Radial annular component and helical axial components coupled to and extending from the radial component

A fluid distribution system (208) is provided for a reactor vessel (200) defining a reaction chamber (202). The fluid distribution system (208) may include a radial distribution component (224) positionable within the reaction chamber (202) and adjacent a vessel inlet (212) at an end portion of the reactor vessel (200). The radial distribution component (224) may include one or more annular distribution conduits (230) configured to receive a fluid mixture provided to the reactor vessel (200). The fluid distribution system (208) may also include an axial distribution component (226) positionable within the reaction chamber (202) to extend from the radial distribution component (224) along a longitudinal axis of the reactor vessel (200). The axial distribution component (230) may include a plurality of helical conduits (236) fluidly coupled with the one or more annular distribution conduits (230) and configured to receive the fluid mixture from the one or more annular distribution conduits (230) and to disperse the fuel mixture uniformly within the reaction chamber (202).

BACKGROUND

In industrial processes, chemical reactions may occur in a reaction chamber of a vessel commonly referred to as a reactor vessel. Generally, to maximize the efficacy of some chemical reactions in reactor vessels, it is advantageous to carefully control the spatial distribution of one or more fluid flow streams within the reaction chamber. Various approaches to achieve this spatial distribution are known in the art. For example, one conventional approach includes the use of a gas distribution system disposed in the reaction chamber. The gas distribution system may include a sparger in fluid communication with the reactor vessel inlet and extending along a longitudinal axis of the reactor vessel. The sparger may carry multiple transverse gas distribution arms axially spaced from one another. Each arm may define multiple ports that provide fluid communication into a region of the reaction chamber surrounding the gas distribution system.

Although the gas distribution system disclosed above may provide suitable fluid flow distribution, the gas distribution system may have certain drawbacks. For example, the gas distribution system may have prohibitive mechanical limitations in applications including reaction chambers filled or loaded with solid particulate filler provided for thermal mass and/or catalytic effects in certain reactions. Often, in such cases, the gas distribution system disposed in the reaction chamber has to accommodate relative motion between the solid particulate filler, the reactor vessel, and the gas distribution system components. This relative motion can be caused by uneven heating and differing thermal expansion coefficients of the various gas distribution system components, e.g., the sparger and transverse distribution arms. In particular, when the reaction vessel is subject to heat-up or cool-down transients, the gas distribution system may move vertically with respect to the solid particulate filler. Accordingly, such movement may put deleterious stress levels on at least the transverse distribution arms and the particles of the solid particulate filler, thereby resulting in several failure modes arising from pulverized particles of the solid particulate filler and/or compromised gas distribution system components.

What is needed, therefore, is a fluid distribution system for a reactor vessel which provides suitable spatial distribution of one or more fluid streams within the reaction chamber of the reactor vessel while addressing the structural and functional drawbacks noted above.

SUMMARY

Embodiments of the disclosure may provide a fluid distribution system for a reactor vessel defining a reaction chamber. The fluid distribution system may include a radial distribution component positionable within the reaction chamber and adjacent a vessel inlet at an end portion of the reactor vessel. The radial distribution component may include a fluid distribution system inlet configured to couple with the vessel inlet and receive a fluid mixture provided to the reactor vessel. The radial distribution component may also include one or more annular distribution conduits fluidly coupled with the fluid distribution system inlet and configured to receive the fluid mixture provided to the fluid distribution system. The fluid distribution system may also include an axial distribution component positionable within the reaction chamber to extend from the radial distribution component along a longitudinal axis of the reactor vessel. The axial distribution component may include a plurality of helical conduits fluidly coupled with the one or more annular distribution conduits and configured to receive the fluid mixture from the one or more annular distribution conduits and to disperse the fuel mixture uniformly within the reaction chamber.

Embodiments of the disclosure may further provide a reactor vessel. The reactor vessel may include a longitudinal axis and a housing extending along the longitudinal axis and having an outer surface and an inner surface, the inner surface defining a reaction chamber configured to receive a dispersed fluid mixture therein. The reactor vessel may also include a vessel inlet disposed at a first end of the housing and fluidly coupled to the reaction chamber, and a vessel outlet disposed at a second end of the housing axially opposing the first end of the housing, the vessel outlet fluidly coupled to the reaction chamber. The reactor vessel may further include a fluid distribution system disposed within the reaction chamber and fluidly coupled to the vessel inlet. The fluid distribution system may include a radial distribution component disposed adjacent the first end of the housing and fluidly coupled to the vessel inlet. The radial distribution component may be configured to receive a fluid mixture provided to the reactor vessel. The fluid distribution system may also include an axial distribution component extending from the radial distribution component along the longitudinal axis of the reactor vessel. The axial distribution component may include a plurality of helical conduits fluidly coupled with the radial distribution component and configured to receive the fluid mixture from the radial distribution component and to disperse the fuel mixture uniformly within the reaction chamber.

Embodiments of the disclosure may further provide a gas turbine system. The gas turbine system may include a compressor configured to receive a fluid mixture from a fuel source and an oxygen source and compress the fluid mixture. The fluid mixture may include a fuel component and an oxygen component. The gas turbine system may also include a reactor vessel fluidly coupled to the compressor and configured to receive a compressed fluid mixture in a reaction chamber defined by an inner surface of a housing of the reactor vessel and to oxidize the fuel component of the fluid mixture, thereby generating thermal energy. The reactor vessel may include a fluid distribution system configured to uniformly disperse the compressed fluid mixture within the reaction chamber. The fluid distribution system may include a radial distribution component disposed adjacent an end portion of the housing and fluidly coupled to a vessel inlet of the reactor vessel. The radial distribution component may be configured to receive the compressed fluid mixture provided to the reactor vessel. The fluid distribution system may also include an axial distribution component extending from the radial distribution component along a longitudinal axis of the reactor vessel. The axial distribution component may include a plurality of helical conduits fluidly coupled with the radial distribution component and configured to receive the compressed fluid mixture from the radial distribution component and to disperse the compressed fluid mixture uniformly within the reaction chamber. The gas turbine system may further include an expander fluidly coupled to the reactor vessel and configured to convert the thermal energy generated by the compressed fluid mixture to mechanical energy.

DETAILED DESCRIPTION

FIG. 1illustrates a schematic of an exemplary gas turbine system100, according to one or more embodiments of the disclosure. The gas turbine system100may be configured to oxidize fuel and use the heat energy released by the oxidation process to generate mechanical energy and, in some embodiments, to generate electrical power. The fuel may be a component of a fluid mixture supplied at least in part by an oxygen source102and a fuel source104in fluid communication with the gas turbine system100. As configured, the gas turbine system100illustrated inFIG. 1may oxidize all or substantially all of the fuel component of the fluid mixture, such that little or no fuel is wasted or discharged into the environment.

The oxidation of the fuel component of the fluid mixture may occur in a reactor vessel106of the gas turbine system100. Referring now toFIG. 2with continued reference toFIG. 1,FIG. 2illustrates a perspective view of the reactor vessel200, with a portion removed for visibility, which may be used in place of the reactor vessel106of the gas turbine system100ofFIG. 1, according to one or more embodiments of the disclosure. The reactor vessel200may be configured to receive the fluid mixture and to oxidize the fuel component of the fluid mixture in a reaction chamber202defined by an interior perimeter204of a housing206of the reactor vessel200. The reactor vessel200may include a fluid distribution system208disposed within the reaction chamber202and configured to distribute the fluid mixture including at least the fuel component and an oxygen component from the oxygen source102throughout one or more oxidation zones in the reaction chamber202where the fuel component of the fluid mixture is oxidized. In an exemplary embodiment, the fluid distribution system208may distribute the fluid mixture into multiple locations in one or more oxidation zones of the reaction chamber202, thereby sustaining oxidation by receiving heat from the reaction chamber202but imparting heat of oxidation back to the reaction chamber202to sustain a continuous oxidation process as additional fluid mixture flows into the reaction chamber202.

The fuel source104may be configured to provide the fuel component of the fluid mixture to the gas turbine system100for sustaining the oxidation process in the reaction chamber202. The fuel source may be, in one or more embodiments, a subterranean well, a pipeline, a storage tank, or an output or byproduct from another chemical process at the site of the gas turbine system100. For example, the fuel source may be or include a hydrocarbon well, a hydrocarbon pipeline, a cattle belch, a swampland, a rice farm, and fermented organic matter. Other fuel source examples may be or include manure, municipal waste, wetlands, and drilling and recover operations.

The fuel source104may provide a single type of fuel and/or multiple types of fuels, one or all of which may be oxidized in the same reaction chamber202. The fuel source may provide hydrocarbon fuels including, but not limited to, methane, ethane, propane, butane, kerosene, and gasoline. In other embodiments, the fuel source may provide a fuel including include nitrogen or carbon dioxide in addition to one or more hydrocarbons. In still other embodiments, the fuel source may provide hydrogen fuel. The fuel provided by the fuel source104to the gas turbine system100may be initially gaseous or may be in a liquid or solid phase before being converted to a gas or vapor. In some embodiments, the fuel source may include a gasifier that generates gaseous fuel from solids. In other embodiments, the fuel source may provide fuel mixed with water, and fuel from the fuel source104includes water vapor.

The oxygen source102may be configured to provide oxygen for the oxidation process in the reaction chamber202. The oxygen source102may provide a gas containing oxygen, which may be mixed with the fuel from the fuel source104prior to oxidizing the fuel component of the fluid mixture. In one embodiment, the oxygen source102may be or include air from the atmosphere surrounding the gas turbine system100. In another embodiment, the oxygen source102may be or include air from a tank or cylinder of compressed or non-compressed air. The air provided from the oxygen source102may contain oxygen at any concentration sufficient for the oxidation of the fuel. In addition to oxygen, the air provided from the oxygen source102may include other gases including, but not limited to, nitrogen and argon.

The gas turbine system100may further include a compressor108and a gas expander110. In embodiments in which electrical power is generated, the gas turbine system100may also include a generator112. As illustrated inFIG. 1, the generator112may be mechanically coupled to the gas expander110via a common shaft114. In other embodiments, a rotary shaft (not shown) of the generator112and a drive shaft (not shown) of the gas expander110may be coupled via a coupling or a gearbox (not shown). In operation, the heat energy released by the oxidation process in the reactor vessel200may be converted to mechanical energy via the gas expander110. In embodiments including the generator112, the converted mechanical energy of the gas expander110may drive the generator112directly via the common shaft114, or indirectly via the gearbox, thereby generating electrical power. The generated electrical power may be used to power other components (e.g., actuators, control systems, sensors, and electric motors) of the gas turbine system100or may be provided to an electrical grid116in electrical communication with the gas turbine system100.

In some embodiments, the compressor108may be coupled to the gas expander110via the common shaft114. In other embodiments, a rotary shaft (not shown) of the compressor108and a drive shaft (not shown) of the gas expander110may be coupled via a coupling or a gearbox (not shown). The gas expander110may drive the compressor108directly via the common shaft114, or indirectly via the gearbox. In other embodiments, the compressor108may be operative coupled to and driven by a driver other than the gas expander110. For example, the driver may be a motor and more specifically may be an electric motor, such as a permanent magnet motor, and may include a stator (not shown) and a rotor (not shown). It will be appreciated, however, that other embodiments may employ other types of electric motors including, but not limited to, synchronous motors, induction motors, and brushed DC motors. The driver may also be a hydraulic motor, an internal combustion engine, a steam turbine, or any other device capable of driving the compressor either directly or through a power train.

The compressor108may be fluidly coupled to the fuel source104and the oxygen source102via lines118,120, and122. Accordingly, the oxygen provided from the oxygen source102and the fuel provided from the fuel source104may be mixed with one another and the resulting fluid mixture having a fuel component and an oxygen component may be fed to the compressor108via line118. The gas turbine system100may further include a mixer (not shown) configured to receive a fluid including oxygen from the oxygen source102via line120and a fluid including fuel from the fuel source104via line122to mix the fluids received and to provide the resulting fluid mixture to the compressor108via line118. In other embodiments, the oxygen may be mixed with the fuel without a mixer. For example, the oxygen may be fed via line120to mix with the fuel in line122and form the fluid mixture within line122before proceeding to the compressor108via line118. The fluid mixture provided to the compressor108may be a homogeneous mixture, or in some embodiments, may be a heterogeneous mixture.

The compressor108may be configured to compress the fluid mixture provided from the fuel source104and the oxygen source102. To that end, the fluid mixture may flow through a compressor inlet (not shown) of the compressor108, where the fluid mixture in an exemplary embodiment may be drawn to and through an impeller (not shown) of the compressor108driven by the gas expander110, thereby increasing the static pressure and/or velocity of the fluid mixture. The fluid mixture may be directed to a diffuser (not shown) of the compressor108, where kinetic energy of the fluid mixture is converted into increased static pressure. The compressed fluid mixture may be discharged from the compressor108to line124via a compressor outlet (not shown).

The oxidation process typically requires heat for the fuel component of the fluid mixture to be oxidized. Accordingly, in an exemplary embodiment, the gas turbine system100may also include a heat exchanger126fluidly coupled with the compressor108via line124and configured to pre-heat the fluid mixture received from the compressor108prior to the fluid mixture being fed into the reactor vessel200. The heat exchanger126may also be fluidly coupled with the gas expander110and configured to receive exhaust gas from the gas expander110via line128. The heat exchanger126may utilize heat provided from the exhaust gas to pre-heat the fluid mixture flowing therethrough. In an exemplary embodiment, the heat exchanger126may transfer thermal energy from the higher temperature exhaust gas provided by the gas expander110to the lower temperature fluid mixture received from the compressor108, thereby pre-heating the fluid mixture. Accordingly, the heat exchanger126may be in some embodiments a gas-to-gas heat exchanger, such as a shell and tube heat exchanger, adapted to also receive a flow of the exhaust gas as a heating medium for increasing the temperature of the fluid mixture. In other embodiments, the heat exchanger126may be a plate/fin heat exchanger or a printed circuit heat exchanger, without departing from the scope of the disclosure. In another embodiment, the heat exchanger126may utilize heat provided from an external source (e.g., waste heat stream) in place of or in addition to the exhaust gas from the gas expander110to pre-heat the fluid mixture flowing therethrough.

In an exemplary embodiment, the reactor vessel200may be fluidly coupled with the heat exchanger126and thus may receive the pre-heated fluid mixture from the heat exchanger126via line130. In another embodiment, the reactor vessel200may be directly fluidly coupled to the compressor108, such that the compressor108may communicate the fluid mixture into the reactor vessel200without the fluid mixture being pre-heated. The reaction chamber202may be configured to retain the fluid mixture received from the heat exchanger126, or compressor108in other embodiments, and to retain the fluid mixture in the reaction chamber202as the fuel component of the fluid mixture oxidizes.

As most clearly seen inFIG. 2, the reactor vessel200may have a longitudinal axis210extending along an axial length of the reactor vessel200, and the housing206of the reactor vessel200may form or be coupled to a vessel inlet212at an axial end214thereof. The vessel inlet212may be in fluid communication with the heat exchanger126(or compressor108in embodiments in which the heat exchanger126is absent), such that the fluid mixture may enter the reaction chamber202via line130and the vessel inlet212. The housing206of the reactor vessel200may form or be coupled to a vessel outlet216at an axial end218thereof axially opposing the vessel inlet212. The vessel outlet216may be in fluid communication with the gas expander110, such that the oxidized fluid mixture may exit the reaction chamber202via the vessel outlet216and line132and enter the gas expander110.

The housing206may be a single unitary piece (not shown) or may be formed from separate housing components206aand206bas illustrated inFIG. 2. The separate housing components206a,206bmay include a first housing component206aincluding the vessel inlet212and a generally cylindrical sidewall220, and a second housing component206bincluding the vessel outlet216. The first and second housing components206a,206bmay be coupled to each other via one or more fasteners (not shown). Exemplary fasteners include, but are not limited to, bolts, clamps, and the like.

The interior perimeter204or inner surface of the housing206defining the reaction chamber202may be lined with insulating refractory material. In addition to the refractory material liner, the reaction chamber202may be filled with a solid particulate, referred to as filler material222. The filler material222may be a high temperature, heat-absorbing and/or heat-resistant material, such as ceramic or rock. The filler material222may have a thermal mass that stabilizes temperatures for gradual oxidation of the fuel by transmitting heat to the incoming gases of the fluid mixture and receiving heat from the oxidized gases. In some cases, the thermal mass of the refractory material liner in the reaction chamber202may act as a dampener, absorbing heat and preventing excessive temperatures that could damage the gas expander110and/or produce unwanted byproducts (e.g., nitrogen oxides, carbon dioxides, volatile organic compounds and/or others). In some cases, the thermal mass of the refractory material liner in the reaction chamber202may provide a temporary source of heat energy, which may help sustain oxidation of the fuel.

Generally, the reaction chamber202defined by the inner perimeter204of the housing206may have any geometry and/or orientation, and may define a primary direction of flow of the fluid mixture through the reaction chamber202(e.g., from the vessel inlet212to the vessel outlet216) dependent on the structure of the reaction chamber202. For example, the reaction chamber202shown inFIG. 2has an internal geometry with a vessel outlet216near the upper axial end218of the reaction chamber202. As such, inFIG. 2, the fluid mixture flows through the reaction chamber202primarily in an upward direction. Notably, within the primary direction of flow of the fluid mixture through the reaction chamber202, there may be non-primary flows such as localized swirls, eddies, slipstreams and otherwise.

The volume and shape of the reaction chamber202in conjunction with the fluid distribution system208may be sized and configured to provide a controlled flow and flow rate through the reaction chamber202to allow for sufficient dwell time for the complete oxidation of the fuel component of the fluid mixture. To that end, the reactor vessel200may include one or more sensors (not shown) disposed in the reaction chamber202and configured to detect properties such as temperature, pressure, flow rate, or other properties relevant to the startup and/or operation of the gas turbine system100. The reaction chamber202may also include internal structures and/or devices (not shown) that control aspects of the oxidation process. For example, the reaction chamber may include flow diverters, valves, and/or other features that control temperature, pressure, flow rate, and/or other aspects of fluids in the reaction chamber202.

As discussed, the fluid distribution system208may be disposed in the reaction chamber202of the reactor vessel200.FIGS. 3A-3Dfurther illustrate multiple views of the fluid distribution system208. Specifically,FIGS. 3A-3Cillustrate respective rear, top, and isometric views of the fluid distribution system208ofFIG. 2, according to one or more embodiments of the disclosure.FIG. 3Dillustrates an enlarged view of the portion of the fluid distribution system208indicated by the box labeled3D ofFIG. 3C, according to one or more embodiments of the disclosure.

The fluid distribution system208may be disposed within the reaction chamber202and fluidly coupled with the vessel inlet212. As arranged, the fluid distribution system208may be configured to disperse the fluid mixture into the reaction chamber202in multiple locations therein to distribute the fluid mixture substantially throughout the reaction chamber202. In an exemplary embodiment, the fluid distribution system208may distribute the fluid mixture such that heat released by oxidization of the fuel component in the fluid mixture maintains a temperature substantially throughout the reaction chamber202at a temperature sufficient to oxidize the fuel component in the fluid mixture.

The fluid distribution system208may include a radial distribution component224and an axial distribution component226fluidly coupled with one another. The radial distribution component224may be disposed adjacent the vessel inlet212and may include a fluid distribution system inlet228fluidly coupled with the vessel inlet212and one or more annular distribution conduits230(two are shown) fluidly coupled with one another and with the fluid distribution system inlet228. Although two annular distribution conduits230are illustrated, one of ordinary skill in the art will be appreciate that the disclosure is not limited thereto, and the fluid distribution system208may include one annular distribution conduit230in one embodiment, and in other embodiments, the distribution may include three or more annular distribution conduits230.

In an exemplary embodiment, the fluid distribution system inlet228may have a radially extending portion232and an axially extending portion234, thereby forming an elbow fluidly connecting the vessel inlet212and the annular distribution conduits230. In another embodiment, the fluid distribution system inlet228may form a T-shape, thereby fluidly connecting the vessel inlet212and the one or more annular distribution conduits230. The configuration of the fluid distribution system inlet228may vary based at least on the fluid mixture, the flow rate of the fluid mixture, the configuration of the reaction chamber202and the components included therein. In an exemplary embodiment, the fluid distribution system inlet228may be configured to position the annular distribution conduits230adjacent, e.g., in close proximity to, the axial end214of the reactor vessel200having the vessel inlet212. By positioning the annular distribution conduits230accordingly, the annular distribution conduits230may be less susceptible to axial relative motions during thermal transients.

The annular distribution conduits230may be disposed in a nesting relationship such that each annular distribution conduit230is radially offset from another annular distribution conduit230as disposed in the reaction chamber202. As arranged, the annular distribution conduits230may be concentric, and each annular distribution conduit230may have opposing ends terminating in the fluid distribution system inlet228, such that fluid communication may be provided between the fluid distribution system inlet228and the respective annular distribution conduit230. As illustrated, each end of the annular distribution conduit230is fluidly coupled with the fluid distribution system inlet228along the radially extending portion thereof232; however, one of ordinary skill in the art will be appreciate that the disclosure is not limited thereto, and each end of the annular distribution conduit230may be fluidly coupled with the fluid distribution system inlet228along the axially extending portion234thereof in some embodiments.

As discussed, the axial distribution component226of the fluid distribution system208may be fluidly coupled with the radial distribution component224and disposed within the reaction chamber202. In one or more embodiments, the axial distribution component226may include a plurality of helical conduits236extending from the annular distribution conduits230and along the longitudinal axis210of the reactor vessel200. In another embodiment, the axial distribution component226may include a plurality of helical conduits236extending from the fluid distribution system inlet228and along the longitudinal axis210of the reactor vessel200. In other embodiments, the axial distribution component226may include a plurality of helical conduits236extending from the fluid distribution system inlet228and one or more of the annular distribution conduits230and along the longitudinal axis210of the reactor vessel200. As illustrated inFIG. 2, the plurality of helical conduits236may extend from the fluid distribution system inlet228and each of the annular distribution conduits230and along the longitudinal axis210of the reactor vessel200.

The plurality of helical conduits236may be fluidly coupled with the annular distribution conduits230and arranged circumferentially spaced from one another along each annular distribution conduit230. In an exemplary embodiment, each of the helical conduits236is uniformly spaced from one another along each annular distribution conduit230. As uniformly spaced along each annular distribution conduit230, the plurality of helical conduits236may be configured to provide a uniform spatial distribution of the fluid mixture flowing therethrough and into the reaction chamber202. The number of helical conduits236in the axial distribution component226may be based at least in part on the intended flow capacity of the fluid distribution system208including the radial distribution component224thereof.

In an exemplary embodiment, each of the helical conduits236may extend substantially the axial length of the reaction chamber202. As most clearly illustrated inFIG. 3B, each of the helical conduits may have a helix axis238about which the helical conduit236turns or curves in a spiral form. Each complete turn (360 degree turn) of the helical conduit236about the helix axis238may define the diameter240of the helical conduit. In an exemplary embodiment, the diameter240of each of the helical conduits236may be about a third of a lateral diameter242of the reaction chamber.

A tangent line244at any point along the helical conduit236may make a constant angle α with a transverse axis246perpendicular to the helix axis238. Such an angle α may be referred to herein as a helix angle α and is illustrated most clearly inFIG. 3A. In an exemplary embodiment, the helix angle α may be greater than about forty-five degrees to minimize relative movement effects. In another embodiment, the helix angle α may be greater than about fifty degrees. In another embodiment, the helix angle α may be greater than about fifty-five degrees. In another embodiment, the helix angle α may be greater than about sixty degrees.

As shown inFIG. 3D, each helical conduit236may have a tubular sidewall248forming one or more nozzles250configured to spatially distribute the fluid mixture into the reaction chamber202. In one or more embodiments, each of the one or more nozzles250may be cast as a separate piece and may be coupled to the helical conduit236via a welded connection or other suitable coupling or fastening method known in the art. Each nozzle250may be formed from a generally conical inward distortion252and a generally conical outward distortion254of the tubular sidewall248defining a fluid dispersion orifice256oriented to disperse fluid mixture flowing therethrough toward the vessel inlet212as indicated by arrow F. One or more of the fluid dispersion orifices256may be sized and configured to provide a fixed flow capacity with a favorable pressure drop and flow dispersion characteristics.