A turboexpander, also referred to as a turbo-expander or an expansion turbine, is a centrifugal or axial-flow turbine, through which a high-pressure gas is expanded to produce work that is often used to drive a compressor or generator. [1] [2] [3]
Because work is extracted from the expanding high-pressure gas, the expansion is approximated by an isentropic process (i.e., a constant-entropy process), and the low-pressure exhaust gas from the turbine is at a very low temperature, −150 °C or less, depending upon the operating pressure and gas properties. Partial liquefaction of the expanded gas is not uncommon.
Turboexpanders are widely used as sources of refrigeration in industrial processes such as the extraction of ethane and natural-gas liquids (NGLs) from natural gas, [4] the liquefaction of gases (such as oxygen, nitrogen, helium, argon and krypton) [5] [6] and other low-temperature processes.
Turboexpanders currently in operation range in size from about 750 W to about 7.5 MW (1 hp to about 10,000 hp).
Although turboexpanders are commonly used in low-temperature processes, they are used in many other applications. This section discusses one of the low-temperature processes, as well as some of the other applications.
Raw natural gas consists primarily of methane (CH4), the shortest and lightest hydrocarbon molecule, along with various amounts of heavier hydrocarbon gases such as ethane (C2H6), propane (C3H8), normal butane (n-C4H10), isobutane (i-C4H10), pentanes and even higher-molecular-mass hydrocarbons. The raw gas also contains various amounts of acid gases such as carbon dioxide (CO2), hydrogen sulfide (H2S) and mercaptans such as methanethiol (CH3SH) and ethanethiol (C2H5SH).
When processed into finished by-products (see Natural-gas processing), these heavier hydrocarbons are collectively referred to as NGL (natural-gas liquids). The extraction of the NGL often involves a turboexpander [7] and a low-temperature distillation column (called a demethanizer) as shown in the figure. The inlet gas to the demethanizer is first cooled to about −51 °C in a heat exchanger (referred to as a cold box), which partially condenses the inlet gas. The resultant gas–liquid mixture is then separated into a gas stream and a liquid stream.
The liquid stream from the gas–liquid separator flows through a valve and undergoes a throttling expansion from an absolute pressure of 62 bar to 21 bar (6.2 to 2.1 MPa), which is an isenthalpic process (i.e., a constant-enthalpy process) that results in lowering the temperature of the stream from about −51 °C to about −81 °C as the stream enters the demethanizer.
The gas stream from the gas–liquid separator enters the turboexpander, where it undergoes an isentropic expansion from an absolute pressure of 62 bar to 21 bar (6.2 to 2.1 MPa) that lowers the gas stream temperature from about −51 °C to about −91 °C as it enters the demethanizer to serve as distillation reflux.
Liquid from the top tray of the demethanizer (at about −90 °C) is routed through the cold box, where it is warmed to about 0 °C as it cools the inlet gas, and is then returned to the lower section of the demethanizer. Another liquid stream from the lower section of the demethanizer (at about 2 °C) is routed through the cold box and returned to the demethanizer at about 12 °C. In effect, the inlet gas provides the heat required to "reboil" the bottom of the demethanizer, and the turboexpander removes the heat required to provide reflux in the top of the demethanizer.
The overhead gas product from the demethanizer at about −90 °C is processed natural gas that is of suitable quality for distribution to end-use consumers by pipeline. It is routed through the cold box, where it is warmed as it cools the inlet gas. It is then compressed in the gas compressor driven by the turboexpander and further compressed in a second-stage gas compressor driven by an electric motor before entering the distribution pipeline.
The bottom product from the demethanizer is also warmed in the cold box, as it cools the inlet gas, before it leaves the system as NGL.
The operating conditions of an offshore gas conditioning turbo-expander/recompressor are as follows: [8]
Turbo-expander | Recompressor | |||
---|---|---|---|---|
Inlet | Outlet | Inlet | Outlet | |
Temperature °C | 11.0 | –13.0 | 22.0 | 40.0 |
Pressure barg | 75.0 | 39.31 | 38.62 | 47.24 |
Flow kg/hr | 27728 | 20658 | ||
Molecular weight | 22.08 | 20.74 | ||
Energy recovered/used kW | 345 | 345 |
The figure depicts an electric power-generation system that uses a heat source, a cooling medium (air, water or other), a circulating working fluid and a turboexpander. The system can accommodate a wide variety of heat sources such as:
The circulating working fluid (usually an organic compound such as R-134a) is pumped to a high pressure and then vaporized in the evaporator by heat exchange with the available heat source. The resulting high-pressure vapor flows to the turboexpander, where it undergoes an isentropic expansion and exits as a vapor–liquid mixture, which is then condensed into a liquid by heat exchange with the available cooling medium. The condensed liquid is pumped back to the evaporator to complete the cycle.
The system in the figure implements a Rankine cycle as it is used in fossil-fuel power plants, where water is the working fluid and the heat source is derived from the combustion of natural gas, fuel oil or coal used to generate high-pressure steam. The high-pressure steam then undergoes an isentropic expansion in a conventional steam turbine. The steam turbine exhaust steam is next condensed into liquid water, which is then pumped back to steam generator to complete the cycle.
When an organic working fluid such as R-134a is used in the Rankine cycle, the cycle is sometimes referred to as an organic Rankine cycle (ORC). [9] [10] [11]
A refrigeration system utilizes a compressor, a turboexpander and an electric motor.
Depending on the operating conditions, the turboexpander reduces the load on the electric motor by 6–15% compared to a conventional vapor-compression refrigeration system that uses a throttling expansion valve rather than a turboexpander. [12] Basically, this can be seen as a form of turbo compounding.
The system employs a high-pressure refrigerant (i.e., one with a low normal boiling point) such as: [12]
As shown in the figure, refrigerant vapor is compressed to a higher pressure, resulting in a higher temperature as well. The hot, compressed vapor is then condensed into a liquid. The condenser is where heat is expelled from the circulating refrigerant and is carried away by whatever cooling medium is used in the condenser (air, water, etc.).
The refrigerant liquid flows through the turboexpander, where it is vaporized, and the vapor undergoes an isentropic expansion, which results in a low-temperature mixture of vapor and liquid. The vapor–liquid mixture is then routed through the evaporator, where it is vaporized by heat absorbed from the space being cooled. The vaporized refrigerant flows to the compressor inlet to complete the cycle.
In the case where the working fluid remains gaseous into the heat exchangers without undergoing phase changes, this cycle is also referred to as reverse Brayton cycle or "refrigerating Brayton cycle".
The combustion flue gas from the catalyst regenerator of a fluid catalytic cracker is at a temperature of about 715 °C and at a pressure of about 2.4 barg (240 kPa gauge). Its gaseous components are mostly carbon monoxide (CO), carbon dioxide (CO2) and nitrogen (N2). Although the flue gas has been through two stages of cyclones (located within the regenerator) to remove entrained catalyst fines, it still contains some residual catalyst fines.
The figure depicts how power is recovered and utilized by routing the regenerator flue gas through a turboexpander. After the flue gas exits the regenerator, it is routed through a secondary catalyst separator containing swirl tubes designed to remove 70–90% of the residual catalyst fines. [13] This is required to prevent erosion damage to the turboexpander.
As shown in the figure, expansion of the flue gas through a turboexpander provides sufficient power to drive the regenerator's combustion air compressor. The electrical motor-generator in the power-recovery system can consume or produce electrical power. If the expansion of the flue gas does not provide enough power to drive the air compressor, the electric motor-generator provides the needed additional power. If the flue gas expansion provides more power than needed to drive the air compressor, then the electric motor-generator converts the excess power into electric power and exports it to the refinery's electrical system. [14] The steam turbine is used to drive the regenerator's combustion air compressor during start-ups of the fluid catalytic cracker until there is sufficient combustion flue gas to take over that task.
The expanded flue gas is then routed through a steam-generating boiler (referred to as a CO boiler ), where the carbon monoxide in the flue gas is burned as fuel to provide steam for use in the refinery. [14]
The flue gas from the CO boiler is processed through an electrostatic precipitator (ESP) to remove residual particulate matter. The ESP removes particulates in the size range of 2 to 20 micrometers from the flue gas. [14]
The possible use of an expansion machine for isentropically creating low temperatures was suggested by Carl Wilhelm Siemens (Siemens cycle), a German engineer in 1857. About three decades later, in 1885, Ernest Solvay of Belgium attempted to use a reciprocating expander machine, but could not attain any temperatures lower than −98 °C because of problems with lubrication of the machine at such temperatures. [2]
In 1902, Georges Claude, a French engineer, successfully used a reciprocating expansion machine to liquefy air. He used a degreased, burnt leather packing as a piston seal without any lubrication. With an air pressure of only 40 bar (4 MPa), Claude achieved an almost isentropic expansion resulting in a lower temperature than had before been possible. [2]
The first turboexpanders seem to have been designed in about 1934 or 1935 by Guido Zerkowitz, an Italian engineer working for the German firm of Linde AG. [15] [16]
In 1939, the Russian physicist Pyotr Kapitsa perfected the design of centrifugal turboexpanders. His first practical prototype was made of Monel metal, had an outside diameter of only 8 cm (3.1 in), operated at 40,000 revolutions per minute and expanded 1,000 cubic metres of air per hour. It used a water pump as a brake and had an efficiency of 79–83%. [2] [16] Most turboexpanders in industrial use since then have been based on Kapitsa's design, and centrifugal turboexpanders have taken over almost 100% of the industrial gas liquefaction and low-temperature process requirements. [2] [16] The availability of liquid oxygen revolutionized the production of steel using the basic oxygen steelmaking process.
In 1978, Pyotr Kapitsa was awarded a Nobel physics prize for his body of work in the area of low-temperature physics. [17]
In 1983, San Diego Gas and Electric was among the first to install a turboexpander in a natural-gas letdown station for energy recovery. [18]
Turboexpanders can be classified by loading device or bearings.
Three main loading devices used in turboexpanders are centrifugal compressors, electrical generators or hydraulic brakes. With centrifugal compressors and electrical generators the shaft power from the turboexpander is recouped either to recompress the process gas or to generate electrical energy, lowering utility bills.
Hydraulic brakes are used when the turboexpander is very small and harvesting the shaft power is not economically justifiable.
Bearings used are either oil bearings or magnetic bearings.
A heat engine is a system that converts heat to usable energy, particularly mechanical energy, which can then be used to do mechanical work. While originally conceived in the context of mechanical energy, the concept of the heat engine has been applied to various other kinds of energy, particularly electrical, since at least the late 19th century. The heat engine does this by bringing a working substance from a higher state temperature to a lower state temperature. A heat source generates thermal energy that brings the working substance to the higher temperature state. The working substance generates work in the working body of the engine while transferring heat to the colder sink until it reaches a lower temperature state. During this process some of the thermal energy is converted into work by exploiting the properties of the working substance. The working substance can be any system with a non-zero heat capacity, but it usually is a gas or liquid. During this process, some heat is normally lost to the surroundings and is not converted to work. Also, some energy is unusable because of friction and drag.
The Brayton cycle, also known as the Joule cycle, is a thermodynamic cycle that describes the operation of certain heat engines that have air or some other gas as their working fluid. It is characterized by isentropic compression and expansion, and isobaric heat addition and rejection, though practical engines have adiabatic rather than isentropic steps.
A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor.
A combined cycle power plant is an assembly of heat engines that work in tandem from the same source of heat, converting it into mechanical energy. On land, when used to make electricity the most common type is called a combined cycle gas turbine (CCGT) plant, which is a kind of gas-fired power plant. The same principle is also used for marine propulsion, where it is called a combined gas and steam (COGAS) plant. Combining two or more thermodynamic cycles improves overall efficiency, which reduces fuel costs.
The Rankine cycle is an idealized thermodynamic cycle describing the process by which certain heat engines, such as steam turbines or reciprocating steam engines, allow mechanical work to be extracted from a fluid as it moves between a heat source and heat sink. The Rankine cycle is named after William John Macquorn Rankine, a Scottish polymath professor at Glasgow University.
For fluid power, a working fluid is a gas or liquid that primarily transfers force, motion, or mechanical energy. In hydraulics, water or hydraulic fluid transfers force between hydraulic components such as hydraulic pumps, hydraulic cylinders, and hydraulic motors that are assembled into hydraulic machinery, hydraulic drive systems, etc. In pneumatics, the working fluid is air or another gas which transfers force between pneumatic components such as compressors, vacuum pumps, pneumatic cylinders, and pneumatic motors. In pneumatic systems, the working gas also stores energy because it is compressible.
A chiller is a machine that removes heat from a liquid coolant via a vapor-compression, adsorption refrigeration, or absorption refrigeration cycles. This liquid can then be circulated through a heat exchanger to cool equipment, or another process stream. As a necessary by-product, refrigeration creates waste heat that must be exhausted to ambience, or for greater efficiency, recovered for heating purposes. Vapor compression chillers may use any of a number of different types of compressors. Most common today are the hermetic scroll, semi-hermetic screw, or centrifugal compressors. The condensing side of the chiller can be either air or water cooled. Even when liquid cooled, the chiller is often cooled by an induced or forced draft cooling tower. Absorption and adsorption chillers require a heat source to function.
A feedwater heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feedwater reduces the irreversibilities involved in steam generation and therefore improves the thermodynamic efficiency of the system. This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feedwater is introduced back into the steam cycle.
A thermal power station, also known as a thermal power plant, is a type of power station in which the heat energy generated from various fuel sources is converted to electrical energy. The heat from the source is converted into mechanical energy using a thermodynamic power cycle. The most common cycle involves a working fluid heated and boiled under high pressure in a pressure vessel to produce high-pressure steam. This high pressure-steam is then directed to a turbine, where it rotates the turbine's blades. The rotating turbine is mechanically connected to an electric generator which converts rotary motion into electricity. Fuels such as natural gas or oil can also be burnt directly in gas turbines, skipping the steam generation step. These plants can be of the open cycle or the more efficient combined cycle type.
A binary cycle is a method for generating electrical power from geothermal resources and employs two separate fluid cycles, hence binary cycle. The primary cycle extracts the geothermal energy from the reservoir, and secondary cycle converts the heat into work to drive the generator and generate electricity.
An absorption refrigerator is a refrigerator that uses a heat source to provide the energy needed to drive the cooling process. Solar energy, burning a fossil fuel, waste heat from factories, and district heating systems are examples of heat sources that can be used. An absorption refrigerator uses two coolants: the first coolant performs evaporative cooling and then is absorbed into the second coolant; heat is needed to reset the two coolants to their initial states. Absorption refrigerators are commonly used in recreational vehicles (RVs), campers, and caravans because the heat required to power them can be provided by a propane fuel burner, by a low-voltage DC electric heater or by a mains-powered electric heater. Absorption refrigerators can also be used to air-condition buildings using the waste heat from a gas turbine or water heater in the building. Using waste heat from a gas turbine makes the turbine very efficient because it first produces electricity, then hot water, and finally, air-conditioning—trigeneration.
A steam–electric power station is a power station in which the electric generator is steam-driven: water is heated, evaporates, and spins a steam turbine which drives an electric generator. After it passes through the turbine, the steam is condensed in a condenser. The greatest variation in the design of steam–electric power plants is due to the different fuel sources.
Economizers, or economisers (UK), are mechanical devices intended to reduce energy consumption, or to perform useful function such as preheating a fluid. The term economizer is used for other purposes as well. Boiler, power plant, heating, refrigeration, ventilating, and air conditioning (HVAC) may all use economizers. In simple terms, an economizer is a heat exchanger.
Vapour-compression refrigeration or vapor-compression refrigeration system (VCRS), in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and is the most widely used method for air conditioning of buildings and automobiles. It is also used in domestic and commercial refrigerators, large-scale warehouses for chilled or frozen storage of foods and meats, refrigerated trucks and railroad cars, and a host of other commercial and industrial services. Oil refineries, petrochemical and chemical processing plants, and natural gas processing plants are among the many types of industrial plants that often utilize large vapor-compression refrigeration systems. Cascade refrigeration systems may also be implemented using two compressors.
A transcritical cycle is a closed thermodynamic cycle where the working fluid goes through both subcritical and supercritical states. In particular, for power cycles the working fluid is kept in the liquid region during the compression phase and in vapour and/or supercritical conditions during the expansion phase. The ultrasupercritical steam Rankine cycle represents a widespread transcritical cycle in the electricity generation field from fossil fuels, where water is used as working fluid. Other typical applications of transcritical cycles to the purpose of power generation are represented by organic Rankine cycles, which are especially suitable to exploit low temperature heat sources, such as geothermal energy, heat recovery applications or waste to energy plants. With respect to subcritical cycles, the transcritical cycle exploits by definition higher pressure ratios, a feature that ultimately yields higher efficiencies for the majority of the working fluids. Considering then also supercritical cycles as a valid alternative to the transcritical ones, the latter cycles are capable of achieving higher specific works due to the limited relative importance of the work of compression work. This evidences the extreme potential of transcritical cycles to the purpose of producing the most power with the least expenditure.
Thermodynamic heat pump cycles or refrigeration cycles are the conceptual and mathematical models for heat pump, air conditioning and refrigeration systems. A heat pump is a mechanical system that transmits heat from one location at a certain temperature to another location at a higher temperature. Thus a heat pump may be thought of as a "heater" if the objective is to warm the heat sink, or a "refrigerator" or “cooler” if the objective is to cool the heat source. The operating principles in both cases are the same; energy is used to move heat from a colder place to a warmer place.
In thermal engineering, the organic Rankine cycle (ORC) is a type of thermodynamic cycle. It is a variation of the Rankine cycle named for its use of an organic, high-molecular-mass fluid whose vaporization temperature is lower than that of water. The fluid allows heat recovery from lower-temperature sources such as biomass combustion, industrial waste heat, geothermal heat, solar ponds etc. The low-temperature heat is converted into useful work, that can itself be converted into electricity.
The term subcooling refers to a liquid existing at a temperature below its normal boiling point. For example, water boils at 373 K; at room temperature (293 K) liquid water is termed "subcooled". Subcooled liquids are frequently used in refrigeration cycles, steam turbine cycles, and some rocket engines use subcooled propellants.
The Hygroscopic cycle is a thermodynamic cycle converting thermal energy into mechanical power by the means of a steam turbine. It is similar to the Rankine cycle using water as the motive fluid but with the novelty of introducing salts and their hygroscopic properties for the condensation. The salts are desorbed in the boiler or steam generator, where clean steam is released and superheated in order to be expanded and generate power through the steam turbine. Boiler blowdown with the concentrated hygroscopic compounds is used thermally to pre-heat the steam turbine condensate, and as reflux in the steam-absorber.
Heat engines, refrigeration cycles and heat pumps usually involve a fluid to and from which heat is transferred while undergoing a thermodynamic cycle. This fluid is called the working fluid. Refrigeration and heat pump technologies often refer to working fluids as refrigerants. Most thermodynamic cycles make use of the latent heat of the working fluid. In case of other cycles the working fluid remains in gaseous phase while undergoing all the processes of the cycle. When it comes to heat engines, working fluid generally undergoes a combustion process as well, for example in internal combustion engines or gas turbines. There are also technologies in heat pump and refrigeration, where working fluid does not change phase, such as reverse Brayton or Stirling cycle.