PF00443 desired. Separating the drive turbine 404 and the power turbine 406 allows for individual control of the two shafts 408.

[0043] The power generation system 400 includes a full bypass flow 410 and a bypass valve 232 that are similar to the bypass flow 230 and bypass valve 232 of the power generation system 300. In the power generation system 400, the full bypass flow 410 is operable to deliver a portion of the hot working fluid 220 from a point upstream of the drive turbine 404 to the exhaust 228. A partial bypass flow 412 includes a bypass valve 232 and is operable to direct a portion of the hot working fluid 220 from a point between the drive turbine 404 and the power turbine 406 to the exhaust 228. Thus, the full bypass flow 410 bypasses both the drive turbine 404 and the power turbine 406 while the partial bypass flow 412 bypasses only the power turbine 406.

[0044] As one of ordinary skill in the art will realize, many different arrangements and additional components could be employed to improve the operation or efficiency of the power generation systems illustrated herein. The power generation system 200, the power generation system 300, and the power generation system 400 are three examples of those different arrangements.

[0045] FIG. 5 illustrates a center casing 500 attached to a compressor casing 502. To facilitate the goal of making the power generation system compact, the compressor casing 502 is attached directly to the center casing 500. The center casing 500 replaces the combustion section 104 of the gas turbine engine 100 of FIG. 1 and includes a plurality of outlets 504 that cooperate to define a warm fluid outlet and a plurality of inlets 506 that cooperate to define a hot fluid inlet.

[0046] In the illustrated construction, the center casing 500 includes a frustoconical wall 508 that defines the outlets 504 (warm fluid outlets) and a cylindrical wall 510 that defines the inlets 506 (hot fluid inlets). The outlets 504 and the inlets 506 are equally spaced around the central axis 108 of the center casing 500. In the illustrated construction, there are six outlets 504 and six inlets 506 with other constructions including a different number of outlets 504 or inlets 506 and / or a different arrangement of the outlets 504 or inlets 506.

[0047] FIG. 6 is a section view of the center casing 500 that better illustrates the interior. As shown, the center casing 500 includes a bearing casing 602, several bearing struts 604, and aDocket No. 2024PF00443 divider wall 606. The bearing casing 602 receives a bearing, typically a journal bearing that partially supports the shaft 408 between the compressor 210 and the turbine 212 for rotation. Of course, other bearing types and arrangements of the bearing casing 602 may be employed as required.

[0048] The bearing struts 604 extend from one or both of the cylindrical wall 510 and the frustoconical wall 508 to the bearing casing 602 to provide structural support for the bearing casing 602. In the illustrated construction, six struts are equally spaced around the central axis 108 with other arrangements and quantities being possible.

[0049] The divider wall 606 extends from the outer most surface of the interior of the center casing 500 which may be defined by one or both of the cylindrical wall 510 and the frustoconical wall 508 to the bearing casing 602. Thus, the divider wall 606 divides the center casing 500 into an outlet side which includes the outlets 504 and an inlet side which includes the inlets 506.

[0050] FIG. 7 illustrates one arrangement of the warm fluid collector 302 and the hot fluid collector 304. In this arrangement, the warm fluid collector 302 consists of a number of individual outlet pipes 702 with the number corresponding to the number of outlets 504. Thus, each outlet 504 includes its own dedicated outlet pipe 702 that directs a portion of the compressed working fluid 218 from the compressor 210 to the heat exchanger 204, the recuperator 226, or any other component downstream of the compressor 210.

[0051] The hot fluid collector 304 includes a number of inlet pipes 704 that corresponds to the number of inlets 506. Thus, each inlet 506 includes its own dedicated inlet pipe 704 that directs a portion of the hot working fluid 220 from the heat exchanger 204 to the turbine 212.

[0052] FIG. 8 illustrates another arrangement of the warm fluid collector 302 and the hot fluid collector 304. In this arrangement, the warm fluid collector 302 includes a warm fluid manifold 802 and the hot fluid collector 304 includes a hot fluid manifold 804. The warm fluid manifold 802 is arranged to collect all the compressed working fluid 218 from the various outlets 504 and direct all the compressed working fluid 218 to the heat exchanger 204, the recuperator 226, or any other component downstream of the compressor 210.Docket No. 2024PF00443

[0053] The hot fluid collector 304 in the arrangement of FIG. 8 includes the hot fluid manifold 804 which receives all the hot working fluid 220 from the heat exchanger 204 and directs that hot working fluid 220 to the various inlets 506.

[0054] FIG. 9 illustrates another arrangement of the warm fluid collector 302 and the hot fluid collector 304. In the construction of FIG. 9, the warm fluid collector 302 includes a warm fluid volute 902, or outlet scroll case that is arranged to efficiently collect the warm compressed working fluid directly from the outlet of the compressor 210 or from the various outlets 504. Specifically, the warm fluid volute 902 continuously increases in size as it extends around the compressor 210 toward its volute outlet 904 which allows it to efficiently receive increasing flow without unwanted and undesirable pressure drops.

[0055] Similarly, the hot fluid collector 304 includes a hot fluid volute 906 that is arranged to efficiently and evenly distribute hot working fluid 220 received from the heat exchanger 204 directly to an annular inlet of the turbine 212 or to each of the inlets 506. The hot fluid volute 906, or inlet scroll case continuously reduces in size from a volute inlet 908 to the hot fluid volute 906 as it extends around the turbine 212 to reduce undesirable pressure drops within the hot fluid volute 906.

[0056] It should be noted that in many constructions, the warm fluid volute 902 and the hot fluid volute 906 cooperate to serve many of the functions of the center casing 500 such that the center casing can be omitted. Another structure may be required to provide a bearing support or other functions but the warm fluid volute 902 and the hot fluid volute 906 operate to perform all of the functions related to fluid movement.

[0057] FIG. 10 illustrates an arrangement in which the complete power generation system 200 minus the heat source 202 is sized and arranged to fit on a trailer 1002 that can be easily transported by a truck 1004. This arrangement allows for the quick and easy deployment of the power generation system 200, as well as the other power generation systems illustrated and described herein. There are limitations to the size of the power generation system 200 that can be fit on the trailer 1002. However, the arrangement described herein allows for a power generation system 200 that generates at least 2 MW of useable electrical power and up to about 30 MW with the most common systems producing between 4 MW and 10 MW. All theDocket No. 2024PF00443 auxiliary equipment including, pumps, valves, heat exchangers, control systems, cooling, fans, support structure, etc. are sized and arranged to fit on the trailer 1002 for easy transportation.

[0058] FIG. 11 illustrates another arrangement of a trailer 1102 that is sized to support the complete power generation system 200 minus the heat source 202 and the support structure is sized and arranged to fit on a trailer 1102 that can be easily transported by a truck 1004. This arrangement allows for the quick and easy deployment of the power generation system 200, as well as the other power generation systems illustrated and described herein using a smaller trailer 1102 than that shown in FIG. 10 which allows for more local transportation, transportation to more isolated locations, and transportation on smaller roads and highways.

[0059] As with the arrangement of FIG. 10, the arrangement of FIG. 11 allows for a power generation system 200 that generates at least 2 MW of useable electrical power and up to about 30 MW with the most common systems producing between 4 MW and 10 MW. All the auxiliary equipment including, pumps, valves, heat exchangers, control systems, cooling, fans, etc. are sized and arranged to fit on the trailer 1102 for easy transportation.

[0060] In operation, the power generation system 200, 300, 400 is first transported to the site where the power generation is needed. In some constructions, the components are mounted on skids in a way that allows for their removal and placement as a few units or assemblies. The components are then connected to one another for operation. The center casing 500 is then connected to the heat source 202 and the generator 224 is connected to a power grid or other load for operation.

[0061] During operation, the compressor 210 is rotated to produce the compressed working fluid 218. The compressed working fluid 218 flows into the center casing 500 and exits via the outlets 504 and the warm fluid collector 302. The warm fluid collector 302 directs the compressed working fluid 218 to the recuperator 226 and / or the heat exchanger 204 where the compressed working fluid 218 is heated to a desired temperature and discharged as the hot working fluid 220.

[0062] The hot working fluid 220 enters the hot fluid collector 304 which in turn distributes the hot working fluid 220 to each of the inlets 506 of the center casing 500. From the inlets 506, the hot working fluid 220 enters the turbine 212. As the hot working fluid 220 flows through the turbine 212 it expands and the turbine 212 extracts energy to drive the compressorDocket No. 2024PF00443 210 and the generator 224 or other load that may be powered by the turbine 212. In the power generation systems 200, 300 the turbine 212 is on a common shaft with the compressor 210 such that the compressor 210 and generator 224 are driven together. In contrast, the power generation system 400 separates the turbine 212 into the drive turbine 404 that drives the compressor 210 and the power turbine 406 which is on a separate shaft and drives the generator 224.

[0063] After passing through the turbine 212, the hot working fluid 220 is discharged as exhaust gas 222. In open systems, the working fluid 214 is air that is drawn in from the atmosphere with the exhaust gas 222 being discharged into the atmosphere. In some constructions, the exhaust gas 222 may be treated or conditioned prior to discharge or may be discharged to a heat recovery system to extract energy from the exhaust gas 222 prior to its ultimate discharge into the atmosphere. In fact, the power generation system 200 includes the recuperator 226 which receives the exhaust gas 222 and uses the excess heat of the exhaust gas 222 to preheat the compressed working fluid 218 prior to its entry into the heat exchanger 204.

[0064] In closed systems, the working fluid 214 may be air or another gas (e.g., helium, carbon dioxide, etc.) that is drawn from a storage source such as a tank. In these arrangements, additional heat is generally removed from the exhaust gas 222 by routing the exhaust gas 222 through the recuperator 226 to preheat the compressed working fluid 218.

[0065] The arrangement utilizes a compact and modular compressor 210, center casing 500, and turbine 212, that allows for the compact arrangement. In addition, the arrangement of the center casing 500, the warm fluid collector 302, and the hot fluid collector 304 further improves efficiency and flexibility to allow for the connection to virtually any external heat source 202.

[0066] The disclosed system provides a means for capturing created sustainable, green and / or excess thermal energy and converting it into electrical energy. Typically, excess thermal energy is released as a byproduct of industrial processes, power generation, or even from mechanical equipment. The disclosed system contributes to reducing greenhouse gas emissions by lowering the demand for additional fossil fuel consumption.

[0067] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations,Docket No. 2024PF00443 and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.

[0068] None of the description in the present application should be read as implying that any particular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.

Claims

Docket No. 2024PF00443CLAIMSWhat is claimed is:1 . A power generation system that uses a heating fluid that is heated by a heat source, the power generation system comprising: a compressor operable to compress a working fluid and to discharge a compressed working fluid; a warm fluid collector coupled to the compressor to receive the compressed working fluid via a warm fluid outlet; a heat exchanger including a hot fluid path through which the heating fluid flows and a cool fluid path through which the compressed working fluid flows, the heat exchanger operable to transfer heat from the heating fluid to the compressed working fluid to produce a hot working fluid; a generator operable to produce a flow of electrical power; a turbine operable in response to the receipt of the hot working fluid to drive the compressor and the generator; and a hot fluid collector coupled to the turbine to direct the hot working fluid into the turbine via a hot fluid inlet.

2. The power generation system of claim 1, wherein the heat source includes a noncarbon producing heat source.

3. The power generation system of claim 1, wherein the compressor includes a multi-stage axial flow compressor, and the working fluid includes air.

4. The power generation system of claim 1, wherein the warm fluid collector includes an outlet scroll case that connects directly to the compressor to receive the compressed working fluid therefrom.

5. The power generation system of claim 4, wherein the hot fluid collector includes an inlet scroll case that connects directly to the turbine to deliver the hot working fluid from the heat exchanger to the turbine.Docket No. 2024PF004436. The power generation system of claim 1, further comprising a center casing directly connected to the compressor and defining the warm fluid outlet and directly connected to the turbine and defining the hot fluid inlet.

7. The power generation system of claim 6, wherein the warm fluid outlet includes a plurality of outlets, and the hot fluid inlet includes a plurality of inlets.

8. The power generation system of claim 7, wherein the warm fluid collector includes a warm fluid manifold that connects to each outlet of the plurality of outlets to receive the compressed working fluid from the center casing.

9. The power generation system of claim 7, wherein the hot fluid collector includes a hot fluid manifold that connects to each inlet of the plurality of inlets to discharge the hot working fluid into the center casing.

10. The power generation system of claim 7, wherein the warm fluid collector includes a plurality of outlet pipes with each outlet pipe connected to one of the outlets of the plurality of outlets to receive the compressed working fluid from the center casing.

11. The power generation system of claim 7, wherein the hot fluid collector includes a plurality of inlet pipes with each inlet pipe connected to one of the inlets of the plurality of inlets to deliver the hot working fluid from the heat exchanger to the turbine.

12. The power generation system of claim 1, wherein the turbine includes a multistage axial flow turbine.

13. The power generation system of claim 12, wherein the turbine includes a drive turbine that operates to drive the compressor and a power turbine that operates to drive the generator.

14. The power generation system of claim 13, wherein the drive turbine and the compressor include a first rotor and the power turbine, and the generator include a second rotor separate from the first shaft.Docket No. 2024PF0044315. The power generation system of claim 13, wherein the power generation system is sized to be fully supported on a single trailer for movement as a complete unit and is operable to generate between 2 MW and 30 MW of electrical power.

16. The power generation system of claim 13, wherein the power generation system is sized to be fully supported on a single trailer for movement as a complete unit and is operable to generate between 4 MW and 10 MW of electrical power.

17. The power generation system of claim 1, further comprising a recuperator, wherein the hot working fluid is discharged from the turbine as a spent working fluid, and wherein the spent working fluid passes through the recuperator to pre-heat the compressed working fluid prior to its entry into the heat exchanger.

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