ORC Heat Recovery With Bypass Control for Gas Temperature Limits
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Solution Overview
Problem
There is a need for systems and methods to generate electrical power in organic Rankine cycle (ORC) operations near pumping stations or gas processing facilities while maintaining the temperature of compressed gas to prevent volatile condensation and ensure efficient compressor operation.
Innovation Solution
The system includes heat exchangers with bypass valves and flow control devices to regulate the temperature of the gas by diverting the gas flow and adjusting the working fluid flow rate, ensuring the gas remains within a specified operating range to prevent condensation and optimize compressor performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heat is transferred from compressed gas to working fluid in ORC operation, then electrical power is generated, but gas temperature drops below the threshold causing volatiles to condense
Solution Approach 1:
An intermediate heat exchanger is introduced between the compressed gas and the ORC working fluid. This intermediate fluid acts as a mediator, absorbing heat from the compressed gas and then transferring it to the ORC working fluid. This two-stage heat transfer process allows electrical power generation while preventing the gas temperature from dropping below the condensation threshold, thus resolving the contradiction between power generation and temperature maintenance.
2Reliability
If gas temperature is maintained above threshold to prevent condensation, then equipment reliability is improved, but electrical power generation efficiency decreases
Solution Approach 1:
The intermediate fluid serves as a thermal buffer that protects the compressed gas from excessive cooling. By using this mediator, the system can extract maximum heat energy for power generation while ensuring the gas temperature remains above the condensation threshold, thus maintaining equipment reliability without significantly compromising power output.
Solution Approach 2:
The system changes the thermal parameters of the heat transfer process by introducing an intermediate fluid with specific thermal properties. This allows optimization of the heat transfer efficiency while maintaining the gas temperature within the safe operating range, thereby balancing power generation efficiency with equipment reliability.
3Manufacturing precision
If bypass valves and flow control devices are added to regulate gas temperature, then temperature control precision is improved, but system complexity increases
Solution Approach 1:
The intermediate heat exchanger provides inherent temperature control capability through its design parameters (heat transfer area, fluid flow rate). This passive control mechanism reduces the need for complex active control systems with multiple bypass valves and flow control devices, thereby achieving temperature control precision with moderate system 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
This approach effectively generates electrical power while maintaining the gas temperature within the desired range, preventing volatiles from condensing and ensuring efficient compressor operation, thereby maximizing power output and equipment performance.
Implementation Method 1
the heat from the heat source causes the working fluid in the loop to change phases from a liquid to a vapor
Implementation Method 2
The vaporous working fluid may then flow to a gas expander, causing the gas expander to rotate
Implementation Method 3
The rotation of the gas expander may cause a generator to generate electrical power
Implementation Method 4
The condenser or heat sink may cool the working fluid, causing the working fluid to change phase from the vapor to the liquid
Data Source
AI summary
Systems and generating power in an organic Rankine cycle (ORC) operation to supply electrical power. In embodiments, an inlet temperature of a flow of gas from a source to an ORC unit may be determined. The source may connect to a main pipeline. The main pipeline may connect to a supply pipeline. The supply pipeline may connect to the ORC unit thereby to allow gas to flow from the source to the ORC unit. Heat from the flow of gas may cause the ORC unit to generate electrical power. The outlet temperature of the flow of the gas from the ORC unit to a return pipe may be determined. A bypass valve, positioned on a bypass pipeline connecting the supply pipeline to the return pipeline, may be adjusted to a position sufficient to maintain temperature of the flow of gas above a threshold based on the inlet and outlet temperature.