Device for converting heat energy into mechanical energy
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Solution Overview
Problem
Conventional systems for converting thermal energy into mechanical energy face inefficiencies due to poor separation of heat transfer fluids and gases, leading to suboptimal operation and reduced efficiency, particularly in systems using Pelton turbines and Rankine cycles, where isothermal expansion is not achieved, resulting in low energy conversion and high losses.
Innovation Solution
A kinetic energy converter design that includes a steam generator for isothermal expansion and a deflector to separate heat transfer fluids and high-temperature gases efficiently, using a combination of steam generators and deflectors to achieve optimal separation and isothermal expansion, enhancing the conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional Pelton turbine is used to convert thermal energy into mechanical energy, then the turbine can operate with a two-phase jet, but the separation of heat transfer fluid and thermodynamic fluid is insufficient (less than 98% separation efficiency)
Solution Approach 1:
The turbine wheel is divided into multiple independent nozzles arranged radially around the periphery, with each nozzle receiving a portion of the two-phase jet. This segmentation allows better control of fluid flow paths and reduces mixing between heat transfer fluid and thermodynamic fluid, achieving over 98% separation efficiency while maintaining energy conversion effectiveness.
2Device complexity
If ball-bearings are mounted inside the converter tank to support the impulse wheel, then the structure is simplified, but the bearings cannot withstand high temperature operation and high-speed rotation, resulting in very low equipment lifetime
Solution Approach 1:
The ball-bearings are extracted from the high-temperature environment inside the converter tank and mounted outside on a support structure. The impulse wheel shaft extends through a sealed bearing housing that is thermally isolated from the hot two-phase jet, allowing standard ball-bearings to operate in ambient temperature conditions while the impulse wheel itself operates at high temperature, thereby extending equipment lifetime significantly.
3Temperature
If ball-bearings are mounted outside the converter tank with rotating seals to ensure tightness, then high temperature operation is possible, but the seals are not perfectly tight and may leak, which is dangerous as heat transfer fluid can inflame spontaneously in contact with air
Solution Approach 1:
A flexible membrane seal made of heat-resistant material is used at the shaft penetration point. The membrane is clamped between a flange inside the converter tank and a support structure outside, creating a flexible barrier that maintains tightness while accommodating thermal expansion and vibration. This flexible seal design prevents leakage of heat transfer fluid to the external environment, eliminating fire hazards while allowing high-temperature operation.
4Ease of manufacture
If polytropic expansion is used in conventional turbines, then the expansion process is simple, but heat exchange and friction occur during expansion, reducing the mechanical energy recovered compared to isothermal expansion
Solution Approach 1:
The two-phase jet is pre-formed in a nozzle before entering the impulse wheel, with the thermodynamic fluid vaporized and mixed with heat transfer fluid in a controlled manner. This preliminary preparation ensures that the expansion process begins with optimal conditions for isothermal behavior, maximizing energy recovery while maintaining manufacturing simplicity. The nozzle geometry is designed to create a homogeneous two-phase mixture that expands efficiently through the impulse wheel blades.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables improved separation of heat transfer fluids and gases, achieving higher efficiency in converting thermal energy into mechanical energy, with the kinetic energy converter ensuring dependable operation and increased energy output by maintaining isothermal conditions and reducing losses.
Implementation Method 1
the first path being thermally coupled to the second path so as to form steam from the first fluid
Implementation Method 2
the chamber being configured to perform isothermal expansion of the first fluid in the chamber by means of fractioned expansion by a plurality of elementary isothermal expansions
Implementation Method 3
the second outlet of the chamber being connected to the second inlet of the steam generator, the first path being thermally coupled to the second path so as to heat the first fluid between each expansion
Implementation Method 4
a mixing device connected to the first outlet of the chamber and to the second outlet of the steam generator and configured so as to mix the first fluid in vapour form with a heat transfer fluid to obtain a two-phase mixture
Implementation Method 5
the jet being injected onto said blades so as to drive the shaft in rotation and to transform the axial kinetic energy of the jet into rotational kinetic energy of the shaft
Data Source
AI summary
A converter of kinetic energy from a jet formed by a heat transfer fluid and a gas at high temperature, includes: at least one injector of the jet from at least one source of heat transfer fluid and of high-temperature gas, an impulse wheel mounted rotating secured to a shaft extending along an axis substantially perpendicularly to the injector and including a plurality of asymmetric blades, a tank surrounding said impulse wheel and at least one deflector extending underneath the blades.