Hermetically-Sealed Expander-Generator for Ammonia Process Energy Recovery
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Solution Overview
Problem
Existing power generating devices for chemical production processes, such as synthetic ammonia, are inefficient in capturing energy from working fluids at high temperatures and pressures, leading to increased energy costs from reliance on the power grid.
Innovation Solution
An expander-generator with a hermetically-sealed housing containing a shaft with high and low pressure expander sections, where the working fluid is expanded to rotate the shaft and generate power, with a generator coupled to the shaft to convert this rotation into useful work.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single-stage expander is used, then the device complexity is low, but the energy capture efficiency is insufficient
Solution Approach 1:
The expander is divided into two separate stages: a high-pressure expander and a low-pressure expander. Each stage operates at optimized pressure conditions to maximize energy extraction. The high-pressure expander handles the initial expansion from high pressure to intermediate pressure, while the low-pressure expander completes the expansion to atmospheric pressure, thereby improving overall energy capture efficiency without excessive complexity
Solution Approach 2:
The patent introduces a pressure dimension differentiation by operating expanders at different pressure levels. Instead of a single-stage expansion, the system creates a multi-level pressure gradient approach, expanding the working fluid through high-pressure and low-pressure stages sequentially, which allows for more efficient energy extraction across different pressure ranges
2Power
If high pressure expansion is used, then the power generation is increased, but the device complexity increases
Solution Approach 1:
The power generation system is segmented into high-pressure and low-pressure expander sections, each contributing to the overall power output. The high-pressure expander generates power from the initial high-pressure working fluid, while the low-pressure expander generates additional power from the intermediate-pressure fluid, collectively increasing total power generation while distributing system complexity across modular sections
Solution Approach 2:
The patent merges the high-pressure expander and low-pressure expander into a single integrated system with a common shaft and generator. This combination allows both expansion stages to contribute to power generation simultaneously, increasing overall power output while sharing common components (shaft, generator, housing) to manage device complexity
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 expander-generator effectively captures and converts the energy of working fluids, reducing energy costs by generating power onsite and improving efficiency through the sequential expansion of fluids in high and low pressure sections.
Implementation Method 1
The expander may be configured to receive and expand a working fluid and discharge the working fluid
Implementation Method 2
the working fluid is expanded to rotate the shaft and thereby generate useful work for the generator
Data Source
AI summary
An expander-generator is disclosed. The expander-generator is disposed within a hermetically-sealed housing and includes a high-pressure expander stage and a low-pressure expander stage. A working fluid, such as ammonia, is introduced into the high and low pressure expander stages and expanded therein so as to provide rotational torque to a shaft. A generator, such as a motor, pump, or compressor, may be coupled to a free end of the shaft such that rotation of the shaft will provide useful work for the generator.