Systems and methods utilizing gas temperature as a power source
Systems and generating power in an organic Rankine cycle (ORC) operation to supply electrical power. In embodiments, an inlet temperature of a flow of gas from a source to an ORC unit may be determined. The source may connect to a main pipeline. The main pipeline may connect to a supply pipeline. The supply pipeline may connect to the ORC unit thereby to allow gas to flow from the source to the ORC unit. Heat from the flow of gas may cause the ORC unit to generate electrical power. The outlet temperature of the flow of the gas from the ORC unit to a return pipe may be determined. A bypass valve, positioned on a bypass pipeline connecting the supply pipeline to the return pipeline, may be adjusted to a position sufficient to maintain temperature of the flow of gas above a threshold based on the inlet and outlet temperature.
1. A controller to control electrical power generated by an organic Rankine cycle (ORC) operation in a vicinity of a pumping station during gas compression and transport, thereby to supply electrical power to one or more of operational equipment, a grid power structure, or an energy storage device, the controller comprising:
(a) a first set of one or more inputs, each in signal communication with one of one or more heat exchanger outlet temperature sensors and one of one or more main pipeline temperature sensors, each one of one or more heat exchanger outlet temperature sensors to provide a gas outlet temperature of a compressed gas flow from one of one or more heat exchangers, each one of the one or more main pipeline temperature sensors to provide a gas supply temperature of a compressed gas flow from an associated main pipeline to an associated one of one or more heat exchangers, each of the one or more heat exchangers to facilitate heat transfer from an associated compressed gas flow to an associated working fluid, the associated working fluid flowing through one of the one or more heat exchangers;
a first set of inputs/outputs, each of the inputs/outputs in signal communication with one of one or more working fluid flow control devices and one or more main pipeline valves, the controller configured to:
in response to the gas outlet temperature being within a selected operating temperature range, transmit a signal to adjust an associated working fluid flow control device, thereby to control (1) temperature of the compressed gas flowing away from the associated heat exchanger and (2) temperature of the associated working fluid flow, the associated working fluid flow causing an ORC unit to generate electrical power in an ORC operation, and
in response to the gas supply temperature being below a first threshold, transmit a signal to adjust an associated main pipeline valve, thereby to divert the compressed gas flow away from the associated heat exchanger; and
(b) a second set of one or more inputs, each in signal communication with one of one or more heat exchanger inlet temperature sensors, each one of one or more heat exchanger inlet temperature sensors to provide a gas inlet temperature of a compressed gas flow from one of one or more compressors,
wherein each of the inputs/outputs are in signal communication with one of one or more heat exchanger valves, and
wherein the controller further is configured to:
in response to the gas inlet temperature being above a second threshold, adjust one or more of (1) an associated heat exchanger valve position, thereby to cause compressed gas to flow through an associated heat exchanger and indirectly transfer heat to a working fluid, or (2) an associated working fluid flow control device, thereby to indirectly adjust heat transfer from the compressed gas to the working fluid.
2. The controller of claim 1 , further comprising:
a third set of one or more inputs, each in signal communication with one of one or more heat exchanger working fluid outlet temperature sensors, each one of one or more heat exchanger working fluid outlet temperature sensors to provide a working fluid outlet temperature of a working fluid flow from one of one or more heat exchangers, and
wherein adjustment of the one or more of (1) an associated heat exchanger valve position or (2) an associated working fluid flow control device further is based on the working fluid outlet temperature.
3. The controller of claim 2 , wherein the working fluid flow control device comprises one or more of a fixed speed pump, a variable speed pump, a control valve, or an actuated valve, and wherein the controller is in communication with one of the one or more heat exchanger outlet temperature sensors, one of the one or more main pipeline temperature sensors, one or more working fluid flow control devices, and one or more main pipeline valves.
4. The controller of claim 1 , wherein the selected operating temperature range comprises a range of temperatures including a lowest allowable temperature of the compressed gas that prevents condensation of volatiles within the compressed gas flow.
5. The controller of claim 4 , wherein the volatiles within the compressed gas flow comprise ethane, propane, butane, heavy alkanes having 7 to 12 carbon atoms, thiols, mercaptans, carbon dioxide, cyclohexane, naphthene, benzene, toluene, xylene, or ethylbenzene.
6. The controller of claim 1 , wherein the working fluid comprises an intermediate working fluid, the intermediate working fluid comprising a fluid with a higher vaporous phase change threshold.
7. The controller of claim 6 , wherein the intermediate working fluid comprises water.
8. The controller of claim 6 , wherein the phase change threshold is defined by a temperature at which a working fluid of the ORC unit exhibits a vaporous phase change from a liquid phase change.
9. The controller of claim 1 , wherein the working fluid comprises an organic working fluid, and wherein the organic working fluid includes one or more of pentafluoropropane, carbon dioxide, ammonia and water mixtures, tetrafluoroethane, isobutene, propane, pentane, perfluorocarbons, or other hydrocarbons.
10. A controller to control electrical power generated by an organic Rankine cycle (ORC) operation in a vicinity of a pumping station during gas compression and transport, thereby to supply electrical power to one or more of operational equipment, a grid power structure, or an energy storage device, the controller comprising:
a first set of one or more inputs, each in signal communication with one of one or more heat exchanger inlet temperature sensors, each one of one or more heat exchanger inlet temperature sensors to provide a gas inlet temperature of a compressed gas flow supplied from a main pipeline connected to one of one or more compressors;
a second set of one or more inputs, each in signal communication with one of one or more heat exchanger outlet temperature sensors, each one of one or more heat exchanger outlet temperature sensors to provide a gas outlet temperature of a compressed gas flow from one of one or more heat exchangers; and
a first set of inputs/outputs, each of the inputs/outputs in signal communication with one or more main pipeline valves, one of one or more heat exchanger valves, and one of one or more gas bypass valves, the controller configured to:
in response to the gas inlet temperature being above a first threshold, maintain an associated heat exchanger valve position, thereby to cause gas to flow through an associated heat exchanger and indirectly transfer heat to a working fluid, the working fluid causing an ORC unit to generate electrical power when in an ORC operation,
in response to the gas outlet temperature being within a selected operating temperature range, transmit a signal to adjust one or more of the associated heat exchanger valve position and associated gas bypass valve position, thereby to cause a portion of the flow of gas to be diverted away from the associated heat exchanger and adjust a temperature of the gas flowing away from the associated heat exchanger, and
in response to the gas inlet temperature being below a second threshold, transmit a signal to adjust an associated main pipeline valve, thereby to divert the compressed gas flow away from the associated heat exchanger.
11. The controller of claim 10 , wherein each of the inputs/outputs are in signal communication with one of one or more working fluid flow control devices, and
wherein the controller further is configured to in response to the gas inlet temperature being above a threshold, adjust an associated working fluid flow control device, thereby to indirectly adjust heat transfer from the gas to the working fluid.
12. The controller of claim 10 , wherein the associated gas bypass valve position is adjusted to drive the temperature of the flow of gas to a lowest operating temperature.
13. The controller of claim 12 , wherein the lowest operating temperature comprises a temperature above which volatiles condense in the flow of gas.
14. The controller of claim 10 , wherein the gas includes one or more of compressed (1) natural gas, (2) renewable natural gas, (3) landfill gas, or (4) organic waste gas, and wherein the controller is in communication with one of the one or more heat exchanger inlet temperature sensors, one of the one or more heat exchanger outlet temperature sensors, one or more main pipeline valves, one of one or more heat exchanger valves, or one of one or more gas bypass valves.
15. A controller to control electrical power generated by an organic Rankine cycle (ORC) operation in a vicinity of a pumping station during gas compression and transport, thereby to supply electrical power to one or more of operational equipment, a grid power structure, or an energy storage device, the controller comprising:
a first set of one or more inputs, each in signal communication with one of one or more heat exchanger inlet temperature sensors, each one of one or more heat exchanger inlet temperature sensors to provide a gas inlet temperature of a compressed gas flow supplied from a main pipeline connected to one of one or more compressors;
a second set of one or more inputs, each in signal communication with one of one or more heat exchanger outlet temperature sensors, each one of one or more heat exchanger outlet temperature sensors to provide a gas outlet temperature of a compressed gas flow from one of one or more heat exchangers; and
a first set of inputs/outputs, each of the inputs/outputs in signal communication with one or more main pipeline valves, one of one or more heat exchanger valves, one of one or more gas bypass valves, and one of one or more working fluid flow control devices, the controller configured to:
in response to the gas inlet temperature being above a first threshold, adjust an associated heat exchanger valve position, thereby to cause gas to flow through an associated heat exchanger and indirectly transfer heat to a working fluid, the working fluid causing an ORC unit to generate electrical power in an ORC operation,
in response to the gas outlet temperature being within a selected operating temperature range, transmit a signal to adjust one or more of the associated heat exchanger valve position, associated gas bypass valve position or associated working fluid flow control devices, thereby to control temperature of the gas flowing away from the associated heat exchanger, and
in response to the gas inlet temperature being below a second threshold, transmit a signal to adjust an associated main pipeline valve, thereby to divert the compressed gas flow away from the associated heat exchanger.
16. The controller of claim 15 , further comprising:
a third set of one or more inputs, each in signal communication with one of one or more heat exchanger working fluid outlet temperature sensors, each one of one or more heat exchanger working fluid outlet temperature sensors to provide a working fluid outlet temperature of a working fluid flow from one of one or more heat exchangers.
17. The controller of claim 16 , wherein the associated heat exchanger valve, the associated gas bypass valve, and the associated working fluid flow control devices are adjusted based on (1) the gas inlet temperature, (2) the gas outlet temperature, and (3) the working fluid outlet temperature, thereby to drive the ORC unit to generate a maximum amount of electrical power.
18. The controller of claim 17 , further comprising an input in signal communication with an ambient temperature sensor, the ambient temperature sensor to measure an ambient temperature of the pumping station.
19. The controller of claim 18 , wherein the associated heat exchanger valve, the associated gas bypass valve, and the associated working fluid flow control devices further are adjusted based on ambient temperature, and wherein the controller is in communication with one of the one or more heat exchanger inlet temperature sensors, one of the one or more heat exchanger outlet temperature sensors, one or more main pipeline valves, one of one or more heat exchanger valves, one of one or more gas bypass valves, and one of one or more working fluid flow control devices.
20. A method for generating power in a vicinity of a pumping station during gas compression and transport, the method comprising:
determining an inlet temperature of a flow of compressed gas from a source to a heat exchanger, the source connected to a main pipeline, the main pipeline connected to a supply pipeline, and the supply pipeline connected to the heat exchanger, thereby to allow compressed gas to flow from the source to the heat exchanger, the heat exchanger positioned to transfer heat from the flow of compressed gas to a flow of a working fluid, thereby to form a heated working fluid, the heated working fluid utilized to generate power;
determining an outlet temperature of the flow of the compressed gas from the heat exchanger to a return pipeline;
in response to a determination that the flow of the compressed gas is within a selected operating temperature range, adjusting the flow of working fluid to a percentage sufficient to maintain temperature of the flow of compressed gas within the selected operating temperature range that prevents condensation of volatiles within the compressed gas;
in response to the determination that the flow of the compressed gas is within the selected operating temperature range, adjusting a bypass valve to a position sufficient to maintain the temperature of the flow of compressed gas within a selected operating temperature range, the bypass valve positioned on a bypass pipeline, the bypass pipeline positioned to connect the supply pipeline to the return pipeline, the bypass pipeline positioned to allow via the bypass valve a portion of the flow of compressed gas therethrough, thereby to cause the flow of compressed gas to be diverted directly from the supply pipeline to the return pipeline to increase temperature of the flow of compressed gas from the heat exchanger, and
in response to the determination that the flow of the compressed gas is below the selected operating temperature range, adjusting a main pipeline valve to a position sufficient to divert the flow of compressed gas away from the heat exchanger.
21. The method of claim 20 , further comprising:
sensing, via an ambient temperature sensor, ambient temperature of an environment external to the main pipeline, the supply pipeline, the return pipeline, and the heat exchanger; and
determining the temperature drop of the flow of compressed gas after passage through the heat exchanger based on the outlet temperature, the ambient temperature, and a predicted temperature drop differential, the heat exchanger positioned in the vicinity of the pumping station.
22. The method of claim 21 , further comprising:
sensing, via a working fluid outlet temperature sensor, an outlet temperature of the flow of working fluid from the heat exchanger.
23. The method of claim 22 , wherein one or more of adjustment of (1) the flow of working fluid or (2) bypass valve position further is based on one or more of the ambient temperature, the inlet temperature of a flow of compressed gas, the outlet temperature of a flow of compressed gas, or the outlet temperature of the flow working fluid from the heat exchanger.
24. A system for generating electrical power in a vicinity of a pumping station during gas compression and transport, the system comprising:
one or more supply pipelines, each one of the one or more supply pipelines connected to an associated main pipeline;
one or more heat exchanger valves, each one of the one or more heat exchanger valves positioned on an associated supply pipeline and associated with one of one or more gas compressors, each one of the one or more heat exchanger valves to divert flow of compressed gas from an associated main pipeline;
one or more main pipeline valves, each one of the one or more main pipeline valves positioned on the associated main pipeline and positioned between a connection point between the associated supply pipeline and an associated return pipeline, each one of the one or more main pipeline valves to divert flow of compressed gas from the associated main pipeline to the associated supply pipeline;
one or more heat exchanger inlet temperature sensors, each of the one or more heat exchanger inlet temperature sensors positioned on the supply pipeline prior to an associated heat exchanger valve and to provide a gas inlet temperature, the gas inlet temperature defined by a temperature of compressed gas flowing from the associated main pipeline connected to one of one or more gas compressors;
one or more heat exchangers, each of the one or more heat exchangers associated with one of the one or more heat exchanger valves and one of the one or more heat exchanger inlet temperature sensors, each of the one or more heat exchangers including a first fluid path to accept the flow of compressed gas from one of the one or more supply pipelines via one of the one or more heat exchanger valves and output the flow of compressed gas to a return pipeline connected to the associated main pipeline and a second fluid path to accept and output a flow of an intermediate working fluid, each of the one or more heat exchangers to indirectly transfer heat from the flow of compressed gas to the flow of the intermediate working fluid, thereby to form a heated intermediate working fluid, the heated intermediate working fluid used to generate electrical power;
one or more heat exchanger outlet temperature sensors, each of the one or more heat exchanger outlet temperature sensors associated with one of the one or more heat exchangers and to provide a gas outlet temperature, the gas outlet temperature defined by a temperature of compressed gas flowing from the associated one of one or more heat exchangers;
one or more bypass pipelines, each of the one or more bypass pipelines connecting an associated supply line to an associated return line; and
one or more gas bypass valves, each one of the one or more gas bypass valves positioned on an associated bypass pipeline and associated with one of the one or more heat exchangers and to divert a portion of flow of the compressed gas from one of the one or more heat exchangers based on associated gas inlet temperature and gas outlet temperature.
25. The system of claim 24 , further comprising:
one or more flow control devices, each one of the one or more flow control devices positioned on each one of one or more working fluid return heat exchanger pipelines, and each of the one or more flow control devices to control flow of intermediate working fluid to the one or more heat exchangers, thereby to control temperature of the intermediate working fluid flowing through the one or more heat exchangers and temperature of the flow of compressed gas.
26. The system of claim 25 , further comprising:
one or more working fluid outlet temperature sensors, each one of the one or more working fluid outlet temperature sensors positioned at or near a working fluid outlet of each one of the one or more heat exchangers, and each of the one or more working fluid outlet temperature sensors to determine temperature of working fluid output from one of the one or more heat exchangers; and
one or more working fluid inlet temperature sensors, each one of the one or more working fluid inlet temperature sensors positioned at or near a working fluid inlet of each one of the one or more heat exchangers, and each of the one or more working fluid inlet temperature sensors to determine temperature of working fluid input into one of the one or more heat exchangers.
27. The system of claim 26 , wherein an opened/closed position of each of the one or more flow control devices is based on one or more of each working fluid input temperature, each working fluid output temperature, each gas inlet temperature, or each gas outlet temperature.
28. A controller to control electrical power generated in a vicinity of a pumping station during gas compression and transport, the controller comprising:
a first set of one or more inputs, each in signal communication with one of one or more heat exchanger outlet temperature sensors, each one of one or more heat exchanger outlet temperature sensors to provide a gas outlet temperature of a compressed gas flow from one of one or more heat exchangers, each of the one or more heat exchangers to facilitate heat transfer from an associated compressed gas flow to an associated working fluid, the associated working fluid flowing through one of the one or more heat exchangers;
a second set of one or more inputs, each in signal communication with one of one or more heat exchanger inlet temperature sensors, each one of one or more heat exchanger inlet temperature sensors to provide a gas inlet temperature of a compressed gas flow from one of one or more compressors;
a third set of one or more inputs, each in signal communication with one of one or more main pipeline temperature sensors, each one of one or more main pipeline temperature sensors to provide a gas supply temperature of a compressed gas flow from one of one or more compressors; and
a first set of inputs/outputs, each of the inputs/outputs in signal communication with one or more main pipeline valves, one of one or more working fluid flow control devices, one of one or more heat exchanger valves, one of one or more gas bypass valves, the controller configured to:
in response to the gas outlet temperature being within a selected operating temperature range, transmit a signal to adjust one or more of an associated heat exchanger valve position, associated gas bypass valve position, or associated working fluid flow control devices, thereby to control temperature of the gas flowing away from the associated heat exchanger,
in response to the gas inlet temperature being below a first threshold, adjust an associated heat exchanger valve position, thereby to prevent an amount of gas to flow through the associated heat exchanger, and
in response to the gas supply temperature being below a second threshold, adjust an associated main pipeline valve position, thereby to prevent an amount of gas to flow in direction towards the associated heat exchanger.
29. The controller of claim 28 , wherein each of the one or more working fluid flow control devices are adjusted to maximize heat transfer from a flow of gas to an associated flow of working fluid, thereby to maximize electrical power generation, and wherein the controller is in communication with one of the one or more heat exchanger outlet temperature sensors, one of the one or more heat exchanger inlet temperature sensors, one of one or more main pipeline temperature sensors, one or more main pipeline valves, one of one or more working fluid flow control devices, one of one or more heat exchanger valves, and one of one or more gas bypass valves.
30. A controller to control electrical power generated by an organic Rankine cycle (ORC) operation in a vicinity of a pumping station during gas compression and transport, thereby to supply electrical power to one or more of operational equipment, a grid power structure, and an energy storage device, the controller comprising:
a first set of one or more inputs, each in signal communication with one of one or more heat exchanger outlet temperature sensors and one of one or more main pipeline temperature sensors, each one of one or more heat exchanger outlet temperature sensors to provide a gas outlet temperature of a compressed gas flow from one of one or more heat exchangers, each one of the one or more main pipeline temperature sensors to provide a gas supply temperature of a compressed gas flow from an associated main pipeline to an associated one of one or more heat exchangers, each of the one or more heat exchangers to facilitate heat transfer from an associated compressed gas flow to an associated working fluid, the associated working fluid flowing through one of the one or more heat exchangers; and
a first set of inputs/outputs, each of the inputs/outputs in signal communication with one of one or more working fluid flow control devices and one or more main pipeline valves, the controller configured to:
in response to the gas outlet temperature being within a selected operating temperature range, transmit a signal to adjust an associated working fluid flow control device, thereby to control (1) temperature of the compressed gas flowing away from the associated heat exchanger and (2) temperature of the associated working fluid flow, the associated working fluid flow causing an ORC unit to generate electrical power in an ORC operation, and the selected operating temperature range comprising a range of temperatures including a lowest allowable temperature of the compressed gas that prevents condensation of volatiles within the compressed gas flow, and
in response to the gas supply temperature being below a first threshold, transmit a signal to adjust an associated main pipeline valve, thereby to divert the compressed gas flow away from the associated heat exchanger.
31. The controller of claim 30 , further comprising:
(a) a second set of one or more inputs, each in signal communication with one of one or more heat exchanger inlet temperature sensors, each one of one or more heat exchanger inlet temperature sensors to provide a gas inlet temperature of a compressed gas flow from one of one or more compressors,
wherein each of the inputs/outputs are in signal communication with one of one or more heat exchanger valves, and
wherein the controller is further configured to:
in response to the gas inlet temperature being above a second threshold, adjust one or more of (1) an associated heat exchanger valve position, thereby to cause compressed gas to flow through an associated heat exchanger and indirectly transfer heat to a working fluid, or (2) an associated working fluid flow control device, thereby to indirectly adjust heat transfer from the compressed gas to the working fluid; and
(b) a third set of one or more inputs, each in signal communication with one of one or more heat exchanger working fluid outlet temperature sensors, each one of one or more heat exchanger working fluid outlet temperature sensors to provide a working fluid outlet temperature of a working fluid flow from one of one or more heat exchangers, and
wherein adjustment of the one or more of (1) an associated heat exchanger valve position or (2) an associated working fluid flow control device is further based on the working fluid outlet temperature.
32. The controller of claim 31 , wherein the working fluid flow control device comprises one or more of a fixed speed pump, a variable speed pump, a control valve, or an actuated valve, and wherein the controller is in communication with one of the one or more heat exchanger outlet temperature sensors, one of the one or more main pipeline temperature sensors, one or more working fluid flow control devices, and one or more main pipeline valves.
33. The controller of claim 30 , wherein the working fluid comprises an intermediate working fluid comprising a fluid with a higher vaporous phase change threshold.
34. The controller of claim 33 , wherein the intermediate working fluid comprises water.
35. The controller of claim 34 , wherein the phase change threshold is defined by a temperature at which a working fluid of the ORC unit exhibits a vaporous phase change from a liquid phase change.
36. The controller of claim 30 , wherein the working fluid comprises an organic working fluid, and wherein the organic working fluid includes one or more of pentafluoropropane, carbon dioxide, ammonia and water mixtures, tetrafluoroethane, isobutene, propane, pentane, perfluorocarbons, or other hydrocarbons.