TECHNICAL FIELD
[0001] The present invention relates to a generator device.
BACKGROUND ART
[0002] Conventionally, as disclosed in Patent Document 1 below, there is a known binary
generator device in which a power generator is driven by an expander provided in a
circulation pipe through which a working medium is circulated. As shown in Fig. 7,
in this binary generator device disclosed in Patent Document 1, an evaporator 71,
an expander 72, a condenser 73, and a circulation pump 74 are connected to a circulation
pipe 75 in this order. The evaporator 71 evaporates a working medium with discharged
hot water discharged from factories or hot water from hot springs as a heat source
medium. On the outlet side of the evaporator 71 in a flow passage through which the
heat source medium flows, a temperature measurement means 76 is provided. Based on
a measured value of this means, the rotation number of the circulation pump 74 is
adjusted. That is, when a temperature of the hot water on the outlet side of the evaporator
71 becomes a higher temperature than a target value, the temperature of the hot water
on the outlet side is lowered by increasing the rotation number of the circulation
pump 74.
[0003] In the above binary generator device disclosed in Patent Document 1, in a case where
the temperature of the hot water serving as a heat source is increased, the temperature
of the hot water flowing out from the evaporator 71 is lowered by increasing the rotation
number of the circulation pump 74. Thereby, the temperature of the hot water flowing
out from the evaporator 71 can be held within a predetermined range. However, in this
binary generator device, there is still a problem that the device cannot deal with
a case where the temperature of the hot water (heat source medium) is radically increased.
That is, when the temperature of the hot water on the outlet side of the evaporator
71 is increased, adjustment is made to increase the rotation number of the circulation
pump 74. However, in a case where temperature of the hot water is radically increased,
an increase in a flow rate of the working medium does not catch up, so that an overheat
level of an outlet of the evaporator is temporarily increased. Therefore, there is
a problem that a packing or the like of a flange that exists in a route running from
the evaporator 71 to the expander 72 has to be made of a heat-resistant material.
CITATION LIST
PATENT DOCUMENT
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to be able to suppress an increase in a temperature
of a working medium on the outlet side of a heater in a generator device.
[0006] A generator device according to one aspect of the present invention includes an expander
that expands a gaseous working medium, a condenser that condenses the working medium
expanded in the expander, a pump that pressurizes the working medium condensed in
the condenser, a heater that evaporates at least part of the working medium pressurized
in the pump with heat of a heat source medium, and a cooling means that cools the
working medium in an overheat state where the working medium has a preliminarily fixed
temperature or higher on the downstream side of the heater.
BRIEF DESCRIPTION OF DRAWINGS
[0007]
[Fig.1] Fig. 1 is a diagram schematically showing a configuration of a generator device
according to a first embodiment of the present invention.
[Fig. 2] Fig. 2 is a chart for explaining control actions in the generator device
according to the first embodiment.
[Fig.3] Fig. 3 is a diagram schematically showing a configuration of a generator device
according to a second embodiment of the present invention.
[Fig. 4] Fig. 4 is a chart for explaining control actions in the generator device
according to the second embodiment.
[Fig.5] Fig. 5 is a diagram schematically showing a configuration of a generator device
according to one of other embodiments of the present invention.
[Fig. 6] Fig. 6 is a diagram schematically showing a configuration of a generator
device according to one of other embodiments of the present invention.
[Fig.7] Fig. 7 is a diagram schematically showing a configuration of a conventional
binary generator device.
DESCRIPTION OF EMBODIMENTS
[0008] Hereinafter, modes for carrying out the present invention will be described in detail
with reference to the drawings.
[0009] A generator device 1 according to a first embodiment is a power generation system
in which the Rankine cycle is utilized, and includes a condenser 6, a circulation
pump 8, a heater 10, and an expander 14 as shown in Fig. 1. The condenser 6, the circulation
pump 8, the heater 10, and the expander 14 are provided in a circulation flow passage
4 in this order. In the generator device 1 according to the present embodiment, a
circulation circuit in which a working medium flows through the heater 10, the expander
14, the condenser 6, and the circulation pump 8 in order through the circulation flow
passage 4 is formed. A refrigerant having a lower boiling point than that of water
is used as the working medium.
[0010] A power generator 16 is connected to the expander 14. By expanding the gaseous working
medium in the expander 14, force to drive the power generator 16 can be taken out.
[0011] The condenser 6 is to condense and make the gaseous working medium discharged from
the expander 14 a liquid working medium. The condenser 6 has a working medium flow
passage 6a through which the gaseous working medium flows, and a cooling medium flow
passage 6b through which a cooling medium such as cooking water flows. The cooling
medium flow passage 6b is connected to a cooling circuit 61. Through the cooling medium
flow passage 6b, the cooling medium such as cooling water supplied from this cooling
circuit 61 flows. The working medium flowing through the working medium flow passage
6a is condensed by heat exchange with the cooling medium flowing through the cooling
medium flow passage 6b.
[0012] The circulation pump 8 is provided on the downstream side of the condenser 6 (between
the heater 10 and the condenser 6) in the circulation flow passage 4, to circulate
the working medium in the circulation flow passage 4. The circulation pump 8 pressurizes
the liquid working medium condensed in the condenser 6 up to predetermined pressure
and feeds the working medium to the heater 10. As the circulation pump 8, a centrifugal
pump including an impeller as a rotor, a gear pump whose rotor includes a pair of
gears, and the like are used.
[0013] The heater 10 is provided on the downstream side of the circulation pump 8 (between
the circulation pump 8 and the expander 14) in the circulation flow passage 4. The
heater 10 has a working medium flow passage 10a through which the working medium flows,
and a heat source medium flow passage 10b through which a heat source medium flows.
The heat source medium flow passage 10b is connected to a heat source medium circuit
62. Through this heat source medium flow passage 10b, a heat source medium supplied
from an external heat source flows. The working medium flowing through the working
medium flow passage 10a is evaporated by heat exchange with the heat source medium
flowing through the heat source medium flow passage 10b. The heat source medium includes,
for example, hot water and water vapor.
[0014] In the circulation flow passage 4, a shutoff valve (on-off valve) 21 is provided
between the heater 10 and the expander 14. The shutoff valve 21 is usually opened
but closed at the time of stopping the expander 14 and the like, for example at the
time of abnormality of the expander 14.
[0015] In the circulation flow passage 4, a bypass means 23 and a cooling means 25 are provided.
The bypass means 23 has a bypass passage 23a bypassing the expander 14, and an on-off
valve 23b provided in the bypass passage 23a. The on-off valve 23b is usually closed
but opened at the time of stopping the expander 14 and the like, for example at the
time of rotation abnormality of the expander 14. By opening the on-off valve 23b,
the working medium flowing out from the heater 10 is introduced into the condenser
6 without being introduced into the expander 14.
[0016] The cooling means 25 is to cool the gaseous working medium evaporated in the heater
10 (that is, to draw sensible heat from the working medium), and has a cooling passage
25a, and a cooling valve (on-off valve) 25b provided in the cooling passage 25a. A
one end part of the cooling passage 25a is connected to a part between the circulation
pump 8 and the heater 10 in the circulation flow passage 4. Therefore, the liquid
working medium flows into the cooling passage 25a. The other end part of the cooling
passage 25a is connected to a part between the heater 10 and the expander 14 in the
circulation flow passage 4. Therefore, the liquid working medium flowing through the
cooling passage 25a is united with the gaseous working medium flowing out from the
heater 10.
[0017] The cooling passage 25a is formed by a pipe thinner than a pipe forming the circulation
flow passage 4. Therefore, through the cooling passage 25a, the working medium flows
at a sufficiently small flow rate in comparison to the working medium flowing through
the circulation flow passage 4. It should be noted that a throttle or a capillary
tube (not shown) may be alternatively provided in the cooling passage 25a.
[0018] The cooling valve 25b is usually closed but opened when a command is received from
a controller 30 to be described later.
[0019] In the circulation flow passage 4, a temperature sensor 32 and a pressure sensor
34 are provided between a part to which a downstream end of the cooling passage 25a
is connected and the expander 14. The temperature sensor 32 detects a temperature
of the working medium flowing out from the heater 10 to be introduced into the shutoff
valve 21 and the expander 14. The pressure sensor 34 detects pressure of the working
medium flowing out from the heater 10 to be introduced into the shutoff valve 21 and
the expander 14.
[0020] In the generator device 1, the controller 30 that performs drive control of the circulation
pump 8, and open/close control of the on-off valves 21, 23b, 25b is provided. Functions
of the controller 30 include a pump control means 30a and a cooling control means
30b.
[0021] The pump control means 30a is a means for controlling the rotation number of the
circulation pump 8, and performs the drive control of the circulation pump 8 in such
a manner that an overheat level of the working medium derived from detection values
of the temperature sensor 32 and the pressure sensor 34 is held within a preliminarily
set range.
[0022] The cooling control means 30b is a means for controlling open/close of the cooling
valve 25b, and executes the open/close control of the cooling valve 25b based on the
temperature of the working medium flowing out from the heater 10. That is, the cooling
control means 30b outputs a command for opening the cooling valve 25b in a case where
the working medium on the downstream side of the heater 10 is judged to be in an overheat
state from the detection values of the temperature sensor 32 and the pressure sensor
34, and when the detection value of the temperature sensor 32 is judged to be a preliminarily
fixed temperature (reference temperature) or higher. As this reference temperature,
a temperature that does not damage a packing or the like (not shown) provided in a
connection part of the shutoff valve 21 is set. That is, the temperature of the working
medium at an outlet of the heater 10 is controlled in such a manner that the packing
is not damaged by heat received from the working medium even in a case where the packing
is not made of a heat-resistant material.
[0023] The cooling control means 30b also executes the close control of the cooling valve
25b in such a manner that cooling is made within a range where the temperature of
the working medium on the downstream side of the heater 10 is maintained to be a saturation
temperature or higher. That is, in order to maintain the temperature of the working
medium to be introduced into the expander 14 to be the saturation temperature or higher,
the cooling control means 30b outputs a command for closing the cooling valve 25b
when a preliminarily fixed closing condition is met. This closing condition includes,
for example, the fact that the overheat level of the working medium obtained from
the detection values of the temperature sensor 32 and the pressure sensor 34 is a
predetermined temperature or higher. It should be noted that the temperature of the
working medium at this time is a temperature lower than the above reference temperature.
[0024] Hereinafter, operation actions of the power generation system according to the first
embodiment will be described. At the time of normal operation, the shutoff valve 21
is opened, whereas the on-off valve 23b of the bypass passage 23a and the cooling
valve 25b are closed.
[0025] When the circulation pump 8 is driven, the liquid working medium fed out from the
circulation pump 8 flows into the working medium flow passage 10a of the heater 10.
This working medium is heated and evaporated by the heat source medium flowing through
the heat source medium flow passage 10b. The working medium evaporated in the heater
10 is introduced into the expander 14. By introducing the working medium into the
expander 14, the expander 14 is driven and rotated, and thereby the power generator
16 is driven to generate electric power. The working medium expanded from the expander
14 is discharged to the circulation flow passage 4. The gaseous working medium discharged
from the expander 14 is introduced into the working medium flow passage 6a of the
condenser 6. In the condenser 6, the working medium is cooled and condensed by the
cooling medium flowing through the cooling medium flow passage 6b. This liquid working
medium flows through the circulation flow passage 4 and is suctioned into the circulation
pump 8. In the circulation flow passage 4, such circulation is repeated and the electric
power is generated in the power generator 16.
[0026] At the time of operation of the generator device 1, the rotation number of the circulation
pump 8 is controlled in such a manner that the overheat level of the working medium
on the downstream side of the heater 10 is held within a predetermined range. That
is, as shown in Fig. 2, the detection values P1, T1 of the pressure sensor 34 and
the temperature sensor 32 are inputted to the controller 30 (Step ST1), and the pump
control means 30a controls the circulation pump 8 based on the detections values P1,
T1 in such a manner that the overheat level of the working medium is held within a
preliminarily fixed range (Step ST2).
[0027] After confirming whether or not the working medium is in an overheat state based
on the detection values P1, T1 of the pressure sensor 34 and the temperature sensor
32, the cooling control means 30b judges whether or not the detection value T1 of
the temperature sensor 32 is a preliminarily set reference temperature (upper limit
value) Tr or lower (Steps ST3, ST4). It should be noted that an overheat state indicates
a state where the temperature detection value T1 is higher than the saturation temperature
of the working medium with the pressure detection value P1. In a case where the working
medium is in an overheat state, and in a case where the detection value T1 of the
temperature sensor 32 is judged to exceed the reference temperature Tr, the cooling
valve 25b is opened (Step ST5). Such a situation occurs for example in a case where
an increase in the rotation number of the circulation pump 8 cannot deal with a radical
increase in the temperature of the heat source medium to be introduced into the heater
10, or the like.
[0028] When the cooling valve 25b is opened, part of the liquid working medium emitted
from the circulation pump 8 is split into the cooling passage 25a. The liquid working
medium flowing through the cooling passage 25a is united with the working medium in
an overheat state in the circulation flow passage 4. Therefore, the gaseous working
medium flowing out from the heater 10 toward the shutoff valve 21 and the expander
14 through the circulation flow passage 4 is cooled by gasifying the united liquid
working medium. The liquid working medium introduced from the cooling passage 25a
into a part on the downstream of the heater 10 in the circulation flow passage 4 only
needs to lower the temperature of the gaseous working medium in the circulation flow
passage 4 flowing out from the heater 10, that is, only needs to draw sensible heat.
Thus, a large heat amount is not required in comparison to a case where latent heat
is to be drawn. Therefore, the above liquid working medium only needs to be a small
amount.
[0029] It should be noted that since the cooling passage 25a is formed by a thin pipe in
comparison to the circulation flow passage 4, a flow of a large amount of the working
medium through the cooling passage 25a is prevented. Therefore, an amount of the working
medium to flow into the heater 10 through the circulation flow passage 4 is not reduced
enough to influence an amount of the working medium caught in the heater 10, and the
overheat level is hardly further increased.
[0030] In a state where the cooling valve 25b is opened, it is judged whether or not the
overheat level SH calculated from the detection values T1, P1 of the temperature sensor
32 and the pressure sensor 34 is a reference overheat level (lower limit value) SHr
or higher (Step ST6). When the overheat level SH becomes lower than the reference
overheat level SHr, the cooling valve 25b is closed (Step ST7). Thereby, the operation
is returned to the normal operation in which the working medium emitted from the circulation
pump 8 is introduced into the heater 10 without being split into the cooling passage
25a.
[0031] As described above, in the first embodiment, the cooling means 25 cools the working
medium in an overheat state where the temperature on the downstream side of the heater
10 is a preliminarily fixed value or higher. Therefore, the temperature of the working
medium flowing out from the heater 10 to flow into the expander 14 can be suppressed.
Thus, even in a case where the temperature of the heat source medium is radically
increased, or the like, an increase in the temperature of the working medium can be
effectively suppressed. Consequently, there is no need for making the packing or the
like of a flange that exists in a route running from the heater 10 to the expander
14 of a heat-resistant material. There is also no need for a measure of making a class
of an insulating material used in the power generator 16 higher, or the like.
[0032] In the first embodiment, the cooling means 25 cools the working medium by uniting
the working medium split from the downstream side of the pump and the upstream side
of the heater 10 into the circulation flow passage 4. Therefore, a configuration as
the generator device 1 can be suppressed from being complicated, and the working medium
can be more effectively cooled.
[0033] In the first embodiment, the working medium on the downstream side of the heater
10 is maintained to be the saturation temperature or higher. Thus, the liquid working
medium can be prevented from being introduced into the expander 14. Therefore, power
generation efficiency can be prevented from lowering.
[0034] In the first embodiment, the working medium in an overheat state is cooled by utilizing
vaporization heat of the working medium. Thus, the working medium can be more effectively
cooled. That is, the working medium in an overheat state can be cooled with a tiny
amount of the cooling medium. In particular, since the working medium split from the
downstream side of the circulation pump 8 is used as the cooling medium, an amount
of the working medium fed from the circulation pump 8 to the heater 10 is only slightly
reduced. Therefore, even when the working medium is split from the working medium
emitted from the circulation pump 8, there is almost no influence.
[0035] Fig. 3 shows a generator device 1 according to a second embodiment. In the generator
device 1 according to the second embodiment, the cooling means 25 may have a heat
exchanger 25f that cools a working medium in an overheat state with a heat medium
introduced from an exterior such as vapor, high-temperature air, and hot water. For
example, this heat exchanger 25f is applied to a case where a heat source medium circuit
62 connected to a heater 10 is formed by a flow passage through which the supercharged
air to an engine (not shown) flows. The heat exchanger 25f is provided on the downstream
side of the heater 10 in a circulation flow passage 4. Into a cooling flow passage
25e of the heat exchanger 25f, surplus vapor may be introduced from a steam system
(not shown) provided in a vessel which is equipped with the engine. In a case where
the engine is high-load operated, for example the supercharged air of about 150°C
or higher is introduced into the heater 10. Therefore, the working medium flowing
through a working medium flow passage 10a of the heater 10 is heated until a temperature
of the working medium becomes about 150°C. In this case, by reducing an opening degree
of a cooling valve (pressure reduction means) 25b provided in a cooling passage 25a
of a cooling means 25, pressure of the heat medium is reduced, and thereby a temperature
of the heat medium is lowered. Thereby, the working medium in an overheat state flowing
through a working medium flow passage 25d of the heat exchanger 25f can be cooled.
It should be noted that in a case where the engine is low-load operated, the working
medium may sometimes be insufficiently heated in the heater 10. Thus, at this time,
the heat exchanger 25f can also function as a superheater that heats and brings the
working medium into an overheat state.
[0036] As shown in Fig. 4, in a power generation system according to this embodiment, it
is confirmed whether or not the working medium is in an overheat state based on detection
values P1, T1 of a pressure sensor 34 and a temperature sensor 32 (Step ST3). In a
case where the working medium is in an overheat state, and in a case where the detection
value T1 of the temperature sensor 32 is judged to exceed a reference temperature
Tr (Step ST4), a cooling control means 30b performs control of constricting the cooling
valve 25b (Step ST11). Thereby, the pressure of the heat medium is reduced, and the
working medium is cooled in the heat exchanger 25f (sensible heat of the working medium
is drawn).
[0037] In a state where the cooling valve 25b is constricted, it is judged whether or not
an overheat level SH calculated from the detection values T1, P1 of the temperature
sensor 32 and the pressure sensor 34 is a reference overheat level (lower limit value)
SHr or higher (Step ST6). When the overheat level SH becomes lower than the reference
overheat level SHr, the control of constricting the cooling valve 25b is cancelled
(Step ST7). At this time, in a case where the working medium is insufficiently heated,
the working medium can be supplementarily heated, and the overheat level SH of the
working medium can be increased.
[0038] It should be noted that the present invention is not limited to the above first and
second embodiments but can be variously modified or improved within a range not departing
from the gist thereof. For example, in the above first embodiment, the working medium
split from the circulation flow passage 4 is united with the working medium of the
circulation flow passage 4 again on the downstream side of the heater 10, and heat
exchange is performed directly with the working medium. Alternatively, as shown in
Fig. 5, heat exchange may be performed indirectly between the working medium split
into the cooling passage 25a and the working medium of the circulation flow passage
4.
[0039] Specifically, the cooling means 25 has a cooling heat exchanger 25c arranged on the
downstream side of the heater 10 in the circulation flow passage 4. In this cooling
heat exchanger 25c, a working medium flow passage 25d connected to the circulation
flow passage 4 and a cooling flow passage 25e connected to the cooling passage 25a
are provided.
[0040] A one end part (upstream end part) of the cooling passage 25a is connected to a part
between the circulation pump 8 and the heater 10 in the circulation flow passage 4.
The other end part (downstream end part) of the cooling passage 25a is connected to
a part between the expander 14 and the condenser 6 in the circulation flow passage
4. Since the downstream end part of the cooling passage 25a is placed on the suction
side of the circulation pump 8 in the circulation flow passage 4, the working medium
split into the cooling passage 25a easily flows.
[0041] The liquid working medium split from the circulation flow passage 4 to the cooling
passage 25a is gasified while cooling the working medium of the working medium flow
passage 25d in an overheat state in the cooling heat exchanger 25c. The gasified working
medium is returned from the cooling passage 25a to the upstream side of the condenser
6 in the circulation flow passage 4.
[0042] In the above first embodiment, the working medium in an overheat state is cooled
by the liquid working medium. Alternatively, as shown in Fig. 6, the working medium
in an overheat state may be cooled with a cooling medium (cooling water) of a cooling
circuit 61 passing through the condenser 6. Specifically, a one end part (upstream
end part) of the cooling passage 25a is connected to a part on the downstream side
of the condenser 6 in the cooling circuit 61. The cooling medium flowing through the
cooling passage 25a is returned to the cooling circuit 61. With this configuration,
the cooling medium in the cooling flow passage 25e cools the working medium of the
working medium flow passage 25d in an overheat state in the cooling heat exchanger
25c.
[0043] In the above embodiments, a jacket covering part of a pipe part between the heater
10 and the expander 14 in the circulation flow passage 4 may be provided, and the
working medium flowing out from the heater 10 may be indirectly cooled by letting
the working medium or the cooling medium in the jacket.
[0044] The cooling valve 25a may be a valve whose opening degree is adjustable.
[0045] Hereinafter, outlines of the above embodiments will be described.
[0046] In the above embodiment, the cooling means cools the working medium in an overheat
state where the temperature on the downstream side of the heater is a preliminarily
fixed value or higher. Therefore, the temperature of the working medium flowing out
from the heater to flow into the expander can be suppressed. Thus, even in a case
where the temperature of the heat source medium is radically increased, or the like,
the increase in the temperature of the working medium can be effectively suppressed.
Consequently, there is no need for making the packing or the like of the flange that
exists in the route running from the heater to the expander of a heat-resistant material.
There is also no need for a measure of making a class of the insulating material used
in the power generator higher, or the like.
[0047] The cooling means may cool the above working medium in an overheat state with the
working medium split from the downstream side of the pump and the upstream side of
the heater. In this mode, the working medium in an overheat state is cooled with the
working medium emitted from the pump. Thus, the configuration as the generator device
can be suppressed from being complicated.
[0048] The cooling means may cool the above working medium in an overheat state by uniting
the working medium split from the downstream side of the pump with the working medium
on the downstream side of the heater. In this mode, the working medium is cooled by
uniting the working medium split from the downstream side of the pump with the working
medium in an overheat state. Therefore, the working medium can be more effectively
cooled.
[0049] The cooling means may cool within a range where the temperature of the working medium
on the downstream side of the heater is maintained to be the saturation temperature
or higher. In this mode, the liquid working medium can be prevented from being introduced
into the expander. Therefore, the power generation efficiency can be prevented from
lowering.
[0050] The cooling means may cool the working medium in an overheat state by utilizing vaporization
heat. In this mode, the working medium in an overheat state is cooled by utilizing
vaporization heat. Thus, the working medium can be more effectively cooled. That is,
the working medium in an overheat state can be cooled with a tiny amount of the cooling
medium. In particular, in a case where the working medium split from the downstream
side of the pump is used as the cooling medium, the amount of the working medium fed
from the pump to the heater is only slightly reduced. Therefore, even when the working
medium is split from the working medium emitted from the pump, there is almost no
influence.
[0051] The cooling means may have the working medium flow passage and the cooling flow passage,
and have the heat exchanger arranged on the downstream side of the heater, and the
pressure reduction means provided in a heat medium circuit which is connected to the
cooling flow passage. The pressure reduction means may reduce the pressure of the
heat medium in such a manner that when the working medium is in an overheat state
where the working medium has a preliminarily fixed temperature or higher, the working
medium is cooled in the heat exchanger.
[0052] In this mode, when the working medium is in an overheat state where the working medium
has a preliminarily fixed temperature or higher, in the heat exchanger, the pressure
of the working medium flowing through the working medium flow passage is reduced by
the pressure reduction means of the heat medium circuit and the working medium is
cooled with the heat medium flowing through the cooling flow passage. Meanwhile, in
a case where the working medium is insufficiently heated in the heater, the working
medium is heated with the heat medium in the heat exchanger. Therefore, the heat exchanger
can cool the working medium in a case where the working medium is excessively heated,
and also supplementarily heat the working medium in a case where the working medium
is insufficiently heated.
[0053] As described above, according to the above embodiments, the increase in the temperature
of the working medium on the outlet side of the heater can be suppressed in the generator
device.