Control system for gas turbine in material treatment unit

Abstract

This invention discloses systems and methods for control of a gas turbine or a gas turbine generator, where the gas turbine is connected to a dryer vessel in which gas turbine exhaust gases are used to heat treat a material in the dryer vessel. The control system comprises one or more sensors for temperature, moisture and/or flow rate in the dryer vessel and/or of the material inside, entering and/or exiting the dryer vessel and a controller responsive to the sensor for controlling the fuel and/or air flow into the gas turbine. This control system and method enables providing the appropriate heat output from the gas turbine to meet the process heat required for the desired material treatment. Optionally, the gas turbine can be a liquid fuel turbine engine, or a reciprocating engine can be substituted for the turbine engine.

1 . A material treatment apparatus comprising:
 a gas turbine having combustion air and fuel inlets;   a dryer vessel connected to and adapted for receiving exhaust gases from the gas turbine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases;   a temperature sensor for detecting the temperature at a desired location in the dryer vessel; and   a controller responsive to the temperature sensor for controlling the combustion air flow or the fuel flow to the turbine.   
     
     
         2 . The apparatus according to  claim 1  wherein the gas turbine comprises a gas turbine generator. 
     
     
         3 . The apparatus according to  claim 1  further comprising a moisture sensor adapted for sensing at a desired location the moisture content of the heat treated material and wherein the controller is also responsive to the moisture sensor. 
     
     
         4 . The apparatus according to  claim 2  wherein the controller is responsive to the temperature sensor without regard to electrical output of the generator. 
     
     
         5 . The apparatus according to  claim 2  wherein the controller is primarily responsive to the temperature sensor and secondarily responsive to the electrical output of the generator. 
     
     
         6 . The apparatus according to  claim 1  further comprising a turbine exhaust gas temperature sensor and wherein the controller is primarily responsive to the dryer vessel temperature sensor and secondarily responsive to the turbine exhaust gas temperature sensor. 
     
     
         7 . A material treatment apparatus comprising:
 a gas turbine having combustion air and fuel inlets;   a dryer vessel connected to and adapted for receiving exhaust gases from the gas turbine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases;   a temperature sensor for detecting the temperature of the heated material at a desired location in the dryer vessel or at a desired location downstream of the dryer vessel; and   a controller responsive to the temperature sensor for controlling the combustion air flow or the fuel flow to the turbine.   
     
     
         8 . The apparatus according to  claim 7  wherein the gas turbine comprises a gas turbine generator. 
     
     
         9 . The apparatus according to  claim 7  further comprising a moisture sensor adapted for sensing at a desired location the moisture content of the heat treated material and wherein the controller is also responsive to the moisture sensor. 
     
     
         10 . The apparatus according to  claim 8  wherein the controller is responsive to the temperature sensor without regard to electrical output of the generator. 
     
     
         11 . The apparatus according to  claim 8  wherein the controller is primarily responsive to the temperature sensor and secondarily responsive to the electrical output of the generator. 
     
     
         12 . The apparatus according to  claim 7  further comprising a turbine exhaust gas temperature sensor and wherein the controller is primarily responsive to the dryer vessel temperature sensor and secondarily responsive to the turbine exhaust gas temperature sensor. 
     
     
         13 . A method for controlling a material treatment apparatus comprising a gas turbine having a combustion air inlet and a fuel inlet and a dryer vessel connected to the gas turbine and having a temperature sensor therein and being adapted for receiving exhaust gases from the gas turbine and adapted for receiving material for treatment therein with heat from the exhaust gases, the method comprising:
 using the sensed temperature for controlling the combustion air flow or the fuel flow to the turbine.   
     
     
         14 . A method according to  claim 13  wherein the gas turbine comprises a gas turbine generator. 
     
     
         15 . A method according to  claim 13  wherein the apparatus further comprises a moisture sensor adapted for sensing at a desired location the moisture content of the heat treated material and the method further comprising:
 using the sensed moisture content for controlling the combustion air flow or fuel flow to the turbine. 
 
     
     
         16 . A method according to  claim 14  wherein the sensed temperature is used for control without regard to electrical output of the generator. 
     
     
         17 . A method according to  claim 14  wherein the sensed temperature is primarily used for control and secondarily the electrical output of the generator is used. 
     
     
         18 . A method according to  claim 13  wherein the apparatus further comprises a turbine exhaust gas temperature sensor and the method further comprising:
 using the dryer vessel sensed temperature primarily for control and secondarily using the turbine exhaust gas sensed temperature. 
 
     
     
         19 . A method for controlling a material treatment apparatus comprising a gas turbine having a combustion air inlet and a fuel inlet; a dryer vessel connected to the gas turbine and adapted for receiving exhaust gases from the gas turbine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases; and a temperature sensor for sensing the temperature of the material at a desired location in the dryer vessel or downstream of the dryer vessel, the method comprising:
 using the sensed temperature for controlling the combustion air flow or the fuel flow to the turbine.   
     
     
         20 . A method according to  claim 19  wherein the gas turbine comprises a gas turbine generator. 
     
     
         21 . A method according to  claim 19  wherein the apparatus further comprises a moisture sensor adapted for sensing at a desired location the moisture content of the heat treated material and the method further comprising:
 using the sensed moisture content for controlling the combustion air flow or fuel flow to the turbine. 
 
     
     
         22 . A method according to  claim 20  wherein the sensed temperature is used for control without regard to electrical output of the generator. 
     
     
         23 . A method according to  claim 20  wherein the sensed temperature is primarily used for control and secondarily the electrical output of the generator is used. 
     
     
         24 . A method according to  claim 19  wherein the apparatus further comprises a turbine exhaust gas temperature sensor and the method further comprising:
 using the dryer vessel sensed temperature primarily for control and secondarily using the turbine exhaust gas sensed temperature. 
 
     
     
         25 . A material treatment apparatus comprising:
 a reciprocating engine having combustion air and fuel inlets;   a dryer vessel connected to and adapted for receiving exhaust gases from the reciprocating engine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases;   a temperature sensor for detecting the temperature at a desired location in the dryer vessel; and   a controller responsive to the temperature sensor for controlling the combustion air flow or the fuel flow to the engine.   
     
     
         26 . A material treatment apparatus comprising:
 a reciprocating engine having combustion air and fuel inlets;   a dryer vessel connected to and adapted for receiving exhaust gases from the reciprocating engine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases;   a temperature sensor for detecting the temperature of the heated material at a desired location in the dryer vessel or at a desired location downstream of the dryer vessel; and at a desired location in the dryer vessel; and   a controller responsive to the temperature sensor for controlling the combustion air flow or the fuel flow to the engine.   
     
     
         27 . A method for controlling a material treatment apparatus comprising a reciprocating engine having a combustion air inlet and a fuel inlet and a dryer vessel connected to the reciprocating engine and having a temperature sensor therein and being adapted for receiving exhaust gases from the reciprocating engine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases, the method comprising:
 using the sensed temperature for controlling the combustion air flow or the fuel flow to the engine.   
     
     
         28 . A method for controlling a material treatment apparatus comprising a reciprocating engine having a combustion air inlet and a fuel inlet; a dryer vessel connected to the reciprocating engine and adapted for receiving exhaust gases from the reciprocating engine and adapted for receiving material for treatment in the dryer vessel with heat from the exhaust gases; and a temperature sensor for sensing the temperature of the material at a desired location in the dryer vessel or downstream of the dryer vessel, the method comprising:
 using the sensed temperature for controlling the combustion air flow or the fuel flow to the engine.   
     
     
         29 . A gas turbine engine comprising:
 an exhaust connection adapted to transmit at least a portion of the turbine exhaust gases into a dryer vessel and adapted to substantially preclude introduction of outside air into the dryer vessel with the exhaust gases.   
     
     
         30 . A gas turbine according to  claim 29  comprising a gas turbine generator. 
     
     
         31 . A gas turbine according to  claim 30  wherein the exhaust connection is adapted to transmit substantially all the turbine exhaust gas into the dryer vessel. 
     
     
         32 . A gas turbine engine comprising:
 a fuel and/or combustion intake air controller adapted to be responsive to a temperature sensor positioned to sense the temperature at a desired location in a dryer vessel connected to and receiving exhaust gases from the gas turbine.   
     
     
         33 . A gas turbine according to  claim 32  comprising a gas turbine generator. 
     
     
         34 . A gas turbine engine comprising:
 a fuel and/or combustion intake air controller adapted to be responsive to a temperature sensor positioned to sense the temperature at a desired location of material treated in a dryer vessel connected to and receiving exhaust gases from the gas turbine.   
     
     
         35 . A gas turbine according to  claim 34  comprising a gas turbine generator. 
     
     
         36 . A controller for a material treatment system, including a gas turbine or reciprocating engine having its exhaust connected to a dryer vessel which is adapted for treating material with heat from the exhaust, comprising:
 a programmable computer adaptable for processing information from sensors detecting preselected conditions of the gas turbine operation, the dryer vessel operation or the material before, during or after treatment in the dryer vessel; for prioritizing sensor inputs for control and for commanding actuators for combustion air or fuel flow to the gas turbine.   
     
     
         37 . A controller according to  claim 36  further comprising a programmable aspect for commanding actuators for material flow to the dryer vessel.