CONFIGURATION

DESCRIPTION

TECHNICAL FIELD [0001] The present disclosure concerns turbomachines. Specifically, embodiments disclosed herewith concern integral compressor-expander arrangements.

BACKGROUND ART

[0002] In several industrial applications a need exist to boost the pressure of a gas eous flow. Dynamic compressors, such as in particular centrifugal compressors, are often used to compress a gaseous flow. The compressor is driven by mechanical power, which is delivered by a driver, such as an electric motor. In several industrial facilities streams of compressed gas must be expanded. In order to recover mechani cal power, the expansion is performed in an expander. In some known configura tions, an expander and a compressor are combined in an integral compressor- expander arrangement, which also can include an electric machine. When the me chanical power generated by the expander is balanced by the mechanical power re quired to drive the compressor, the configuration is a so called expander-compressor. The electric machine can be operated in an electric generator mode, when the power generated by the expander exceeds the power required to drive the compressor, such that the excess mechanical power is converted into electrical power. When the power generated by the expander is less than the power required to drive the compressor, the electric machine is driven in a motor mode, to provide supplemental power to drive the compressor.

[0003] An integral expander-compressor of this kind is disclosed for instance in US2013/0091869.

[0004] An important aspect in the design of combined compressor-expander con figurations consists in an efficient energy recovery and optimal operation of the compressor stages. Continuous efforts are made in order to improve efficiency and reliability of operation of these machines. SUMMARY

[0005] In embodiments disclosed herein a the turbomachine is provided, which comprises a casing arrangement and a shaft supported for rotation in the casing ar rangement. The shaft is rotatingly supported by at least a first bearing unit and a sec ond bearing unit adapted to rotatingly support the shaft in the casing arrangement. A first compressor section and a second compressor section are provided in the casing arrangement. The first compressor section comprises a first compressor impeller mounted on the shaft for rotation therewith, and the second compressor section com prises a second compressor impeller mounted on the shaft for rotation therewith. The turbomachine further comprises a first turboexpander and a second turboexpander mounted on the shaft for rotation therewith in the casing arrangement, adapted to generate mechanical power by expanding a gaseous flow therethrough and driving the first compressor section and the second compressor section.

[0006] In particularly preferred embodiments, the entire power required to drive the compressor sections is provide by the turboexpanders, such that no external electric machine is required and the shaft can be sealingly housed inside the casing arrange ment. No gaskets or seals on rotary machine components are needed, to reduce leak ages towards the environment. A completely sealed casing is obtained.

[0007] In some embodiments, the turboexpanders are arranged in series, such that partly expanded gas from the most upstream turboexpander is further expanded in the most downstream turboexpander. The enthalpy drop across the turbomachine is thus divided in two parts. This allows operating the turbomachine at limited rotation al speeds. To provide more reliable operation, the impellers of the turboexpanders and of the compressor sections can be mounted in a stacked configuration, rather than in a shrink-fit configuration, such that safer operation is ensured even at high ro tational speeds. In this way high power rates can achieved without limitations due to the risk of loosening the impeller-shaft coupling due to centrifugal forces. The com bination of serially arranged turboexpanders and stacked shaft allows to design high power-rated turbomachines, capable of exploiting considerable pressure drops across the turboexpanders. This may result in efficient energy recovery. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A more complete appreciation of the disclosed embodiments of the inven tion and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

Fig. l illustrates a cross-sectional view of an embodiment of a turbomachine according to the present disclosure;

Fig. 2 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 3 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 4 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 5 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 6 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 7 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 8 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 9 illustrates a schematic of a further embodiment of a turbomachine ac cording to the present disclosure;

Fig. 10 illustrates a schematic of a further embodiment of a turbomachine according to the present disclosure;

Fig. 11 illustrates a schematic of a further embodiment of a turbomachine according to the present disclosure; and

Fig. 12 illustrates a schematic of a further embodiment of a turbomachine according to the present disclosure.

DETAILED DESCRIPTION

[0009] The turbomachine according to the present disclosure includes a single shaft, on which several impellers are mounted. The impellers include two turboex- pander impellers and two compressor impellers. The turboexpanders provide the en tire power required to drive the compressor impellers, such that the rotating compo nents of the compressor sections and of the turboexpanders can be housed in a sealed casing arrangement, with no rotating shaft extending outside the casing, such that seals are not required and leakages are avoided. In some embodiments, the shaft is a stacked shaft, such that higher rotational speeds can be achieved due to the absence of the shrink fit connection.

[0010] Turning now to Fig.l, a first embodiment of a turbomachine 1 comprising an integral compressor-expander configuration is shown in a cross-sectional view taken along a sectional plane containing the rotation axis A-A of the turbomachine 1.

[0011] The turbomachine 1 comprises a casing arrangement 3. As used herein, the term“casing arrangement” can be understood as a single casing housing a rotating shaft, or a plurality of compartments connected to one another with a rotating shaft extending through the compartments. In the embodiment of Fig. l, the casing ar rangement 3 comprises a first central compartment 3A and to side compartments 3B, 3C. The central compartment 3A house the compressor sections of the turbomachine

I. The compressor sections, cumulatively labeled 5, can include a first compressor section 5 A and a second compressor section 5B. In the embodiment of Fig. 1, the first compressor section 5A and the second compressor section 5B each include a single compressor stage with a single impeller. Other embodiments can include a larger number of sections, and/or one, some or all compressor sections may include more than one impeller.

[0012] In the embodiment of Fig.l the first compressor section 5 A includes a com pressor impeller 7 A and the second compressor section 5B includes a compressor impeller 7B.

[0013] In Fig. l the compressor sections 5 A, 5B are arranged in line, such that a single gaseous flow enters the most upstream compressor section 5 A, is compressed therein and the partly compressed gaseous flow is delivered to the second, most downstream compressor section 5B to be compressed further. The casing arrange ment 3, therefore, includes a single compressor inlet 9 and a single compressor outlet

I I [0014] The turbomachine 1 further includes a first turboexpander 13 housed in the compartment 3B and a second turboexpander 15 housed in the compartment 3C. Each turboexpander 13, 15 comprises a gas inlet 13.1, 15.1, and a gas outlet 13.2, 15.2, respectively. The turboexpander 13 comprises a turboexpander impeller 19 and the turboexpander 15 comprises a turboexpander impeller 21.

[0015] In preferred embodiments, one or both turboexpander impellers 19, 21 are arranged in an overhung configuration, i.e. they are supported at respective first and second ends of a rotating shaft 23, which freely project beyond respective bearing units 25, 27. The overhung configuration of the turboexpanders makes the discharge of the expanded gas flow easier. Also, access to the turboexpander impellers 19, 21 is made easier, for instance for maintenance or repairing purposes.

[0016] The bearing units 25, 27 can include active magnetic bearings. In general, the bearing units 25, 27 provide radial and axial support for the shaft 23. For in stance, each bearing unit 25, 27 may have a radial bearing 25.1 and 27.1, respective ly. At least one of the bearing units 25, 27 may further include an axial bearing, as shown by way of example at 25.2. If a single axial bearing is provided, this latter has a bi-directional axial bearing function. In other embodiments, each bearing unit may include a half axial bearing, the two half-axial bearings providing each an axial sup porting function in one direction only.

[0017] In the embodiment of Fig. 1 the turboexpanders 13, 15 are centripetal turbo expanders, i.e. the gas flow enters the respective impeller radially at an impeller inlet and exits the impeller axially at an impeller outlet. The inlets of the turboexpander impellers 19, 21 are shown at 19.1 and 21.1, and the turboexpander impeller outlets are shown at 19.2 and 21.2, respectively. The gas flows radially inwardly from the inlet towards the rotation axis A-A and is deflected by the impeller towards a sub stantially axial direction at the turboexpander exit. Variable inlet guide vanes (IGVs) schematically shown at 13.5 and 15.5 can be provided between a respective inlet ple num 13.4 and 15.4 and the turboexpander impeller 19, 21. Variable inlet guide vanes improve the flexibility of the turbomachine, since the angle of deflection of the gas flow entering the respective turboexpander impeller 19, 21 can be adapted to the op erating conditions, specifically to the rotational speed of the turbomachine. [0018] The turbomachine 1 can have a stacked configuration, wherein both turbo expander impellers 19, 21 and both compressor impellers 7 A, 7B are integrally formed with a respective portion of the shaft 23, and the shaft portions are stacked to one another to form the shaft 23. More specifically, in Fig.1 the shaft 23 includes six shaft portions, labeled 23.1, 23.2, 23.3, 23.4, 23.5 and 23.6. The shaft portion 23.1 is integrally formed with the turboexpander impeller 19. The shaft portion 23.2 extends through the first bearing unit 25 and is torsi onally coupled at one end with the first shaft portion 23.1 and at the opposite end with a first end of the third shaft portion 23.3. This latter is integrally formed with the first compressor impeller 7A. The sec ond end of the third shaft portion 23.3 is torsionally coupled with a first end of the fourth shaft portion 23.4, which is in turn integrally formed with the second com pressor impeller 7B. The second end of the fourth shaft portion 23.3 is torsionally coupled with a first end of the fifth shaft portion 23.5, which extends through the second bearing unit 27. The second end of the fifth shaft portion 23.5 is torsionally coupled to the sixth shaft portion 23.6, which is integrally formed with the turboex pander impeller 21.

[0019] By forming each impeller integrally, i.e. monolithically with the respective shaft portion, a turbomachine rotor is obtained, which can be rotated at higher speeds than a rotor where the impellers are mounted by shrink fitting.

[0020] Each pair of torsionally coupled shaft portions are connected by means of a tie rod and a pair of mutually engaging front teeth, for instance by means of a Hirth coupling, including tapered teeth that mesh together on the end faces of each of the two mutually coupled shaft portions. Tie rods connecting the various shaft portions are schematically shown at 31.1, 31.2 and 31.3.

[0021] The various turboexpander and compressor sections of the turbomachine 1 can be fluidly coupled according to various configurations. With continuing refer ence to Fig.1, a first configuration of the fluid couplings is schematically shown in Fig.2. In this embodiment, the turboexpanders 13, 15 are arranged in sequence, such that a flow of compressed gas is expanded partially in the first turboexpander 13 and subsequently further expanded in the second turboexpander 15. The gas outlet 13.2 of the first turboexpander 13 is fluidly coupled to the gas inlet 15.1 of the second tur boexpander 15. This configuration is particularly advantageous since, the enthalpy drop is split in the two sequentially arranged turboexpanders 13, 15 and the rotational speed of the shaft 23 can be maintained at lower values.

[0022] The compressor sections 5 A, 5B are also arranged in series, i.e. in sequence, such that the same gas flow is processed sequentially in the first compressor section 5 A and in the second compressor section 5B.

[0023] In other embodiments the turboexpanders 13, 15 can be arranged in parallel rather than in series. This may be preferred, for instance, if the pressure drop of the gas expanded in the turboexpanders is relatively small, but the gas flow rate is high. With continuing reference to Fig.1, an embodiment with paralleled turboexpanders 13, 15 is shown in the schematic of Fig.3. The same reference numbers of Fig.1 are used in Fig.3 to designate the same parts or components. In the configuration of Fig.3 a flow of compressed gas to be expanded in the turboexpanders 13, 15 is split in two partial flows, which are expanded in the two turboexpanders 13, 15 arranged in par allel. The compressor sections 5 A, 5B of Fig. 3 are arranged in series as shown in Figs 1 and 2.

[0024] In some embodiments, the compressor sections 5 A, 5B can be intercooled. With continuing reference to Fig.1, in Fig.4 a turbomachine 1 with intercooled com pressor is schematically shown. The same reference numbers designate the same el ements, parts or components already described in connection with Fig. l. In the schematic embodiment of Fig. 4, the casing arrangement 3 comprises a first com pressor inlet 9 A, fluidly coupled to the first compressor section 5 A. Partially com pressed gas is discharged at the delivery side of the first compressor section 5 A through a first compressor outlet 11 A, which is fluidly coupled to an inlet side of a heat exchanger of an intercooler globally labeled 12. The exit side of the heat ex changer is fluidly coupled to a second gas inlet 9B, through which the partly com pressed and cooled gas is delivered to the second compressor section 5B. The casing arrangement further comprises a second compressor outlet 1 IB, through which the compressed gas is delivered.

[0025] The turboexpanders 13, 15 of the turbomachine 1 of Fig.4 can be arranged in series or in parallel, according to any of the above described arrangements.

[0026] While in the schematic of Fig. 4 the compressor sections 5 A, 5B are in se- ries, in other embodiments, the compressor sections 5 A, 5B can be in parallel.

[0027] The compressor and turboexpander sections of the turbomachine 1 can be arranged according to further possible configurations, some of which are described hereon, reference being made to Figs 5 to 12. The main components of the tur bomachine 1 shown in Figs. 5 to 12 are labeled with the same reference numbers used in Fig. l. The various machine components can be configured as described above in connection with Fig.l, unless differently specified in the following descrip tion.

[0028] In Fig.5 a schematic of a further configuration of the turbomachine 1 is shown, wherein the two compressor sections 5 A, 5B are arranged in parallel. A flow of gas to be compressed is split into two partial streams, which are delivered to the suction side of the two compressor sections 5 A, 5B through first and second com pressor inlets 9 A, 9B. Each compressor section 5 A, 5B is fluidly coupled to a respec tive compressor outlet 11 A, 1 IB. Similarly to Figs. 1 to 4, also in the embodiment of Fig. 5 the compressor sections 5 A, 5B are arranged in an in-between bearing config uration, between the two bearing units 25 and 27. The turboexpanders are arranged on the external sides of the turbomachine, with the respective turboexpander impel lers in an overhung configuration, as shown in detail in Fig. l, supported at the free ends of the shaft 23, which extend beyond the bearing units 25, 27. In the schematic of Fig.5 the compressor sections 5 A, 5B are arranged in a back-to-back arrangement, i.e. the two delivery sides (compressor outlets 11 A, 11B) of the compressor sections 5 A, 5B face each other and are arranged between the suction sides (compressor inlets 9 A, 9B) of the compressor sections.

[0029] Fig.6 illustrates a configuration which differs from the one shown in Fig.5 in view of a sealing arrangement 40 arranged between the two compressor sections 5 A, 5B. The two compressor sections 5 A, 5B can therefore process different gaseous flows, which are maintained separate from one another. By way of example, the compressor sections 5 A, 5B are arranged in a reversed position with respect to the one of Fig. 5, i.e. the suction sides (compressor inlets 9 A, 9B) are facing each other, while the delivery sides (compressor outlets 11 A, 1 IB) are facing away from one an other. The compressor sections 5 A, 5B are again arranged in an in-between bearing configuration, while the turboexpanders 13, 15 are overhung, with the relevant im- pellers supported by the shaft ends cantileverly extending beyond the respective bearing units 25, 27.

[0030] With continuing reference to Figs. 1 to 6, a further configuration of the tur bomachine 1 according to the present di sclosure is shown in Fig.7. The same refer ence numbers designate the same or equivalent parts as already described above. The turbomachine 1 of Fig.7 comprises two compressor sections 5 A, 5B which can be ar ranged face-to-face or back-to-back and in-between bearings. Fig.7 illustrates a face- to-face configuration, but the compressor sections could be arranged back-to-back as shown in Fig.5, with or without an intermediate sealing arrangement 40. In the con figuration of Fig. 7 the compressor sections 5 A, 5B are arranged in series. The flow of gas to be processed by the compressor 5 is sucked by the first compressor section 5 A through the first compressor inlet 9A and is delivered through the first compres sor outlet 11 A. In the exemplary embodiment of Fig.7, the first compressor outlet 11A is fluidly coupled to the second compressor inlet 9B through an intercooler, again labeled 12. Gas at the final pressure is delivered through the second compres sor outlet I IB. The first and second turboexpanders 13, 15 can be arranged in an overhung configuration, with the respective turboexpander impellers supported in an overhung fashion at the ends of the shaft 23, which cantileverly projects from the bearing arrangements 25, 27. The two turboexpanders 13, 15 can be arranged in se ries, whereby the discharge of the first turboexpander 13 is fluidly coupled to the in let of the second turboexpander 15, such that the flow of compressed gas is expanded sequentially in two steps.

[0031] Fig.8 illustrates the same arrangement of Fig. 7, but with the turboexpanders 13, 15 in a parallel configuration.

[0032] In the above described embodiments the turboexpanders are arranged on the sides of the turbomachine 1 and the compressor sections 5 A, 5B are arranged in- between bearings in the intermediate portion of the turbomachine. This configuration is particularly beneficial both in terms of accessibility to the turboexpander compo nents, as well as in terms of fluid dynamic efficiency. As a matter of fact, on the one hand accessibility to the turboexpander impellers 19, 21 is facilitated. Also, the vari able inlet guide vanes 13.5 and 15.5 and relevant actuators are more readily accessi ble. On the other hand, since the turboexpander impellers 19, 21 are usually centripe- tal impellers, the outlet flow of the exhaust (expanded) gas is made easier if free space is available axially at the discharge side of the impeller. No additional diffusers are required to divert the direction of flow. Fluid dynamic losses are minimized.

[0033] However, in currently less preferred embodiments, a different arrangement of the turboexpanders and of the compressor sections is not excluded. With continu ing reference to Fig. l, in Fig. 9 an embodiment is shown, wherein the compressor sections 5 A, 5B are arranged at the terminal ends of the turbomachine 1, while the turboexpanders 13, 15 are arranged in an in-between bearing configuration, in the central area of the turbomachine 1, between the compressor sections 5 A, 5B. The gas processed by the compressor sections 5 A, 5B enters the turbomachine 1 through a first compressor inlet 9L and is partly compressed by the first compressor section 5 A, which delivers the partly compressed gas through a first compressor outlet 11A towards a second compressor inlet 9B. The gas entering the second compressor inlet 9B is further compressed by the second compressor section 5B and delivered through the second compressor outlet 1 IB. An intercooler 12 can be provided between the first compressor outlet 11 A and the second compressor inlet 9B, to remove heat from the partly compressed gas before this latter is further compressed in the second com pressor section 5B.

[0034] The compressor impellers 7 A, 7B can be supported in an overhung configu ration at the ends of shaft 23, which project cantileverly beyond the first and second bearing units 25, 27.

[0035] The turboexpander impellers 19, 21 can be supported in an in-between bear ing arrangement in the central portion of the shaft 23, between the bearing units 25, 27. The two turboexpanders 13, 15 can be arranged in series or in parallel, as de scribed above in conjunction with Figs. 1 to 8.

[0036] With continuing reference to Figs. 1 to 9, a further embodiment is shown in Fig.10. The turbomachine 1 of Fig.10 again compri ses first and second turbo expanders 13, 15, first and second compressor sections 5 A, 5B and a common shaft 23, rotatingly supported in the casing arrangement 3 (not shown in Fig.10). The shaft 23 can be a stacked shaft as described above in conjunction with Fig. l. Such stacked configuration can be advantageously used also in the embodiments of Figs 2 to 9. [0037] Differently form Figs. 1 to 9, in Fig.10 both the compressor impellers 7 A, 7B as well as the turboexpander impellers 19, 21 are in an in-between bearings ar rangement, since the both the compressor sections 5 A, 5B as well as the turboex panders 13, 15 are arranged between the bearing units 25, 27.

[0038] The fluid coupling between the compressor sections 5 A, 5B can be such that the compressor sections 5 A, 5B are arranged in series or in parallel. Moreover, while in the schematic of Fig.10 the compressor sections 5 A, 5B are shown in an in-line configuration, in other embodiments the compressor sections 5 A, 5B can be arranged back-to-back or face-to-face, as shown in Fig. 5 or 6 for instance. Either one or the other of the various arrangements can be preferred, depending upon different factors. In particular, a back-to-back or face-to-face configuration can be more beneficial in terms of thrust balancing, since the axial forces generated during operation by the two compressor impellers on the shaft 23 are oriented in opposite directions and are therefore at least partially balanced. An in-line configuration may be more beneficial in terms of simplified flow passages, as can be appreciated from Fig.1. If no inter cooling is required, an in-line configuration may avoid the need for double inlet and outlet ducts through the casing.

[0039] While in Fig.10 the compressor sections 5 A, 5B are adjacent to one another and similarly the turboexpanders 13, 15 are arranged in a back-to-back arrangement one adjacent to the other, different arrangements are possible, with compressor sec tions and turboexpanders located in an interleaved configuration, i.e. with one com pressor section arranged between two turboexpanders. Also, the turboexpanders can be arranged in an in-line rather than in a back-to-back configuration.

[0040] With continuing reference to Figs. 1 to 10, Fig.11 illustrates a yet further embodiment of the turbomachine 1. In this embodiment, the second turboexpander 15 and the first compressor section 5 A are arranged in an in-between bearing config uration between the bearing units 25, 27. The first turboexpander 13 is arranged in an overhung configuration on one end of the shaft 23 which proj ects cantileverly be yond the bearing unit 25, while the second compressor section 5B is arranged in an overhung configuration on the other end of the shaft 23 which projects cantileverly beyond the bearing unit 27. By way of example the two turboexpanders 13, 15 are arranged in series. In other embodiments, the turboexpanders 13, 15 can be arranged in parallel. The compressor sections 5 A, 5B can be in parallel or in series with or without intercooling.

[0041] Finally, with continuing reference to Figs 1 to 11, a yet further embodiment of the turbomachine 1 according to the present disclosure is shown in Fig. 12. The embodiment of Fig. 12 differs from the embodiment of Fig. 11 mainly in that the tur boexpanders 13, 15 are arranged in parallel. The compressor sections 5 A, 5B are ar ranged in series with an intercooler 12 therebetween.

[0042] In all embodiments disclosed herein, the shaft can be supported by two radi al bearings and one or two thrust bearings. In particular, if two thrust bearings are provided, so-called half-thrust bearings can be used, each of which supports an axial thrust in one direction only. In some embodiments, therefore, two bearing unit can be provided: each bearing unit has a radial bearing function and both also have an axial bearing (thrust bearing) function, each however in one direction only. In other em bodiments, each bearing unit has a radial bearing function and only one of them has a thrust (axial) bearing function in both directions.

[0043] In preferred embodiments, each bearing unit can include one or more active magnetic bearings.

[0044] While the invention has been described in terms of various specific embod iments, it will be apparent to those of ordinary skill in the art that many modifica tions, changes, and omissions are possible without departing from the spirit and scope of the claims. In addition, unless specified otherwise herein, the order or se quence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Specifically, in each of the configurations described above the two compressor sections can be arranged either in series or in parallel, unless dif ferently specified. Also, the two turboexpanders can be alternatively in series or in parallel, unless differently specified.