BACKGROUND OF THE INVENTION
This invention relates generally to apparatuses and methods for injecting
fluids and more specifically to an injector and associated method for injecting
combustion fluids into a combustion chamber.
Description of Related Art
The combustion of carbon-based compounds, or carbonaceous fuels, is
widely used for generating kinetic and electrical power. In one typical electric
generation system, a carbonaceous fuel such as natural gas is mixed with an oxidizer
and combusted in a combustion device called a gas generator. The resulting combusted
gas is discharged to, and used to rotate, a turbine, which is mechanically coupled
to an electric generator. The combusted gas is then discharged to one or more additional
combustion devices, called reheaters, where the combusted gas is mixed with additional
fuel and/or oxidizer for subsequent combustion. The reheaters, which typically generate
pressures lower than those found in the gas generator, discharge the reheated gas
to one or more turbines, which are also coupled to the electric generator.
The combustion in the gas generator and reheaters results in high
temperatures and pressures. In some low-emission systems, pure oxygen is used as
the oxidizer to eliminate the production of nitric oxides (NOx) and sulfur oxides
(SOx) that typically result from combustion with air. Combustion of carbonaceous
gases with pure oxygen can generate combustion temperatures in excess of 5000° F.
Such extreme conditions increase the stress on components in and around the combustion
chambers, such as turbine blades and injectors. The stress increases the likelihood
of failure and decreases the useful life of such components.
Injectors are used to inject the combustion components of fuel and
oxidizer into the gas generator and the combusted gas, fuel, and/or oxidizer into
the reheaters. Because of their position proximate to the combustion chamber, the
injectors are subjected to the extreme temperatures of the combustion chamber. The
injectors may also be heated by the passage of preheated combustion components therethrough.
Failure of the injectors due to the resulting thermal stress caused by overheating
increases operating costs, increases the likelihood of machine downtime, and presents
an increased danger of worker injury and equipment damage.
One proposed injector design incorporates a mixer for combining a
coolant with the fuel before the fuel is combusted. For example, U.S. Patent No.
6,206,684 to Mueggenburg describes an injector assembly 10 that includes
two mixers 30, 80. The first mixer 30 mixes an oxidizer with a fuel,
and the second mixer 80 mixes coolant water with the prior mixed fuel and
oxidizer. The mixture then flows through a face121 to a combustion chamber
12 for combustion. The coolant water reduces the temperature of combustion
of the fuel and, thus, the stress on system components. One danger presented by
such a design is the possibility of "flash back," or the combustion flame advancing
from the combustion chamber into the injector. Flash back is unlikely in an injector
outlet that has a diameter smaller than the mixture's "quenching distance." Thus,
flash back can be prevented by limiting the size of the injectors. Undesirably,
however, a greater number of small injectors is required to maintain a specified
flow rate of the combustion mixture. The increased number of injectors complicates
the assembly. Small injectors are also typically less space-efficient because the
small injectors require more space on the face than would a lesser number of large
injectors that achieve the same flow rate. Space on the face is limited, so devoting
more space to the injectors leaves less space for other uses, such as for mounting
other components. The small injectors are also subject to further complications
due to their size. For example, small passages and outlets in the injectors can
become blocked by particulates present in the fuel, oxidizer, or coolant. Thus,
the reactants must be carefully filtered before passing through the injector. Moreover,
typical reheaters are not designed to accommodate liquids, so the coolant water
cannot be used in them.
In another proposed oxygen-fed combustion cycle, the gas generator
is eliminated and gaseous combustion components are provided for initial combustion
in a gas turbine combustor. The gas turbine combustor, sometimes also called a reheater,
is similar to the reheater of the conventional cycle described above in that all
of the inputs are in gaseous form. Cooling is achieved by diluting the combustion
components with recirculated flue gas comprising steam and carbon dioxide. The flue
gas dilutes the oxygen content in the combustion device and thus the combustion
temperature. One such cycle, described as "Combined Cycle Fired with Oxygen," is
discussed in "New Concepts for Natural Gas Fired Power Plants which Simplify the
Recovery of Carbon Dioxide," by Bolland and Saether, Energy Conversion Management,
Vol. 33, No. 5-8, pp. 467-475 (1992). Advantageously, this cycle effectively reduces
combustion temperatures, and the elimination of the gas generator simplifies the
system. No special turbines are required for receiving hot gases from a gas generator,
and the gas turbine combustor can discharge to a turbine that is designed for use
with a conventional reheater. However, the gas turbine combustor is incompatible
with the injectors designed for conventional gas generators, which provide inadequate
flow rates and do not provide recirculated gases to the combustion chamber. Further,
injectors for gas generators are typically designed to operate at the higher operating
pressures found in a gas generator and are inoperable or inefficient when used in
a lower pressure gas turbine combustor or reheater. Nor is the gas turbine combustor
compatible with injectors designed for conventional reheaters, because the gas turbine
combustor requires a lower pressure drop across the injectors than that provided
in conventional reheaters.
Moreover, as the availability and price of various combustion fuels
change, it is sometimes desirable to change the type of combustion fuel that is
used. However, because different combustion fuels have different characteristics,
such as heating values, conventional injectors must be adjusted or replaced in order
to provide efficient service with the different fuels. Thus, changing the type of
fuel that is combusted in a system requires servicing the injectors and thereby
interrupting service, reducing output, and increasing costs.
Thus, there exists a need for an apparatus and method for injecting
fluid components of combustion into a combustion chamber of a combustion device.
The apparatus and method should provide for injection of a recirculated gas to limit
the temperature of the injector to decrease thermal stress, likelihood of failure,
and operating costs. The injectors should be compatible with combustion devices
that inject gaseous coolants, including reheaters, and should provide efficient
injection and mixture of combustion gases of various types and heating values.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an injector and an associated method
for injecting and mixing gases, comprising a carbonaceous fuel and oxygen, into
a combustion chamber of a combustion device. The injector may have an annular space
proximate to its perimeter, through which a recycled mixture of steam and carbon
dioxide can be injected to limit the combustion temperature, thereby decreasing
thermal stress on components in and around the combustion chamber. Further, the
injector has different jets, which can be used to separately inject different combustion
fuels. Thus, the same injector can permit different combustion fuels to be altematingly
injected, each under the proper conditions. The injector is compatible with combustion
devices that inject only gaseous fluids, including a reheater. The injector can
be used in a reheater that recombusts a combusted gas that is discharged from a
gas generator and turbine. Alternatively, the injectors can be used in a reheater
that is the initial combustion device in a power generation cycle.
According to one aspect of the present invention, there is provided
an injector for injecting combustion fluids into a combustion chamber. The injector
includes an injector body that defines an injector face facing the combustion chamber,
a main bore, and at least one main jet extending from the injector face to the main
bore. A first plurality of fuel jets extend from the injector face and are fluidly
connected to a first fuel inlet, typically by means of a first fuel manifold. Similarly,
a second plurality of fuel jets extend from the injector face and are fluidly connected
to a second fuel inlet, typically by means of a second fuel manifold. The central
axis of each of the fuel jets defines a converging angle relative to one of the
main jets such that fluid flowing from the fuel manifolds into the combustion chamber
through the fuel jets impinges on a stream of fluid flowing from the respective
main jet. The converging angle may be between about 10° and 45° such that convergence
occurs in the combustion chamber. According to other aspects of the invention, a
center of each of the main jets is located at least about 4 inches from the centers
of the other main jets, and each of the main jets has a diameter of at least about
1 inch.
The main bore may be fluidly connected to a source of oxidizing fluid
substantially free of nitrogen and sulfur, the first fuel manifold may be fluidly
connected to a first source of fuel, including hydrogen and carbon monoxide, and
the second fuel manifold may be fluidly connected to a second source of fuel, including
methane. Each of the first and second manifolds comprise an annular space that extends
circumferentially around at least one of the main jets. In another embodiment, each
of the second fuel jets may be smaller in cross sectional area than each of the
first fuel jets. As such the fuel jets may be tailored to the delivery requirements
necessary for the particular type of fuel to be injected via the fuel jets.
In one advantageous embodiment, the injector also includes a first
sleeve that defines an interior space. The injector body is positioned in the interior
space such that a first annular space is defined between the injector body and the
first sleeve. In one aspect of the invention, the first annular space is fluidly
connected to a source of a recycle gas comprising steam and carbon dioxide. In another
aspect, the injector includes a recycle gas inlet and a second sleeve which defines
a second annular space between the first and second sleeves. The first sleeve defines
at least one first sleeve aperture fluidly connecting the first annular space to
the second annular space, and the second sleeve defines at least one second sleeve
aperture fluidly connecting the second annular space to the recycle gas inlet. In
a further aspect, the injector includes a circumferential passage that extends along
the perimeter of the second sleeve and fluidly connects the second annular space
to the recycle gas inlet so that gas enters the recycle gas inlet and flows generally
in a first direction in the second annular space and a second, generally opposite,
direction in the first annular space. According to another aspect of the invention,
the injector body also defines a coolant chamber that is configured to receive and
circulate a coolant fluid.
The present invention also provides a method of injecting combustion
fluids into a combustion chamber. At least one stream of oxidizing fluid, including
oxygen and substantially free of nitrogen and sulfur, is injected into the combustion
chamber. The oxidizing fluid may be injected in streams located with at least about
4 inches between their centers, and each stream may have a diameter of at least
about 1 inch. A first combustion fuel and a second combustion fuel are altematingly
injected through fuel jets into the combustion chamber and impinged on the stream
of oxidizing fluid. The fuel can be injected through a manifold defining an annular
space that extends circumferentially around at least one of the main jets, and can
be injected at a converging angle between about 10° and 45° relative to the stream
of oxidizing fluid such that convergence occurs in the combustion chamber. The method
also includes combusting the fuel with the oxygen. In one aspect of the present
invention, a recycle gas including steam and carbon dioxide is injected into the
combustion chamber through a first annular space at an inside perimeter of the combustion
chamber, for example, to limit the combustion temperature to about 4000° F. In another
aspect, a coolant fluid is circulated through at least one coolant chamber in an
injector body.
Thus, the present invention provides an injector and method for injecting
combustion fluids, for example, into a gas generator or reheater, through a first
and second plurality of fuel jets. Different combustion fluids can be injected through
fuel jets and combusted efficiently, thereby increasing the versatility of the injector
and decreasing the necessity of replacing or modifying the injector. Additionally,
the injector and method limit the temperature of the injector and decrease the thermal
stress on the components, thereby decreasing the likelihood of failure and the operating
costs.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Having thus described the invention in general terms, reference will
now be made to the accompanying drawings, which are not necessarily drawn to scale,
and wherein:
- Figure 1 is a partial cut-away isometric view of an injector according to the
present invention;
- Figure 2 is another partial cut-away isometric view of the injector of Figure
1;
- Figure 3 is an elevation view of the injector of Figure 1;
- Figure 4 is a partial cross-sectional view of the injector of Figure 3 as seen
from line 4-4; and
- Figure 5 is a schematic of a power generation cycle that is compatible with
the injector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter
with reference to the accompanying drawings, in which preferred embodiments of the
invention are shown. This invention may, however, be embodied in many different
forms and should not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey the scope of the invention to those skilled
in the art. Like numbers refer to like elements throughout.
There is shown in Figure 1 an injector 10 according to the
present invention, which is used to inject fluids into a combustion chamber
100. The injector 10 has an injector body 14 with an injector
face 12 that is oriented towards the combustion chamber 100. The injector
body 14 also includes a plurality of jets 20, 32, 52 that are fluidly
connected to one or more inlets 18, 34, 54 as discussed further below. The
fluids enter the injector body 14 through the inlets 18, 34, 54 and are injected
into the combustion chamber through the jets 20, 32, 52. A first sleeve
80, which is generally shown as a hollow cylindrical tube, surrounds the
injector body 14 and defines part of the combustion chamber 100. A
first annular space 82 is defined between the outside of the injector body
14 and the inside of the first sleeve 80. A recycle gas inlet
84, which is fluidly connected to the first annular space 82, supplies
a recycle gas through the annular space 82 to the inside perimeter of the
first annular space 82 and the combustion chamber 100.
The combustion that results in the combustion chamber 100 is
a combustion of a fuel and oxygen. The fuel can be, for example, a carbonaceous
gas such as methane, ethane, propane, or a mixture of hydrocarbons and may be derived
from crude oil or a biomass fuel. Two advantageous carbonaceous fuels are methane
and a synthesis gas, or syngas, which includes hydrogen and carbon monoxide. The
carbonaceous fuel can be in liquid, gaseous, or combined phases. The oxygen is supplied
in an oxidizing fluid. In one advantageous embodiment of the invention, the carbonaceous
fuel and the oxygen are supplied in gaseous form and substantially free of nitrogen
and sulfur. In the context of this patent, the phrase "substantially free of nitrogen
and sulfur" indicates a combined content of less than 0.1 percent nitrogen and sulfur
by weight and preferably less than 0.01 percent. Oxygen can be separated from atmospheric
air according to methods known in the art and may include trace gases, such as argon.
The combustion of fuel and oxygen in the combustion chamber
100 generates a combusted gas and causes an increase in temperature and gas
volume and a corresponding increase in pressure. The combusted gas is discharged
to a power take-off device, such as a turbine, and useful energy is generated for
use or storage. For example, the turbine can be coupled to an electric generator,
which is rotated to generate electricity.
As shown in Figure 2, the oxidizing fluid is supplied through the
main inlet 18 to a main bore 16 of the injector body 14. The
oxidizing fluid flows from the main bore 16 through the injector face
12 and into the combustion chamber 100 via a plurality of main jets
20. Six main jets 20 are shown in the illustrated embodiment, but
any number of jets 20 may be provided. The diameter of the main jets
20 is chosen so that predetermined flow rates of oxidizing fluid through
the main jets 20 can be achieved by supplying the oxidizing fluid to the
main inlet 18 at predetermined pressures higher than the pressure in the
combustion chamber 100. In one advantageous embodiment, each of the main
jets 20 has a diameter at the injector face12 of at least about 1
inch, and a center of each of the main jets 20 is at least about 4 inches
from the centers of the other main jets 20. The oxidizing fluid flows into
the combustion chamber 100 as streams emitted from the main jets
20, which, in the illustrated embodiment, are generally oriented parallel
to a central axis that extends lengthwise through the main bore 16 of the
injector body 14.
A first fuel enters the first fuel inlet 34 and flows through
a first fuel downcomer 38 to a first fuel manifold 30. The first fuel
manifold 30 is an interior space defined by the injector body 14 that
fluidly connects the downcomer 38, and hence the first fuel inlet
34, to the first fuel jets 32. As shown in Figures 2 and 4, the first
fuel manifold 30 of the illustrated embodiment comprises both an annular
chamber 42 that extends circumferentially around the main jets
18 and a central chamber 40 located central to the main jets
18. The central chamber 40 and the annular chamber 42 are fluidly
connected by tunnels (not shown) that are generally perpendicular to the main jets
18. It is appreciated that there are numerous alternative configurations
of the first fuel manifold 30, the downcomer 38, and the first fuel
inlet34 for fluidly connecting the first fuel source to the first fuel jets
34.
The first fuel is discharged from the first fuel jets 32 into
the combustion chamber 100. In the illustrated embodiment, 24 first
fuel jets are provided, with 4 located at spaced intervals around each of the main
jets 20, though any number of first fuel jets 32 can be provided.
Each of the first fuel jets 32 is configured such that a central axis of
each first fuel jet 32 converges with a central axis of the respective main
jet 20 in the combustion chamber 100 so that fuel discharged from
the first fuel jets 32 impinges on the stream of oxidizing fluid flowing
from the respective main jet20.
Similar to the first fuel, a second fuel enters the second fuel inlet
54 and flows through a second fuel downcomer (not shown) to a second fuel
manifold 50. The second fuel manifold 50 is an interior space defined
by the injector body 14 that fluidly connects the second fuel downcomer,
and hence the second fuel inlet 54, to the second fuel jets 52. As
shown in Figure 4, the second fuel manifold 50 of the illustrated embodiment
comprises 6 annular chambers, each extending circumferentially around one of the
main jets 20. The annular chambers are fluidly connected to one another by
tunnels (not shown) that extend in a direction generally perpendicular to the main
jets 20. In the illustrated embodiment, 24 second fuel jets are provided,
with 4 located at spaced intervals around each of the main jets 20. Each
of the second fuel jets 52 is also configured such that a central axis of
each second fuel jet 52 converges with the central axis of the respective
main jet 20 in the combustion chamber 100 so that fuel discharged
from each of the second fuel jets 52 into the combustion chamber
100 impinges on the stream of oxidizing fluid flowing from the respective
main jet 20.
The converging angle between each of the fuel jets 32, 52 and
the respective main jet 20 affects the extent to which the fuel is mixed
with the oxidizing fluid as well as the location in the combustion chamber
100 at which the fuel and oxidizing fluid are sufficiently mixed for combustion
to occur. The distance between each of the fuel jets 32, 52 and the respective
main jet 20 also affects the mixing of the fuel and oxidizing fluid. If the
mixing and the combustion of the fuel and oxidizing fluid occur close to the injector
face 12, the injector face 12 and the injector 10 may be more
subject to the heat generated by the combustion and require additional cooling.
In one advantageous embodiment of the present invention, each of the first and second
fuel jets 32, 52 defines a converging angle relative to one of the main jets
20 of between about 10° and 45°. In another embodiment, the fuel jets are
configured such that fuel flowing from the fuel jets 32, 52 impinges on the
stream of oxidizing fluid flowing from the respective main jet 20 in a region
located within about 2 inches of the injector face 12. Thus, the fuel that
is discharged through the jets 32, 52 mixes with the oxidizing fluid and
facilitates a uniform combustion of the fuel. However, the fuel is not mixed and
combusted so close to the jets 20, 32, 52 that the combustion occurs in the
injector 10.
The arrangement of the first and second fuel jets 32, 52 is
shown in Figure 3. It is appreciated that any number of first and second fuel jets
32, 52 can be provided, including a single first and second jet
32, 52 for each main jet 20. Preferably, the first and second jets
32, 52 are arranged symmetrically about the main jets 20, but asymmetric
arrangements are also possible. Also, while jets 32, 52 in the illustrations
have a round cross section, other shapes are also possible. For example, one or
both of the first and second fuel jets 32, 52 can be a single jet that defines
a slot extending circumferentially around all or part of the main jets
20. Further, Figure 3 illustrates the difference in cross-sectional size
between the first fuel jets 32 and the second fuel jets 52. Although
any size of jets 32, 52 can be used, the size of the jets 32, 52 preferably
is chosen in consideration of the heating value of the fuels, the operating pressure,
and the number of jets 32, 52. For example, the diameters of the jets
32, 52 can be calculated according to the required mass flow rate of fuel
for the desired combustion and the necessary momentum of the fuel into the combustion
chamber100 for proper mixing with the oxidizing fluid. The required mass
flow rate of different fuels may vary according to the heating values of the fuels,
though it may be desirable to inject the different fuels with similar momentum to
ensure proper mixing of each fuel with the oxidizing fluid. Thus, the differently
sized jets 32, 52 allow the use of different fuels while still maintaining
the same rate of heat generation and the same momentums of the fuels. For example,
in the embodiment shown in Figure 3, the first fuel jets 32 are approximately
three times the diameter of the second fuel jets52. Thus, if the first fuel
jets 32 are used for a first fuel that has a heating value of approximately
one-third of the heating value of the second fuel, the amount of heat generated
by the two fuels will be similar if the two fuels have equivalent densities and
are injected at similar momentums.
The relative sizes of the injector 10 and jets 20, 32, 52
are also shown in Figure 3. In one embodiment, the diameter of the injector
10 is about 12.5 inches wide, and the diameters of the fuel jets
32, 52 are at least about 0.1 inch. The main jets 20 are about one
inch in diameter at the injector face 12, and a center of each of the main
jets 20 is at least about 4 inches from the centers of the other main jets
20.
In one advantageous embodiment, the second fuel jets 52 are
used to inject natural gas, which is approximately 90 percent methane. The first
fuel jets 32 are used to inject a synthesis comprising carbon monoxide, hydrogen,
and carbon dioxide. The synthesis gas can be generated by using steam and oxygen
for the gasification of petcoke, which is about 90 percent solid carbon by weight,
moisture, and ash. The first fuel and the second fuel can be injected simultaneously,
but according to one advantageous embodiment of the present invention, only one
of the first and second gases is injected at a time. Thus, fuel gas that is used
for combustion can be changed without changing the injector 10 and can be
chosen according to other criteria such as availability, price, and efficiency.
Additionally, it is understood that additional jets can be provided to further improve
the versatility of the injector 10. For example, the injector 10 can
include a third set of fuel jets (not shown) with a corresponding fuel manifold
and inlet, thus allowing a third fuel source to be independently supplied to the
combustion chamber 100. The configuration of each of the first and second
plurality of fuel jets 32, 52, and any additional fuel jets, can be tailored
to inject a particular type of gas under particular conditions. For example, the
number and size of the first fuel jets 32 and the spacing and angle between
the first jets 32 and the main jets 20 can be tailored specifically
for the injection of a particular fuel through the first jets 32, for example,
a synthesis gas comprising hydrogen and carbon monoxide. Similarly, the second fuel
jets 52, and any additional sets of fuel jets, can be configured for other
fuels such as methane or natural gas.
As shown in Figures 1 and 2, a second sleeve 90 circumferentially
surrounds the first sleeve 80, defining a second annular space
94 between the two sleeves 80, 90. The second annular space
94 is fluidly connected to a circumferential passage 86, which extends
around the second sleeve 90, and to a diluent gas inlet 84. The diluent
gas inlet 84 is fluidly connected to a source of diluent gas (not shown).
Thus, the diluent gas enters the diluent gas inlet 84 and flows through the
circumferential passage 86 and into the second annular space 94 through
the second sleeve apertures92. The diluent gas flows through the second annular
space 94 in a direction that is generally opposite to the direction of the
oxidizing fluid and the fuel in the jets 20, 32, 52. From the second annular
space 94, the diluent gas flows through a plurality of first sleeve apertures
88 that fluidly connect the second annular space 94 and the first
annular space 82. Once in the first annular space 82, the diluent
gas reverses its direction of flow and flows toward the combustion chamber
100, where it is then mixed with and becomes part of the combustion gas in
the combustion chamber 100. The diluent gas dilutes the combustion gas and
moderates the temperature of the combustion. Although liquid diluents can also be
used, a gaseous diluent is preferred. Various diluent gases can be used including,
in one advantageous embodiment, a recycle gas from a turbine in which the combustion
gas from the combustion chamber100 is expanded. The recycle gas comprises
steam and carbon dioxide. The degree of cooling that is provided by the recycle
gas depends on the combustion temperature, the flow rate of the gases into the combustion
chamber 100, the temperature of the recycle gas, and the composition of the
recycle gas. Preferably, the temperature in the combustion chamber 100 is
reduced to at least about 4000° F, and most preferably to about 2000° F.
The injector 10 can also be cooled by a coolant fluid such
as water that flows through a coolant chamber (not shown). The coolant chamber is
an interior gap defined by the injector body 10, which is fluidly connected
to a coolant inlet 72 and a coolant outlet 74. Coolant fluid is pumped
into the coolant inlet 72 and discharged from the coolant outlet
74. It will be appreciated that various configurations of coolant chambers
can be used as are known in the art.
In one advantageous embodiment of the present invention, the injector
10 is used to inject gases into a combustion chamber 100 that is compatible
only with gases. For example, the injector 10 can be used to inject a carbonaceous
gas, gaseous oxygen, and a mixture of steam and carbon dioxide into a reheater that
is used to combust gases in an electricity generation plant. The reheater can recombust
an exhaust gas that is discharged from a gas generator and turbine, as discussed
in U.S. Patent Application No. [...], titled "LOW-EMISSION, STAGED-COMBUSTION POWER
GENERATION," filed concurrently herewith and the entirety of which is incorporated
herein by reference. Alternatively, the reheater can be the initial combustion device
in a power generation cycle as shown, for example, in Figure 5.
The power generation cycle shown in Figure 5 includes a reheater
140 that receives oxygen and a carbonaceous gas, for example, a synthesis
gas, for combustion. The oxygen is generated in an air separation unit
110, which removes at least most of the nitrogen from the air and discharges
the oxygen substantially free of nitrogen and sulfur. The nitrogen can be removed
using a cryogenic process, as will be understood by one of ordinary skill in the
art. In that case, the cryogenic nitrogen that is derived from the process can be
sold or used in subsequent cooling processes in the power generation cycle. In other
embodiments, the oxidizing fluid can be derived from sources other than the air
separation unit 110, for example, from a storage tank, delivery pipeline,
or other oxygen generation apparatuses that are known in the art.
In the illustrated embodiment of Figure 5, the synthesis gas, or syngas,
is generated in a syngas generator 120. The syngas generator 120 is
shown for illustrative purposes only, and it is understood that syngas can be obtained
by other processes known in the art. Further, combustion gases other than syngas
can be used. For example, the combustion gas can comprise methane, ethane, propane,
or a mixture of hydrocarbons and may be derived from crude oil or a biomass fuel.
The oxidizing fluid is compressed by compressors 112, 114 and
delivered to the reheater 140 and the syngas generator 120. The syngas
generator 120 includes a gasifier 126 that also receives water and
petroleum coke, or petcoke, from water and petcoke sources 122, 124. The
petcoke is gasified in the gasifier 126 to form an exhaust gas that includes
the syngas, as known in the art. The syngas comprises hydrogen, carbon monoxide,
and carbon dioxide, and in this embodiment specifically comprises about 50 percent
carbon monoxide, 34.2 percent hydrogen, and 15.8 percent carbon dioxide. The syngas
is passed through a high temperature heat recoverer 128 and a low temperature
heat recoverer 130, both of which are thermally coupled to a heat recovery
steam generator 150, described below.
The syngas is then discharged to the reheater 140. The syngas
enters the reheater 140 through the injectors 10, as do the oxygen
and a diluent. The diluent is a recycle gas that includes steam and carbon dioxide.
The diluent dilutes the oxygen in the reheater, limiting the temperature in the
reheater 140. The product gas is combusted in the combustion chamber
100 of the reheater 140 to form a combusted gas or combustion product,
which is discharged to a primary turbine 142. The combustion product is expanded
in the primary turbine 142 and energy is generated by rotating an electric
generator 146 that is mechanically or hydraulically coupled to the primary
turbine 142. The combustion product from the primary turbine 142 is
discharged to the heat recovery steam generator 150 where the combustion
product is cooled. The heat recovery steam generator 150 acts as a heat exchanger
by using thermal energy of the combustion product discharged from the primary turbine
142 to heat an intermediate exhaust gas from the high temperature heat recoverer
128. The intermediate exhaust gas is then discharged to a first turbine
160. The intermediate exhaust gas is discharged from the first turbine
160 to the heat recovery steam generator 150 where it is reheated
and discharged to a second turbine 162 and then a third turbine
164. The intermediate exhaust gas is expanded in the turbines 160, 162,
164, and the temperature and pressure of the intermediate exhaust gas are decreased.
The operating pressures of the turbines 160, 162, 164 decrease consecutively
so that the second turbine 162 operates at a pressure that is lower than
that of the first turbine160 and higher than that of the third turbine
164. The turbines 160, 162, 164 are coupled to an electric generator
166, which is rotated by the turbines 160, 162, 164 and generates
electricity. Subsequently, the intermediate exhaust gas is discharged to a condenser
168 and a pump 170, which returns the condensed exhaust to the syngas
generator 120.
The combustion product is cooled in the heat recovery steam generator
150. A first portion of the combustion product is recycled from the heat
recovery steam generator 150 to a compressor 144, which compresses
the combustion product and discharges the combustion product as the diluent to the
reheater 140. Bleed lines 148 connect the compressor 144 to
the primary turbine 142. The compressor 144 can be driven by a shaft
that also couples the primary turbine 142 to the electric generator146.
Although not shown, a single drive shaft may be driven by all of the turbines142,
160, 162, 164, and the same shaft may also drive the compressor 144.
In the embodiment of Figure 5, the diluent comprises approximately 67 percent steam
and 33 percent carbon dioxide, though the actual proportions can vary.
A second portion of the combustion product is discharged to a high
pressure compressor 172 where it is compressed to liquefy the carbon dioxide
in the combustion product. The carbon dioxide is then discharged via a carbon dioxide
outlet 174 and water is discharged through a water outlet 176. The
carbon dioxide and water may be recycled for use in other parts of the generation
cycle or discharged.
Many modifications and other embodiments of the invention will come
to mind to one skilled in the art to which this invention pertains having the benefit
of the teachings presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the invention is not to be limited to the
specific embodiments disclosed and that modifications and other embodiments are
intended to be included within the scope of the appended claims. Although specific
terms are employed herein, they are used in a generic and descriptive sense only
and not for purposes of limitation.