Apparatus for extracting energy from waste heat

Abstract

Brayton cycle apparatus for extracting energy from waste heat released by industrial devices are disclosed. An exemplary apparatus comprises a common structure to which the main components of a Brayton cycle are mounted in an in-use configuration to define a transportable unit for integration with an industrial device. Associated systems and methods are also disclosed.

1 . A Brayton cycle apparatus for extracting energy from waste heat released from an industrial device, the apparatus comprising:
 an air compressor configured to receive ambient air and compress the ambient air;   an air turbine configured for fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air;   a working fluid heater configured to facilitate transfer of the waste heat to the compressed air at a location upstream of the air turbine during operation;   an electric generator configured to be drivingly coupled to the air turbine for converting some of the energy extracted by the air turbine into electrical energy; and   a common structure to which the air compressor, the air turbine, the working fluid heater and the electric generator are mounted in an in-use configuration to define a transportable unit for integration with the industrial device.   
     
     
         2 . The apparatus as defined in  claim 1 , wherein the working fluid heater is at least partially disposed into a base of the common structure. 
     
     
         3 . The apparatus as defined in  claim 1 , wherein the common structure comprises a support platform, the air turbine and the air compressor being disposed on an upper side of the support platform and the working fluid heater being disposed on a lower side of the support platform. 
     
     
         4 . The apparatus as defined in  claim 1 , wherein the working fluid heater is disposed vertically below the air compressor and the air turbine. 
     
     
         5 . The apparatus as defined in  claim 1 , wherein the working fluid heater is disposed vertically below the generator. 
     
     
         6 . The apparatus as defined in  claim 1 , wherein the air compressor comprises a first compressor stage and a second compressor stage and the apparatus comprises an intercooler mounted to the common structure, the intercooler being configured to cool the air between the first compressor stage and the second compressor stage of the air compressor during operation. 
     
     
         7 . The apparatus as defined in  claim 1 , wherein the working fluid heater comprises a recuperator configured to facilitate heat transfer from exhaust air from the air turbine to the compressed air upstream of the air turbine. 
     
     
         8 . The apparatus as defined in  claim 7 , comprising a steam generator mounted to the common structure and coupled to receive a first heat-carrying fluid from the recuperator and facilitate heat transfer from the first heat-carrying fluid to water to produce steam during operation. 
     
     
         9 . The apparatus as defined in  claim 8 , wherein the steam generator is coupled to receive a second heat-carrying fluid from the working fluid heater and facilitate heat transfer from the second heat-carrying fluid to the water to produce the steam during operation. 
     
     
         10 . The apparatus as defined in  claim 1 , comprising a steam generator mounted to the common structure and configured to receive a heat-carrying fluid from the working fluid heater and facilitate heat transfer from the heat-carrying fluid to water to produce steam during operation. 
     
     
         11 . The apparatus as defined in  claim 1 , wherein the common structure comprises an upper portion and a lower portion, the upper portion being configured to interface with a lower portion of a common structure of another Brayton cycle apparatus to permit vertical stacking. 
     
     
         12 . The apparatus as defined in  claim 1 , wherein the working fluid heater comprises a fuel-burning auxiliary heater configured to heat the compressed air upstream of the air turbine. 
     
     
         13 . The apparatus as defined in  claim 1 , wherein the common structure comprises a skid. 
     
     
         14 . A system comprising:
 an industrial device configured to release waste heat; and   a Brayton cycle apparatus for extracting energy from the waste heat released by the industrial device, the apparatus comprising:
 an air compressor configured to receive ambient air and compress the ambient air; 
 an air turbine in fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air; 
 a working fluid heater configured to facilitate transfer of the waste heat to the compressed air at a location upstream of the air turbine during operation; 
 an electric generator drivingly coupled to the air turbine for converting some of the energy extracted by the air turbine into electrical energy; and 
 a common structure to which the air compressor, the air turbine, the working fluid heater and the electric generator are mounted to define a transportable unit integrated with the industrial device. 
   
     
     
         15 .- 24 . (canceled) 
     
     
         25 . The system as defined in  claim 14 , comprising an organic Rankine cycle device operatively coupled to receive a flow of air exhausted by the air turbine. 
     
     
         26 . (canceled) 
     
     
         27 . The system as defined in  claim 14 , wherein the industrial device comprises an incinerator. 
     
     
         28 . The system as defined in  claim 14 , wherein the industrial device comprises a fired heater. 
     
     
         29 .- 30 . (canceled) 
     
     
         31 . The system as defined in  claim 14 , wherein:
 the Brayton cycle apparatus is a first Brayton cycle apparatus and the system comprises a second Brayton cycle apparatus; and   the system comprises a support structure supporting the first Brayton cycle apparatus above the second Brayton cycle apparatus in a vertically stacked relationship during operation.   
     
     
         32 . (canceled) 
     
     
         33 . A method for integrating a Brayton cycle apparatus with an industrial device releasing waste heat, the method comprising:
 assembling an air compressor, an air turbine, a working fluid heater and an electric generator in an in-use configuration on a common structure to define a transportable Brayton cycle unit;   transporting the transportable Brayton cycle unit to a location of the industrial device; and   integrating the transportable Brayton cycle unit with the industrial device to permit the transportable Brayton cycle unit to extract energy from the waste heat.   
     
     
         34 .- 40 . (canceled) 
     
     
         41 . The method as defined in  claim 33 , wherein integrating the transportable Brayton cycle unit with the industrial device comprises vertically stacking the transportable Brayton cycle unit with another transportable Brayton cycle unit. 
     
     
         42 . The method as defined in  claim 33 , comprising operatively coupling a combustion device to receive a flow of air exhausted by the air turbine of the transportable Brayton cycle unit. 
     
     
         43 . A Brayton cycle apparatus comprising:
 an air compressor configured to receive ambient air and compress the ambient air;   an air turbine configured for fluid communication with the air compressor for receiving the compressed air and extracting energy from the compressed air;   an electric generator configured to be drivingly coupled to the air turbine for converting some of the energy extracted by the air turbine into electrical energy; and   a common structure to which the air compressor, the air turbine and the electric generator are mounted in an in-use configuration to define a transportable unit for integration with the industrial device.   
     
     
         44 .- 46 . (canceled)