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WO 2014/144290 Al 18 September 2014 (18.09.2014) P O P C T

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WO 2014/144290 Al 18 September 2014 (18.09.2014) P O P C T (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization International Bureau (10) International Publication Number (43) International Publication Date WO 2014/144290 Al 18 September 2014 (18.09.2014) P O P C T (51) International Patent Classification: (81) Designated States (unless otherwise indicated, for every F02G 1/02 (2006.0 1) F01B 1/00 (2006.0 1) kind of national protection available): AE, AG, AL, AM, F02G 1/06 (2006.0 1) F25B 1/02 (2006.0 1) AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, F02G 5/02 (2006.01) BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, (21) International Application Number: HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR, PCT/US2014/028635 KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME, (22) International Filing Date: MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, 14 March 2014 (14.03.2014) OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, (25) Filing Language: English TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, (26) Publication Language: English ZW. (30) Priority Data: (84) Designated States (unless otherwise indicated, for every 13/836,790 15 March 2013 (15.03.2013) US kind of regional protection available): ARIPO (BW, GH, GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ, (71) Applicant: LIGHTSAIL ENERGY, INC. [US/US]; 914 UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, Heinz Ave., Berkeley, California 94710 (US). TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV, (72) Inventors: CONEY, Michael; The Pinnocks, Broad MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, Town, Swindon, Wiltshire SN4 7RG (GB). WAZNI, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, Karim; 118 Tuscany Way, Danville, California 94506 KM, ML, MR, NE, SN, TD, TG). (US). FONG, Danielle; 815 Alice St., Oakland, California 94607 (US). CRANE, Stephen E.; 3970 Piner Rd., Santa Published: Rosa, California 95401 (US). BERLIN JR., Edwin P.; — with international search report (Art. 21(3)) 2447 Scout Rd., Oakland, California 9461 1 (US). — before the expiration of the time limit for amending the (74) Agent: RAUDEBAUGH, Kevin W.; 6100 219th ST S.W., claims and to be republished in the event of receipt of STE 580, Mountlake Terrace, Washington 98043 (US). amendments (Rule 48.2(h)) (54) Title: ENERGY RECOVERY FROM COMPRESSED GAS Air In l Compressed air Exhaust gas 20 90 Power Comp -©- -23 heater 22 i 30 50 52 1 1 Fuel 56 o FIG. 1 (57) Abstract: An expansion system utilizes external combustion of its residual warm exhaust air, in order to heat incoming com pressed air. The heat of this external combustion is communicated to the incoming compressed air through a heat exchanger. The ex pansion system may be incorporated into an energy storage device also featuring a compressed air storage unit supplied by a com - o pressor. Where the stored supply of compressed air is depleted, the energy storage device may continue to supply electricity on de mand through operation as a heat engine, with the compressor being driven directly (e.g. on a same rotating shaft) or indirectly (via generated electrical power) by the expansion system. Multiple expanders of the same or different types (e.g. rotating, reciprocating), o may be utilized in parallel and/or in series (e.g. multiple stages) depending upon the particular application. Multi-stage embodiments featuring internal combustion in low pressure stages, may be particularly suited for placement in vehicles. ENERGY RECOVERY FROM COMPRESSED GAS BACKGROUND [0001] Recently, approaches employing compressed gas as an energy storage medium, have emerged. In particular, compressed air is capable of storing energy at densities comparable to lead-acid batteries. Moreover, compressed gas does not involve issues associated with a battery such as limited lifetime, materials availability, or environmental friendliness. SUMMARY [0002] An expansion system receives hot compressed air at high pressure, expands it to a lower pressure and lower, but still high temperature, exhausts the hot air, then utilizes external combustion of fuel in the hot exhaust air, in order to heat incoming compressed air to a high temperature. The heat of this external combustion is communicated to the incoming compressed air through a heat exchanger, which may be of a tubular type. The expansion system may be incorporated into an energy storage device also featuring a compressed air storage unit supplied by a compressor. Where the stored supply of compressed air is depleted, the energy storage device may continue to supply electricity on demand through operation as a heat engine, with the compressor being driven directly (e.g. on a same rotating shaft) or indirectly (via generated electrical power) by the expander. Multiple expanders of the same or different types (e.g. rotating, reciprocating), may be utilized in parallel and/or in series (e.g. multiple stages) depending upon the particular application. Multi-stage embodiments featuring internal combustion may be particularly suited for placement in vehicles in addition to static applications. BRIEF DESCRIPTION OF THE DRAWINGS [0003] Figure 1 is a simplified view of an example of an air expansion system with external combustion heating. [0004] Figure 1A is a schematic view showing an embodiment of a multi-stage air expansion system with external combustion heating. [0005] Figure 2 shows an example of the pressure profile in the stage 3 cylinder. [0006] Figures 3-4 show inlet valve lift profiles for stage 1 and 2 expanders, respectively. [0007] Figures 5-6 show exhaust valve lift profiles for stage 1 and 2 expanders, respectively. [0008] Figure 7 shows expansion system power variation as a function of speed, for two systems with the same bore and stroke but different maximum design speeds. [0009] Figure 8 shows expansion system efficiency as a function of speed, for two different systems with the same bore and stroke but different maximum design speeds [0010] Figure 9 shows cycle efficiency as a function of speed, for two different expansion systems with the same bore and stroke but different maximum design speeds [0011] Figure 10 shows expansion system energy output ratio as a function of speed, for two different systems with the same bore and stroke but different maximum design speeds. [0012] Figure 11 shows variation of the inlet valve closing crank angle as the air source pressure changes. [0013] Figure 12 shows variation of the stage 1 air inlet temperature as the source pressure changes [0014] Figure 13 shows variation of air mass flow with source pressure. [0015] Figure 14 shows variation of power output versus air source pressure. [0016] Figure 15 shows expansion system efficiency and complete cycle efficiency at constant air flow. [0017] Figure 16 shows expansion system and complete cycle efficiency with varying air flow. [0018] Figure 17 shows energy output ratio versus air source pressure. [0019] Figure 18 shows expansion system energy output per unit mass of air versus source pressure. [0020] Figure 19 shows integrated energy output/input versus air storage pressure for 100 m volume. [0021] Figure 20 shows expansion system power output versus air storage pressure. [0022] Figure 2 1 compares expansion system and cycle efficiency of a 3-stage mixed reciprocating expansion system with a mixed system having a turbine expander in the 3rd stage. [0023] Figure 22. Comparison of electrical power output of a 3-stage reciprocating expansion system with a mixed system having a turbine expander in the 3rd stage. [0024] Figure 23 shows an embodiment of a 2-stage air expansion system with external combustion. [0025] Figure 24 is a diagram of an embodiment of a 2-stage expansion system adapted for application in a road vehicle and incorporating "extended range" capability and regenerative braking. [0026] Figure 25 plots variation of mechanical power with air source pressure at two fixed speeds and fixed air mass flows. [0027] Figure 26 plots variation in stage pressure ratios and closing crank-angle of the Stage 1 inlet valves at 2400 rpm. [0028] Figure 27 plots variation in stage pressure ratios and closing crank-angle of the Stage 1 inlet valves at 300 rpm. [0029] Figure 28 plots expansion system mechanical efficiency at constant speed and air flow. [0030] Figure 29 plots energy output ratio at constant speed and air flow. [0031] Figure 30 plots cycle mechanical efficiency at constant speed and air flow. [0032] Figure 3 1 is a simplified view of a 2-stage expansion system with a 4-stroke internal combustion expander at the low pressure stage and a 2-stroke external combustion expander at the high pressure stage. [0033] Figure 32 shows a simplified view of an exhaust gas separation valve. [0034] Figure 33 shows a two stage expansion system with internal combustion in the low pressure stage and cooling using an exhaust gas cooler. [0035] Figure 34 shows a 2-stage expansion system with 4-stroke internal combustion expanders in both stages. [0036] Figure 35 shows a simplified view of an embodiment of an air fuse. [0037] Figures 36A and 36B show different configurations of a hybrid vehicle utilizing compressed gas and internal combustion. [0038] Figure 37 shows a reciprocating cylinder configurable between different cycles. DESCRIPTION [0039] Compressed air energy storage during off-peak periods can efficiently utilize surplus power from renewable and other sources.
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