Abstract:
A multistage two-phase turbine having multiple stages to receive fluid, each stage having an inlet and outlet comprising nozzles at the inlet to each stage to accelerate the fluid that consists of a mixture of gas and liquid, to form two-phase jets; a rotating separator structure to receive and separate the two-phase jets into gas streams and liquid stream in each stage; the turbine having a rotating output shaft, and there being structure to convert the kinetic energy of the liquid streams into shaft power; structure to remove the separated liquid from at least one stage and transfer it to nozzles at the next stage; structure to remove the separated liquid from the last stage and transfer it to primary outlet structure; and structure to remove the separated gas from at least one stage and transfer it to a secondary outlet structure.

Description:
BACKGROUND OF THE INVENTION 
     This application is a continuation of prior U.S. application Ser. No. 09/303,631 filed May 3, 1999, now U.S. Pat. No. 6,122,915 which is a continuation of prior U.S. application Ser. No. 08/761,220 filed Dec. 6, 1996, now U.S. Pat. No. 5,946,915, which is a divisional of prior U.S. Ser. No. 08/472,657 filed Jun. 7, 1995, now U.S. Pat. No. 5,664,420, which is a continuation in part of prior U.S. application Ser. No. 08/378,733 filed Jan. 26, 1995 now U.S. Pat. No. 5,525,034, which is a continuation in part of prior U.S. application Ser. No. 07/878,605 filed May 5, 1992 now U.S. Pat. No. 5,385,446. 
    
    
     This invention relates generally to two-phase turbines, and more particularly to an improved multistage, single rotor turbine driven by an input mixture of gas and liquid, and capable of generating shaft power, while simultaneously separating the gas and liquid phase components in one or more expansions, and also increasing the pressure of the separated liquid phase component. 
     There is need for an improved two-phase turbine having the above multistage characteristics. There is need for improved processes in which such a turbine is employed. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide an improved turbine structure and processes in which it is employed meeting the above needs. Basically, the improved multistage two-phase turbine has one or more stages to receive fluid, each stage having an inlet and an outlet, and comprises: 
     a) nozzles at the inlet to each stage to accelerate the fluid that consists of a mixture of gas and liquid, to form two-phase jets, 
     b) a rotating separator structure to receive and separate the two-phase jets into gas streams and liquid streams in each stage, 
     c) the turbine having a rotating output shaft, and there being means to convert the kinetic energy of the liquid streams into shaft power, 
     d) means to remove the separated liquid from at least one stage and transfer it to nozzles at the next stage, 
     e) means to remove the separated liquid from the last stage and transfer it to primary outlet structure, 
     f) means to remove the separated gas from each stage and transfer it to secondary outlet structure or optionally, 
     g) means to remove the separated gas from each stage and transfer it to the nozzles at the next stage. 
     It is another object to provide such a turbine, and including means in at least one stage to convert the kinetic energy of the gas stream to shaft power. Means may also be employed in at least one stage to recover the kinetic energy of the separated liquid stream as pressure. 
     Another object is to provide turbine axial flow blades associated with at least one rotating separator structure to convert the gas stream kinetic energy to shaft power. 
     A further object includes the provision of means separating the stages wherein the nozzles are an integral part of the means. 
     Yet another object includes the provision of means to separate two components of the separated liquid stream from at least one stage, and to separately remove each liquid component from the stage. In this regard, a diffuser may be positioned to remove the heavier of two liquid components from at least one stage, or a liquid stream receiving nozzle may be employed to remove the heavier of two liquid components from at least one stage. Additionally, structure may be provided to coalesce a dispersed liquid component into a continuous phase in the rotating separator structure of at least one stage. 
     The improved turbine may be used in a process requiring one or more successive reductions in pressure of a mixture of steam and brine flowing from a geothermal well. The referenced turbine produces power, while separating the steam, so that it can be utilized at lower pressures in a conventional steam turbine. The separated brine pressure can be increased such that it can be re-injected into the ground with no pump. 
     The turbine can also be used in a process involving combined liquid and gas flows require several successive reductions in pressure with separation at each succeeding pressure level. One example is the production of oil and gas from a high pressure well. The two-phase flow is flashed at several pressures, each lower than the preceding pressure. At each flash the gas is separated from the liquid, so that it can be recompressed. The separated liquid is subsequently flashed to a lower pressure and the evolved gas again separated. 
     The turbine can also be utilized in a process requiring multiple two-phase flashes in the conversion of waste heat from a prime mover to useful power. In this regard, if a liquid is heated and flashed several times to produce vapor at several pressures to operate a multiple pressure vapor turbine, a more efficient conversion of the waste heat to power is possible. 
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
    
    
     DRAWING DESCRIPTION 
     FIG. 1 is a system block diagram showing use of a two-phase turbine in generation of power from geothermal fluids; 
     FIG. 2 is a system block diagram showing a high production oil/gas process with four stages of pressure reduction; 
     FIG. 3 is a graph of heat transfer vs. temperature, waste heat bottoming cycles; 
     FIG. 4 is a system block diagram showing coupling of a multistage two-phase turbine with a steam turbine and generator; 
     FIG. 5 is an axial cross section taken through a multistage two-phase turbine; 
     FIG. 6 is a cross section taken through diffuser and nozzle structure of a multistage two-phase turbine; 
     FIG. 7 is an axial cross section taken through a multistage two-phase turbine characterized by processing of two separated liquid stream components; 
     FIG. 7 a  is a fragmentary section showing details of a rotor with a diffuser for water; 
     FIG. 7 b  is a fragmentary section showing details of a rotor with a liquid nozzle for water; 
     FIG. 8 is a partial axial cross section taken through the installation of a multistage, or single stage, two-phase turbine in the bore of an oil and gas well, such that separated water is injected into another part of the field; 
     FIG. 9 is a partial axial cross section taken through the installation of a multistage or single stage two-phase turbine in the bore of an oil and gas well, such that separated water is transported to the surface; 
     FIG. 10 is a system block diagram showing a multistage, or single stage, two-phase turbine installed on the sea floor, producing separated gas, oil and water streams and power from an oil and gas well; and 
     FIG. 11 is a system block diagram showing a multistage, or single stage, two-phase turbine installed on the sea floor, producing separated gas, oil, and water streams from an oil and gas well, and driving a gas compressor to produce high-pressure gas. 
    
    
     DETAILED DESCRIPTION 
     A single rotor turbine has previously been developed to generate power from a mixture of gas and liquid, while simultaneously separating the gas from the liquid and increasing the pressure of the separated liquid phase. This turbine produces power from a single reduction in pressure of the mixture of gas and liquid. 
     An example is the reduction of pressure of a mixture of steam and brine flowing from a geothermal well, as seen in FIG.  1 . The referenced turbine  10  drives a generator  11  to produce power, while separating the steam, so that it can be utilized at a lower pressure in a conventional steam turbine. See steam flow at  12  to a flash tank  13 , and steam flow at  14 , to the steam turbine. The pressure of separated brine at  15  can be increased such that it can be re-injected into the ground at  16  with no pump. The geothermal wall is seen at  17 . 
     Some processes involving combined liquid and gas flows require several successive reductions in pressure with separation at each succeeding pressure level. One example, as seen in FIG. 2, is the production of oil and gas from a high pressure well. The two-phase flow at  20  is flashed at several pressures, noted at  21 - 24 , each lower than the preceding pressure. At each flash, the gas is separated from the liquid, so that it can be recompressed. See gas discharges at  21   a  to  24   a  connected to recompression stages  25  to  27  discharging at  28 . The separated liquid is subsequently flashed to a lower pressure, and the evolved gas again separated. See liquid lines  30 - 33 . 
     Another process requiring multiple two-phase flashes is the conversion of waste heat from a prime mover to useful power. FIG. 3 shows the transfer of heat from an exhaust stream into a vaporizing fluid (curve A). The constant temperature region of the vaporizing fluid means the energy conversion efficiency at each point (for example T v ) is much lower than the efficiency which could be attained if energy conversion occurred at the exhaust temperature T. The Carnot efficiency, η c , for converting the element of heat, dQ, to power is η c =1−T 3 /T v  for the vapor bottoming cycle of FIG.  3 . The Carnot efficiency for a cycle operating at the hot gas temperature, T, is η c =1−T 3 /T. If liquid is heated (curve B) and flashed several times to produce vapor at several pressures to operate a multiple pressure vapor turbine, a more efficient conversion of the waste heat to power is possible. 
     FIG. 4 shows a power cycle, which operates on this principle. Liquid is heated in flowing from  113  to  104  in a heat exchanger  119  by heat from an exhaust steam at  102  to  103  in duct  99 . The liquid is flashed to a lower pressure at  105  in a multistage two-phase turbine  114  (to be described later). The vapor from the turbine flows through a superheater  120  and is heated to a higher temperature at  106 . The vapor is then ducted to the inlet of a vapor turbine  115 . 
     The separated liquid at pressure within the multistage two-phase turbine is flashed to a lower pressure at  107 . The vapor is separated at pressure  107  and is ducted to an induction port  115   a  of the vapor turbine  115 . The separated liquid is flashed within the multistage two-phase turbine to a yet lower pressure at  108 . The vapor is separated at pressure  108  and is ducted to another induction port  115   b  of the vapor turbine. 
     The mixed vapor flows within the vapor turbine  115  are expanded to an outlet pressure at  109 . The vapor flows are condensed in a condenser  116  and pumped to a mixer  117 . 
     The separated liquid at  108  is internally pressurized and delivered at  118 , and flows to the mixer  117  where it is mixed with the condensed vapors. The resulting liquid flow is pumped back to the liquid heat exchanger  119 . 
     For some applications, the liquid heat exchanger  119  may be used to produce a mixture of heated liquid and vapor at  104 , which is ducted to the multistage two-phase turbine  114  and flashed to lower pressure at  105 . 
     The multistage two-phase turbine utilized in the power cycle shown in FIG. 4 is seen in FIG. 5. A gas and liquid mixture, or flashing liquid, is introduced through a port  234 , to nozzles  213 . The pressure is reduced in the nozzles, accelerating the gas and liquid mixture, to form high-velocity, two-phase jets at  201 . The jets impinge onto a rotating separator member  214  of a multistage rotor  215  separating the liquid into a liquid layer  203 . 
     If the tangential jet velocity is greater than the circumferential velocity of the rotating separator member  214 , the liquid velocity is reduced by frictional coupling to the member, and power is transferred to the rotor. If the tangential velocity is less, the liquid velocity is increased by frictional coupling to the member, and power is transferred from the rotor. This mechanism provides a method for producing power from high velocity jets in one stage of the rotor, to be used to increase the liquid velocity in another stage of the rotor, where the jet velocity may be lower. 
     The separated gas flows through gas blading  221  to the first exit port  202 . The axial gas blading shown converts the gas kinetic energy to power of the rotor. 
     The separated liquid from the first rotating separator flows into a scoop  216  and is transferred through a pipe  204  and passage  217  in the diaphragm between the first and second stage to nozzles  205 . The pressure is lowered in the nozzles to the pressure in the next stage. High velocity two-phase jets  218  are formed, which impinge on the second stage separator rotor  219 . The separated liquid forms a layer  220 . The separated gas flows through gas blades  206 , transferring power to the rotor, and subsequently out the second stage port  207 . 
     The separated liquid from the second rotating separator flows into a scoop  222  and is fed by a pipe  208  into a passage in the diaphragm between the second and third stage. The passage feeds the liquid into nozzles  224 , where it is flashed to the pressure in the third stage forming high velocity jets  209 . The two-phase jets impinge on the third stage separator rotor  225 . The liquid separates, forming a layer  226 . The separated gas flows through gas blades  210 , transferring power to the rotor. The gas then leaves through the third stage port  211 . 
     The separated liquid flows into a scoop  227 , which may be contoured to slow the liquid to a lower velocity than the entering velocity, effecting a pressure increase. The liquid is ducted through a pipe  212  to the liquid exit port  218 . 
     The rotating structure  215 , shaft  233 , and separator rotors  214 ,  219 , and  225  are fixed together, and all rotate as one body at the same speed. Seals  229  and  230  are provided at each end to seal the gas from leaking. Seals  231  and  232  are provided in each diaphragm to seal the gas from leaking from a stage at high pressure to one at lower pressure. 
     A detail of a scoop or diffuser arrangement is shown in FIG.  6 . The separated liquid layer  301  enters the scoop  302 . The scoop structure  303  may feature a diverging area, in which case the liquid velocity is slowed to a lower value than the entering value at  302 . 
     The liquid enters a passage  304  and flows to a nozzle  305 , which is interconnected to the passage. The pressure is reduced in the nozzle, causing the liquid to flash and form a two-phase jet at  306 . The two-phase jet impinges on the rotating separator surface  307  of the next stage, forming a liquid layer  308 . The separated gas flows through gas blades  309 . 
     The complex oil and gas process shown in FIG. 2 may be replaced by a single multistage two-phase turbine shown in FIG. 7, simplifying and greatly reducing the size of needed apparatus. 
     A high-pressure mixture of oil, gas, and water is introduced to the unit through inlet ports ( 1 )′. The mixture flows through passages ( 2 )′ to two-phase nozzles ( 3 )′. 
     The pressure is reduced in the nozzles, causing the mixture to be accelerated and additional light components in the oil to vaporize. Two-phase jets ( 4 )′ are formed. The jets impinge on the rotating surface of the first stage rotating separator surface ( 5 )′. Energy transfer occurs, as described in FIG.  5 . 
     The liquid forms a layer of oil and water. The oil, which is lighter, forms a layer on the surface and flows through passages ( 8 )′ to the opposite side of the supporting disc ( 10 )′. The oil is collected by a scoop ( 9 )′ which is submerged in the oil layer. 
     The water, which has a higher density than the oil, is centrifuged to the outer part ( 7 )′ of the rotating separator ( 11 )′. A coalescing structure ( 12 )′ may be provided to assist the separation of the water from the oil. The water, at high pressure, due to the centrifugal force, expands through liquid nozzles ( 13 )′, flowing through passages ( 14 )′ to an annulus ( 15 )′. The water flows from the turbine through an outlet port ( 16 )′. The reaction forces from the water jets leaving the nozzles ( 13 )′ transfer power to the rotor. 
     Another method of removing the separated water is shown in FIG. 7 a . A diffuser  401  is wholly submerged in the water layer  402 . The water flows out the tube  403  at a rate controlled by the inlet size and a throttling valve. This method may be used for any stage. 
     Referring back to FIG. 7, the separated gas flows through gas blades ( 17 )′, which may be radial inflow as shown, or axial flow, and leaves the turbine through an exit port ( 18 )′. Kinetic energy and pressure in the gas is converted to power in the rotor by the gas blades. 
     The separated oil from the first stage flows from the diffuser ( 9 )′ into passages ( 19 )′, which carry the flow to two-phase nozzles ( 20 )′. The flow is flashed to the pressure of the second stage in the nozzles, causing additional light components of the oil to vaporize, forming two-phase jets ( 21 )′. The jets impinge on the surface ( 22 )′ of the second rotating separator structure ( 23 )′ forming a layer of oil. The oil flows to the opposite side of the supporting disc ( 25 )′ through passages ( 24 )′. The oil enters the inlet of a diffuser ( 26 )′ immersed in the oil layer. The oil flows into passages ( 27 )′, which feed nozzles ( 28 )′. 
     Water, which may still be entrained in the oil, is centrifuged to the outer part ( 30 )′ of the second stage rotating separator. The water at high pressure is expanded through liquid nozzles ( 31 )′ and flows through passages ( 32 )′ to a volute ( 33 )′. The separated water subsequently flows through the turbine through the second stage water exit port ( 34 )′. The separated gas flows from the turbine through the second stage gas exit port ( 35 )′. 
     The oil from the second stage is expanded to the third stage pressure in the third stage nozzles ( 28 )′. Remaining light components in the oil flash, forming two-phase jets ( 29 )′. 
     The jets impinge on the surface ( 36 )′ of the third rotating separator structure ( 37 )′ forming a layer of oil. The oil flows to the opposite side of the supporting disc ( 38 )′ through passages ( 39 )′. The oil enters the inlet of a diffuser ( 40 )′ immersed in the oil layer. The oil is pressurized by slowing the inlet velocity in the diffuser structure ( 41 )′. The pressurized oil leaves the turbine through the oil exit ports ( 42 )′. 
     Water, which may still be entrained in the oil, is centrifuged to the outer part ( 43 )′ of the third stage rotating separator. The water at high pressure is expanded through liquid nozzles ( 44 )′ and flows through passages ( 45 )′ to a volute ( 46 )′. The separated water subsequently flows through the turbine through the second stage water exit port ( 47 )′. The separated gas flows from the turbine through the third stage gas exit port ( 54 )′. 
     The multistage two-phase turbine for oil, gas and water has seals ( 48 )′ and ( 49 )′ on each end of the shaft ( 55 )′ to prevent gas from leaking from the casing. The unit has seals ( 50 )′ and ( 51 )′ in the diaphragms ( 52 )′ and ( 53 )′ between stages to reduce gas leakage from a high pressure stage to a lower pressure stage. 
     Power is transferred to the rotor by the liquid for stages where the two-phase nozzle jet ( 4 )′, ( 21 )′ and ( 29 )′ tangential velocity is greater than the circumferential velocity of the separator surface ( 6 )′, ( 22 )′ and ( 36 )′, and from the separated gas energy in at least the first stage. Power is transferred from the rotor to the liquid, if the tangential velocity of any stage is less than the circumferential velocity of the separator surface. 
     An induction generator can be connected to the shaft ( 55 )′. See generator  80 . If there is a net power transfer to the rotor from the states, power will be generated at  81 . If not, the generator will require power input at  82 , and will be operated as a motor to maintain the desired circumferential velocity. A power input control is seen at  83 . 
     In FIG. 8, a rotary separator turbine  503  is installed in the bore of a gas or oil well  517 . Two-phase flow consisting of gas and oil and/or water at  501  flows into the rotary separator turbine through entrance ports  502 . The flow is expanded and separated in one or more stages, as shown in FIGS. 5 and 7. 
     Separated water and other liquids  509  and  510  for a two-stage unit are discharged through pipes  511  and  512  at a pressure higher than the pressure of the entering flow  501 . The separated water and liquids may be piped to another part of the strata  518  and discharged at a higher pressure  519  than the pressure of the entering flow  501 . The two strata may be separated by a seal  520 . The separated oil, if any, at  514  and  515  may be piped to the surface at  513  and  515 . Separated gas at  505  and  506  may be piped to the surface at  507 . Power generated may be transmitted to the surface through cables  516 . The pressure of the two-phase flow  501  can be isolated from the lower pressure region of the well  521  by a seal  504 . 
     In another variation shown in FIG. 9, the separated water at  505 ′ and  509 ′ leave the rotary separator turbine and are piped at  510 ′ and  511 ′ to the surface or another location for disposal. 
     In FIG. 10, the multistage two-phase turbine  604  is installed on the sea floor  601  within a protective enclosure  620  on a support  619 . A mixture of gas and oil and/or water and/or sand  603  flows from a well head  602  into the rotary separator turbine  604 . The flow is expanded in one or more stages, as seen in FIG.  7 . Separated gas  605 ,  607 , and  609  (for three stages) leave the multistage two-phase turbine and are piped at  606 ,  608 , and  610  to a delivery point or compressor. Separated oil at  621  is piped at  622  to a delivery point. 
     Separated water and/or solids at  611 ,  613  and  615  are piped at  612 ,  614  and  616  for disposal. The multistage two-phase turbine unit may drive a generator  617 . The power is transmitted by cables  618  to the surface or to other components within the protective enclosure  620  or elsewhere requiring power. 
     In FIG. 11, which is similar to FIG. 10, the multistage two-phase turbine drives a gas compressor  623  instead of a generator. The gas flow is expanded internally through each pressure drop. The gas leaving the last stage at  609  flows through external or internal passages  610  to gas compressor  623 . The compressor increases the pressure, and the high pressure outlet gas  624  flows through a pipe  625  to a delivery point. 
     The general method of operation contemplated by the FIG. 8 form of the invention, for processing a multi-component fluid mixture in a sub-surface well, and employing a rotary separator, includes the steps: 
     a) positioning the separator in the well at a depth to receive the mixture, 
     b) operating the separator to separate and pressurize at least one component of the mixture, 
     c) and flowing the pressurized and separated component lengthwise of the well, away from the separator. 
     The one component typically consists of one of the following: 
     i) gas 
     ii) liquid 
     iii) water 
     iv) hydrocarbon gas 
     v) hydrocarbon liquid. 
     The positioning step may include lowering the separator  503  in the well to the operating depth, as shown; and a pipe string or strings may be lowered in operative relation to the separator, and flowing the separated component upwardly in the pipe string. Such strings may include one or more of the strings shown at  515 ,  505 ,  506 ,  507 , and  513 . Upper extents of such strings may be considered as constituting one form of lowering means. 
     The method also contemplates the flowing step to include flowing the component under pressure into the formation in which the well is located. 
     As referred to above, a rotary separator, usable in the above method, includes nozzle means to accelerate the fluid, to form a two-phase jet, and the operating step includes recovering at least one phase produced by the two-phase jet. 
     Also, the operating step may include centrifugally pressurizing another phase produced by the jet. The rotary structure in  503  may be considered as advantageously driven by the pressure of the inlet fluid at  501 . 
     The disclosure of the above referenced U.S. patent applications are incorporated herein by reference.