Direct Steam Generator with CONVAPORATOR Exhaust Separation
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Solution Overview
Problem
Direct Steam Generators (DSGs) have not been adopted in large-scale power generation due to the adverse effects of multi-phase flow, where steam is mixed with exhaust constituents, affecting steam turbine blades and condensers, leading to inefficiencies and the lack of existing large-scale DSG-based systems in production.
Innovation Solution
A system comprising a Direct Steam Generator fluidly coupled with a CONVAPORATOR Unit (CU), which separates steam from combustion exhaust constituents using a condenser and evaporator portion, allowing for efficient steam generation and separation, followed by electricity production through a turbine and generator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a Direct Steam Generator is used to generate steam, then energy conversion efficiency is improved, but the steam becomes mixed with exhaust constituents which adversely affects turbine blades and condensers
Solution Approach 1:
The system divides the steam generation and exhaust handling into separate streams. The DSG generates steam efficiently while the exhaust constituents are routed separately through the CONVAPORATOR unit, preventing contamination of the steam turbine system while maintaining high energy conversion efficiency
Solution Approach 2:
The CONVAPORATOR unit acts as an intermediary device between the DSG and the steam turbine. It receives the mixed steam-exhaust flow, separates the constituents, and delivers clean steam to the turbine, thus mediating the harmful interaction between efficient steam generation and exhaust contamination
2Adaptability or versatility
If a Direct Steam Generator operates in subcritical or supercritical pressure systems, then operational capability is improved, but the multi-constituent flow problem becomes more significant
Solution Approach 1:
The system segments the flow paths to handle different pressure regimes. The DSG can operate at subcritical or supercritical pressures to generate steam, while the CONVAPORATOR unit separates the constituents before the steam enters the turbine, allowing versatile pressure operation without exacerbating the multi-constituent problem
3Productivity
If steam turbine blades are exposed to multi-phase flow with exhaust constituents, then power generation continues, but blade performance and condenser efficiency deteriorate
Solution Approach 1:
The CONVAPORATOR unit serves as an intermediary that protects the steam turbine blades and condenser from direct exposure to harmful exhaust constituents. It separates the steam from exhaust gases, delivering clean steam to the turbine while maintaining continuous power generation with preserved component reliability
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 system achieves high efficiency in electricity generation, exceeding 50% energy conversion from Natural Gas, with minimized NOx production and separated exhaust gases, enabling the exploitation of DSG's inherent higher efficiency.
Implementation Method 1
The CU can be configured to route the saturated steam or superheated steam and combustion exhaust constituents through a condenser portion of the CU via a condenser side steam conduit and can be configured to condense the super-heated steam or saturated steam to form a condensate
Implementation Method 2
The evaporator portion can be configured to evaporate the condensate from the separation tank and water return system via heat transfer between the condenser portion and evaporator portion to form steam
Data Source
AI summary
Embodiments of the present disclosure include a system, method, and apparatus comprising a direct steam generator configured to generate saturated steam or superheated steam and combustion exhaust constituents. A CONVAPORATOR™ Unit (CU) can be fluidly coupled to the direct steam generator. The CU can be configured to route the saturated steam or superheated steam and combustion exhaust constituents through a condenser portion of the CU via a condenser side steam conduit and can be configured to condense the super-heated steam or saturated steam to form a condensate. A separation tank and water return system can be fluidly coupled to a condenser side condensate conduit of the condenser portion of the CU. The separation tank and water return system can be configured to separate the combustion exhaust constituents from the condensate. An evaporator portion of the CU can be fluidly coupled with the separation tank and water return system via an evaporator side condensate conduit. The evaporator portion can be configured to evaporate the condensate from the separation tank and water return system via heat transfer between the condenser portion and evaporator portion to form steam. A turbine can be fluidly coupled with the evaporator portion of the CU via an evaporator side steam conduit.