Abstract:
An energy separation and recovery system wherein energy forms which might otherwise be wasted are employed in conjunction with a heat exchanger and a super heater to generate steam in a substantially closed-loop system wherein the heat supply is an open system. The superheated steam is transmitted to an engine to generate power which may be used to supply electrical energy. The electrical energy may be employed external to the system. Stepped diameter tubing carries water, or other vaporizable fluids, through the heat exchanger into the super heater while simultaneously exposing the carried water or fluid to incrementally higher temperature heated gas. Variable bellows, attached operatively to end plates accommodate the differential expansion of the tubing. The energy generation system includes a control module to permit the generation of steam and electricity at such times as there is sufficient heat to permit the generation of superheated steam. 
     The energy separation and recovery system may, alternatively, be employed to provide the power to an engine or other device or may provide an energy source to an alternative power consumption device which does not result in the generation of power.

Description:
COPYRIGHT NOTICE 
       [0001]    A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright whatsoever in all forms currently known or otherwise developed. 
       BACKGROUND OF THE INVENTION 
       [0002]    This invention relates to energy separation and recovery systems and heat exchangers and more particularly to a novel compact, low back pressure heat exchanger which employs a novel exchanger/super heater configuration to generated superheated steam and a steam engine which operates in conjunction with the energy generator to provide a source of energy which is of sufficient magnitude to generate commercially viable quantities of power. 
         [0003]    Over the years there have been numerous attempts to utilize the waste heat generated by the internal combustion engine to augment the power of the engine or supplement it by using the waste steam to run a steam turbine or other power plant. The inventions known in the prior art include utilizing the exhaust emitted by the internal combustion engine to heat water which will result in the creation of steam to run a steam turbine or other similar device to generate power which will augment or otherwise supplement that generated by the internal combustion engine. 
         [0004]    Generally, the prior art discloses the use of waste heat from either or both of the primary sources of heat from the internal combustion engine, those being the hot exhaust gases that are vented from the engine by means of the exhaust pipe system and the heat vented by the engine block through the radiator system by means of the liquid cooled or air cooled systems generally employed in today&#39;s automobiles and trucks. Additional heat is vented by the block and moving parts of the engine, but inasmuch as that heat is not captured by either the radiation system or the exhaust system, it is effectively lost for purposes of motive power generation. 
         [0005]    Heat can be recovered from a high temperature source and converted into work utilizing the well-known Rankine cycle. The heat is extracted from a high temperature heat source, for example a combustion exhaust gas stream, into a working fluid. The working fluid, which is initially liquid, is evaporated and the resulting pressurized working fluid vapor passes into an expansion turbine where work is generated to recover at least some of the heat energy extracted from the high temperature source. By using very high temperatures for the heat source and very low temperatures for the heat sink, high efficiency can be achieved for the heat recovery step. 
         [0006]    The expansion turbine vapor exhaust, which is at a reduced temperature and pressure, passes to a condenser which is in thermal contact with a low temperature heat sink, typically a very large body of water or ambient air. The heat of condensation is rejected to the low temperature heat sink typically by cooling water, which is discharged into a large body of water or into the atmosphere by means of a cooling tower. Alternatively, air cooling is used with the heated air being discharged directly into the atmosphere. The ultimate heat sink remains at an essentially constant temperature relative to the thermal load rejected by condensation of the turbine exhaust. The heat thus rejected is not used for any beneficial purpose and cannot be utilized within the process which provides the source of the high temperature heat. It is therefore lost. 
         [0007]    In U.S. application Ser. No. 12/214,835, there is disclosed accumulated energy system. Heat is employed in conjunction with a super heater/evaporator to generate steam, which is then stored in an energy accumulator which retains the stored energy by way of a heated water containment unit. The heated water containment unit accretes the energy and, upon attainment of a predetermined pressure and liquid level, steam is transmitted to a steam engine to generate power which may be used to run a generator and supply electricity. The heat may be from an internal combustion engine or other instrumentality which generates a sufficient quantity of heated exhaust gas to generate the requisite steam. 
         [0008]    Separation and recovery may also be employed in connection with a hydrocarbon stream to vaporize it and thereby modify it. An example of such a system is described in United States Patent Application No. 2009/0324488 to Goodman, Wayne. The system includes a heat exchanger configured to transfer heat from the exhaust stream to a hydrocarbon stream. The heat exchanger may be a separate device from the catalyst element, or the heat exchanger and the catalyst element may be the same device. The heat exchanger described may be configured to allow heat exchange with the exhaust stream during some periods of operation and to block heat exchange with the exhaust stream during other periods of operation and may include a control to permit a fraction of the exhaust stream flowing to the heat exchanger, allowing a controllable fraction of heat from the exhaust stream to exchange with the hydrocarbon stream and/or catalyst element. 
         [0009]    Systems are also known and described for accumulating steam by using the waste heat generated by a power plant and then using the steam to power a turbine or other power generation device. An example of such a system is described in U.S. Letters Pat. No. 4,555,905 and the patents and literature set forth therein. 
         [0010]    A further example of such a system is described in U.S. Patent Application No. 2009/0301078 to Chillar, Rahul for a system that recaptures the waste heat discharge by power plant auxiliary systems. The system is used for increasing the efficiency of a power plant, wherein the power plant comprises at least one gas turbine and a heat recovery steam generator (HRSG), the system comprising: at least one auxiliary system; wherein the auxiliary system is in fluid communication with at least one component of the power plant and removes waste heat received from the at least one component of the power plant. A condenser is integrated with the HRSG, wherein the condenser receives condensate from the HRSG and comprises a condensate loop. The condensate loop transfers a portion of the condensate to an inlet portion of the auxiliary system and a heat recovery loop utilizes the condensate to transfer waste heat from the auxiliary system to the HRSG. The heat recovery loop increases the temperature of the condensate prior to returning to the HRSG which reduces the work performed by the HRSG and increases the efficiency of the power plant. Such systems may increase the efficiency of the power plant, but do not provide for an open, superheated steam system. 
         [0011]    Today, in many areas of the world, pollution and related environmental concerns, has resulted in the implementation of severe pollution controls on waste disposal. It has also been determined that landfills and other degradable biomasses generate methane and other gases which modify the environment and add to global warming and other deleterious effects on the atmosphere. One initial solution is to capture the methane and other gaseous wastes and employ them, to the extent possible, to generate power. However, that often has the corollary effect of generating heat and other waste gasses. 
         [0012]    By way of example, United States Application No. 2009/0173688 to Phillips, Roger describes the use of waste heat for sludge treatment and energy generation. In recent years the disposal of sludge in landfill and/or agricultural applications has proven ecologically sensitive. While short term disposal can have a positive effect on crop production, heavy metals and other contaminants in the material make long term disposal problematic, not to mention aesthetically disagreeable in certain areas. Additionally, state and local authorities are enforcing stricter regulatory standards and mandating better management practices for safe sludge disposal and use, making sludge disposal even more difficult for these facilities. These issues will become more and more critical in light of the fact that many facilities have reached their capacity to process effluent from an expanding industry and customer base. 
         [0013]    Waste heat can be produced by a number of different sources, including, without limitation, power generation (coal-fired, natural gas fired, nuclear, etc.), wood product processing (pulp &amp; lumber mills) and various other heat-producing processes including without limitation, waste heat produced from a biofuel, a reciprocating engine, a gas generator set, a gas turbine set, landfill, a by-product of landfill degradation and combinations thereof. An apparatus can consist of heat exchangers installed in the heat stream from the heat source, where heat can be captured prior to other forms of disposal. The apparatus can include all necessary valves, ducts, fans, pumps, and piping to redirect the heated material. It can control the delivery of waste heat to downstream drying and/or thermal processing stages using, in one embodiment, an automated control system. 
         [0014]    Besides the internal combustion engine, there are numerous other sources of exhaust heat which may be employed to accumulate energy and generate power. One such source is the exhaust heat generated by the burning of methane gas at land fills and other similar locations. 
         [0015]    The present technology for solid wastes is to deposit trash into landfills that may be covered over with soil and green plants when full. The separation of waste water (sewage) solid components will be sent to the landfills and the liquid components piped into bodies of water (ocean, lakes, and rivers). Trash may also be burned and sometimes converted to electricity. In rural areas, sewage waste has been used as soil complement or used in methane producing systems (mostly animal waste) usually used directly for home use (usually in 3rd world countries) or used as a source on large farms. 
         [0016]    The major problem of landfills may be the lack of land, especially in urban settings. The sad stories of trash from East Coast (USA) and from Taiwan cities loaded on barges in search of dump sites, emphasize the enormity of the problem. The offensive odors generated and the proliferation of vermin, birds, dogs, and other organisms attracted to trash sites are undesirable. The production of methane, CO.sub.2 and other gases is a serious source of environmental pollution. The large area covered by the landfills precludes the capping of the landfill to harvest the methane and other gases for productive uses. Thus, methane is usually directed for harvest via tubing and other capping and delivery methods. 
         [0017]    By way of example, U.S. Pat. No. 5,288,170 to Cummings; James B. describes a system for disposing waste in the landfill and means for disposing sludge in the landfill with the waste. The system is also comprised of means for collecting gas produced within the landfill resulting from the sludge mixed with the waste and means for generating electrical energy from the collected gas. The generating means is in fluidic communication with the collecting means. Preferably, the generating means includes an electrical generator which burns the gas to produce electricity. Preferably, the means for disposing the waste in the landfill includes at least one truck and/or at least one railroad car. Preferably, the means for disposing sludge in the landfill includes at least one sealable or covered container which can also be transported by truck or train. 
         [0018]    In a preferred embodiment, the gas collecting means includes a plurality of gas extraction wells located throughout the landfill, a piping network connected to the extraction wells, pumping means for moving gas produced within the landfill into the piping network and containment means in communication with the piping network for storing collected gas. 
       SUMMARY OF THE INVENTION 
       [0019]    To overcome one or more of the drawbacks in the current energy technology and methods of employing waste heat exhaust gases, the current invention employs a dual core system comprised of a super heater and a heat exchanger. A finned tube array is disposed in connection with the heat exchanger to heat water and generate steam. A continuous tubing matrix directs a flow of fluid in a direct transverse to the direction of the waste heat and toward incrementally higher temperature of the waste heat. Waste heat exhaust gases are first passed over the tubing array of the super heater to superheat the steam within the super heater core. The waste heat exhaust gases are then passed over the heat exchanger segment of the unit to heat the water within the heat exchanger. The tubing array from the heat exchanger to the super heater is incrementally stepped up in diameter to achieve the open core flow and provide the superheated steam output. The superheated steam is transmitted to a steam engine to generate power which may be used to run a generator and supply electricity. The engine includes a control system to permit the generation of steam and electricity at such times as there is sufficient heat to permit the generation of superheated steam. 
         [0020]    The energy separation and recovery system may, alternatively, be employed to provide the power to a power grid in order to provide electrical energy and thereby obtain a credit or funds for the insertion of such electrical energy into the grid for which a system user may receive compensation or credit. The energy separation and recovery system may also be employed to drive an engine or other device or may provide an energy source to an alternative power consumption device. 
         [0021]    The energy separation and recovery system may, alternatively, be employed to provide the power to one or more energy consumption portions of the overall energy generation system. By way of example only, a portion of the power may be used within the electrical system of the heat exchanger itself in order to keep it operational during periods of time where startup is required via supplemental battery power. 
         [0022]    The energy separation and recovery system may, alternatively, be employed to provide the power to additional energy consumption items within or without the facility, such as providing electricity to local homes. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS 
         [0023]    The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For purposes of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings: 
           [0024]      FIG. 1  illustrates a block flow diagram for an exemplary system for separating, recovering, and storing or transferring the electricity generated by the use of the waste heat exhaust gases into an electric grid or network, in accordance with one embodiment of the present invention. 
           [0025]      FIG. 1A  is a detailed exemplary and diagrammatic view of a waste energy separation and recovery system, in accordance with one embodiment of the present invention. 
           [0026]      FIG. 2A  is a side view of an exemplary view of a heat exchanger/super heater system for the separation and recovery of waste heat energy, in accordance with one embodiment of the present invention. 
           [0027]      FIG. 2B  is a side view of an exemplary view of a heat exchanger/super heater system for the separation and recovery of waste heat energy, in accordance with another embodiment of the present invention. 
           [0028]      FIG. 2C  is a side view of an exemplary view of a heat exchanger/super heater system for the separation and recovery of waste heat energy, in accordance with an embodiment of the present invention wherein the system also serves as a muffler. 
           [0029]      FIG. 3  is a detailed side view of an exemplary view of a heat exchanger/super heater system for the separation and recovery of the waste heat energy, in accordance with one embodiment of the present invention. 
           [0030]      FIG. 4  is a detailed view of an exemplary arrangement of the continuous tubing employed in connection with the heat exchanger and super heater configuration, in accordance with one embodiment of the present invention. 
           [0031]      FIG. 5  is a detailed interior top view of a vortex fin assembly of the heat exchanger, before vacuum brazing, in accordance with one embodiment of the present invention. 
           [0032]      FIG. 6  is a detailed sectional view of tube and vortex fin interface, after vacuum brazing, in accordance with one embodiment of the present invention. 
           [0033]      FIG. 7  is a plan view of a single illustrative vortex fin plate structure for disposition within the heat exchanger, in accordance with one embodiment of the present invention. 
           [0034]      FIG. 7A  is a detailed interior view of a segment of a vortex fin plate of the heat exchanger, in accordance with one embodiment of the present invention. 
           [0035]      FIG. 8  is an illustrative view of the gas flow pattern around a tube within the heat exchanger configuration, in accordance with one embodiment of the present invention. 
           [0036]      FIG. 9  is an interior view of two corresponding heads for linking adjacent piping structures of the heat exchanger and super heater to form the continuous path in accordance with one embodiment of the present invention. 
           [0037]      FIG. 10  is a detailed sectional view of the heat exchanger and super heater structure illustrating the adjacent hole structures through which the heat exchanger and super heater piping is disposed, in accordance with one embodiment of the present invention. 
           [0038]      FIG. 11  is a diagrammatic representation illustrating the introduction of exhaust heat through the decrement staged piping of the system and the water input and superheated steam output for a single illustrative segment in accordance with one embodiment of the present invention. 
           [0039]      FIG. 12  is a cross-sectional view illustrating the super heater structure and the head and end plate assemblies for linking adjacent segments of piping in accordance with one embodiment of the present invention. 
           [0040]      FIG. 13  is a detail view taken of a corner of  FIG. 12  illustrating the expandable section between the main core casing structure and the head and end plate assemblies for linking adjacent segments of piping in accordance with one embodiment of the present invention. 
           [0041]      FIG. 14  is an illustrative view of an expandable bellows segment operatively associated with the head and end plate assemblies depicting the differential expansion as the result of the introduction of waste heat into the system in accordance with one embodiment of the present invention. 
           [0042]      FIG. 15  is an illustrative view of the head to end plate interface showing the interlocking head with expanded tube detail in accordance with one embodiment of the present invention 
           [0043]      FIG. 16  is an exploded illustrative view of the head to end plate interface showing the illustrative gaskets depicted thereon in accordance with one embodiment of the present invention. 
           [0044]      FIG. 17  is an illustrative view of the assembled heat exchanger, fin assembly and superheater cores in association with the expandable bellows segment operatively disposed with the head and end plate assemblies and illustrative gaskets depicted thereon in accordance with one embodiment of the present invention. 
           [0045]      FIG. 18  is an illustrative view of an assembled multi-core heat exchanger and super heater assembly in accordance with one embodiment of the present invention. 
           [0046]      FIG. 19  is an illustrative view of an assembled multi-core heat exchanger and super heater assembly having vertically stacked tubing to provide multiple heat exchangers and super heaters to provide steam to multiple engines or other applications in accordance with one embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0047]    Certain terminology may be used in the following description for convenience only and is not limiting. The words “lower” and “upper” and “top” and “bottom” designate directions only and are used in conjunction with such drawings as may be included to fully describe the invention. The terminology includes the above words specifically mentioned, derivatives thereof and words of similar import. 
         [0048]    Where a term is provided in the singular, the inventors also contemplate aspects of the invention described by the plural of that term. As used in this specification, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise, e.g. “a waste heat source”. Thus, for example, a reference to “a method” includes one or more methods, and/or steps of the type described therein and/or which will become apparent to those persons skilled in the art upon reading this disclosure. 
         [0049]    Unless defined otherwise, all technical and scientific terms used herein have the same meaning or meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, constructs and materials are described herein. All publications mentioned herein, whether in the text or by way of numerical designation, are incorporated herein by reference in their entirety. Where there are discrepancies in terms and definitions used by reference, the terms used in this application shall have the definitions given herein. 
         [0050]    Referring to  FIG. 1 ,  FIG. 1A  and  FIG. 2A , in a preferred embodiment of the invention, the energy separation and recovery system  20  is located proximate to an energy source  10  which is generating gas or other combustible material. Gas  12  is transferred from the energy source  10  and is piped into a gas powered generator system  14  provided for generating electricity. A by-product of the generation of electricity is the thermal conversion of the gas  12  into essentially complete products of combustion. The gas powered generator system  14  serves simultaneously to produce electrical energy  16  and waste heat exhaust gases  18 . The electrical energy  16  may be directly transmitted to a energy supplier such as the national grid  19 . Alternatively it may actually be used to provide electricity to operate equipment at the energy source  10  site. The waste heat exhaust gases  18  are passed through a combustion exhaust duct system  21  and is utilized by the separation and recovery system  20  to generate additional electrical power  22  which may similarly be transmitted to an energy supplier or used to operate equipment at the site or elsewhere. 
         [0051]    The separation and recovery system  20  and the electrical power generating systems may be positioned within a single structure. The structure may also house a steam engine drivingly connected to an electrical generator, and a condenser and a condensate recovery system all of which will be further delineated and exemplified in an embodiment of the invention. The structure can also house suitable condensate feed water systems to flow feed water in a loop through the separation and recovery system  20 . 
         [0052]    In the exemplary embodiment of the invention, hot waste exhaust gases  18  are flowed through the intake super heater side of the separation and recovery system  20  thereby reduce the temperatures of the waste heat exhaust gases  18  from approximately 1000° F. (620° C.) to approximately 600° F. (350° C.). The 600° F. waste heat exhaust gas  18  is continually flowed through the heat exchange elements of the separation and recovery system  20 . Upon exiting the heat exchanger  30  the balance of the now cooled waste heat exhaust gas  18  is appropriately vented. 
         [0053]    It is to be understood that the temperatures set forth above are merely illustrative and may be altered to optimize the particular separation and recovery system or the use to which the superheated steam is ultimately put. 
         [0054]    Referring to  FIG. 1A  and  FIG. 4 , the waste heat exhaust gases  18  from the generator system  14  are directed via an exhaust piping system  24  to the super heater  26 . A portion of the waste heat exhaust gases  18  may be diverted from the system if the temperatures are in excess of that which is required to provide superheated steam. A leading tube section  25  of the super heater  26  is that area proximate to the super heater steam outflow  40 , as is best seen in  FIG. 4 . 
         [0055]    The waste heat exhaust gases  18  are sequentially passed from the leading tube section  25  of the super heater  26  through to trailing tube section  27  of super heater  26  and traverse sequentially a leading tube section  29  and a trailing tube section  31  portion of the heat exchanger  30 . As is best illustrated in  FIG. 11 , the heat exchanger  30  is comprised of decreasing diameter tubing  33  such that, in the illustrated embodiment, approximately one half of the heat exchanger  30  nearest the leading tube section  25  is comprised of one diameter tubing and the second portion of the heat exchanger  30  nearest the trailing tube section  31  is comprised of a smaller diameter tubing. 
         [0056]    Continuing to refer to  FIG. 1A  and  FIGS. 2 and 3 , the waste heat exhaust gases  18  from which the energy has been separated are vented to the atmosphere by exhaust duct  34 . Although the following description will refer to water as the fluid being employed, it is understood by those skilled in the art that other fluids may be employed to achieve similar results. Accordingly, as is illustrated in  FIG. 1A , a water pump  50  takes water  51  from water tank  52  and causes it to flow through an initial series of one or more pre-heater sections  300 , consisting of tubing  301  having a diameter which is substantially similar to the diameter of the trailing tube section  31  of the heat exchanger  30 . The pre-heater sections  300  may be employed to heat the water or other fluid to a predetermined initial temperature which is, ideally, just below the boiling point of the fluid medium used. As can be seen from  FIG. 1A , the pre-heater sections  300  may have a control valve system  302  to permit selective activation or deactivation of one or more of the sections  300 . This permit the predetermined temperature to be accurately maintained based upon the initial temperature of the fluid. 
         [0057]    In the event that less than all of the pre-heater sections  300  are employed, a by-pass tubing section  303  is interposed to permit the fluid to be introduce into the trailing tube section  31  of the heat exchanger  30  at input port  305 . As is best seen in  FIG. 1A  and  FIG. 10 , the water  51  travels through a first series of tubes  304 , which are the smallest diameter tubes employed in the system. In one embodiment of the heat exchanger  30 , a number of spaced ⅜″ stainless steel tubes  304  are longitudinally disposed in an array which is transverse to the direction of flow of the gas  18 . The array is designed to simultaneously maximize the tube area which is exposed to the flow of gas, while at the same time the array is arranged to minimize the effect which it has on back-pressure of the gas  18 . The array may vary according to the specific embodiment and application for the energy separation and recovery system. This first series of tubes  304  are positioned such that the longitudinal axis of each tube is substantially perpendicular to the gas  18  flow. 
         [0058]    Continuing to refer to  FIGS. 1A and 10 , the water  51  travels through the first series of tubes  304  into a second series of tubes  306  which are of a larger diameter then the first series of tubes  304 . The first and second series of tubes form the heat exchanger  30  core. The gases  18  encounter the second series of tubes  306  at a higher temperature than they encounter the first series of tubes  304 . It can be seen that the temperature gradient for the water  51  which has been pumped into the tubes  304  at inlet  305  is such that the temperature of the water within the second series of tubes  306  is higher then that in the first series of tubes at  304 . 
         [0059]    Continuing to refer to  FIGS. 1A and 10  and  FIG. 4 , the water  51 , which has now been turned to steam  58  by the action of the energy separation and recovery system  20 , travels through the leading tube section  29  of the heat exchanger  30  into the trailing tube section  27  of the super heater  26  via connecting tube  307 . Depending on the particular application and the temperature of the gas, a steam dryer assembly  310  may be advantageously interposed between the leading tube section  29  and the trailing tube section  27 . The steam dryer assembly  310  constitutes a drying stage where, in the event that the steam from the heat exchanger  30  is wet, it may be appropriately dried and made ready for super heating. 
         [0060]    Continuing to refer to  FIGS. 1A ,  2 ,  3 ,  4  and  FIG. 11 , the dry steam enters into the super heater  26  of the separation and recovery system  20 , such that the temperature of the gas  18  at the trailing tube section  27  of the super heater  26  is a lower temperature than at the leading tube section  25  of the super heater  26 . Accordingly, the steam  58  encounters increasingly hotter gases  18  as it travels from the trailing tube section  27  to the leading tube section  25  of the super heater  26 . It can be appreciated that the temperature gradient for the steam  58  as it enters the super heater  26  is such that the steam  58  at the superheated steam exit port  308  is at substantially higher temperature than the steam at the entrance port  307  of the super heater  26 . 
         [0061]    During the travel of the steam  58  from the trailing tube section  27  to the leading tube section  25  of the super heater  26 , the steam  58  becomes superheated steam  59 . The superheated steam  59  is directed via a superheated steam exit port  308  to a steam engine  42 . In general, the reciprocating steam engine  42  produces rectilinear motion in a piston by the supply of high-pressure, high temperature steam to a cylinder. In the instant invention, superheated steam  59  is employed to drive the cylinder (not shown). In most reciprocating piston engines the steam reverses its direction of flow at each stroke (counter flow), entering and exhausting from the cylinder by the same port. In the steam engine  42  illustratively employed in connection with the instant invention, the superheated steam  59  enters from an entry port  44  and exits from an exit port  45  in proximity to the entry port  44  and both located on the head section  100  of the steam engine  42 , in order to complete the engine cycle, which occupies one rotation of the crank and two piston strokes. The cycle comprises several events—admission, expansion and exhaust. The steam engine  42  then changes the rectilinear motion of the pistons into rotary motion using a crank shaft (not shown) and rotates a driveshaft  47 . A reciprocating steam engine  42  may also reverse the rectilinear motion direction of the piston using the inertial force of a flywheel installed at the crank shaft unit. 
         [0062]    Because the superheated steam  59  loses heat as the energy is being taken from it, the superheated steam  59  sequentially becomes dry steam, wet steam and eventually water  51 . In order to accommodate the decrease in temperature and the increase in moisture content the various steam components (also referred to as phases) can be drawn off at various points from the steam engine  42 . By way of example reference is again made to  FIG. 1A  which shows the transfer of the various steam components in various phases. Dry steam  70  is collected from the piston blowby  71  and is conducted via tubing  72  to a tank  84 . Wet steam  73  is collected from the oil sump  74  and conducted via tubing  75  to the tank  84 . Additional wet steam  76  and water  51  are collected from the reserve oil reservoir  77  and conducted via tubing  78  to the tank  84 . The steam  70 ,  73  and  76 , after being conducted to tank  84 , is conducted via ducting  79  to the water tank  52  where it is employed to recharge the energy separation and recovery system  20 . 
         [0063]    The superheated steam  59  exits from the exit port  45  as depleted steam  130  through a discharge pipe  48  which is connected to and passes through the reserve oil reservoir  77 . The depleted steam  130  still contains sufficient energy to be employed to heat the oil within the reserve oil reservoir  77  to maintain it at a predetermined temperature. The depleted steam  130  continues through discharge pipe  48  to a condenser  80  where it is cooled by a fan assembly  82  and the resultant water  51  is transferred through piping  49  and returned to the water tank  52 . As a part of the recapture mechanism, water from the several steam draw points is captured in tank  84  and is re-circulated to the water tank  52 . 
         [0064]    Referring to  FIGS. 2A ,  2 B and  2 C there is shown various illustrative configurations of the energy separation and recovery system  20  in combination with an illustrative energy source  10 . The energy separation and recovery system  20  is first shown in  FIG. 2A  with a gating assembly  110  disposed in line with the exhaust duct  21  and having a pair of hinged diverter (not shown) disposed within the upper and lower sections of the gating assembly  110 . The gating assembly  110  is designed to permit the gas  18  to either be diverted into the energy separation and recovery system  20 , or to be exhausted to the atmosphere in the event that the energy separation and recovery system  20  is being serviced. This permits the energy source  10  to remain in continuous operation. The exhaust gas  18  is ultimately passed through a muffler  18 A in order to reduce the noise which would otherwise be generated by the exhaust gas  18 . 
         [0065]      FIG. 2B  illustrates the energy separation and recovery system  20  in combination with an illustrative energy source  10  where the system  20  is operatively connected to the energy source  10  for continuous operation.  FIG. 2C  illustrates the energy separation and recovery system  20  in combination with an illustrative energy source  10  where the system  20  is operatively connected to the energy source  10  to permit the substantially continuous use of the system  20 . In such a configuration, the energy separation and recovery system  20  may be advantageously used to provide sufficient noise abatement and thereby eliminate the use of a muffler. 
         [0066]    Referring again to  FIG. 1A  there is shown an expanded and detailed view of certain operative portions of the separation and recovery system  20 . The steam engine  42  is, in the preferred embodiment a Voith steam expander. The steam engine  42  is drivingly associated with a generator  90 . The steam engine  42 , which is powered by the superheated steam derived by the separation and recovery system  20 , rotationally engages the generator  90 . In the preferred embodiment the generator  90  is an alternating current generator. The alternating current is passed through to an inverter  92  which then permits the electricity to be transferred to an energy supplier  19  such as the national grid. 
         [0067]    Referring again to  FIG. 4  in conjunction with  FIGS. 5 ,  7  and  7 A, there is shown a preferred embodiment of a vortex fin array  200  which is disposed perpendicular to the heat exchange tubing  304  and  306 . The vortex fin array  200  is comprised of a series of circular apertures  202  through which the heat exchange tubing  304  and  306  extends. The heat exchange tubing  304  and  306  is affixed to the vortex fin array  200 . In a preferred embodiment of the invention, the vortex fin array  200  and the heat exchange tubing  304  and  306  are braised to further increase the heat transfer between the waste heat exhaust gas  18  and the water  51  traveling through the respective heat exchange tubing  304  and  306 . 
         [0068]    Referring to  FIG. 7A  there is shown a view of one portion of a representative section of heat exchange tubing  304  or  306  and a pair of associated vortex fins  204 . The heat exchange tubing  304  or  306  extends in a substantially perpendicular orientation relative to the fin array  200 . The vortex fins  204  are in an orientation substantially parallel the longitudinal axis of the heat exchange tubes  304  or  306  and at a 45° orientation relative to the flow direction of the waste gas  18 . Referring to  FIG. 6 , there is shown a sectional view of the interface between tubes  304  or  306  and the fin array  200 . A braze  206  is circumferentially disposed around the entire tube  304  or  306  to bond the respective tube to the vortex fin array  200 . 
         [0069]    The fins  204  are elevated from the surface of the vortex fin array  200  in a direction substantially parallel to the longitudinal axis of the respective heat exchange tubes  304  and  306  and are advantageously disposed on the rear section  210  of each heat exchange tube  304  and  306 , where the rear section  210  is defined as that portion of the heat exchange tube  304  and  306  which is down stream from the direction of flow of the waste heat exhaust gases  18 . In a preferred embodiment of the invention twin fins  204  are punched into the vortex fin array  200  such that each fin  204  is substantially perpendicular to the vortex fin array  200 . Each fin  204  is disposed at an angle which is approximately 45° from the direction of flow of the exhaust heat gases  18 . Each fin  204  extends upwardly and has an upper edge  206  which is substantially similar in length to the length of the fin  204  where each of the fins  204  is affixed to the vortex fin array plate  200 . The purpose of the fins  204  is to disturb the airflow around the rear section  210  of each of the heat exchanger tubes  304  and  306  for increased heat transfer. 
         [0070]    Referring to  FIG. 8  there is shown a diagrammatic representation of the flow of waste heat exhaust gases  18  around the heat exchanger pipes  304  and  306 . With the introduction of the fins  204 , the flow is disturbed on the rear section  210  represented by arrow Fd such that the flow is diverted approximately 45° causing the waste heat exhaust gas  18  to curl backward and further contact the heat exchanger pipes  304  and one  306 . 
         [0071]    Referring to  FIG. 9  there is shown an interior view of a pair of heads  400  which comprises two corresponding heads  402 A and  402 B for linking adjacent piping structures within the heat exchanger  30  and within the super heater  26  to form a continuous path through each and therefore through both, in accordance with one embodiment of the present invention. Each of the corresponding heads  402 A and  402 B is comprised of a series of semicircular virtual pipe bends  404 , each of which straddles sequential sections of straight heat exchanger tubes  304  and  306  or super heater tubes  308 , to provide the travel channel for the fluid within each tube and the travel path for the fluid through all of the tubes  304 ,  306  and  308 . As is best seen in  FIG. 9 , the inlet  405 , in the upper right most corner of head  402 A has inserted therein representative tube  304 -A 1 . The insertion and expansion of the tubes  304 ,  306  and  308  into each head  402  will be discussed hereinafter. Representative tube  304 -A 1  extends through the heat exchanger  30  and the other end is inserted into the upper left most corner of head  402 B at virtual pipe bend  404 -A 1 /A 2 . A second representative tube  304 -A 2  is inserted at the lower section of virtual pipe bend  404 -A 1 /A 2  and extends into the upper section of virtual pipe bend  404 -A 2 /A 3  located on head  402 A. As can be best appreciated by referring to  FIG. 9  and  FIG. 12 , the tubes extend between the two heads  402 A and  402 B in a substantially parallel configuration to permit the fluid to flow from one to the other with minimal obstruction. 
         [0072]    The configuration shown and describe above, when viewed with reference to  FIG. 10 , illustrates the internal pumping system which permits the fluid to travel though the piping structure in the heat exchanger  30  and the super heater  26  without the necessity of any additional mechanical pumping mechanism deployed within either the heat exchanger  30  or the super heater  26 .  FIG. 10  illustrates the parallel piping structure of the heat exchanger  30  and the super heater  26  in which the heads  402  has been removed to permit the viewing of the tubes  304 ,  306  and  308 . In the illustrative embodiment shown in  FIG. 10 , the super heater  30  is shown as a square core structure and the heat exchanger  26  is shown as a circular core structure. It will be appreciated that the core configuration can be adapted to optimize the energy separation and recovery which is accomplished by the system and will generally be a function of, among other things, the input gas temperature and the desired output super heated steam which is being delivered for end use. In  FIG. 10 , it can be seen that the super heater  30  is situated on a raised bed  150  within the system cabinet  160 . There is also a corresponding roof structure  152  over the super heater  30  such that between the raised bed  150  and the roof structure  152 , the gas  18  is required to pass around the tubes  308  of the super heater  30 , rather than being able to circumvent the tubes  308 . As the result of the circular configuration of the heat exchanger  26  which is shown in  FIG. 10 , the upper and lower circumferential portions of the heat exchanger  26  are in close proximity to the upper and lower portions of the system cabinet  160  in order to cause the gas  18  to flow over the tubes  304  and  306  of the heat exchanger  26 . 
         [0073]    The virtual pipe bends  404  provide numerous advantages over traditional pipe bends which would otherwise be used to connect sequential sections of straight pipe  304 ,  306  and  308  as is illustratively shown in  FIG. 11  and  FIG. 12 . A traditional pipe bend radius on a ¾″ tube is approximately 1.75 inches. When bending a tube or pipe, the material is generally thinner on the out side surface and crumpled on the inside edge thereby creating weaknesses. Additionally once fluid is forced to change direction rapidly, as would occur when it is forced around a tight bend, water hammer can occur and over time eat into the tube bend and causing a failure. By providing a virtual pipe bend  404 , thicker material can be employed to provide greater strength and less likelihood of failure at the pipe bend juncture. Another advantage of employing virtual pipe bends  404  on a separation and recovery system  20  is that each head  402  can be removed in order to permit the full disassembly of the heat exchanger  30  and the super heater  26  and thereby access the straight tube sections  304  and  306  or  308 , respectively to permit cleaning or repair of those sections as well as the virtual pipe bends  404 . Another advantage is that the internal straight sections  304 ,  306  and  308  can be changed to give greater heat exchange  30  volume or super heater  26  area as is required in any particular application. 
         [0074]    Referring to  FIGS. 10 ,  11 ,  12 ,  13  and  17 , there is shown a preferred embodiment of the heads  402  and a gasket  420  arrangement in order to provide a fluid return route through the virtual pipe bends  404  in the heat exchanger  30  and super heater  26  elements of the separation and recovery system  20 . A gasket  420  is interposed between the head  402  of the heat exchanger  30  core and the tube plate  422  which carries the tubes  304 ,  306  or  308 . As is shown illustratively in  FIG. 17 , two parallel and sequential heat exchanger tubes  304  or  306  (or super heater tubes  308 ) are juxtaposed to each virtual pipe bend  404 , which provides the fluid return conduit between sequential sections of straight pipe  304 ,  306  or  308 . Viewing the sequential piping designations shown in  FIG. 9  and the cross-section shown in  FIG. 12 , is can be appreciated that the flow path of the fluid medium used to separate and recover the energy from the gas  18  is in substantially continuous contact with the energy carrying gas  18 . At the same time the tubes  304 ,  306  and  308  are situated behind one another to minimize the back pressure from the heat exchanger  26  and the super heater  30 . 
         [0075]    It is to be appreciated that although water has been used as an example above, the system may also be employed with other liquids/fluids/plasmas which are able to be vaporized and transmit energy thereby. 
         [0076]    As is best illustrated in  FIGS. 12 ,  14  and  17 , each head  402  is affixed to the tube plate  422  with a gasket  420  interposed there between and two parallel and sequential heat exchanger tubes  304  or  306  are secured to the tube plates  422  such that each virtual pipe bend  404  provides the fluid return conduit between sequential sections of straight pipe  304  and  306 . A bellows  430  is welded to the external casing  432  and extends outwardly therefrom to provide a flexible segment to accommodate lateral displacement due to heat expansion of the pipes  304  or  306  which are connected to the two tube plates  422 . The exterior edge of the bellows  430  has affixed thereto a flange  434  to which the head  402  is affixed. Because the heating differential between the input side of the separation and recovery system  20  and the output side may vary by over 300° C., the expansion of the tubes  304 ,  306  and  308  and related assemblies is not equal throughout the flow area of the gas  18 . In the area closest to the input of the gas  18  where the temperature is approximately 1000° F., the tubes  308  will tend to expand more along the longitudinal axis at the entrance area of the super heater  26 . Similarly the leading area of the heat exchanger  30  will be at a higher temperature than the trailing portion of the heat exchanger  30 . In order to accommodate the differential expansion of the tubes  304 ,  306  and  308 , the bellows  430  permits the heads  402  to accommodate the differential expansion by lateral movements at either end to accommodate expansion along the longitudinal axis of the tubes  304 ,  306  and  308 . 
         [0077]    Referring to  FIG. 14  there is shown illustratively the operation of the bellows system  430  as the result of the application of energy carrying gas  18  from a heat source through the super heater  26  and the heat exchanger  30 . As can be appreciated, the greater the heat the more the individual tubes are likely to expand along their respective longitudinal axis. The bellows system  430  is designed to allow for that uneven expansion without causing a reduction in the efficiency of the unit or leaks of the superheated steam. At the same time by permitting the expansion it maintains the tubes  304 ,  306  and  308  in parallel alignment thereby permitting the steam to enter and exit the virtual pipe bends  404  of the heads  402  with minimal distortion or backflow problems. 
         [0078]    Referring to  FIG. 15  there is shown a graphic representation of the head  402  interlocked to the tube plate  422  with the gasket  420  interposed between the head  402  and the tube plate  422 . As is illustrated in  FIG. 15 , each tube  304 ,  306  or  308  sits approximately 0.5 mm proud of the exterior most edge of the tube plate  422  in the area of the virtual pipe bend  404 . A series of tube role grooves  424  are circumferentially disposed within each hole in the tube plate  422 . Each tube  304 ,  306  and  308  is pressure fitted into the respective hole such that the metal is compressed in the area where the tube and the tube plate meet. The resultant radial pressure results in the formation of tube role expansions  426  in the location of each tube which is adjacent to a corresponding tube role groove  424 . Thus, as can be seen graphically in  FIG. 15 , a mating and sealing arrangement is thereby obtained to hold each tube  304 ,  306  or  308  to the head without the need for welding. 
         [0079]    Referring to  FIG. 17  there are shown in diagrammatic representation form the core which houses the tubes  304  and  306  or  308  of either the heat exchanger  30  or the super heater  26  to the heads  404  with illustrative bellows  430  at either end of the heads  404 . It is also illustratively depicted that the bellows  430  are secured to the outer portion  432  of the housing so as to provide a secure seal and prevent any escape of gas  18 , while provide the angular movement necessary to accommodate the differential expansion of the tubes  304 ,  306  and  308 . This can be appreciated to be a representation which shows the separation and recovery system  20  in a non-heated mode where substantially equal temperature is maintained throughout. In such a state the tubes  304 ,  306  and  308  would remain approximately of equal length and the bellows  430  a would not be required to perform any differential movement of the heads  404 . In contradistinction, by referring to  FIG. 14  there are shown the variable expansion which occurs during operation of the separation and recovery system  20  and the manner in which the bellows  430  is differentially moved in accordance with the relative expansion along the lateral axis of each of the tubes  304 ,  306  and  308 . 
         [0080]    Referring to  FIG. 18 , there is shown an illustrative example of a multi-core energy separation and recovery system  20 , in accordance with another embodiment of the invention. The housing contains a series of super heaters  30  which contact the gas  18  before the heat exchangers  26  contact the gas  18 . The number of heat exchangers  26  and super heaters  30  may be varied depending upon the particular application, the input temperatures and the desired output temperatures and use to which the superheated steam is to be put. Similarly, the tubing system may run from one or more heat exchangers into a single super heater or from a single heat exchanger into one or more super heaters. As is shown in  FIG. 19 , it is a further object of this invention to provide the capability of dividing the core structure of either the heat exchanger, super heater or both so that the energy which has been separated and recovered can be used to run separate steam engines on independent or coordinated steam circuits or be use for several applications simultaneously. 
         [0000]    Test Data from a System Test 
         [0000]                                                                                                                                    Steam Expander                        Steam       Waste Heat Engine       Steam    inlet            Power       Torq   Exhaust   KW       Inlet   Pressure       KW   RPM   Nm   Temp C.   Elec   RPM   Temp C.   BAR               257.5   1350   1860   621   17.11   1295   364   37.6                        Compact Heat Exchanger                Water In       Temp Diff   Outlet           l/min       in/out   Temp C.               4.5       250.2   370.8                    
Test Data from a System with Differing Input Power and Resultant Output from Steam Engine
 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 PWR KW 
                 KW Out 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 151.52 
                 8 
               
               
                   
                 189.39 
                 10 
               
               
                   
                 227.27 
                 12 
               
               
                   
                 265.15 
                 14.5 
               
               
                   
                 303.03 
                 18 
               
               
                   
                   
               
             
          
         
       
     
         [0081]    For the purposes of promoting an understanding of the principles of the invention, reference has been made to the embodiments illustrated in the drawings and specific language used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0082]    Any experimental (including simulation) results are exemplary only and are not intended to restrict any inventive aspects of the present application. Any theory, mechanism of operation, proof, or finding stated herein is meant to further enhance understanding of the present invention and is not intended to make the present invention in any way dependent upon such theory, mechanism of operation, proof, or finding. It should be understood that while the use of the word preferable, preferably or preferred in the description above indicates that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one,” “at least a portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the selected embodiments have been shown and described and that all changes, modifications and equivalents that come within the spirit of the invention as defined herein or by any claims that follow are desired to be protected. 
         [0083]    Although the control systems have been described generally, aspects of the control algorithm and the interrelationship between the algorithm, the sensed parameters and the controlled elements are also a part of the invention. By way of example, valve designs and controls form important inventive concepts that have applicability in other separation and recovery and steam generation systems. 
         [0084]    In addition, although a methane landfill incinerator may be employed as a source of gas to power the engine which is providing the gas  18 , it is merely one example to describe the inventive concepts set forth herein. It is understood that a conventional incinerator or other source of high temperature waste heat may be employed, as well as a source of waste heat from burning of such material as natural gas, particularly flash gas at well head locations. 
         [0085]    Although the description herein recites water as the fluid, that is not meant to limit the scope of this invention and is used for illustrative purposes only. Those skilled in the art may substitute other appropriate fluids, depending on circumstances and applications, consistent with the inventive concepts disclosed herein. 
         [0086]    It will be appreciated also by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.