Magnetic Coupling Turbine Generator for Natural Gas Pressure Recovery

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Solution Overview

Problem

The natural gas production and transmission industry wastes significant energy due to pressure differential, and existing power generation methods are unreliable, maintenance-intensive, or unsafe in hazardous environments, particularly at well sites and city gates.

Innovation Solution

An integrated turbine generator with a static seal pressure boundary isolates the electrical system from the turbine and rotor, using a turbine rotor attached to a shaft with permanent magnets, enclosed in a pressure-tight, magnetically transparent shell, generating electricity without dynamic seals, thus ensuring safety and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solar panels or thermoelectric generators are used to generate electricity at remote locations, then electrical power can be provided, but the systems require gas cleaning maintenance and are dependent on gas quality

Engineering Contradiction:

Improveelectrical power availabilityVSAvoidgas cleaning requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention extracts the electrical generation function from the gas processing system by using a turbine-generator that operates independently of gas quality. The turbine captures pressure differential energy directly from the gas flow without requiring the gas to contact or clean the generator components, separating the power generation function from gas handling requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The turbine acts as an intermediary device that converts pressure differential energy into mechanical rotation, which then drives the generator. This intermediary mechanism allows the system to harness energy from the gas pressure differential without requiring direct contact between the gas and the electrical generation components, eliminating the need for gas cleaning.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If dynamic seals are used to isolate the generator from the turbine, then the electrical system can be protected, but fluid leaks and contamination risks increase

Engineering Contradiction:

Improveelectrical system protectionVSAvoidfluid leak risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces the mechanical dynamic seal system with a magnetic coupling system. The turbine rotor and generator rotor are coupled through magnetic fields that can transmit rotational force without physical contact, eliminating the need for dynamic seals and the associated risks of fluid leakage and contamination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

A magnetic field acts as an intermediary between the turbine rotor and generator rotor, transmitting rotational energy without requiring direct mechanical contact or seals. This magnetic coupling allows the system to maintain complete isolation between the gas-filled turbine chamber and the electrical generator components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the turbine rotor operates at high speed to generate more power, then electricity production increases, but dynamic seals wear faster and reliability decreases

Engineering Contradiction:

Improveelectricity generation rateVSAvoiddynamic seal durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention replaces the mechanical dynamic seal system with a magnetic coupling system that has no moving contact parts. This allows the turbine rotor to operate at high speeds without the wear and reliability issues associated with dynamic seals, as the magnetic coupling can accommodate high rotational speeds without mechanical degradation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution efficiently harnesses pressure differential energy, providing reliable and safe electrical power independent of weather or gas quality, with reduced maintenance and no risk of fluid leaks or contamination, allowing high-speed operation and effective battery charging.

Implementation Method 1

using the pressure differential typically found in natural gas production and transmission systems

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

a rotor assembly which includes a shaft and a generator rotor assembly containing permanent magnets around its periphery

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS8067851B2Differential pressure generator

Publication Date: 2011.11.29 PARKER INTANGIBLES LLC

AI summary

An electrical generator (10) powered by fluid pressure in a flow line includes a turbine housing (23) and control valve (11). The turbine housing houses a rotor (29) and a plurality of turbine blades (33) which are rotated by fluid passing from the flow line through the turbine housing. A bearing (22) within the turbine housing guides rotation of the rotor, and supports a plurality of magnets (28). Cap member (23) is sealed to the turbine housing, and a stator (40) external of the cap member generates electricity in response to a plurality of rotating magnets.