US 7,124,589 B2Granted

Power cogeneration system and apparatus means for improved high thermal efficiencies and ultra-low emissions

OwnerDavid Nearyinventor

Life of this patent

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Abstract

A power cogeneration system employing a partially-open gaseous fluid cycle method and apparatus devices for oxy-fuel combustion conversion of a given hydrocarbon composition fuel's heat-value energy into mechanical or electrical power energy, and transferred useful heat energy, with accompanying large reductions of consumed fuel and undesirable exhaust emissions.

Claims15

Dependent claims

An improved partially-open oxygen-fuel fired turbine powered cogeneration cycle system, with high system thermal efficiencies and low fugitive system exhaust gas emissions for use in generating electric power and for heating of process fluids or gases exclusively using liquid or gaseous hydrocarbon fuel, the cogeneration system comprising:

(a) a gas turbine/generator unit assembly configured to operate within the partially-open cycle to develop a shaft mechanical energy output, the gas turbine power assembly including,
(1) an exhaust gas recycle compressor section configured to compress an inlet supplied re-circulated recycle gas to a higher pressure and temperature prior to the now identified ‘primary re-pressurized recycle gas’ being discharged from the gas turbine power assembly,
(2) one or more combustion chamber assemblies in which supplied controlled streams of fuel, predominant oxygen mixture, cooled primary re-pressured recycle gas are mixed and combusted in the presence of an additional controlled supplied second stream of ‘working motive composition gases’,
(3) a hot gas expander power turbine assembly connected to and downstream of a hot exhaust gas flow conduiting means therein providing an interconnecting supplied stream of highly superheated working motive exhaust gases between the upstream connected combustion chamber assembly's outlet and the downstream connected hot gas expander, the supplied flow of working motive fluid gases then being expanded through the expander turbine assembly to produce an efficient energy conversion into mechanical horsepower transmitted by the expander turbine's output shaft;
(b) an electric generator shaft-driven by supplied mechanical horsepower transmitted through shaft means from the expansion turbine's output shaft, the generator further including,
(1) a shaft connecting means which can include a shaft connected gearbox and shaft couplings,
(2) an electric power output transmitted through conduiting means to a control room module which therein can contain the turbine power assembly's PLC control panel, electrical switchgear, and motor control center, whereby electric power production is controlled and distributed to the power cogeneration facility's electrical grid and/or connected electric utility grid;
(b) a first conduit transporting combustion chamber exhaust gases and having two ends, one end downstream of and connected to the combustion chamber assembly, the other first conduit end connected to the hot gas expander power turbine assembly,
(c) a hot gas expander power turbine assembly configured to accept and expand the higher pressure and higher temperature exhaust gases from the combustion chamber assembly to a lower pressure and lower temperature power turbine exhaust condition to produce mechanical horsepower transmitted by the turbine's output shaft, the turbine exhaust being discharged into a second conduit,
(d) a second conduit transporting the hot gas expander turbine's discharged exhaust gases containing recoverable waste heat, the second conduit having two ends, one end downstream of and connected to the hot gas expander turbine assembly, the second conduit's downstream end having two parallel-positioned branches,
(1) the first branch of the second conduit configured to transport a first portion of the hot gas expansion turbine's discharged gases, the first branch end connected downstream to the inlet of a waste heat recovery unit exchanger,
(2) the second branch of the second conduit configured to transport a second portion of the hot gas expander turbine's discharged gases, the second branch end-connected downstream to the inlet of a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger, the second branch additionally comprising an auxiliary side-branch end-connected to a blind flange closure means;
(e) a waste heat recovery unit exchanger inlet connected to the downstream end of the first branch of the second conduit, the waste heat recovery unit exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied by the first branch of the second conduit to the exchanger unit's two integral parallel contained heat exchanger sections containing supplied inlet flows of primary re-pressurized recycle gases,
(f) a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger inlet connected to the downstream end of the second branch of the second conduit, the first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied through the second branch of the second conduit, the recoverable waste heat transferred to an exchanger fluid exchanger section connected to either process fluid circuit stream flows supplied from a remote source or to steam generation fluid circuit stream flow originating from another source,
(g) a third conduit referred to as a ‘re-circulated exhaust gas manifold’ transporting recirculated exhaust gases, the third conduit having two ends, one end upstream of and connected to a downstream positioned second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the third conduit's upstream end connecting to two parallel-positioned branches,
(1) the first branch of the third conduit configured to transport a first controlled portion of recirculated exhaust gases, the first branch upstream end connected to the outlet of the waste heat recovery unit exchanger,
(2) the second branch of the third conduit configured to transport a second controlled portion of recirculated exhaust gases, the second branch upstream end connected to the outlet of the waste heat recovery steam generator or waste heat recovery process fluid heat exchanger;
(h) a second waste heat recovery steam generator or waste heat recovery process fluid exchanger inlet connected to the third conduit transporting recirculated exhaust gases, the waste heat exchanger configured to transfer recoverable waste heat energy from the third conduit's recirculated exhaust gases to either a process fluid stream flow supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(i) a fourth conduit having two ends and referred to as an exhaust gas distribution manifold which transports recirculated exhaust gases at a reduced temperature, the fourth conduit having two ends, one end upstream connected to the outlet of the second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the fourth conduit's other end connected to a blind flange closure means, the fourth conduit having two side branches,
(1) the first side-branch of the fourth conduit configured to transport and exhaust or vent a controlled lesser mass first flow portion of the exhaust gas distribution manifold's recirculated exhaust gas to atmosphere during the system's operation in a steady-state mode of power generation,
(2) the second side-branch of the fourth conduit configured to transport a second and predominant portion of the total mass flow of the fourth conduit's re-circulated exhaust gases to an inlet of a primary recycle compressor;
(j) a primary recycle gas compressor having an inlet connected to the fourth conduct's second branch's downstream end, the primary recycle gas compressor including,
(1) a compressor input shaft accepting a connected mechanical shaft drive means, the shaft means providing a direct source of power connection to one or more high pressure stages within the hot gas expander turbine,
(2) the primary recycle compressor configured as either a centrifugal or axial type,
(3) a means to increase the pressure and temperature of the compressor's supplied recirculated gases predominantly comprising a mixture of carbon dioxide and water vapor gases of low superheat temperature, and to discharge the gases into a downstream connected fifth conduit;
(k) the fifth conduit configured to transport the primary recycle compressor's discharged flow of primary re-pressurized recycle gases, the fifth conduit having two ends and a side branch, one end downstream of and connected to the primary recycle compressor, and the fifth conduit's side branch downstream end-connected to and transporting a third controlled lesser flow portion of primary re-pressurized recycle gases to the gas inlet of an air-cooled heat exchanger, the fifth conduit's downstream-positioned second end comprising two parallel-positioned end branches,
(1) the first end branch of the fifth conduit configured to transport a controlled first portion of primary re-pressurized recycle gases end-connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's first parallel-positioned gas section therein further transporting the supplied primary re-pressurized recycle gases,
(2) the second end branch of the fifth conduit configured to transport a controlled second portion of primary re-pressurized recycle gases, the second branch end connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's second parallel-positioned gas section therein further transporting primary re-pressurized recycle gases;
(l) a sixth conduit configured to transport a first stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the sixth conduit having two ends, one end downstream of and connected to the outlet header of the first parallel gas section contained within the waste heat gas recovery unit exchanger, the sixth conduit's second end downstream connected to the tertiary zone contained within the combustion chamber assembly,
(m) a seventh conduit configured to transport a second stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the conduit having two ends, one end downstream of and connected to the outlet header of the second parallel gas section contained within the waste heat gas recovery unit exchanger, the seventh conduit second end downstream connected to the primary combustion zone contained within the combustion chamber assembly,
(n) an eighth conduit configured to transport a controlled flow stream of the liquid or gaseous hydrocarbon fuel, the eighth conduit having two ends, one end downstream of and connected to the source of the fuel, the eight conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(o) a ninth conduit configured to transport a controlled flow stream of the predominant oxygen gas mixture, the ninth conduit having two ends, one end downstream of and connected to the source of the predominant oxygen gas mixture, the ninth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(p) a tenth conduit configured to transport a third and lesser portion of reduced temperature primary re-pressurized recycle gases, the tenth conduit having two ends, one end downstream of and connected to the gas outlet of the air-cooled heat exchanger, the tenth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(q) a means for system control and safety monitoring configured to maintain the cited system's generated power performance, control of gas stream flows, and stream gases in their cited superheated gaseous state.

31 more elements

(a) a gas turbine/generator unit assembly configured to operate within the partially-open cycle to develop a shaft mechanical energy output, the gas turbine power unit assembly including,
(1) one or more combustion chamber assemblies in which supplied controlled streams of fuel, predominant oxygen mixture, and cooled primary re-pressured recycle gas are mixed and combusted in the presence of an additional controlled supplied second stream of ‘working motive composition gases’,
(2) a hot gas expander power turbine unit assembly connected to and downstream of a hot exhaust gas flow conduiting means therein providing an interconnecting supplied stream of highly superheated combustion chamber assembly exhaust gases between the upstream connected combustion chamber assembly's outlet and the downstream connected hot gas expander power turbine unit assembly, the supplied flow of working motive fluid gases then being expanded through the hot gas expander power turbine unit assembly to produce an efficient energy conversion into mechanical horsepower transmitted by the expander power-turbine unit's output shaft;
(b) an electric generator shaft-driven by supplied mechanical horsepower transmitted through shaft means from the hot gas expander power turbine unit's output shaft, the generator further including,
(1) a shaft connecting means which can include a shaft connected gearbox and shaft couplings,
(2) an electric power output transmitted through conduiting means to a control room module which therein can contain the turbine power assembly's PLC control panel, electrical switchgear, and motor control center, whereby electric power production is controlled and distributed to the power cogeneration facility's electrical grid and/or connected electric utility grid;
(b) a first conduit conveying combustion chamber exhaust gases and having two ends, one end downstream of and connected to the combustion chamber assembly, the other first conduit end connected to the hot gas expander power turbine unit assembly,
(c) a hot gas expander power turbine unit assembly configured to accept and expand the higher pressure and higher temperature exhaust gases from the combustion chamber assembly to a lower pressure and lower temperature power turbine unit exhaust condition to produce mechanical horsepower transmitted by the power turbine unit's output shaft, the turbine exhaust being discharged into a second conduit,
(d) a second conduit transporting the hot gas expander power turbine unit's discharged exhaust gases containing recoverable waste heat, the second conduit having two ends, one end downstream of and connected to the hot gas expander turbine unit assembly, the second conduit's downstream end having two parallel-positioned branches,
(1) the first branch of the second conduit configured to transport a first portion of the hot gas expansion turbine's discharged gases, the first branch end connected downstream to the inlet of a waste heat recovery unit exchanger,
(2) the second branch of the second conduit configured to transport a second portion of the hot gas expander turbine's discharged gases, the second branch end-connected downstream to the inlet of a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger, the second branch additionally comprising an auxiliary side-branch end-connected to a blind flange closure means;
(e) a waste heat recovery unit exchanger inlet connected to the downstream end of the first branch of the second conduit, the waste heat recovery unit exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied by the first branch of the second conduit to the exchanger unit's two integral parallel contained heat exchanger sections containing supplied inlet flows of primary re-pressurized recycle gases as further described later,
(f) a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger inlet connected to the downstream end of the second branch of the second conduit, the first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied through the second branch of the second conduit, the recoverable waste heat transferred to an exchanger fluid exchanger section connected to either process fluid circuit stream flows supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(g) a third conduit referred to as a ‘re-circulated exhaust gas manifold’ transporting recirculated exhaust gases, the third conduit having two ends, one end upstream of and connected to a downstream positioned second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the third conduit's upstream end connecting to two parallel-positioned branches,
(1) the first branch of the third conduit configured to transport a first controlled portion of recirculated exhaust gases, the first branch upstream end connected to the outlet of the waste heat recovery unit exchanger,
(2) the second branch of the third conduit configured to transport a second controlled portion of recirculated exhaust gases, the second branch upstream end connected to the outlet of the waste heat recovery steam generator or waste heat recovery process fluid heat exchanger;
(h) a second waste heat recovery steam generator or waste heat recovery process fluid exchanger inlet connected to the third conduit transporting recirculated exhaust gases, the waste heat exchanger configured to transfer recoverable waste heat energy from the third conduit's recirculated exhaust gases to either a process fluid stream flow supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(i) a fourth conduit having two ends and referred to as an exhaust gas distribution manifold which transports recirculated exhaust gases at a reduced temperature, the fourth conduit having two ends, one end upstream connected to the outlet of the second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the fourth conduit's other end connected to a blind flange closure means, the fourth conduit having two side branches,
(1) the first side-branch of the fourth conduit configured to transport and exhaust or vent a controlled lesser mass first flow portion of the exhaust gas distribution manifold's recirculated exhaust gas to atmosphere during the system's operation in a steady-state mode of power generation,
(2) the second side-branch of the fourth conduit configured to transport a second and predominant portion of the total mass flow of the fourth conduit's re-circulated exhaust gases to an inlet of a primary recycle compressor;
(j) a primary recycle gas compressor having an inlet connected to the fourth conduct's second branch's downstream end, the primary recycle gas compressor including,
(1) a compressor input shaft accepting a connected mechanical shaft drive means, the shaft means providing either a direct source of power connection to an electric motor or steam turbine driver, or alternately the shaft drive means therein comprising a gear box with couplings that can be end-connected to either the electric motor or the steam turbine driver,
(2) the primary recycle gas compressor configured as either a centrifugal or axial type,
(3) a means to increase the pressure and temperature of the compressor's supplied recirculated gases predominantly comprising a mixture of carbon dioxide and water vapor gases of low superheat temperature, and to discharge the gases into a downstream connected fifth conduit;
(k) the fifth conduit configured to transport the primary recycle compressor's discharged flow of primary re-pressurized recycle gases, the fifth conduit having two ends and a side branch, one end downstream of and connected to the primary recycle compressor, and the fifth conduit's side branch downstream end-connected to and transporting a third controlled lesser flow portion of primary re-pressurized recycle gases to the gas inlet of an air-cooled heat exchanger, the fifth conduit's downstream-positioned second end comprising two parallel-positioned end branches,
(1) the first end branch of the fifth conduit configured to transport a controlled first portion of primary re-pressurized recycle gases end-connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's first parallel-positioned gas section therein further transporting the supplied primary re-pressurized recycle gases,
(2) the second end branch of the fifth conduit configured to transport a controlled second portion of primary re-pressurized recycle gases, the second branch end connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's second parallel-positioned gas section therein further transporting primary re-pressurized recycle gases;
(l) a sixth conduit configured to transport a first stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the sixth conduit having two ends, one end downstream of and connected to the outlet header of the first parallel gas section contained within the waste heat gas recovery unit exchanger, the sixth conduit's second end downstream connected to the tertiary zone contained within the combustion chamber assembly,
(m) a seventh conduit configured to transport a second stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the conduit having two ends, one end downstream of and connected to the outlet header of the second parallel gas section contained within the waste heat gas recovery unit exchanger, the seventh conduit second end downstream connected to the primary combustion zone contained within the combustion chamber assembly,
(n) an eighth conduit configured to transport a controlled flow stream of the liquid or gaseous hydrocarbon fuel, the eighth conduit having two ends, one end downstream of and connected to the source of the fuel, the eight conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(o) a ninth conduit configured to transport a controlled flow stream of the predominant oxygen gas mixture, the ninth conduit having two ends, one end downstream of and connected to the source of the predominant oxygen gas mixture, the ninth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(p) a tenth conduit configured to transport a third and lesser portion of reduced temperature primary re-pressurized recycle gases, the tenth conduit having two ends, one end downstream of and connected to the gas outlet of the air-cooled heat exchanger, the tenth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(q) a means for system control and safety monitoring configured to maintain the cited system's generated power performance, control of gas stream flows, and stream gases in their cited superheated gaseous state.

30 more elements

A partially-open oxygen-fuel fired turbine powered cogeneration cycle system with high system thermal efficiencies and low fugitive system exhaust gas emissions for use in generating electric power and for heating of process fluids or gases through the exclusive use of liquid or gaseous hydrocarbon fuel, the system incorporating supplementary means that enables the system to sustain or to increase a production of heated process fluids and/or steam or hot water, regardless of the partially-open cogeneration system's production of mechanical or electric power, the partially-open cogeneration system including:

(a) a gas turbine/generator unit assembly configured to operate within the partially-open cycle to develop a shaft mechanical energy output, the gas turbine power assembly including,
(1) an exhaust gas recycle compressor section configured to compress an inlet supplied re-circulated recycle gas to a higher pressure and temperature prior to the now identified ‘primary re-pressurized recycle gas’ being discharged from the gas turbine power assembly,
(2) one or more combustion chamber assemblies in which supplied controlled streams of fuel, predominant oxygen mixture, cooled primary re-pressured recycle gas are mixed and combusted in the presence of an additional controlled supplied second stream of ‘working motive composition gases’,
(3) a hot gas expander power turbine assembly connected to and downstream of a hot exhaust gas flow conduiting means therein providing an interconnecting supplied stream of highly superheated working motive exhaust gases between the upstream connected combustion chamber assembly's outlet and the downstream connected hot gas expander, the supplied flow of working motive fluid gases then being expanded through the expander turbine assembly to produce an efficient energy conversion into mechanical horsepower transmitted by the expander turbine's output shaft;
(b) an electric generator shaft-driven by supplied mechanical horsepower transmitted through shaft means from the expansion turbine's output shaft, the generator further including,
(1) a shaft connecting means which can include a shaft connected gearbox and shaft couplings,
(2) an electric power output transmitted through conduiting means to a control room module which therein can contain the turbine power assembly's PLC control panel, electrical switchgear, and motor control center, whereby electric power production is controlled and distributed to the power cogeneration facility's electrical grid and/or connected electric utility grid;
(b) a first conduit transporting combustion chamber exhaust gases and having two ends, one end downstream of and connected to the combustion chamber assembly, the other first conduit end connected to the hot gas expander power turbine assembly,
(c) a hot gas expander power turbine assembly configured to accept and expand the higher pressure and higher temperature exhaust gases from the combustion chamber assembly to a lower pressure and lower temperature power turbine exhaust condition to produce mechanical horsepower transmitted by the turbine's output shaft, the turbine exhaust being discharged into a second conduit,
(d) a second conduit transporting the hot gas expander turbine's discharged exhaust gases containing recoverable waste heat, the second conduit having two ends, one end downstream of and connected to the hot gas expander turbine assembly, the second conduit's downstream end having two parallel-positioned branches,
(1) the first branch of the second conduit configured to transport a first portion of the hot gas expansion turbine's discharged gases, the first branch end connected downstream to the inlet of a waste heat recovery unit exchanger,
(2) the second branch of the second conduit configured to transport a second portion of the hot gas expander turbine's discharged gases, the second branch end-connected downstream to the inlet of a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger, the second branch additionally comprising an auxiliary side-branch end-connected to flange-connecting conduit supplying a transported flow of supplementary oxygen-fuel fired heater-burner exhaust gases;
(e) a waste heat recovery unit exchanger inlet connected to the downstream end of the first branch of the second conduit, the waste heat recovery unit exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied by the first branch of the second conduit to the exchanger unit's two integral parallel contained heat exchanger sections containing supplied inlet flows of primary re-pressurized recycle gases as further described later,
(f) a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger inlet connected to the downstream end of the second branch of the second conduit, the first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied through the second branch of the second conduit, the recoverable waste heat transferred to an exchanger fluid exchanger section connected to either process fluid circuit stream flows supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(g) a third conduit referred to as a ‘re-circulated exhaust gas manifold’ transporting recirculated exhaust gases, the third conduit having two ends, one end upstream of and connected to a downstream positioned second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the third conduit's upstream end connecting to two parallel-positioned branches,
(1) the first branch of the third conduit configured to transport a first controlled portion of recirculated exhaust gases, the first branch upstream end connected to the outlet of the waste heat recovery unit exchanger,
(2) the second branch of the third conduit configured to transport a second controlled portion of recirculated exhaust gases, the second branch upstream end connected to the outlet of the waste heat recovery steam generator or waste heat recovery process fluid heat exchanger;
(h) a second waste heat recovery steam generator or waste heat recovery process fluid exchanger inlet connected to the third conduit transporting recirculated exhaust gases, the waste heat exchanger configured to transfer recoverable waste heat energy from the third conduit's recirculated exhaust gases to either a process fluid stream flow supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(i) a fourth conduit having two ends and referred to as an exhaust gas distribution manifold which transports recirculated exhaust gases at a reduced temperature, the fourth conduit having two ends, one end upstream connected to the outlet of the second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the fourth conduit's other end downstream flanged connected to a later described eleventh conduct, the fourth conduit having two side branches,
(1) the first side-branch of the fourth conduit configured to transport and exhaust or vent a controlled lesser mass first flow portion of the exhaust gas distribution manifold's recirculated exhaust gas to atmosphere during the system's operation in a steady-state mode of power generation,
(2) the second side-branch of the fourth conduit configured to transport a second and predominant portion of the total mass flow of the fourth conduit's re-circulated exhaust gases to an inlet of a primary recycle compressor;
(j) a primary recycle gas compressor having an inlet connected to the fourth conduct's second branch's downstream end, the primary recycle gas compressor including,
(1) a means to increase the pressure and temperature of the compressor's supplied recirculated gases predominantly comprising a mixture of carbon dioxide and water vapor gases of low superheat temperature and to discharge the gases into a downstream connected fifth conduit,
(2) a compressor input shaft accepting a connected mechanical shaft drive means, the shaft means providing either a direct source of power connection to one or more high pressure stages within a hot gas expander turbine, or alternately the shaft drive means therein comprising a gear box with couplings that can be end-connected to either an electric motor or a steam turbine,
(3) a primary recycle gas compressor configuration of either the centrifugal or axial type;
(k) the fifth conduit configured to transport the primary recycle compressor's discharged flow of primary re-pressurized recycle gases, the fifth conduit having two ends and a side branch, one end downstream of and connected to the primary recycle compressor, and the fifth conduit's side branch downstream end-connected to and transporting a third controlled lesser flow portion of primary re-pressurized recycle gases to the gas inlet of an air-cooled heat exchanger, the fifth conduit's downstream-positioned second end comprising two parallel-positioned end branches,
(1) the first end branch of the fifth conduit configured to transport a controlled first portion of primary re-pressurized recycle gases end-connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's first parallel-positioned gas section therein further transporting the supplied primary re-pressurized recycle gases,
(2) the second end branch of the fifth conduit configured to transport a controlled second portion of primary re-pressurized recycle gases, the second branch end connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's second parallel-positioned gas section therein further transporting primary re-pressurized recycle gases;
(l) a sixth conduit configured to transport a first stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the sixth conduit having two ends, one end downstream of and connected to the outlet header of the first parallel gas section contained within the waste heat gas recovery unit exchanger, the sixth conduit's second end downstream connected to the tertiary zone contained within the combustion chamber assembly,
(m) a seventh conduit configured to transport a second stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the conduit having two ends, one end downstream of and connected to the outlet header of the second parallel gas section contained within the waste heat gas recovery unit exchanger, the seventh conduit second end downstream connected to the primary combustion zone contained within the combustion chamber assembly,
(n) an eighth conduit configured to transport a controlled flow stream of the liquid or gaseous hydrocarbon fuel, the eighth conduit having two ends, one end downstream of and connected to the source of the fuel, the eight conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(o) a ninth conduit configured to transport a controlled flow stream of the predominant oxygen gas mixture, the ninth conduit having two ends, one end downstream of and connected to the source of the predominant oxygen gas mixture, the ninth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(p) a tenth conduit configured to transport a third and lesser portion of reduced temperature primary re-pressurized recycle gases, the tenth conduit having two ends, one end downstream of and connected to the gas outlet of the air-cooled heat exchanger, the tenth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(q) an eleventh conduit configured to transport recirculated exhaust gases at a reduced temperature, the fourth conduit having two ends, one end upstream connected to the flanged end outlet of the fourth conduit, referred to as the ‘exhaust distribution manifold’, the eleventh conduct's second end comprising downstream first and second parallel conduit branches,
(1) the first branch end downstream connected to an inlet of a first exhaust recycle gas blower of the speed-control motor-driven type, the first branch of the eleventh conduit incorporating a control valve,
(2) the second branch end downstream connected to an inlet of a second exhaust recycle gas blower of the speed-control motor-driven type, the second branch of the eleventh conduit incorporating a control valve;
(r) a twelfth conduit having two ends, one end downstream of and connected to the outlet of the first exhaust recycle gas blower, the twelfth conduit's second end having downstream communication with the partial-premix subassembly contained within a oxygen-fuel fired combustion heater-burner assembly,
(s) a thirteenth conduit having two ends, one end downstream of and connected to the outlet of the second exhaust recycle gas blower, the thirteenth conduit's second end having downstream communication with the tertiary zone contained within the oxygen-fuel fired combustion heater-burner assembly,
(t) the exhaust recycle gas blowers configured to re-pressurize the blower inlet supplied and slightly superheated recirculated exhaust gases to a increased pressure level required for the gases transport through conduits thirteen and fourteen having end-connection to the downstream-positioned oxygen-fuel fired heater-burner assembly, and
(q) a means for system control and safety monitoring configured to maintain the cited system's generated power performance, control of gas stream flows, and stream gases in their cited superheated gaseous state.

37 more elements

Dependencies are inferred from the claim text.

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Abstract

(a) a gas turbine/generator unit assembly configured to operate within the partially-open cycle to develop a shaft mechanical energy output, the gas turbine power assembly including,
(1) an exhaust gas recycle compressor section configured to compress an inlet supplied re-circulated recycle gas to a higher pressure and temperature prior to the now identified ‘primary re-pressurized recycle gas’ being discharged from the gas turbine power assembly,
(2) one or more combustion chamber assemblies in which supplied controlled streams of fuel, predominant oxygen mixture, cooled primary re-pressured recycle gas are mixed and combusted in the presence of an additional controlled supplied second stream of ‘working motive composition gases’,
(3) a hot gas expander power turbine assembly connected to and downstream of a hot exhaust gas flow conduiting means therein providing an interconnecting supplied stream of highly superheated working motive exhaust gases between the upstream connected combustion chamber assembly's outlet and the downstream connected hot gas expander, the supplied flow of working motive fluid gases then being expanded through the expander turbine assembly to produce an efficient energy conversion into mechanical horsepower transmitted by the expander turbine's output shaft;
(b) an electric generator shaft-driven by supplied mechanical horsepower transmitted through shaft means from the expansion turbine's output shaft, the generator further including,
(1) a shaft connecting means which can include a shaft connected gearbox and shaft couplings,
(2) an electric power output transmitted through conduiting means to a control room module which therein can contain the turbine power assembly's PLC control panel, electrical switchgear, and motor control center, whereby electric power production is controlled and distributed to the power cogeneration facility's electrical grid and/or connected electric utility grid;
(b) a first conduit transporting combustion chamber exhaust gases and having two ends, one end downstream of and connected to the combustion chamber assembly, the other first conduit end connected to the hot gas expander power turbine assembly,
(c) a hot gas expander power turbine assembly configured to accept and expand the higher pressure and higher temperature exhaust gases from the combustion chamber assembly to a lower pressure and lower temperature power turbine exhaust condition to produce mechanical horsepower transmitted by the turbine's output shaft, the turbine exhaust being discharged into a second conduit,
(d) a second conduit transporting the hot gas expander turbine's discharged exhaust gases containing recoverable waste heat, the second conduit having two ends, one end downstream of and connected to the hot gas expander turbine assembly, the second conduit's downstream end having two parallel-positioned branches,
(1) the first branch of the second conduit configured to transport a first portion of the hot gas expansion turbine's discharged gases, the first branch end connected downstream to the inlet of a waste heat recovery unit exchanger,
(2) the second branch of the second conduit configured to transport a second portion of the hot gas expander turbine's discharged gases, the second branch end-connected downstream to the inlet of a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger, the second branch additionally comprising an auxiliary side-branch end-connected to a blind flange closure means;
(e) a waste heat recovery unit exchanger inlet connected to the downstream end of the first branch of the second conduit, the waste heat recovery unit exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied by the first branch of the second conduit to the exchanger unit's two integral parallel contained heat exchanger sections containing supplied inlet flows of primary re-pressurized recycle gases,
(f) a first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger inlet connected to the downstream end of the second branch of the second conduit, the first waste heat recovery steam generator or waste heat recovery process fluid heat exchanger configured to transfer recoverable waste heat energy from the turbine exhaust gases supplied through the second branch of the second conduit, the recoverable waste heat transferred to an exchanger fluid exchanger section connected to either process fluid circuit stream flows supplied from a remote source or to steam generation fluid circuit stream flow originating from another source,
(g) a third conduit referred to as a ‘re-circulated exhaust gas manifold’ transporting recirculated exhaust gases, the third conduit having two ends, one end upstream of and connected to a downstream positioned second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the third conduit's upstream end connecting to two parallel-positioned branches,
(1) the first branch of the third conduit configured to transport a first controlled portion of recirculated exhaust gases, the first branch upstream end connected to the outlet of the waste heat recovery unit exchanger,
(2) the second branch of the third conduit configured to transport a second controlled portion of recirculated exhaust gases, the second branch upstream end connected to the outlet of the waste heat recovery steam generator or waste heat recovery process fluid heat exchanger;
(h) a second waste heat recovery steam generator or waste heat recovery process fluid exchanger inlet connected to the third conduit transporting recirculated exhaust gases, the waste heat exchanger configured to transfer recoverable waste heat energy from the third conduit's recirculated exhaust gases to either a process fluid stream flow supplied from a remote source or to a steam generation fluid circuit stream flow originating from another source,
(i) a fourth conduit having two ends and referred to as an exhaust gas distribution manifold which transports recirculated exhaust gases at a reduced temperature, the fourth conduit having two ends, one end upstream connected to the outlet of the second waste heat recovery steam generator or waste heat recovery process fluid exchanger, the fourth conduit's other end connected to a blind flange closure means, the fourth conduit having two side branches,
(1) the first side-branch of the fourth conduit configured to transport and exhaust or vent a controlled lesser mass first flow portion of the exhaust gas distribution manifold's recirculated exhaust gas to atmosphere during the system's operation in a steady-state mode of power generation,
(2) the second side-branch of the fourth conduit configured to transport a second and predominant portion of the total mass flow of the fourth conduit's re-circulated exhaust gases to an inlet of a primary recycle compressor;
(j) a primary recycle gas compressor having an inlet connected to the fourth conduct's second branch's downstream end, the primary recycle gas compressor including,
(1) a compressor input shaft accepting a connected mechanical shaft drive means, the shaft means providing a direct source of power connection to one or more high pressure stages within the hot gas expander turbine,
(2) the primary recycle compressor configured as either a centrifugal or axial type,
(3) a means to increase the pressure and temperature of the compressor's supplied recirculated gases predominantly comprising a mixture of carbon dioxide and water vapor gases of low superheat temperature, and to discharge the gases into a downstream connected fifth conduit;
(k) the fifth conduit configured to transport the primary recycle compressor's discharged flow of primary re-pressurized recycle gases, the fifth conduit having two ends and a side branch, one end downstream of and connected to the primary recycle compressor, and the fifth conduit's side branch downstream end-connected to and transporting a third controlled lesser flow portion of primary re-pressurized recycle gases to the gas inlet of an air-cooled heat exchanger, the fifth conduit's downstream-positioned second end comprising two parallel-positioned end branches,
(1) the first end branch of the fifth conduit configured to transport a controlled first portion of primary re-pressurized recycle gases end-connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's first parallel-positioned gas section therein further transporting the supplied primary re-pressurized recycle gases,
(2) the second end branch of the fifth conduit configured to transport a controlled second portion of primary re-pressurized recycle gases, the second branch end connected downstream to the inlet gas header of the earlier cited waste heat recovery unit exchanger's second parallel-positioned gas section therein further transporting primary re-pressurized recycle gases;
(l) a sixth conduit configured to transport a first stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the sixth conduit having two ends, one end downstream of and connected to the outlet header of the first parallel gas section contained within the waste heat gas recovery unit exchanger, the sixth conduit's second end downstream connected to the tertiary zone contained within the combustion chamber assembly,
(m) a seventh conduit configured to transport a second stream of invention defined ‘working motive fluid’ composition gases of increased temperature, the conduit having two ends, one end downstream of and connected to the outlet header of the second parallel gas section contained within the waste heat gas recovery unit exchanger, the seventh conduit second end downstream connected to the primary combustion zone contained within the combustion chamber assembly,
(n) an eighth conduit configured to transport a controlled flow stream of the liquid or gaseous hydrocarbon fuel, the eighth conduit having two ends, one end downstream of and connected to the source of the fuel, the eight conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(o) a ninth conduit configured to transport a controlled flow stream of the predominant oxygen gas mixture, the ninth conduit having two ends, one end downstream of and connected to the source of the predominant oxygen gas mixture, the ninth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(p) a tenth conduit configured to transport a third and lesser portion of reduced temperature primary re-pressurized recycle gases, the tenth conduit having two ends, one end downstream of and connected to the gas outlet of the air-cooled heat exchanger, the tenth conduit's second end having downstream flow communication to the partial premixer subassembly within the combustion chamber assembly,
(q) a means for system control and safety monitoring configured to maintain the cited system's generated power performance, control of gas stream flows, and stream gases in their cited superheated gaseous state.

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