Stirling Engine Thermal Recovery for Pyrometallurgical Plants

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Solution Overview

Problem

Existing methods for recovering thermal energy in pyro-metallurgical processes face challenges due to high corrosive gases and the complexity of transporting hot gases for centralized heat conversion, leading to infrastructure complications and inefficiencies.

Innovation Solution

A distributed system utilizing a heat transfer chamber connected to a Stirling engine and mechanical-electrical converter, which captures thermal energy from pyro-metallurgical processes and converts it into electrical energy, reducing the need for transporting hot gases and minimizing contact with corrosive substances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If hot gases are directed to a concentration point for centralized heat conversion, then thermal energy can be converted into electricity using traditional techniques, but the complexity of transporting hot gases increases due to corrosive properties and pressure requirements

Engineering Contradiction:

Improvethermal energy recoveryVSAvoidgas transportation infrastructure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The system divides the centralized heat conversion approach into multiple distributed conversion units (heat exchangers and generators) placed at different locations within the plant. Each unit independently converts thermal energy from hot gases into electrical energy locally, eliminating the need for complex centralized gas transportation infrastructure while maintaining effective thermal energy recovery

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If devices are installed in gas transportation pipelines to recover heat, then thermal energy can be captured, but corrosive gases cause incrustations and metal-inlays that complicate heat transference

Engineering Contradiction:

Improvethermal energy recoveryVSAvoidcorrosive gas damage

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The system introduces heat exchangers as intermediary devices that enable thermal energy transfer from hot gases to working fluid without direct contact between the corrosive gases and the generation equipment. This intermediary approach allows effective heat recovery while protecting the system from corrosive damage and incrustations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system extracts only the thermal energy from the hot gases through heat exchangers, separating the useful energy component from the harmful corrosive properties. The extracted thermal energy is then converted into electrical energy, while the depleted hot gases are discharged without requiring further contact with extraction devices

Inventive Principle:

Principle #2Taking out (Extraction)

3Loss of energy

If traditional steam turbine systems are used for heat conversion, then thermal energy can be converted into electricity, but the infrastructure requirements and system complexity increase

Engineering Contradiction:

Improvethermal energy conversionVSAvoidsteam transportation infrastructure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical steam turbine infrastructure with simpler heat exchanger and generator units that directly convert thermal energy into electrical energy. This substitution eliminates the need for steam generation, steam transportation pipelines, and large-scale turbine systems, reducing overall infrastructure complexity while maintaining effective thermal energy conversion

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

The system effectively generates over 2 kW of electricity per subsystem, providing efficient and economical distributed power generation by converting residual thermal energy into usable electrical energy, reducing infrastructure complexity and corrosive issues.

Implementation Method 1

A heat transfer chamber (1) contained in a cylindrical flanged spool (4) for one or more cameras (1) which captures the heat from the source (5)

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The heat is transferred to a type Alpha, Beta, Gamma (or derivatives) Stirling engine (2) which is responsible for generating the mechanical movement of an axle

Methodology Applied

Scientific EffectStirling cycle: Stirling Cycle

Implementation Method 3

A mechanical-electrical converter (3) converts the mechanical energy into electrical energy that is transported into a concentrator hub (6)

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10539045B2System for recovering thermal energy produced in pyrometallurgical process plants or similar, to convert same into, or generate, electrical energy

Publication Date: 2020.01.21 AMBAR SA

AI summary

The invention relates to a system for recovering thermal energy produced in pyrometallurgical process plants and converting said thermal energy into electrical energy. The system is characterised in that it comprises at least one heat transfer chamber (1) comprising a gas interface section (1A), for separating the subsystem from the corrosive power of, and incrustation generated by, the gases from the heat source or duct (5). The system also comprises a section (1B) for connecting to a Stirling engine (2), which is a thermal engine and which, by means of the cyclical compression and expansion of a gaseous working fluid, at different temperature levels, produces a net conversion of thermal energy into mechanical energy.