Description
Title of Invention: A STEAM GENERATION SYSTEM FOR
THERMAL AND RELATED POWER APPLICATIONS USING
STOICHIOMETRIC OXYHYDROGEN FUEL STOCK
Technical Field
[1] The invention relates to the field of steam-driven power technologies in general, and more specifically to the sub-fields of thermal power generation of electricity for utility distribution to retail electricity customers; electric power generation for the railroad locomotive industry; and turbine-driven propulsion systems for marine and aeronautical applications. In parallel, the invention relates to the field of liquid rocket advanced technology, insofar as the system utilizes hydrogen and oxygen fuel components to generate the heat of vaporization integral to the internal dynamics of the invention. Background Art
[2] The use of super-heated steam under pressure to drive a steam-engine arguably
ushered in the industrial revolution. The generation of electric power using steam- driven turbines operatively associated with generators is the most common power plant configuration worldwide. Railroad locomotives most commonly derive motive power from electric motors driven by diesel-powered generators. Early motive transportation systems, as well as industrial manufacturing systems were contrived using piston- driven flywheels powered by steam generation.
[3] To this day, modern, state-of-the-art thermal power generation systems utilize ultra super-critical steam temperatures and pressures to drive multi-stage, reheat turbine systems in operative communication with a generator set. While the natural gas turbine-generator system has taken a beachhead within the power generation industry, the great bulk of power generation worldwide relies on a system dependent on the combustion of carboniferous fossil-fuels to heat the outside of a boiler tank filled with water, in order to generate steam. Every commercial steam-turbine application has an optimum temperature and pressure range, recommended by its manufacturer; to achieve optimum performance efficiency, the manufacturer recommends that the steam supply to the turbine be maintained in this range.
[4] From a cold start, fossil-fuel-fired thermal power generation systems require from four- to six-hours to generate steam at sufficient temperature and pressure to power their turbines. Recent advances in natural gas-fired auxiliary system research and development have resulted in fast-cycling capability, enabling start-up times under an hour; Siemens, AG recently announced start-up times under forty-minutes using its proprietary Benson technology in parallel with a conventional coal-fired system.
[5] Inherent to the current art of steam generation technology, and characteristic of the boiling of water either by applying heat to a single boiler tank as in the conventional art, or to a matrix of copper tubing as in the Benson technology, a significant portion of the heat energy generated in the combustion process is lost to the exhaust system that ports the products of combustion to the atmosphere for disposal.
[6] The combustion of stoichiometric mixtures of hydrogen and oxygen gases produces the most powerful oxidative reaction known to physical chemistry; hydrogen contains the highest Gross Colorific Value of any know fuel, at 141,790 kiloJoules per kilogram. At atmospheric pressure the combustion reaction burns at approximately 5,165 degrees -Fahrenheit. As this event occurs, the sole product of combustion is steam, albeit at a temperature beyond the temperature-range recommended by any current turbine manufacturer. This temperature is in fact beyond the upper limits of endurance of any known metal, effectively rendering a motive flow body comprised only of the directly-generated products of stoichiometric oxyhydrogen combustion useless for thermal power generation purposes.
[7] In 1971, a report was prepared for the Rocketdyne Division of North American
Rockwell entitled, A Role for Liquid Rocket Advanced Technology in the Electric Power Crisis, by Escher Technology Associates in response to early interest in the application of hydrogen as a fuel to generate steam for power applications. An informal inquiry made of one recent Rocketdyne engineer indicated that research into the use of hydrogen fuel to generate steam for power generation applications was subsequently abandoned due to the excessively exogenous nature of the reaction, and the subsequent system inefficiencies resulting from the need to dissipate such large quantities of heat to ensure turbine-blade survival.
[8] Edward V. Somers was an engineer for Westinghouse Electric Corporation, when he was granted a patent in 1979 for his vision of using hydrogen combustion as a source of steam generation for power applications; preliminary research has failed to reveal evidence that a commercial application of his concept was ever developed.
[9] The current worldwide concern over global warming, and the effects of greenhouse gas emissions into the environment as a by-product of coal combustion, has stimulated heated discussion in many quarters regarding the need for the world to supplant fossil- fuel bases power generation systems with renewable energy generation systems. While renewable energy generation is growing in response to the concern, the ability to store off-peak production of renewable energy in order to maintain a reliable supply to utilities during periods of peak-demand does not yet exist. As the years pass the world's supply of fossil fuels will one-day be exhausted, necessitating humanity's transition to non-fossil-fuel based power generation systems. The use of hydrogen fuel provides perhaps the only combustive alternative to carboniferous fossil-fuel sources.
] A stoichiometric fuel mixture is one in which the volumes of each component are combined in quantities consistent with the exact number of molecules required to effect an exact chemical reaction. In the case of the invention, the fuel mixture consists of stoichiometric hydrogen and oxygen gases in the ratio of two-molar- volumes of hydrogen gas to one-molar- volume of oxygen gas, at Standard Temperature and Pressure. The use of this specific fuel-mix formulation serves dual purposes of generating maximum exogenous heat release, while eliminating the generation of harmful secondary by-products of combustion normally associated with the
combustion of hydrogen fuel in nitrogen-containing air.
Disclosure of Invention
] In the preferred embodiment, the invention consists of a boiler unit of conventional design, to which has been adapted a power head unit, fitted with strategically-located, appropriately-threaded flow-receiving ports, to receive flows of hydrogen gas fuel- stock, oxygen gas fuel-stock, and water for vaporization, located on the exterior surface of the power head unit, each port into the interior of the combined boiler unit and power head unit, thus comprising a sealed assembly, terminating in an array of nozzles of specific size and function, strategically located on the interior of said power head unit, such as to facilitate the operation of the invention.
] The power head unit features a threaded socket into which an ignition glow-plug has been installed such that its distal terminus is located at the focal point of the combined fuel- stock flow as directed by the nozzles of each component gas, and the proximal end of which is connected through an appropriately-rated ignition switching device to a twelve- volt, direct-current power supply of appropriate amperage, in order to initiate combustion within the boiler unit of the invention during a cold-start. An externally- supplied ignition source is necessary only to initiate the combustion reaction within the boiler unit; once it has been initiated, the combustion process within the boiler unit requires only the continuous flow of additional fuel-stock components to be self- sustaining.
] The invention utilizes stoichiometric oxyhydrogen fuel-stock combustion within the interior of the boiler unit to generate sufficient heat to vaporize a flow of water sufficient to drive a conventional steam-turbine generator system, raising the temperature of the resultant motive body of steam to a level consistent with optimum steam conditions at the high-pressure steam inlet. The heat required to vaporize the water- flow within the boiler unit is drawn from the existent motive body of steam generated directly as the product of combustion of the fuel-mixture, thereby simultaneously lowering the temperature of the body of steam generated directly, and raising the temperature of the body of steam generated by the vaporization of system- water flow within the boiler unit.
[14] In the process of steam generation, the only product of combustion is directly- generated steam. The invention requires no exhaust of any kind, thereby eliminating a major source of energy loss, and thereby system inefficiency common to the background art, and resulting in an efficiency in the conversion of Gross Colorific Value to steam energy that is beyond the capability of any existing technology, thereby constituting an advantageous effect of the invention with respect to the background art. Brief Description of the Drawings
[15] Figure 1 represents the preferred embodiment of the invention as claimed in Claim 1, and demonstrates the interaction of the various components of the system claimed, in the operation of the invention in the preferred embodiment, operating in automatic mode. The system management computer system operating a dedicated process-control software program (M) directs the flow of water to the boiler unit (O) by controlling automated valve-systems located within the water-flow control system (G), through which is ported water from the main water storage system (C), the pressure of which is raised above the pressure range recommended by the manufacturer of the target application at the steam inlet, by an auxiliary booster-pump system (D), and ported to the water- flow receiving points (P) located on the exterior surface of the power head unit (N), bolted to the boiler unit by way of a pair of matching flanges (S), from which point the flow of water is then dispersed via fog-head nozzles located within the interior of the power head unit, the resulting nebulized flow being thus discharged into the interior of the boiler unit, where it is vaporized into steam by the combustion of stoichiometric oxyhydrogen fuel-mixture at the most distal point of ignition glow-plug (L). In addition, the process-control software directs the flow of hydrogen gas fuel- stock to the boiler unit by controlling automated valve-systems located within the hydrogen gas-flow control system (H), through which is ported hydrogen gas fuel- stock from the main hydrogen fuel-stock storage system (A), the pressure of which is raised above the pressure range recommended by the manufacturer of the target application at the steam inlet, by an auxiliary booster-pump system (E), and ported to the hydrogen gas fuel-flow receiving point (R) located on the exterior surface of the power head unit (N), from which point the flow of hydrogen gas fuel-stock is then directed by a high-flow nozzle towards a focal point within the interior of the boiler unit at the most distal point of the ignition glow-plug, where it combines with its compliment of oxygen gas fuel-stock in forming the stoichiometric oxyhydrogen fuel-mixture used by the system. In addition, the process-control software directs the flow of oxygen gas fuel-stock to the boiler unit by controlling automated valve-systems located within the oxygen gas-flow control system (I), through which is ported oxygen gas fuel-stock from the main oxygen fuel-stock storage system (B), the pressure of which is raised above the pressure range recommended by the manufacturer of the target application at
the steam inlet, by an auxiliary booster-pump system (F), and ported to the oxygen gas fuel-flow receiving points (Q) located on the exterior surface of the power head unit (N), from which point the flow of oxygen gas fuel-stock is then directed by multiple high-flow nozzles towards a focal point within the interior of the boiler unit at the most distal point of the ignition glow-plug, where it combines with its compliment of hydrogen gas fuel-stock in forming the stoichiometric oxyhydrogen fuel-mixture used by the system. The process-control software receives digital temperature information measured at a point just proximal to the steam inlet of the target application, from a redundant thermistor-array (TS) rated for the range of steam motive flow temperature and pressure conditions at the target inlet, as recommended by the manufacturer of the target application, in order to regulate the ratio of water-flow to the flows of the components of the stoichiometric oxyhydrogen fuel-mixture in the process of steam generation, and thereby optimizing the temperature of the motive body of steam for the operation of the specific target application. The process-control software also receives digital pressure information measured at a point just proximal to the steam inlet of the target application, from a redundant transducer-array (PS) rated for the range of steam motive flow temperature and pressure conditions at the target inlet, as recommended by the manufacturer of the target application, in order to regulate the total flow volumes of each of the components contributory to the steam generation process occurring within the boiler unit, thereby optimizing the pressure of the motive body of steam for the operation of the specific target application.
[16] Figure 2 represents a typical presentation of the power head unit of the invention in the preferred embodiment. Located around the distal terminus of the power head unit, mounting flange (D) is shown with a plurality of bolt-holes (E) the configuration of which matches an identical mounting flange located around the proximal terminus of the boiler unit, such that the two components may be bolted together, forming a single tank assembly. The hydrogen gas fuel-stock receiving-port (A) is shown in the center of the dome portion of the power head unit, directing the flow of hydrogen gas fuel- stock along the central axis of the power head unit by a discrete gas-nozzle, and thus along the central axis of the boiler unit as well. The oxygen gas fuel-stock receiving ports (B) are shown surrounding the hydrogen gas fuel- stock receiving port, and are located at points lateral to the central axis of the power head unit, such that the axis of flow of each component of the total oxygen gas fuel- stock flow is directed by a discrete gas-nozzle to a point along the central axis of the boiler unit, at which the ignition glow-plug terminates at its most distal point. The ignition glow-plug is threaded into the threaded glow-plug socket (F), bored and tapped at a location and angle such that its terminal point locates at the focal point of fuel-stock gas-flow.
Water flow into the system is received at receiving-ports (C), through which water is
ported to high-flow fog-head nozzles designed to generate large volumes of fog-mist, thereby rendering the flow of water nebulized in such a way as to maximize the efficiency of the vaporization of that flow into steam by the combustion of fuel- stock within the boiler unit.
[17] The actual number of receiving ports (A), (B), and (C), and the actual number of flange bolt-holes (E) appearing on an functional incarnation of the invention will vary according to the volume of steam generation required by a specific target application, the receiving-port configuration and the bolt-hole configuration shown in the drawing representing the smallest configuration, capable of driving turbines small enough to generate auxiliary electric power in commercial aircraft systems. Gigawatt- scale thermal power generation systems will require multiple custom-manufactured gas-flow and water nozzles, the configuration of which will be custom-designed by system engineers in response to the requirements of specific target applications, as well as many more bolt-holes of a size and configuration dictated by the requirements of the specific target application, as determined by those same system engineers.
[18] Figure 3 represents the power head unit represented by Figure 2, modified according to Claim 2, so as to represent the inclusion of a plurality of receiving-ports (F) to receive re-pressurized post-stage discharge steam from a primary or intermediate turbine-stage, within a multi-stage reheat-type thermal power generation system. The ignition glow-plug socket (G) found in Figure 3, appeared previously in Figure 2, represented by designator (F).
Modes for Carrying Out the Invention
[19] Operation of the system of the invention in the preferred embodiment from a cold- start, requires that the circuit between the ignition-power source and the ignition glow- plug located within the power head unit is completed via the ignition switching device prior to the initiation of component flows into the interior of the boiler unit of the invention.
[20] Normal operation of the ignition system having been verified, a flow of system- water equal in pounds per hour to the steam- volume requirement to drive a specific steam- driven application, is ported through the power head unit from a water supply system consistent with the background art pertaining to the storage of system-supply-water in conventional thermal power generation applications via a water distribution system consistent with the background art pertaining to the distribution of system- supply- water in conventional thermal power generation applications, and into the interior of the boiler unit of the invention, at a pressure greater than the manufacturer's recommended range for pressure at the specific application's steam inlet. Within the interior of the boiler unit of the invention, high-flow fog-head nozzles located on the inner portion of the power head unit disperse the incoming water-flow in a nebulizing
manner, facilitating a rapid vaporization into steam.
[21] Once water enters the interior of the boiler unit, flows of oxygen-gas and hydrogen- gas fuel-mixture components may be ported from independent gas supply systems consistent with the background art pertaining to the bulk storage of hydrogen and oxygen gases, via independent gas distribution systems consistent with the background art pertaining to the distribution of hydrogen and oxygen gases for industrial applications, by way of independent high-flow gas nozzles located on the inner portion of the power head unit of the invention, at a pressure greater than the manufacturer's recommended range for pressure at the appropriate steam inlet. Within the interior of the boiler unit of the invention, high-flow gas nozzles located on the inner portion of the power head unit combine the two gas fuel-mixture components homogeneously, in preparation for combustion which occurs immediately upon contact with the heated element of the ignition glow-plug, instantaneously generating steam. Upon ignition, the power supply to the glow-pug is interrupted via the ignition switching device.
[22] Regulation of the temperature of the steam motive body driving the target application is effected by adjusting the flow of water in proportion to the original products of combustion, in turn a function of the total flow of fuel-mixture into the boiler unit. Regulation of system temperature can thus be achieved by adjusting the ratio of water injectate to total fuel-mix gas-flows, while maintaining the ratio of hydrogen-flow to oxygen-flow throughout the operational range of the invention, in order to maximize fuel efficiency. Regulation of system pressure can then be achieved by adjusting the total flow of the three flow components in order to increase or decrease the total amount of steam generated in a given period of time, while maintaining the ratio at which the temperature of the motive body of steam is optimal.
[23] In one mode for carrying out the invention, the system can be operated under manual control, using feedback provided by temperature- and pressure-sensing units located immediately proximal to the steam inlet, and within the steam path between the invention and the target application, providing temperature and pressure information to a human system operator. Simply opening and closing supply valves by hand will effectively regulate the flows of the three necessary components: hydrogen gas, oxygen gas, and water in order to effect adjustments in system temperature and pressure, thereby achieving optimum motive body conditions at the steam inlet of any given application.
[24] In another mode for carrying out the invention, the system can also be operated under automatic control, using digital sensor/sender units in place of those sensing units that would otherwise be utilized in a manually-controlled system, those sensor/sender units similarly immediately proximal to the steam inlet, and within the steam path between the invention and the target application, providing temperature and pressure in-
formation in the form of digital data to a system management computer system operating a dedicated process-control software program to enable the process-control software to control the operation of the invention. The process-control software analyzes the constant flow of feedback data, in turn generating operative electronic signals to servo-controlled automated valves in order to actuate said automated valves, thereby making moment-to-moment adjustments to the flows of the three necessary components: hydrogen gas, oxygen gas, and water in order to effect adjustments in system temperature and pressure, thereby achieving optimum motive body conditions at the steam inlet of any given application.
Industrial Applicability
[25] The invention can be deployed in a multi-stage, reheat-cycle type thermal power generation system, whereby a fully-functional automatic- valve equipped system- module of the invention generates a steam supply for its stage, fully independently of multiple similar system- modules, each generating the steam supply for a different stage at temperature and pressure conditions unique to that stage, without the need for fossil- fuels, thereby representing another advantageous effect of the invention with respect to the background art.
[26] The invention can be deployed in a typical Rankine-cycle thermal power generation system as the primary source of steam generation, the resulting system considered closed with respect to the water used by the system for its operation, and thereby consistent with the background art with respect to Rankine-cycle thermal power generation systems. The post-cycle condensate that is returned by such a system to the system- water holding tanks will include both the system- water vaporized by the invention in the steam-generation process, and the water generated as the product of combustion generated by the invention as well, actually resulting in a net water gain to the system overall, representing another advantageous effect of the invention with respect to the background art.
[27] When hydrogen and oxygen fuel-stock gases are generated by electrolysis from the main system water supply of a Rankine-cycle thermal power generation system, and Rankine-cycle system utilizes the invention as its primary source of steam generation, that Rankine-cycle thermal power generation system thus improved, remains closed with respect to water consumption, the Law of Conservation of Matter ensuring that the water required to generate hydrogen and oxygen fuel- stock gases during the electrolysis process is returned to the source from which it originally came, with the exception of such minor leakage as is inherent to modern steam-turbine design. The system thus expanded, therefore requires only an external supply of electric power to operate, representing another advantageous effect of the invention with respect to the background art.
[28] Provided sufficient commercial electrolysis units are available to supply fuel-stock gases in quantities sufficient to operate the system on a gigawatt- scale, and provided sufficient quantities of off-peak intermittent renewable energy generation are available to operate those commercial electrolysis units to the capacity required to operate the system on a gigawatt-scale, the invention is a vital component in a system capable of storing utility-scale quantities of renewable electric power indefinitely, and then capable of generating renewable-sourced electric power on demand, representing another advantageous effect of the invention with respect to the background art.
[29] Inherent to the design of the invention, even ultra super-critical conditions can be achieved at the high-pressure inlet of any commercial steam-turbine application within seconds of start-up, enabling the generation of gigawatt-scale electric power in the time it takes for the target system to spool up to maximum output speed. The application of the invention as the sole-source steam-generating component within a Rankine-cycle thermal power generation system, or as an auxiliary component in parallel with, or tangential to a conventional steam-generation boiler component in an otherwise conventional thermal power generation system, will enable participation by those systems in the ancillary services energy market, with system start-up times consistent with true rolling reserve, yet without the fuel cost of maintaining turbine- ready steam conditions, representing another advantageous effect of the invention with respect to the background art.
[30] Deviating from the preferred embodiment in that such an application requires the use of the power head component of the invention without the accompanying balance of the invention as described in the preferred embodiment, said power head component, separate of the balance of the invention as described in the preferred embodiment can be retrofitted directly to a primary boiler unit, said boiler unit comprising a component in an otherwise conventional thermal power generation system in an alternate manner, that being achieved by cutting a round opening into the most distal end of said boiler unit, at a point above the highest functional water level within said boiler unit, to which a flange could be welded into place such that said welded boiler flange mates to the flange of the power head unit in the same manner as said power head unit might be mated with the boiler unit of the invention in the preferred embodiment, and thereby providing a method by which the existing primary boiler could function in the same manner as the boiler unit of the invention, thus altered to provide such a system with the capacity to generate steam in a manner consistent with the invention, in parallel with the original configuration of such a system. In such a retrofit application, significantly more fuel is required to achieve temperature and pressure conditions consistent with those achieved by the invention in the preferred embodiment, due to the absorption of heat by the body of system- water located within the thus-altered
boiler unit in such a retrofit application. However, that additional heat lost to the body of water in proximity to the generated motive body of steam will raise the temperature of that body of water much more rapidly than might be possible by heating that body of water using the primary fossil-fuel-fired heating system alone, thereby potentially shortening the start-up time of an otherwise conventional system, and representing another advantageous effect of the invention with respect to the background art.
[31] The invention will operate an electric generator unit of a size consistent with those currently providing electric power for railroad locomotive applications, and can be installed within the spatial constraints of those diesel generator systems currently installed in modern railroad locomotives. Railroad trains have the added convenience of the ability to include tank cars containing the three components required by the system, hydrogen, oxygen, and water in bulk quantities, thereby placing those components in the immediate proximity of the invention, thus located within the locomotive. Such a locomotive contributes no carbon-based emissions to the environment, and provides a viable alternative to the industry's current dependence on petroleum-based fuel, representing another advantageous effect of the invention with reference to the background art.
[32] The invention can drive a turbine of the type commonly in operative communication with a propeller, in order to impart inertia to a vehicle or craft operating on land, on or under water, or in the air, providing for an alternative to fossil-fuel based turboprop- type engine systems, representing another advantageous effect of the invention with reference to the background art.
[33] The invention can drive a turbine of the type commonly in operative communication with a fan, in order to impart Newtonian-type reactive inertia to a vehicle or craft operating on land, on or under water, or in the air, providing for an alternative to fossil- fuel based turbofan or turbojet engine systems, representing another advantageous effect of the invention with reference to the background art.
[34] While other applications of the invention are envisioned, and may come to
commercial development in the future, they are not claimed herein; however the general applicability of the invention to any commercial application requiring a motive body of steam to provide motive power, and the use of the invention in any such application is considered by the inventor to be a use protected under such grant or grants as may be afforded to the inventor by this Request.