RECOVERY SYSTEM AND RELATED METHODS

[001 ] This application claims the benefit of priority to U.S. Provisional Patent

Application Nos. 62/567,747, filed October 3, 2017, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

[002] The present disclosure relates generally to systems and methods for waste heat recovery. In particular, certain embodiments of the present disclosure relate to shock absorbing enclosure structures for containing various equipment for waste heat recovery systems.

DESCRIPTION OF RELATED ART

[003] Waste heat recovery systems typically use Rankine thermodynamic cycles to convert thermal energy to kinetic energy and/or electricity. Rankine cycles may use water-steam or organic fluid as their working fluid. In particular, Rankine cycles using organic working fluids, referred to as Organic Rankine Cycles (ORC), have gained increasing support in a wide range of applications, including waste heat recovery and alternative energy (e.g., geothermal, biomass, and solar) sectors, because, among other reasons, organic fluids allow heat recovery from low-grade energy sources due to their lower liquid-vapor transition temperature than that of the water-steam.

[004] Organic fluids, however, may be flammable and have degradation limits. For example, some organic fluids have temperature limits that are not to be exceeded in a thermodynamic cycle. Moreover, depending on the application, some organic fluids may be required to satisfy toxicity, chemical stability, and corrosiveness requirements. Therefore, to reduce the threat for safety, reasonable due care must be exercised to prevent or reduce leakage of the organic working fluid.

[005] A waste heat recovery system operating under a Rankine cycle may typically include pumps, evaporator heat exchangers, high-speed expanders (e.g., turbines), a condenser, electrical components and electronic controllers, and various balance of plant (BoP) components (e.g., tubing, fittings, valves, conduits and cables).

[006] Operating such a waste heat recovery system in a mobile platform, such as, for example, in a locomotive or truck, may require mitigating or substantially reducing extreme vibratory stressors, either actively or passively, to improve the safe performance of the system, especially in an ORC system that uses flammable and/or toxic an organic working fluid. Further, it may be desirable to substantially seal and isolate at least the ORC system in case of leakage of the organic working fluid from the ORC system.

[007] Accordingly, there is a need for an improved waste recovery system that may overcome one or more of the problems discussed above.

SUMMARY

[008] Therefore, various exemplary embodiments of the present disclosure may provide an improved waste recovery system with an enclosure configured to absorb shocks and vibrations whiling enabling segregation and isolation of potentially flammable working fluids by shortening the BoP components and/or reducing the total inventory of working fluid.

[009] To attain the advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, one exemplary aspect of the present disclosure may provide an enclosure for housing a heat conversion system. The enclosure may include a left chamber configured to receive a first component of the heat conversion system, a right chamber configured to receive a second component of the heat conversion system, and a central chamber configured to connect the left chamber and the right chamber. The left chamber, the right chamber, and the central chamber may be disposed on a hood of the locomotive, and the left chamber may be configured to move relative to the central chamber to provide access to a portion of the hood covered by the left chamber.

[010] According to another exemplary aspect, a waste heat conversion system for use in a locomotive may be provided. The waste heat conversion system may include a source heat exchanger thermally coupled to an exhaust stack of the locomotive, and an enclosure for housing at least a motor, an electric generator, and a pump of the waste heat conversion system. The enclosure may define an opening for receiving the exhaust stack of the locomotive extending from a hood of the locomotive to the environment.

[01 1 ] Still another exemplary aspect may provide a thermally segregating enclosure comprising the components forming organic and non-organic Rankine cycles, structurally supported within the thermally segregating enclosure in a manner that favors heat transfer with the environment for certain components forming the cycle, while limiting heat transfer with the environment for other components forming the cycle.

[012] Some exemplary aspects may provide a method for positioning Rankine cycle components within thermally segregating shock absorbing and vibration isolating enclosures comprising cooling channels, heating channels and insulating

compartments to increase the cycle thermodynamic efficiency and power rating by satisfying heat transfer requirements associated with each individual component forming the thermodynamic cycle, while minimizing pumping losses by reducing or eliminating balance of plant components.

[013] Another exemplary aspect of the present disclosure is to provide thermally and vibration controlled compartments within the shock absorbing and vibration isolating enclosure to house battery packs to store the electric energy converted by the Rankine cycle components.

[014] Additional objects and advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention.

[015] It is to be understood that both the foregoing summary description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[016] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the disclosed invention.

[017] Fig. 1 is a perspective view of an enclosure for housing a waste heat recovery system installed on a locomotive, according to an exemplary embodiment of the present disclosure.

[018] Fig. 2 is a perspective view of the enclosure shown in Fig. 1 with a left top and partial bottom panels removed to show the internals of the enclosure, according to one exemplary embodiment.

[019] Fig. 3 is a perspective partially see-through view of the enclosure shown in Figs. 1 and 2, seen from a bottom angle with partial side, front and bottom panels removed to show the internals of the enclosure, according to one exemplary embodiment.

[020] Fig. 4 is a top, see-through view of the enclosure shown in Fig. 1 , according to one exemplary embodiment.

[021 ] Fig. 5 is a perspective view of a support frame of the enclosure shown in Fig. 1 , according to some exemplary embodiments of the present disclosure.

[022] Fig. 6 is a functional side-view schematic of the enclosure shown in Fig. 1 , according to an exemplary embodiment.

[023] Fig. 7 is a functional side-view schematic of the enclosure shown in Fig. 1 , illustrating the ability to rotate a portion of the enclosure to access interior of the enclosure, according to one exemplary embodiment.

DETAILED DESCRIPTION

[024] Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings.

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[025] Various exemplary aspects of the present disclosure may provide an enclosure configured to be retrofitted onto a mobile platform, such as, for example, a locomotive, a truck, and a ship, to isolate and protect components disposed within the enclosure from a number of environmental conditions, such as, for example, vibratory, thermal, and corrosive stressors and also to segregate and seal one component from another.

[026] For example, according to one exemplary aspect of the present disclosure may provide mechanical support by enclosing equipment, structures and

components forming a waste heat recovery system with electronic equipment and electrical load management systems within an enclosure having a shock absorbing and sealing features.

[027] Another exemplary aspect of the present disclosure may provide a structural system that, while enabling mechanical support of thermal-hydraulic components and their balance of plant, may isolate and mitigate vibrations and shocks.

[028] Still another exemplary aspect may provide a shock absorbing enclosure with portions of the enclosure that can be removed or moved to enable access to an area covered by or under the enclosure. Another exemplary aspect may provide segregating compartments within the enclosure with cooling and insulating flow pathways to enhance cooling of selected components requiring cooling or heat transfer insulation to other components, while reducing distances and sizes of the components forming the balance of plant. Another exemplary aspect may provide sealed compartments within the enclosure to contain potentially toxic and flammable fluids.

[029] Consistent with the exemplary aspects discussed above, Figs. 1 -6 illustrate an enclosure 10 for housing a waste heat recovery system in a locomotive, according to one exemplary embodiment of the present disclosure. While the present disclosure will be described in connection with a particular locomotive application, the present disclosure may be applied to, or used in connection with, any other type of locomotives or any other mobile platform, such as, for example, ships, and trucks, that may benefit from the use of a waste heat recovery.

[030] Referring to Fig. 1 , enclosure 10, consistent with the present disclosure, may be configured to be placed on a roof or hood 140 of the locomotive engine 135 or engine block 130. In this exemplary embodiment, enclosure 10 may define, and have components around, an opening 15 for receiving an exhaust stack 125 of a locomotive engine 135. To provide an enhanced structural support for enclosure 10, the engine compartment of locomotive engine block 1 30 may be reinforced with a support frame 40. The upper portion of support frame 40 may be mechanically coupled to enclosure 1 0, while its lower portion is coupled to and supported by a base 1 10 of locomotive engine block 130 to distribute the weight of enclosure 10 and various components contained inside enclosure 1 0. Support frame 40 may be disposed inside or outside of hood 140, and hood 140 may have suitable openings to enable structural engagement between base 1 10 of locomotive engine block 1 30 and enclosure 10.

[031 ] Fig. 5 illustrates support frame 40 in detail, according to one exemplary embodiment. Support frame 40 may comprise a front frame 42 and a rear frame 46. Each of front frame 42 and rear frame 44 may be formed of two vertical posts and a transverse post interconnecting the two vertical posts at their respective top ends. The bottom ends of the two vertical posts may be structurally coupled to base 1 10 of locomotive engine block 130. In the disclosed embodiment, the transverse post may have a shape generally following the shape of hood 140 of locomotive engine block 130.

[032] On each lateral side of support frame 40, the vertical posts of front frame 42 and rear frame 46 may be connected to one another via an inner side beam 52. Between front frame 42 and rear frame 46, support frame 40 may include a middle frame 44 connecting between two inner side beams 52. Middle frame 44 may have substantially identical configuration as that of either front frame 42 or rear frame 46, except that its vertical posts do not extend beyond inner side beams 52. In some exemplary embodiments, middle frame 44 may be identical to front frame 42 and/or rear frame 46 and have vertical posts extending to base 140. In addition to middle frame 44, support frame 40 may include an upper cross beam 45 laterally connecting the two inner side beams 52.

[033] Support frame 40 may further include a suitable structural interface with a shock absorbing mechanism to engage and support enclosure 1 0. For example, as shown in Fig. 5, support frame 40 may include, or be provided with, an outer side beam 54 on each lateral side of support frame 40 and an outer top beam 58 on the top side of support frame 40. Outer side beam 54 may be connected to inner side beam 52 via one or more side dampers 64, and outer top beam 58 may be connected to inner top beam 56 via one or more vertical damper 62.

[034] Dampers 62 and/or 64 may be configured to isolate shock and vibration of locomotive engine block 130 by converting the shock and vibration energy into dispensable form of energy (e.g., thermal energy, deformation energy, etc.).

Dampers 62 and /or 64 may be either an active or passive device known in the art. For example, damper 62 and/or 64 may comprise a hydraulic or pneumatic damper, buffer, or shock absorber. Although dampers 62 and 64 are designated as vertical and side dampers, dampers 62 and 64 may comprise a torsional or rotational vibration damper configured to damp rotational vibrations and irregularities.

[035] In some alternative embodiments, support frame 40 may not be used, and enclosure 1 0 may be mechanically coupled to one or more portions of hood 140 for the required structural support, and dampers 62 and 64 may be structurally associated with hood 140.

[036] Enclosure 10 may be configured to house various components of a waste heat recovery system, according to various exemplary aspects of the present disclosure. For example, a waste heat recovery system, consistent with the present disclosure, may include components configured to convert thermal energy from locomotive engine 135 to electricity and to condition the electricity to, for example, charge batteries 30 and drive electric loads of locomotive engine 135. Such components may include pumps, heat exchangers, electric generators, turbogenerators, motors, electric enclosures, fans, tanks, and auxiliary components, which are designated throughout the disclosure with reference characters 22, 24, 26, and 28. Enclosure 1 0 may also be configured to house one or more batteries 30, as shown in Fig. 4.

[037] Depending on, among various factors, the application of the waste heat recovery system and the type and model of the locomotive, the composition, sizes, and positions of various components of the waste heat recovery system may vary. Accordingly, unless otherwise specifically noted herein, it should be understood that each of reference characters 22, 24, 26, 28, and 30 may interchangeably refer to any, or any group, of components listed above.

[038] As briefly mentioned above, enclosure 10 may define opening 1 5 through which exhaust stack 125 may extend. Exhaust stack 125 may represent a heat generating source from engine 135, and one or more components 22, 24, 26, 28, and 30 of the waste heat recovery system may be thermally coupled to exhaust stack 125 to extract heat energy therefrom. In some exemplary embodiments, a stack heat exchanger 21 may be disposed inside exhaust stack 1 25, as shown in Fig. 4, to extract heat energy from exhaust gas flowing through exhaust stack 125. Stack heat exchanger 21 may be thermally coupled to one or more components 22, 24, 26, 28, and 30 of the waste heat recovery system. Alternatively or additionally, one or more components 22, 24, 26, 28, and 30 of the waste heat recovery system may be coupled to any other heat generating portion of locomotive engine 135, such as, for example, an exhaust pipe or exhaust manifold. [039] As best shown in Figs. 2-5, enclosure 10 may comprise a front panel 31 and a rear panel 39 aligned substantially parallel to one another via a plurality of reinforcing bars 34. In one exemplary embodiment, front panel 31 may be disposed on the engine side of locomotive engine block 130, and rear panel 39 may be disposed on the radiator side of locomotive engine block 1 30. However, the directions of front panel 31 and rear panel 39 may be reversed. Enclosure 10 may also include a central panel 35 disposed between front panel 31 and rear panel 39. Reinforcing bars 34 may structurally engage with central panel 35. Central panel 35 may also include a plurality of openings to allow passage of various electrical and thermal- hydraulic tubing and conduits for components 22, 24, 26, 28, and 30 crossing therethrough. Front panel 31 , central panel 35, and rear panel 39 may be formed of a sufficiently rigid material to function as support beams for enclosure 10.

[040] Front panel 31 may comprise a left panel 31 a, right panel 31 b, and a center panel 31 c between left panel 31 a and right panel 31 b. Similarly, rear panel 32 may comprise a left panel 32a, right panel 32b, and a center panel 32c between left panel 32a and right panel 32b, and central panel 35 may comprise a left panel 35a, right panel 35b, and a center panel 35c between left panel 35a and right panel 35b.

[041 ] Enclosure 10 may include a left side panel 32a to cover the left side of enclosure 1 0 between left panel 32a of front panel 31 and left panel 39a of rear panel 39. Similarly, enclosure 10 may include a right side panel 32b to cover the right side of enclosure 10 between right panel 32b of front panel 31 and right panel 39b of rear panel 39. Enclosure 10 may also include a left bottom panel 37a to cover and seal the left bottom of enclosure 10 between left panel 37a of front panel 37 and left panel 39a of rear panel 39. Similarly, enclosure 10 may include a right bottom panel 37b to cover and seal the right bottom of enclosure 1 0 between right panel 37b of front panel 37 and right panel 39b of rear panel 39.

[042] Enclosure 10 may further include a top panel to cover the top surface of enclosure 1 0. Top panel 38 may include a left top panel 38a, a right top panel 38b, and a center top panel 38c.

[043] Accordingly, enclosure 10 may define a left chamber 70, a right chamber 80, and central chamber 90. Left chamber 70 may be defined by left panel 31 a of front panel 31 , left panel 39a of rear panel 39, left side panel 32a, left bottom panel 37a, left cover panel 38a, and a left wing portion of hood 140 (see seal 137 shown in Fig. 6) of locomotive engine block 130. Right chamber 80 may be defined by right panel 31 b of front panel 31 , right panel 39b of rear panel 39, right side panel 32b, right bottom panel 37b, right cover panel 38b, and a right wing portion of hood 140 (see seal 137 shown in Fig. 6) of locomotive engine block 130. Central chamber 90 may be defined by center panel 31 c of front panel 31 , center panel 39b of rear panel 39, two side panels (not shown) bordering with left chamber 70 and right chamber 80, respectively, and a center portion of hood 140 of locomotive engine block 130.

[044] Each of left chamber 70, right chamber 80, and central chamber 90 may be substantially sealed against the environment and against one another, such that the components disposed inside one chamber 70, 80, or 90 may be protected from the environment and/or other components disposed in other chambers 70, 80, or 90. Sealing chambers 70, 80, and 90 against the environment may also protect the environment from any potential leakage of hazardous material from the components inside chambers 70, 80, and 90 to the environment.

[045] For example, some exemplary embodiments consistent with the present disclosure may employ ORC components with an organic working fluid. All of the ORC components may then be disposed in only one of chambers 70, 80, and 90, such that, in case of leakage of the flammable or toxic organic fluid, the leakage is isolated in only one of chambers 70, 80, and 90 without affecting the components disposed in other chambers 70, 80, or 90, locomotive operators, or the environment.

[046] In some exemplary embodiments, central chamber 90 may not include the two side panels, such that left chamber 70, right chamber 80, and central chamber 90 may form a single, sealed chamber.

[047] According to another exemplary embodiment, central panel 35 may also serve as a segregating wall that partitions any of chambers 70, 80, and 90 into a front chamber and a rear chamber. For example, in the disclosed embodiment, component 22 (e.g., motor and pump head) can be disposed in the front chamber of left chamber 70; component 24 can be disposed in the front chamber of central chamber 90; component 26 can be disposed in the rear chamber of left chamber 70; component 28 can be disposed in the front chamber of right chamber 80; and component 30 can be disposed in the rear chamber of right chamber 80, as best shown in Fig. 4.

[048] Fig. 6 schematically illustrates various features of enclosure 10, according to various exemplary embodiments of the present disclosure. Most of the features have been discussed above and, therefore, any duplicative description will be omitted herein.

[049] For example, Fig. 6 schematically illustrates operational characteristics of various dampers 62, 64, and 66, according to one exemplary embodiment. In addition to vertical dampers 62 and side dampers 64 configured to dampen shock and vibration in the z-axis (see vertical arrow 4 in Fig. 6) and x-axis (see laterally arrow 2 in Fig. 6), respectively, enclosure 1 0 may also include axial damper 66 configured to absorb shock and vibration in the y-axis (see axial arrow 6). For example, either or both of front panel 31 and rear panel 39 may contact a body (e.g., a radiator structure) of locomotive 100, and axial dampers 66 may be disposed on either or both of front panel 31 and rear panel 39, as shown in Figs. 2 and 4, to absorb shock and vibration in the y-axis.

[050] Fig. 6 also schematically illustrates a plurality of vents, including top vent 12, side vent 14, and lateral vent 16, and bottom vent 18 through which air may pass to cool components 22, 24, 26, 28, and 30 disposed inside chambers 70, 80, and 90. One or more vents 12, 14, 16, and 1 8 may be an active vent with a suitable device (e.g., a fan) to force circulation of air therethrough.

[051 ] Fig. 7 schematically illustrates that enclosure 10 of the present disclosure may be configured to allow one or both of left chamber 70 and right chamber 80 to rotate with respect to central chamber 90, so as to gain access to a portion of hood 140 of locomotive 100 that may be covered by enclosure 10.

[052] A coupler 1 7 with a suitable latching mechanism 19 may be disposed adjacent left bottom panel 37a of left chamber 70. Coupler 1 7 may engage with a post 65 (Fig. 6) extending from support frame 40 with side damper 64 disposed therebetween. In some exemplary embodiments, post 65 may be configured to adjust its length.

[053] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.