Liquid-Cooled Generator Expander Heat Recovery Circuit

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Solution Overview

Problem

Mechanical energy conversion losses in generators and transmission systems reduce the efficiency of fluid expansion processes, and additional energy is often required to compensate for the enthalpy decrease during fluid expansion.

Innovation Solution

A device with a common liquid circuit for the generator and expander element, where residual heat from the generator is used to heat the expander element, and the transmission is incorporated into the liquid line to recover heat losses, utilizing a liquid-cooled system with oil as the coolant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a generator is used to convert mechanical energy to electrical energy during fluid expansion, then electrical energy can be generated, but mechanical energy conversion losses occur which reduce process efficiency

Engineering Contradiction:

Improveelectrical energy generationVSAvoidmechanical energy conversion losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The invention recovers the thermal energy that would otherwise be lost during mechanical energy conversion in the generator. The liquid cooling circuit captures waste heat from the generator and transmits it to the expander element, converting a harmful energy loss into a useful heating source that compensates for enthalpy decrease during expansion.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If additional heating is provided to compensate for enthalpy decrease during fluid expansion, then expansion efficiency is maintained, but additional energy input is required

Engineering Contradiction:

Improveexpansion efficiencyVSAvoidadditional energy input for heating

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system uses its own internally generated waste heat to provide the necessary heating for the expander element. The liquid cooling circuit creates a self-contained thermal management system where the generator's waste heat automatically serves to compensate for enthalpy losses, eliminating the need for external energy input.

Inventive Principle:

Principle #25Self-service

3Temperature

If separate cooling and heating systems are used for the generator and expander element, then temperature control is effective, but device complexity and size increase

Engineering Contradiction:

Improvetemperature controlVSAvoidseparate cooling and heating systems

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The invention merges the cooling system for the generator with the heating system for the expander element into a single integrated liquid circuit. This common liquid line serves dual purposes: cooling the generator while simultaneously heating the expander element, thereby reducing system complexity and eliminating redundant components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The liquid cooling circuit performs multiple functions simultaneously: it cools the generator, heats the expander element, and manages thermal energy transfer throughout the system. This multi-functional approach eliminates the need for separate dedicated cooling and heating systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach recovers heat losses to compensate for enthalpy decrease, reduces device size by eliminating the need for additional oil pumps, and enhances efficiency by integrating the transmission and cooling systems within the liquid circuit.

Implementation Method 1

A device with a common liquid circuit for the generator and expander element, where residual heat from the generator is used to heat the expander element

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

liquid-cooled system with oil as the coolant

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The transmission is incorporated into the liquid line to recover heat losses

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4077938B1Device for expanding a fluid

Publication Date: 2024.10.23 ATLAS COPCO AIRPOWER NV

Figure 1~2

AI summary

Device for expanding a fluid, wherein the device (1) is provided with an expander element (2) for expanding the fluid, a generator (3) and a transmission (4) between the two, characterized in that the generator (3) is a liquid-cooled generator and the expander element (2) is heated using liquid, wherein the device (1) is further provided with a common liquid circuit (8) for the generator (3) and the expander element (2), wherein the liquid circuit (8) comprises a liquid pump (10) which can pump up liquid from a liquid reservoir (11), wherein the liquid circuit (8) also comprises a liquid line (9) which runs from the liquid reservoir (11) and which incorporates the liquid pump (10), the generator (3) and the expander element (2).