Packed-Bed Regenerator for Low-Cost Compressed-Air Energy Storage
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Solution Overview
Problem
Current waste heat recovery, combined heat and power, and electricity storage technologies face challenges such as high capital and maintenance costs, environmental impact, and inefficiencies due to the use of conventional heat exchangers and regenerators, which are expensive and require significant materials and maintenance.
Innovation Solution
The implementation of a Thermal Energy Storage system using a packed bed of natural granular material, such as rocks and ores, which eliminates the need for conventional heat exchangers and regenerators by utilizing the granular material as the heat transfer surface, reducing capital costs and environmental footprint, and allowing for efficient waste heat recovery and electricity storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional heat exchangers with fins, plates and tubes are used, then heat transfer efficiency is improved, but capital cost and environmental footprint increase due to high-grade steel material requirements
Solution Approach 1:
The patent extracts the heat transfer function from conventional metal heat exchanger components (fins, plates, tubes) and relocates it to a regenerator system using ceramic bricks or packed bed materials. This separation eliminates the need for extensive high-grade steel structures while maintaining heat transfer effectiveness through alternative materials and mechanisms.
Solution Approach 2:
The regenerator system uses cheaper materials such as ceramic bricks or packed bed materials instead of expensive high-grade steel. These materials can be replaced more easily and at lower cost, reducing the economic burden and environmental footprint associated with material production and disposal.
2Use of energy by moving object
If conventional heat exchangers are used, then heat transfer performance is improved, but maintenance costs and operational complexity increase due to fouling issues
Solution Approach 1:
The regenerator system employs porous materials such as ceramic bricks with internal channels or packed bed materials. These porous structures provide extensive surface area for heat transfer while being inherently resistant to fouling, as the porous structure prevents deposit accumulation and allows for easier cleaning or replacement when needed.
3Productivity
If regenerators with honeycomb or cubic bricks are used, then waste heat recovery efficiency is improved, but capital cost increases due to expensive brick and structure construction
Solution Approach 1:
The patent changes the material parameters from expensive conventional bricks to more economical alternatives such as packed bed materials or different ceramic compositions. It also optimizes the structural parameters by using simpler support structures and more efficient packing arrangements, thereby maintaining heat recovery efficiency while reducing capital costs.
4Productivity
If packed beds operating in series are used, then heat recovery performance is improved, but design complexity and piping requirements increase
Solution Approach 1:
The patent merges multiple packed bed units into a single integrated regenerator structure or combines the charging and discharging functions within a single unit. This consolidation maintains the series operation benefits for heat recovery performance while eliminating the need for complex external piping and valving systems that would be required for separate series-operated units.
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 provides a cost-effective, environmentally friendly, and efficient method for waste heat recovery and electricity storage, reducing fuel consumption and greenhouse emissions while offering a swift payback and long lifespan, suitable for various scales from residential to utility applications.
Implementation Method 1
a packed bed of granular material are used to form a packed bed inside a channel. The heat source passes through the channel to heat up the packed bed.
Implementation Method 2
The heat source passes through the channel to heat up the packed bed. Later, the cold source enters the channel to capture heat from the packed bed.
Implementation Method 3
a compressor, an expander and an electrical machine. The compressor pressurizes the working fluid
Implementation Method 4
The pressurized working fluid is then directed through the expander to an outlet, generating mechanical power
Data Source
AI summary
The present disclosure is directed to an energy storage and retrieval system for the generation of power. A compressor (301) pressurizes ambient air. The pressurized air flow passes through a thermal energy regenerator (280) for thermal energy storage and retrieval and onto an expander (302) for generating mechanical power. The compressor (301) and the expander (302) are coupled to an electrical machine (304) through a common shaft (303). The regenerator (280) comprises one or more Thermal Energy Storage (TES) units which can be coupled to one another in a parallel configuration. The TES units comprise a thermal medium for the storage and retrieval of thermal energy.