Heat energy distribution systems and methods for power recovery

Abstract

Systems and methods are provided for the recovery of mechanical power from heat energy sources via multiple heat exchangers and expanders receiving at least a portion of heat energy from a source. The distribution of heat energy from the source may be portioned, distributed, and communicated to the input of each of the heat exchangers so as to permit utilization of up to all available heat energy. In some embodiments, the system receives heat energy from more than one source at one or more temperatures. Mechanical energy from expansion of working fluid in the expanders may be communicated to other devices to perform useful work or operatively coupled to one or more generators to convert the mechanical energy into electrical energy.

What is claimed is: 
     
         1 . A system for recovering energy from an input flow of fresh air heated by compression, the system comprising:
 A. more than one flow control valve in heated air flow receiving communication with said input flow of heated fresh air; and   B. more than one primary heat exchanger, each said primary heat exchanger in heated fresh air flow receiving communication with at least one of said more than one flow control valve;   
       wherein each of said more than one flow control valves are operative to portion, distribute, and communicate a controllable portion of air flow comprising heat energy from the input flow of heated fresh air to at least one of the more than one primary heat exchangers. 
     
     
         2 . The system of  claim 1  wherein each of said controllable portions of air flow may comprise all, some, or none of the heat energy available from the input flow of heated fresh air. 
     
     
         3 . The system of  claim 2  further comprising one or more intermediate heat exchanger(s) disposed between input flow of heated fresh air and said more than one primary heat exchangers such that air flow comprising heat energy is communicated from said input flow of heated fresh air to each of said more than one primary heat exchangers via at least one of said one or more intermediate heat exchangers. 
     
     
         4 . The system of  claim 2  further comprising at least one organic Rankine cycle (ORC) system comprising an ORC working fluid, at least one expander, at least one condenser, and at least one working fluid pump, wherein at least one of said more than one primary heat exchangers is configured to communicate heat energy to said ORC working fluid for expansion in said at least one expander to generate mechanical power. 
     
     
         5 . The system of  claim 4  further comprising at least one electrical power generator and wherein at least a portion of said generated mechanical power is communicated to said at least one electrical power generator. 
     
     
         6 . The system of  claim 4  comprising more than one ORC system and wherein at least one of said more than one primary heat exchangers is configured to communicate heat energy from the input flow of heated fresh air to two or more of said more than one ORC systems. 
     
     
         7 . The system of  claim 4  wherein at least one controllable portion of air flow comprising heat energy is communicated from the input flow of heated fresh air to at least one of said more than one primary heat exchangers not configured to communicate heat energy to any of the at least one ORC systems. 
     
     
         8 . The system of  claim 1  wherein all of said more than one air flow control valves are in direct air flow receiving communication with said input flow of heated fresh air. 
     
     
         9 . A method of recovering energy from a flow of fresh air heated by compression, the method comprising:
 A. receiving a input flow of fresh air heated by compression; and   B. portioning, distributing, and communicating a controllable portion of heated air flow from said input flow of heated fresh air via more than one air flow control valve, thereby creating and providing more than one controllable portion of heat energy.   
     
     
         10 . The method of  claim 9  wherein each of said more than one controllable portion of air flow comprising heat energy portioned, distributed, and communicated by each of said more than one air flow control valve may comprise all, some, or none of the heat energy available from said input flow of heated fresh air. 
     
     
         11 . The method of  claim 10  further comprising more than one heat exchanger wherein said more than one controllable portions of heat energy are communicated to at least one of said more than one heat exchanger. 
     
     
         12 . The method of  claim 11  wherein at least one of said more than one controllable portion of heat energy communicated to at least one of said more than one heat exchanger is subsequently communicated to another of said more than one heat exchangers. 
     
     
         13 . The method of  claim 11  further comprising the additional steps of:
 A. using one or more organic Rankine cycle (ORC) system(s) each comprising an ORC working fluid, at least one expander, at least one condenser, and at least one working fluid pump, creating heated ORC working fluid by communicating heat energy from at least one of said more than one heat exchangers to said ORC working fluid of at least one of said one or more ORC system(s); and 
 B. expanding said heated ORC working fluid in said at least one expander of said at least one of said one or more ORC system(s) to generate mechanical power. 
 
     
     
         14 . The method of  claim 13  wherein at least one of said one or more ORC system(s) further comprise(s) an electrical power generator in mechanical power receiving communication with said expander, and said method further comprises an additional step of utilizing at least a portion of said mechanical power to generate electrical power via said electrical power generator. 
     
     
         15 . The method of  claim 13  wherein at least one of said more than one controllable portions of heat energy is communicated to at least one of said more than one heat exchangers not configured to communicate heat energy to any of said one or more ORC system(s). 
     
     
         16 . The method of  claim 9  wherein all of said more than one heat transfer flow control valves in heat energy receiving communication with said input flow of heated fresh air are in direct heat energy receiving communication with said input flow of heated fresh air. 
     
     
         17 . A method for generating power from a flow of fresh air heated by compression, the method comprising:
 A. receiving a input flow of fresh air heated by compression;   B. using more than one air flow control valves in heated air flow receiving communication with said input flow of heated fresh air to portion, distribute, and communicate more than one controllable portions of said heated fresh air to more than one heat exchanger via adjustment of any of said more than one air flow control valves;   C. directly or indirectly communicating heat energy from at least one of said more than one heat exchanger to at least one organic Rankine cycle (ORC) system comprising an ORC working fluid, at least one expander, at least one condenser, and at least one working fluid pump; and   D. communicating said heat energy to said ORC working fluid and expanding said heated ORC working fluid in said at least one expander to generate mechanical power.   
     
     
         18 . The method of  claim 17  wherein any of said more than one controllable portions of heated compressed air portioned, distributed, and communicated by each of said more than one air flow control valve may comprise all, some, or none of the heated input flow of fresh air. 
     
     
         19 . The method of  claim 18  wherein said at least one ORC system further comprises an electrical generator in mechanical power receiving communication with at least one of said at least one expander and said method further comprises an additional step of utilizing at least a portion of said mechanical power to generate electrical power. 
     
     
         20 . The method of  claim 18  wherein at least one of said more than one controllable portion of heated compressed air is communicated to at least one of said more than one heat exchangers not communicating heat energy to said ORC working fluid. 
     
     
         21 . The method of  claim 17  wherein all of said more than one heat transfer flow control valves are in direct heated air flow receiving communication with said input flow of heated fresh air.