Heat-Recovery Compressor Assembly for Exhaust-Powered Gas Boosting
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Solution Overview
Problem
Compressor stations in natural gas pipelines face inefficiencies due to the exhaustion of exhaust heat into the atmosphere, which is costly and environmentally harmful, especially when using larger turbines that are not environmentally friendly.
Innovation Solution
A compressor system that includes a first compressor driven by a reciprocating engine or combustion turbine coupled to an exhaust assembly with a heat driven power cycle. This cycle uses exhaust heat to power a generator electrically coupled to an electric motor, which operates a second compressor to supplement the pressurization of the working fluid, while being sealed to prevent environmental leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a large turbine is used to recover exhaust heat, then heat recovery efficiency is improved, but device size and cost increase significantly
Solution Approach 1:
The system divides the compression function into two separate compressors: a primary compressor driven by the prime mover, and a supplemental compressor driven by the electric motor powered by the turbine. This segmentation allows the turbine to be smaller while still achieving significant overall compression enhancement, resolving the contradiction between heat recovery efficiency and device size.
Solution Approach 2:
The electric motor serves multiple functions: it acts as a motor to drive the supplemental compressor during power generation mode, and can potentially function as a generator during braking or load reduction scenarios. This multi-functionality allows for a more compact integrated system design.
2Loss of energy
If traditional turbines are used for heat recovery, then exhaust heat utilization is improved, but environmental harm increases due to harmful working fluids
Solution Approach 1:
The system changes the working fluid parameter from traditional harmful substances to carbon dioxide, which is contained in a closed loop system. This parameter change maintains effective heat recovery while eliminating environmental pollution, as the CO2 is recirculated within the sealed system rather than released into the atmosphere.
Solution Approach 2:
The patent creates a closed, inert environment for the CO2 working fluid, preventing its release into the atmosphere. The sealed system ensures that the CO2 circulates continuously between the turbine, condenser, and evaporator, effectively isolating it from the external environment and eliminating harmful emissions.
3Loss of energy
If exhaust heat is recovered using traditional systems, then energy efficiency is improved, but electrical grid dependency increases
Solution Approach 1:
The system generates its own electrical power needs through the turbine-electric motor configuration. The turbine converts exhaust heat into mechanical energy that drives the supplemental compressor, creating a self-sufficient power source that reduces or eliminates dependency on external electrical grids, particularly valuable for remote compressor stations.
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 over 10% efficiency improvement by recycling exhaust heat to power a supplemental compressor, while preventing environmental leakage of operating fluids, thus addressing the inefficiencies and environmental concerns of traditional compressor stations.
Implementation Method 1
an exhaust assembly that utilizes the exhaust heat from the first compressor as an energy source to power a generator
Implementation Method 2
a generator that converts the exhaust heat into electric current
Implementation Method 3
an electrical motor that operates a second, or supplemental, compressor
Data Source
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AI summary
A system (100) may be provided that may include a first working fluid compressor (102) configured to pressurize a working fluid, and a prime mover (104) coupled to the first working fluid compressor (102) and configured to provide a mechanical input into the first working fluid compressor (102). An exhaust assembly (112, 214) may be coupled to the prime mover and configured to receive exhaust heat from the prime mover (104), the exhaust assembly (112, 214) including a generator (126, 400) configured to generate electric current based on the exhaust heat received by the exhaust assembly (112, 214). A second working fluid compressor (134) may include an electric motor (130, 402) electrically and synchronously coupled to the generator (126, 400) and configured to pressurize the working fluid.