Description:FIELD OF DISCLOSURE
[001] The present disclosure generally relates to a thermal energy storage system, and more specifically, relates to a heat exchanger module system for generating fixed-temperature superheated steam in a solar thermal power plant and method thereof.
BACKGROUND OF THE DISCLOSURE
[002] Thermal systems are at the heart of power production, especially in solar thermal power stations where solar energy is first converted to heat to generate superheated steam for electricity generation through turbines. To achieve the highest turbine efficiency and lifespan, the steam should be provided in a homogeneous, controlled temperature. Under such thermal homogeneity, however, it is difficult to maintain since the solar irradiance fluctuates, there are seasonal and geographical variations.
[003] Traditional designs depend on large external heat exchanger units usually shell-and-tube type installed independently of the thermal storage tank. These designs are not able to provide steam at uniform temperatures since they are very sensitive to solar input fluctuations. This thermal instability negatively impacts turbine performance and longevity. Additionally, the high production and installation cost, combined with a large physical presence, restricts their scalability and feasible deployment in modular or decentralized energy configurations.
[004] Aside from uneven thermal output, current systems are rigid, frequently necessitating special designs suited to individual plant capacities. Expanding such systems or modifying them to accommodate shifting energy needs is time-consuming and expensive. Regular maintenance generally requires system downtime and professional labour, resulting in reduced energy output and increased operating costs. The utilization of heavy, costly materials also adds to logistical complexities and high capital outlay.
[005] The present invention overcomes these limitations by providing a novel, compact, and modular steam generation system suitable for integration in thermal storage tanks. In contrast with conventional external equipment, the system ensures constant steam temperature irrespective of variations in solar input without requiring intricate auxiliary regulation systems. Its local response capability to varying thermal conditions without external control enhances system reliability and minimizes operational stress to turbines.
[006] Furthermore, the lightweight, scalable, and standardized structure of the invention makes fabrication easier, transportation less expensive, and field deployment easier. It is particularly ideal for modular, off-grid, or remote installations with restricted maintenance access. With lower material expenses, minimal installation costs, and low maintenance, the system offers a very energy-efficient, cost-saving alternative to conventional heat exchanger configurations, which allows for more efficient plant operation with increased long-term performance.
[007] Thus, in light of the above-stated discussion, there exists a need for a heat exchanger module system for generating fixed-temperature superheated steam in a solar thermal power plant and method thereof.
SUMMARY OF THE DISCLOSURE
[008] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[009] According to illustrative embodiments, the present disclosure focuses on a heat exchanger module system for generating fixed-temperature superheated steam in a solar thermal power plant and method thereof which overcomes the above-mentioned disadvantages or provide the users with a useful or commercial choice.
[0010] An objective of the present disclosure is to offer a compact and integrated thermal storage system enabling efficient and consistent superheated steam production in solar thermal power plants.
[0011] Another objective of the present disclosure is to obviate the use of bulky, external shell-and-tube heat exchanger units by integrating modular heat exchanger modules (HEMs) directly in the thermal storage infrastructure.
[0012] Yet another objective of the present disclosure is to provide for the delivery of steam at a stable, preselected temperature, independent of variations in solar irradiance, to improve turbine efficiency and operational life.
[0013] Yet another objective of the present disclosure is to provide real-time monitoring and adaptive control of heat exchanger performance to ensure energy optimization and thermal reliability.
[0014] Yet another objective of the present disclosure is to reduce material, maintenance, and logistical expenses by using lightweight components, reduced design complexity, and in-situ servicing without plant shutdown.
[0015] Yet another objective of the present disclosure is to facilitate autonomous, offline operation of the system, particularly in remote or off-grid locations, independently of external controllers or cloud analysis.
[0016] Yet another objective of the present disclosure is to decrease thermal response delay and suppress temperature oscillations via localized control and PID feedback loops for dynamic temperature control.
[0017] Yet another objective of the present disclosure is to optimize the modularity and standardization of thermal energy infrastructure to facilitate faster manufacturing, easier assembly, and convenient replacement of individual modules as required.
[0018] In light of the above, in one aspect of the present disclosure, a heat exchanger module system for generating fixed-temperature superheated steam in a solar thermal power plants disclosed herein. The system comprises thermal storage tank configured to define a fluid flow path for a thermal oil stream and a deionized water stream, the thermal storage tank comprising thermal oil inlet configured to introduce thermal oil into the thermal storage tank, a thermal oil outlet configured to discharge thermal oil from the thermal storage tank after heat exchange, a deionized water inlet configured to introduce deionized water into the thermal storage tank, a plurality of deionized water outlets configured to discharge superheated steam from the thermal storage tank. The system also includes a plurality of heat exchanger module (HEM) units housed within the thermal storage tank, plurality of heat exchanger module (HEM) units configured to facilitate thermal energy exchange between the thermal oil stream and the deionized water stream, thereby generating superheated steam. The system also includes a plurality of sensors configured to detect properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams, generating real-time sensor data. The system also includes a control valve operatively coupled to the deionized water inlet, the control valve configured to regulate the flow of deionized water into the plurality of heat exchanger module (HEM) units. The system also includes a microcontroller operatively connected to the control valve and a plurality of sensors, the microcontroller comprising data input module configured to receive sensor data from the plurality of sensors, a control module configured to process the received sensor data and send control instructions to the control valve, a temperature regulation module configured to monitor and adjust the temperature of the deionized water and thermal oil streams, ensuring efficient thermal energy exchange and maintain a constant superheated steam output, a performance monitoring module configured to evaluate the overall performance of the plurality of heat exchanger module (HEM) units, and adjust operational parameters for optimal energy efficiency, a communication module configured to transmit data within the system, enabling real-time monitoring and data exchange for system optimization.
[0019] In one embodiment, the system comprises a plurality of parabolic troughs configured to capture solar irradiation and heat the thermal oil stream, thereby providing solar thermal energy to the thermal storage tank via the thermal oil inlet.
[0020] In one embodiment, the system further comprises an energy storage unit operatively connected to the plurality of heat exchanger module (HEM) units, the energy storage unit configured to store excess thermal energy generated during periods of low demand and discharge the stored energy to the thermal oil stream, thereby ensuring continuous operation during periods of high demand.
[0021] In one embodiment, the system further comprises a control unit configured to regulate the flow rate of deionized water through the control valve based on sensor data, ensuring efficient thermal energy exchange.
[0022] In one embodiment, the control unit further comprises a proportional-integral-derivative (PID) controller configured to locally regulate the flow rate of deionized water through the control valve based on the temperature at the plurality of deionized water outlet, thereby minimizing thermal response delay and maintaining a constant superheated steam output by suppressing temperature oscillations.
[0023] In one embodiment, the plurality of heat exchanger module (HEM) units further comprises the plurality of grooved aluminium plates configured to enhance thermal energy transfer between the thermal oil stream and the deionized water stream.
[0024] In one embodiment, the plurality of heat exchanger module (HEM) units is configured to enable modular arrangement in series or parallel, allowing for precise control over superheated steam temperature and flow rate by adjusting the number of heat exchanger module (HEM) units.
[0025] In one embodiment, the thermal oil inlet, the thermal oil outlet, the deionized water inlet, and the plurality of deionized water outlet each comprise the plurality of welded circular pipes at interface points of the grooved aluminium plates, the plurality of welded circular pipes configured to connect adjacent of the heat exchanger module (HEM) units and integrate with a main fluid pipeline of the system to ensure structural integrity and efficient fluid transfer.
[0026] In one embodiment, the system further comprises a display panel configured to provide real-time visual feedback on thermal energy flow, storage levels, and operational parameters of the system, thereby enabling on-site monitoring of the system.
[0027] In light of the above, in another aspect of the present disclosure, a method for a heat exchanger module system for generating fixed temperature superheated steam in solar thermal power plants disclosed herein. The method comprises defining a fluid flow path for a thermal oil stream and a deionized water stream within a thermal storage tank. The method also includes introducing thermal oil into the thermal storage tank via a thermal oil inlet. The method also includes introducing deionized water into the thermal storage tank via a deionized water inlet. The method also includes facilitating thermal energy exchange between the thermal oil stream and the deionized water stream via a plurality of heat exchanger module (HEM) units. The method also includes discharging thermal oil from the thermal storage tank after heat exchange via a thermal oil outlet. The method also includes discharging superheated steam from the thermal storage tank via a plurality of deionized water outlets. The method also includes detecting properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams via a plurality of sensors and generating real-time sensor data. The method also includes receiving sensor data from the plurality of sensors via a data input module. The method also includes processing the received sensor data and sending control instructions to the control valve via a control module. The method also includes regulating the flow of deionized water into the plurality of heat exchanger module (HEM) units via a control valve. The method also includes monitoring and adjusting the temperature of the deionized water and thermal oil streams via a temperature regulation module. The method also includes evaluating the overall performance of the plurality of heat exchanger module (HEM) units via a performance monitoring module. The method also includes transmitting data within the system via a communication module.
[0028] These and other advantages will be apparent from the present application of the embodiments described herein.
[0029] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0030] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art can derive other implementations from these accompanying drawings without creative efforts. All of the embodiments or the implementations shall fall within the protection scope of the present disclosure.
[0032] The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:
[0033] FIG. 1 illustrates a block diagram of a heat exchanger module system for generating fixed temperature superheated steam in solar thermal power planting accordance with an exemplary embodiment of the present disclosure;
[0034] FIG. 2 illustrates a flowchart of a method, outlining the sequential steps fora heat exchanger module system for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[0035] FIG. 3 illustrates a flowchart of a method, outlining the sequential steps for a heat exchanger module system for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[0036] FIG. 4 illustrates an exemplary layout of a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[0037] FIG. 5 illustrates an exemplary visualization and the actual prototype representation of the heat exchanger module (HEM) used in a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[0038] Like reference, numerals refer to like parts throughout the description of several views of the drawing.
[0039] A heat exchanger module system for generating fixed temperature superheated steam in solar thermal power plant and a method thereof is illustrated in the accompanying drawings, which like reference letters indicate corresponding parts in the various figures. It should be noted that the accompanying figure is intended to present illustrations of exemplary embodiments of the present disclosure. This figure is not intended to limit the scope of the present disclosure. It should also be noted that the accompanying figure is not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0040] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0041] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It may be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.
[0042] Various terms as used herein are shown below. To the extent a term is used, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0043] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0044] The terms “having”, “comprising”, “including”, and variations thereof signify the presence of a component.
[0045] Referring now to FIG. 1 to FIG. 5 to describe various exemplary embodiments of the present disclosure. FIG. 1 illustrates a block diagram of a heat exchanger module system for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[0046] The system 100 may include a thermal storage tank 114 configured to define a fluid flow path for a thermal oil stream and a deionized water stream, the thermal storage tank 114 comprising a thermal oil inlet 106 configured to introduce thermal oil into the thermal storage tank 114, a thermal oil outlet 140 configured to discharge thermal oil from the thermal storage tank 114 after heat exchange, a deionized water inlet 108 configured to introduce deionized water into the thermal storage tank 114, a plurality of deionized water outlets 142 configured to discharge superheated steam from the thermal storage tank 114. The system 100 may also include a plurality of heat exchanger module (HEM) units 116 housed within the thermal storage tank 114, plurality of heat exchanger module (HEM) units 116 configured to facilitate thermal energy exchange between the thermal oil stream and the deionized water stream, thereby generating superheated steam. The system 100 may also include a plurality of sensors 122 configured to detect properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams, generating real-time sensor data. The system 100 may also include a control valve 110 operatively coupled to the deionized water inlet 108, the control valve 110 configured to regulate the flow of deionized water into the plurality of heat exchanger module (HEM) units 116. The system 100 may also include a microcontroller 128 operatively connected to the control valve 110 and a plurality of sensors 122, the microcontroller 128 comprising a data input module 130 configured to receive sensor data from the plurality of sensors 122, a control module 132 configured to process the received sensor data and send control instructions to the control valve 110, a temperature regulation module 134 configured to monitor and adjust the temperature of the deionized water and thermal oil streams, ensuring efficient thermal energy exchange and maintain a constant superheated steam output, a performance monitoring module 136 configured to evaluate the overall performance of the plurality of heat exchanger module (HEM) units 116, and adjust operational parameters for optimal energy efficiency, a communication module 138 configured to transmit data within the system 100, enabling real-time monitoring and data exchange for system optimization.
[0047] The system 100 comprises a plurality of parabolic troughs 102 configured to capture solar irradiation and heat the thermal oil stream, thereby providing solar thermal energy to the thermal storage tank 104 via the thermal oil inlet 106.
[0048] The system 100 further comprises an energy storage unit 104 operatively connected to the plurality of heat exchanger module (HEM) units 116, the energy storage unit 104 configured to store excess thermal energy generated during periods of low demand and discharge the stored energy to the thermal oil stream, thereby ensuring continuous operation during periods of high demand.
[0049] The system 100 further comprises a control unit 124 configured to regulate the flow rate of deionized water through the control valve 110 based on sensor data, ensuring efficient thermal energy exchange.
[0050] The control unit 124 further comprises a proportional-integral-derivative (PID) controller 126 configured to locally regulate the flow rate of deionized water through the control valve 110 based on the temperature at the plurality of deionized water outlet 142, thereby minimizing thermal response delay and maintaining a constant superheated steam output by suppressing temperature oscillations.
[0051] The plurality of heat exchanger module (HEM) units 116 further comprises the plurality of grooved aluminium plates 118configured to enhance thermal energy transfer between the thermal oil stream and the deionized water stream.
[0052] The plurality of heat exchanger module (HEM) units 116 is configured to enable modular arrangement in series or parallel, allowing for precise control over superheated steam temperature and flow rate by adjusting the number of heat exchanger module (HEM) units.
[0053] The thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of deionized water outlet 142 each comprise the plurality of welded circular pipes 120 at interface points of the grooved aluminium plates 118, the plurality of welded circular pipes 120 configured to connect adjacent of the heat exchanger module (HEM) units 116 and integrate with a main fluid pipeline112 of the system 100 to ensure structural integrity and efficient fluid transfer.
[0054] The system 100 further comprises a display panel 144 configured to provide real-time visual feedback on thermal energy flow, storage levels, and operational parameters of the system, thereby enabling on-site monitoring of the system 100.
[0055] The method 200 may include defining a fluid flow path for a thermal oil stream and a deionized water stream within a thermal storage tank 114. The method 200 may also include introducing thermal oil into the thermal storage tank 114 via a thermal oil inlet 106. The method 200 may also include introducing deionized water into the thermal storage tank 114 via a deionized water inlet 108. The method 200 may include facilitating thermal energy exchange between the thermal oil stream and the deionized water stream via a plurality of heat exchanger module (HEM) units 116. The method 200 may also include discharging thermal oil from the thermal storage tank 114 after heat exchange via a thermal oil outlet 140. The method 200 may also include discharging superheated steam from the thermal storage tank 114 via a plurality of deionized water outlets 142. The method 200 may also include detecting properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams via a plurality of sensors 122, and generating real-time sensor data. The method 200 may also include receiving sensor data from the plurality of sensors 122 via a data input module130. The method 200 may also include processing the received sensor data and sending control instructions to the control valve 110 via a control module 132. The method 200 may also include regulating the flow of deionized water into the plurality of heat exchanger module (HEM) units 116 via a control valve 110. The method 200 may also include monitoring and adjusting the temperature of the deionized water and thermal oil streams via a temperature regulation module 134. The method 200 may also include evaluating the overall performance of the plurality of heat exchanger module (HEM) units 116 via a performance monitoring module 136. The method 200 may also include transmitting data within the system 100 via a communication module 138.
[0056] The thermal storage tank 114 configured to define a fluid flow path for a thermal oil stream and a deionized water stream. The thermal storage tank 114 ensures efficient heat exchange while minimizing heat loss, allowing for the storage of thermal energy for later use.
[0057] In one embodiment, the thermal storage tank 114 is configured to be made from a corrosion-resistant material, such as stainless steel, capable of withstanding high temperatures and pressures. The internal surface of the thermal storage tank 114 may also be coated with a heat-resistant lining to further enhance durability and protect against the corrosive effects of the thermal oil and deionized water.
[0058] In another embodiment, the thermal storage tank 114 is further configured with high-efficiency insulation. The insulation layer can be made from aerogel or polyurethane foam, which reduces thermal losses and ensures that the thermal energy stored within the tank remains at optimal temperatures for extended periods.
[0059] In a further embodiment, the thermal storage tank 114 is further configured with a large thermal energy storage capacity to meet the high demands of industrial or commercial applications. The thermal storage tank 114 may include a high thermal mass material, such as graphite, to increase the heat storage capacity, thereby ensuring that energy is available even during periods of low solar irradiation or high demand.
[0060] The thermal storage tank 114 comprising a thermal oil inlet 106, a thermal oil outlet 140, a deionized water inlet 108, a plurality of deionized water outlets 142.
[0061] The thermal oil inlet 106 configured to introduce thermal oil into the thermal storage tank 114. The thermal oil inlet 106 provides for continuous thermal oil flow from outside sources into the thermal storage tank 114 where it may be subjected to heat exchange with the stream of deionized water. The thermal oil passes through the heat exchanger modules inside the tank, and it transfers the thermal energy to the water, thereby allowing efficient storage of energy and subsequent use as superheated steam.
[0062] In a preferred embodiment, the thermal oil inlet 106 is made from high-temperature-resistant materials like titanium or stainless steel that can withstand the severe conditions related to high-temperature flow of thermal oil. This keeps the thermal oil inlet 106 structurally sound and corrosion-resistant even in the case of continuous heat exchange.
[0063] In a preferred embodiment, the thermal oil inlet 106 is further configured to be provided with advanced sealing devices, like graphite seals or ceramic gaskets, that make sure that the thermal oil is introduced into the tank without leakage, which avoids loss of energy and increases system safety.
[0064] The thermal oil outlet 140 configured to discharge thermal oil from the thermal storage tank 114 after heat exchange. After the thermal oil transfers heat to the deionized water in the tank, it passes out through the thermal oil outlet 140, providing a controlled and continuous circulation of the thermal oil stream throughout the system 100.
[0065] In a preferred embodiment, the thermal oil outlet 140 is made of corrosion-resistant alloys, such as nickel-chromium-based superalloys or stainless steel, to accommodate the thermal and chemical stress of discharged thermal oil following extended high-temperature exposure.
[0066] In another embodiment, the thermal oil outlet 140 is tapered or contoured geometry to reduce pressure drop and facilitate laminar flow as the thermal oil leaves the thermal storage tank 114.
[0067] In another embodiment, the thermal oil outlet 140 is coupled with external reheating units so that discharged thermal oil can be either diverted for additional heating or recycled in other energy units, thus enhancing overall thermal efficiency and minimizing energy wastage.
[0068] The deionized water inlet 108 configured to introduce deionized water into the thermal storage tank 114. The deionized water flows through the deionized water inlet 108 towards the plurality of heat exchanger module (HEM) units 116 in the thermal storage tank 114, where it exchanges heat with the stream of thermal oil to be converted to superheated steam.
[0069] In one preferred embodiment, the deionized water inlet 108 includes an integrated pre-heating and filtration assembly that prevents dirty or unconditioned water from being fed into the thermal storage tank 114. The filtration assembly can include fine mesh filters or activated carbon stages to filter out particulates and contaminants, so that the interior parts of the plurality of heat exchanger module (HEM) units 116will not be fouled or scaled. The pre-heating system, optionally utilizing residual system heat, raises the water temperature to minimize thermal shock and enhance heat transfer efficiency in the conversion of deionized water to superheated steam.
[0070] The plurality of deionized water outlets 142 configured to discharge superheated steam from the thermal storage tank 114. The plurality of deionized water outlets 142 act as points of exit for high-temperature steam, which is then transferred to turbines for electricity generation.
[0071] In one preferred implementation, the plurality of deionized water outlets 142 are made from high-strength heat-resistant alloys like inconel or stainless-steel grades that can be used for high-pressure steam applications. These materials provide excellent mechanical strength, thermal stability, and corrosion resistance under prolonged exposure to superheated steam conditions.
[0072] In yet another embodiment, the plurality of deionized water outlets 142 are internally passivated or coated with anti-scaling materials like polytetrafluoroethylene (PTFE), silicon carbide, or ceramic-based coatings to prevent deposition of minerals or other particulate matter during continuous discharge of superheated steam. Such anti-scaling treatment provides smooth steam flow, minimizes maintenance intervals, and extends the life of the plurality of deionized water outlets 142.
[0073] The system 100 comprises a plurality of parabolic troughs 102 configured to capture solar irradiation and heat the thermal oil stream, thereby providing solar thermal energy to the thermal storage tank 104 via the thermal oil inlet 106.The parabolic troughs 102 are aligned on the north-south or east-west axis depending upon location to receive maximum exposure to the sun during solar daytime. Every parabolic trough of the plurality of parabolic troughs 102 has a reflective surface that is intended to concentrate incoming solar radiation onto a central receiver tube that contains the thermal oil. The reflecting surface of the plurality of parabolic troughs 102 is built out of silver-coated or aluminium-backed glass mirrors to provide high reflectivity and long life. The receiver tubes utilized in the parabolic troughs 102 are fabricated with high-temperature-resistant materials such as stainless steel or coated steel with selective absorber coatings such as black chrome or sputtered multilayer films to enhance thermal absorption with low radiative losses. Additionally, the single-axis or dual-axis solar tracking is provided on the parabolic troughs 102 to dynamically adjust their angle relative to the position of the sun for optimal energy capture efficiency during the course of the day. Thermal oil flowing through the receiver tubes gets heated by concentrated solar radiation and carries the thermal energy to the thermal storage tank 114, where the desired temperature profile is sustained for downstream superheating operations.
[0074] The plurality of heat exchanger module (HEM) units 116 housed within the thermal storage tank 114, plurality of heat exchanger module (HEM) units 116 configured to facilitate thermal energy exchange between the thermal oil stream and the deionized water stream, thereby generating superheated steam. Each of the plurality of heat exchanger module (HEM) units 116 is functionally located to provide maximum surface contact with the circulating thermal oil, facilitating effective heat transfer to the water flow through internal grooves of the plurality of heat exchanger module (HEM) units 116 structure.
[0075] The plurality of heat exchanger module (HEM) units 116 is further configured to enable modular arrangement in series or parallel, allowing for precise control over superheated steam temperature and flow rate by adjusting the number of heat exchanger module (HEM) units. Modular construction allows for increasing or decreasing the number of heat exchanger module (HEM) units as a function of system load, desired steam temperature, or solar thermal input available. Series configuration of the plurality of heat exchanger module (HEM) units 116 leads to cumulative heating, beneficial for use where higher superheated steam temperature is needed, whereas parallel configuration enables higher steam mass flow rate. This modular design offers flexibility in operation, ease of system scaling, and ease of maintenance and expansion.
[0076] The plurality of heat exchanger module (HEM) units 116 further comprises the plurality of grooved aluminium plates 118 configured to enhance thermal energy transfer between the thermal oil stream and the deionized water stream. The plurality of grooved aluminium plates 118 is made of high-conductivity aluminium, wherein the plurality of grooved aluminium plates 118 is manufactured with precise machinery to optimize surface area for heat exchange. The plurality of grooved aluminium plates 118 creates flow channels for the deionized water, while the surrounding thermal storage tank 114 is in contact with thermal oil. The plurality of grooved aluminium plates 118 are in pairs, face-to-face aligned, and secured together with mechanical fasteners with an interposing high-temperature gasket to provide a leak-proof seal. The use of aluminium as the material for construction enhances heat transfer rates, minimizes weight, and promotes ease of fabrication.
[0077] In a preferred embodiment, the plurality of grooved aluminium plates 118 configured to a size of about 304 mm in length, 88.9 mm in width, and 20 mm total plate thickness. The 12 mm diameter grooves are centre-to-centre 8.3 mm apart. These are the dimensions chosen to weigh mechanical strength against thermal efficiency and enable compact stacking of each heat exchanger module (HEM) of the plurality of heat exchanger module (HEM) units 116 within the thermal storage tank 114.
[0078] In one embodiment, the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of deionized water outlet 142 each comprise the plurality of welded circular pipes 120 at interface points of the grooved aluminium plates 118, the plurality of welded circular pipes 120 configured to connect adjacent of the heat exchanger module (HEM) units 116 and integrate with a main fluid pipeline 112 of the system 100 to ensure structural integrity and efficient fluid transfer.
[0079] In one embodiment, the plurality of welded circular pipes 120 is made of a material that is compatible with both the plurality of grooved aluminium plates 118 and corresponding working fluid like stainless steel in the case of the deionized water stream paths and aluminium alloy in thermal oil paths thus maximizing corrosion resistance and heat expansion compatibility.
[0080] In another embodiment, the plurality of welded circular pipes 120can be provided with embedded sealing gaskets or O-rings of high-temperature silicone or PTFE (polytetrafluoroethylene) for long-term operational stability, particularly during thermal cycling and maintenance operations.
[0081] The main pipeline112 is configured to support the controlled transmission of thermal oil and deionized water stream in the system 100. The main fluid pipeline112provides a fluidic linkage between the parabolic troughs 102, the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of heat exchanger module (HEM) units 116. The main pipeline 112 connects with the plurality of welded circular pipes 120 at every heat exchanger module (HEM) of the plurality of heat exchanger module (HEM) units 116juncture for leak-proof union, pressure maintenance, and maximum thermal energy exchange between the plurality of heat exchanger module (HEM) units 116 that are connected.
[0082] In one embodiment, the main pipeline 112 is made of duplex alloy or double-layered stainless steel to withstand high thermal stress and avoid corrosion by long exposure to high-pressure steam and high-temperature thermal oil. The main pipeline 112 can be fitted with internal linings or ceramic coatings for reduced thermal losses over long distances.
[0083] In yet another embodiment, the main pipeline 112 is equipped with flexible coupling sections located at predetermined intervals along its length, the flexible coupling sections designed to accommodate thermal expansion and contraction during high-temperature operation. Such inclusion of flexible sections provides mechanical integrity by discharging thermal and mechanical stresses, hence avoiding accumulations of stresses, material fatigue, or deformation at the main pipeline 112 joints. The flexible coupling sections can be built with corrugated stainless-steel bellows or braided metal hose assemblies, chosen for their mechanical strength and high-temperature resistance.
[0084] The plurality of sensors 122 configured to detect properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams, generating real-time sensor data.
[0085] In one embodiment, the plurality of sensors 122 includes a plurality of temperature sensors at the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of deionized water outlets 142. Temperature sensors are designed to monitor the thermal profile of the fluid streams that enter and leave the plurality of heat exchanger module (HEM) units 116 and thus, monitor the efficiency of heat exchange and superheated steam output temperature.
[0086] In one embodiment, the plurality of sensors 122 includes a plurality of pressure sensors, piezoresistive or capacitive, located at the deionized water inlet 108 and at the plurality of deionized water outlets 142, the pressure sensors being used to monitor internal pressure levels of the deionized water and superheated steam, ensuring safe operation of the system 100 in high-temperature, high-pressure conditions.
[0087] In one embodiment, the plurality of sensors 122 includes a plurality of flow rate sensors located along the main pipeline 112, specifically at the intersections with the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality deionized water outlets 142. The flow rate sensors are designed to measure the volumetric flow rate of the corresponding fluid streams to provide optimal balance between heat supply and steam production.
[0088] In one embodiment, the plurality of sensors 122 includes a plurality of heat flux sensors embedded in the grooved aluminium plates 118 of the plurality of heat exchanger module (HEM) units 116. The heat flux sensors are designed to monitor the thermal energy transfer rate from the thermal oil stream to the deionized water stream, thus facilitating accurate thermal diagnostics and module-level performance assessment.
[0089] The control valve 110 operatively coupled to the deionized water inlet 108, the control valve 110 configured to regulate the flow of deionized water into the plurality of heat exchanger module (HEM) units 116. The control valve 110 is operated on the basis of real-time sensor feedback obtained from the plurality of sensors 122 located near the deionized water inlet 108 and the plurality of deionized water outlets 142, thus providing dynamic regulation of water inflow to achieve preferred pressure and temperature gradients along the plurality of heat exchanger module (HEM) units 116, and to provide optimal conversion of deionized water to superheated steam in the thermal storage tank 114.
[0090] In one embodiment, the control valve 110 is communicatively and fluidly connected with the main pipeline 112, thereby controlling the quantity of deionized water to flow into the plurality of welded circular pipes 120 of the plurality of grooved aluminium plates 118 making up the plurality of heat exchanger module (HEM) units 116.
[0091] The control valve 110 can be made of corrosion-resistant, high-temperature-compatible alloys like stainless steel (SS 316L) or Hastelloy and optionally provided with internal linings of anti-scaling or anti-fouling coatings to enhance lifecycle performance, especially under high-pressure steam conditions encountered at the plurality of heat exchanger module (HEM) unit 116.
[0092] In one embodiment, the control valve 110 can be configured in a multiple units and distributed in control loop, with each control valve 110 controlling independently the flow to an individual plurality of heat exchanger module (HEM) unit 116. This allows for accurate tuning of steam output characteristics, thus improving energy efficiency and responding to load requirements in real-time.
[0093] The system 100 further comprises an energy storage unit 104 operatively connected to the plurality of heat exchanger module (HEM) units 116, the energy storage unit 104 configured to store excess thermal energy generated during periods of low demand and discharge the stored energy to the thermal oil stream, thereby ensuring continuous operation during periods of high demand. The energy storage unit 104 is given phase change material (PCMs) integrated inside the walls of the internal reservoir to improve the energy density as well as the thermal buffering ability. The energy storage unit 104 is further configured with a series of integrated heat coils or serpentine heat exchangers connected to the thermal oil loop, thus facilitating efficient charging and discharging of thermal energy via the thermal oil inlet 106 and the thermal oil outlet 140. The energy storage unit 104 comprises of thermal insulation layers of ceramic fibre, mineral wool, or vacuum-insulated panels are implemented over the thermal storage tank 114 to reduce heat losses during off-peak hours, again enhancing operational efficiency and system dependability during variable energy requirements.
[0094] The system 100 may also include a microcontroller 128 operatively connected to the control valve 110 and a plurality of sensors 122, the microcontroller 128 comprising a data input module 130, a control module 132, a temperature regulation module 134, a performance monitoring module 136 and a communication module 138.
[0095] The data input module 130 configured to receive sensor data from the plurality of sensors 122. The data input module 130 is designed to constantly capture, aggregate, and transmit real-time operating parameters like temperature, pressure, flow rate, and heat flux relating to both the thermal oil and deionized water streams.
[0096] In one embodiment, the data input module 130 includes an analog-to-digital converter (ADC) configured to convert the analog output signals of the plurality of sensors 122 into corresponding digital values. The ADC enables high resolution conversion, allowing accurate capture of data from the plurality of sensors 122 fitted at the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of deionized water outlets 142. This digital conversion enables the system 100 to maintain precise real-time analysis and control.
[0097] The control module 132 configured to process the received sensor data and send control instructions to the control valve 110.
[0098] In one embodiment, control module 132 is further configured to use a series of decision-making algorithms such as rule-based logic control, threshold-triggered control, and fuzzy logic control algorithms. These algorithms are utilized to process sensor data such as, but not limited to, temperature, pressure, flow rate, and heat flux obtained from the plurality of sensors 122. For example, a threshold-triggered algorithm can automatically turn on the control valve 110 to decrease or stop the deionized water inflow if the temperature or pressure within the plurality of heat exchanger module (HEM) units 116 crosses pre-specified safety thresholds. Likewise, fuzzy logic techniques can be used to manage steam generation nonlinear fluctuations through the utilization of linguistic sensor-input-based rules in determining incremental position of the control valve 110.
[0099] In another embodiment, the control module 132 employs time-weighted flow scheduling or forecast flow modulation routines that take into account the rate of solar heating from the parabolic troughs 102 and forecast optimum flow timing of the thermal oil inlet 106 and the deioinized water inlet 108 for maximum steam quality. The control module 132 can also hold recent operating history and carry out comparative analysis in order to enhance flow accuracy and minimize response delay.
[00100] In another embodiment, the system further comprises of a data pre-processing module to remove noise and outliers from real-time sensor data prior to decision-making in order to improve the reliability and responsiveness of control actions from the control module 132.
[00101] The temperature regulation module 134 configured to monitor and adjust the temperature of the deionized water and thermal oil streams, ensuring efficient thermal energy exchange and maintain a constant superheated steam output. The temperature control module 134 is operatively linked to the plurality of sensors 122 and the control valve 110 providing real-time feedback and active control of fluid temperatures throughout the system 100.
[00102] In one embodiment, the temperature control module 134 is further configured to read sensor data from the plurality of sensors 122 such as high-precision thermocouples or RTD (resistance temperature detector) sensors. Based on these sensor data, the temperature control module 134 calculates whether the temperature of either stream varies from the ideal range and formulates corresponding control instructions to vary the control valve 110.
[00103] In yet another embodiment, the temperature regulation module 134 is further configured to operate in harmony with the energy storage unit 104 and the parabolic troughs 102. When there is unstable solar irradiance or variable energy input, the temperature regulation module 134 dynamically controls thermal oil flow rates based on feedback from the energy storage unit 104, thus providing a consistent heat supply to the heat exchanger module (HEM) units 116 and a steady output of steam.
[00104] In another embodiment, the temperature control module 134 includes an adaptive calibration logic that dynamically changes set-point temperatures with respect to time using environmental conditions, seasonal changes, or system degradation. The temperature control module 134 could contain software-embedded thermal models that learn the best temperature profiles across different load conditions and calibrate the system 100 response to avoid underheating or overheating, leading to improved system 100 longevity as well as operating efficiency.
[00105] In another embodiment, the temperature control module 134 has a failsafe routine programmed to send alerts or cause emergency shutdown when anomalous temperature readings persist, thus avoiding overheating, pressure accumulation, or heat-induced damage to the heat exchanger modules and associated components. This adds to the overall reliability and safety of the thermal energy conversion process in the system 100.
[00106] The performance monitoring module 136 configured to evaluate the overall performance of the plurality of heat exchanger module (HEM) units 116, and adjust operational parameters for optimal energy efficiency. The performance monitoring module 136 is operatively connected to the microcontroller 126, the data input module 130, the control module 132, and the temperature regulation module 134 to facilitate real-time analysis and intelligent optimization of the thermal exchange process within the system 100.
[00107] In one embodiment, the performance monitoring module 136 is additionally programmed to capture time-series data from the plurality of sensors 122, such as thermal gradients, flow rates, pressures of the thermal oil inlet 106, the deionized water inlet 108, the thermal oil outlet 140 and the plurality of deionized water outlet 142, and temperature differentials across the plurality of heat exchanger module (HEM) unit 116. The performance monitoring module 136 calculates individual and aggregate performance indicators like heat transfer efficiency, fluid residence time, and thermal lag to detect low-performing units or flow imbalance in the series-parallel network of the plurality of heat exchanger module (HEM) unit 116.
[00108] In yet another embodiment, the performance monitoring module 136 includes an evaluation algorithm that utilizes historical operating history, forecast trend analysis, and threshold comparison to sense incremental fouling, scaling, or thermal conductivity degradation in the plurality of heat exchanger module (HEM) unit 116. Upon sensing, the performance monitoring module 136 produces optimization commands to adjust flow distribution of the thermal oil inlet 106 and the deionized water inlet 108 , raise temperature differentials, or trigger maintenance alerts, thus extending operational life and avoiding catastrophic efficiency collapses.
[00109] In one embodiment, the performance monitoring module 136 consists of a machine learning-based model for performance based upon historical performance records of plurality of heat exchanger module (HEM) units 116. The machine learning-based model has been trained and is so that it makes the operational efficiency and thermal output parameters of plurality of heat exchanger module (HEM) unit 116 at real-time conditions within the system 100. One such example of a machine learning-based model is a gradient boosting regression algorithm, e.g., XGBoost, is used in the microcontroller 128 to learn nonlinear correlations between sensor data and the system 100 performance. According to the estimated values, the performance monitoring module 136 signals to the control module 132 and the temperature regulation module 134 in order to dynamically regulate operational parameters using the control valve 110, thus ensuring maximum thermal energy exchange in the thermal storage tank 114.
[00110] In another embodiment, the performance monitoring module 136 is further configured to interface with the energy storage unit 104, allowing dynamic management of energy input and discharge schedules in accordance with real-time performance of the system 100 and demand forecasting.
[00111] The communication module 138 configured to transmit data within the system 100, enabling real-time monitoring and data exchange for system optimization. The communication module 138 enables smooth transfer of sensor data from the plurality of sensors 122, control instructions from the control module 132, and performance data from the performance monitoring module 136.
[00112] In one embodiment, the communication module 138 includes a wired communication interface like RS-485 or CAN bus to provide strong and noise-immune data exchange among the internal elements of the system 100, especially in industrial settings where electromagnetic interference is common. This provides improved reliability for sensor data transmission and command delivery.
[00113] In another embodiment, the communication module 138 also provides support for secure wireless protocols such as, but not limited to, Zigbee, LoRa, or Bluetooth low energy (BLE) for broadcasting performance logs, operational diagnostics, and maintenance notices to an external maintenance interface or local monitoring terminal. This permits authorized service technicians to receive access to system information for preventive maintenance, fault indication, and system calibration, while not interfering with autonomous system control. Such voluntary wireless feature provides modular scalability and remote access with full standalone system functionality.
[00114] The system 100 further comprises a control unit 124 configured to regulate the flow rate of deionized water through the control valve 110 based on sensor data, ensuring efficient thermal energy exchange. The control unit 124 works to achieve efficient thermal energy exchange within the plurality of heat exchanger module (HEM) units 116. By regulating the flow rate of deionized water, the control unit 124 ensures that the optimal rate of thermal energy transfer is achieved, thereby encouraging the production of superheated steam at a desired and uniform temperature. The regulation of the flow rate is done in real time, using data obtained from sensors measuring critical parameters like temperature, pressure, and flow rate. The plurality of sensors 122 gives real-time feedback that is processed by the control unit 124. In response to this input, the control unit 124 controls the flow rate dynamically through the control valve 110 to account for variations in heat exchange efficiency through thermal loads or operating conditions. This allows the system 100 to hold a steady energy conversion process, maintaining the superheated steam output as optimal and efficient.
[00115] The control unit 124 further comprises a proportional-integral-derivative (PID) controller 126 configured to locally regulate the flow rate of deionized water through the control valve 110 based on the temperature at the plurality of deionized water outlet 142, thereby minimizing thermal response delay and maintaining a constant superheated steam output by suppressing temperature oscillations. The proportional-integral-derivative (PID) controller 126 controls the flow rate of deionized water through the control valve 110 locally by the temperature of the plurality of deionized water outlet 142. Such local regulation tries to avoid thermal response delay and maintain constant superheated steam output by restraining temperature fluctuations. The proportional-integral-derivative (PID) controller 126 is configured to permanently check the temperature of the deionized water at the plurality of deionized water outlet 142, and that is a key parameter used to modify the flow rate of the deionized water.
[00116] In one embodiment, the proportional-integral-derivative (PID) controller 126 may be modified with adaptive gain tuning features. This variation adds an advanced algorithm that dynamically modulates the proportional, integral, and derivative gains in real-time, depending upon the operating conditions of the system. Such as, during episodes of oscillating solar irradiation or thermal load variations, the proportional-integral-derivative (PID) controller 126 can adaptively optimize its parameters to keep the desired thermal response without needing to be adjusted manually. This helps the system 100 to stay efficient and responsive in response to changing environmental conditions, yet again enhancing energy efficiency and system lifespan.
[00117] In one embodiment, the proportional-integral-derivative (PID) controller 126 can further be integrated with an extensive sensor feedback loop of the plurality of the sensors 122. This sensor data from the plurality of the sensors 122 allows the proportional-integral-derivative (PID) controller 126 to execute multivariable control, where deionized water flow regulation is controlled not only on the basis of temperature but also on the pressure and flow rate dynamics. This integration enables a stronger and more responsive control system that can accommodate sophisticated operating situations with greater accuracy.
[00118] The system 100 further comprises a display panel 144 configured to provide real-time visual feedback on thermal energy flow, storage levels, and operational parameters of the system, thereby enabling on-site monitoring of the system 100. Through the presentation of real-time information, the display panel 144 enables users to readily observe the system's performance, such that the thermal energy exchange process is operating as desired and the thermal storage levels are within the specified range. This feature offers important insight into the operational status of the system, enabling prompt adjustments or interventions if needed to ensure optimal performance. Its user-friendly interface provides assurance that intricate system metrics are graphically presented in simple terms, allowing for rapid decision-making and promoting efficient operations. The exhibition of real-time feedback plays a vital role in keeping the system reliable and ensuring that the energy conversion process is consistently maximized throughout the life of the system 100.
[00119] In one embodiment, the display panel 144 is interfaced to the control unit 124 and the plurality of sensors 122, receiving real-time data to display thermal energy flow and storage levels. This allows the operator to monitor system parameters continuously, such as the rate of thermal energy transfer, temperature at critical points in the system 100, and the quantity of thermal energy stored in the thermal storage tank 114. The display panel 144 serves as the interface for users to visualize these values and assess whether the system is operating within the desired parameters. The display panel 144 would employ an LCD or an OLED screen for displaying clear, precise visual graphs of the information.
[00120] In another embodiment, the display panel 144 has an integrated alert system 100 that tracks operating limits like temperature, flow rate, and energy storage. When a limit is reached like a high temperature reading or low energy storage level, the display panel 144 notifies the operator through visual signals such as flashing lights or color coding through a LED and audio alerts such as beeps or alarms through a speaker. The display panel 144 can display color-coded feedback such as red for critical temperatures, yellow for moderate deviations, and also contains an on-screen warning with guidance or recommendations for countermeasures.
[00121] In another embodiment, the display panel 144 is also a local data logger that captures historical performance information for review later. This functionality allows the system 100 to record critical operating information, including thermal energy flow, temperature fluctuations, and energy storage capacity, for situations when the operator is not currently monitoring. The display panel 144 is coupled with an internal storage module such as an SD card or eMMC that records data in formal data formats like CSV or JSON. The operator can, therefore, look back at previous performance or transfer the data for analysis. The display panel 144 could also be coupled wirelessly over Wi-Fi or Bluetooth with outer devices, allowing for the remote monitoring of the performance of the system on mobile or desktop platforms.
[00122] In one embodiment, the display panel 144 further comprises of a touchscreen interface by which the operator can directly interact with the system 100 to change settings like desired temperature setpoints or flow rates. The interactive interface facilitates users to tailor the system 100 operation and adjust parameters in real time according to displayed data. The touchscreen would be capacitive touchscreen, allowing for easy navigation through system settings, operation logs, and performance parameters. GUI (graphical user interface) would provide for instant adjustment and could be set up with on-screen buttons to modify system settings or initiate specific actions such as recalibrating the plurality of sensors 122, thermal flow setpoint adjustments and thereof.
[00123] In one embodiment, the system 100 also includes digital acquisition (DAQ) lines, which convey sensor information from the plurality of sensors 122 to the control unit 124. The DAQ lines are the communication means, conveying real-time data read by the sensors, such as temperature, pressure, and flow rate measurements, to the control unit 124. Upon reception, the data is processed by the control unit 124, which dynamically adjusts the flow control valves 110 via the proportional-integral-derivative (PID) controller 126. The incorporation of DAQ lines into the system 100 guarantees that the control unit 124 obtains precise, real-time data from the plurality of sensors 122, allowing it to make necessary adjustments to the flow control valves 110 in real time. The closed-loop feedback control system enables the proportional-integral-derivative (PID) controller 126 to control the flow rate of deionized water through the plurality of heat exchanger modules (HEM) units 116 so that thermal energy exchange remains within optimal efficiency levels. Consequently, the system 100 is operated at optimal thermal efficiency and consistent steam temperature throughout operation, independent of variations in solar input or system load conditions. This improves the system's overall stability and reliability and enables it to respond to varying conditions and keep producing superheated steam at an efficient rate. Additionally, the display panel 144 would take input information from the DAQ lines, receiving signals from the plurality of sensors 122, and display such information on the screen in real time.
[00124] In one embodiment, the system 100 further comprises a data storage unit operatively connected to the microcontroller 128, configured to store historical operational data received from the plurality of sensors 122 and performance metrics computed by the performance monitoring module 136. The data storage unit enables long-term logging of temperature, pressure, and flow readings at various system locations, including but not limited to the thermal oil inlet 106, the thermal oil outlet 140, the deionized water inlet 108, and the plurality of deionized water outlets 142. This stored data serves as a training dataset for the machine learning-based performance model embedded within the performance monitoring module 136, thereby enhancing prediction accuracy over time. The data storage unit is a non-volatile memory or a local solid-state drive integrated within the microcontroller 128, optionally synchronized with an external cloud-based storage for periodic backup and remote monitoring.
[00125] FIG. 2 illustrates a flowchart of a method 200, outlining the sequential steps for a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[00126] At step 202, the fluid flow path for a thermal oil stream and a deionized water stream is defined within a thermal storage tank 114.
[00127] At step 204, the thermal oil is introduced into the thermal storage tank via a thermal oil inlet 106.
[00128] At step 206, the deionized water is introduced into the thermal storage tank via a deionized water inlet 108.
[00129] At step 208, thermal energy exchange is facilitated between the thermal oil stream and the deionized water stream via a plurality of heat exchanger module (HEM) units 116.
[00130] At step 210, the thermal oil is discharged from the thermal storage tank 114 after heat exchange via a thermal oil outlet 140.
[00131] At step 212, the superheated steam is discharged from the thermal storage tank 114 via a plurality of deionized water outlets 142.
[00132] At step 214, properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams are detected via a plurality of sensors 122 and real-time sensor data is generated.
[00133] At step 216, the sensor data is received from the plurality of sensors 122 via a data input module 130.
[00134] At step 218, the received sensor data is processed and control instructions are sent to the control valve 110 via a control module 132.
[00135] At step 220, the flow of deionized water is regulated into the plurality of heat exchanger module (HEM) units 116 via a control valve 110.
[00136] At step 222, the temperature of the deionized water and thermal oil streams are monitored and adjusted via a temperature regulation module 134.
[00137] At step 224, the overall performance of the plurality of heat exchanger module (HEM) units 116 is evaluated via a performance monitoring module 136.
[00138] At step 226, the data is transmitted within the system via a communication module 138.
[00139] FIG. 3 illustrates a flowchart of a method 300, outlining the sequential steps for a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[00140] At step 302, defining a fluid flow path for a thermal oil stream and a deionized water stream within a thermal storage tank 114.
[00141] At 304, introducing thermal oil into the thermal storage tank 114 via a thermal oil inlet 106.
[00142] At 306, introducing the deionized water into the thermal storage tank via a deionized water inlet 108.
[00143] At step 308, facilitating thermal energy exchange between the thermal oil stream and the deionized water stream via a plurality of heat exchanger module (HEM) units 116.
[00144] At step 310, discharging the thermal oil from the thermal storage tank 114 after heat exchange via a thermal oil outlet 140.
[00145] At step 312, discharging the superheated steam from the thermal storage tank 114 via a plurality of deionized water outlets 142.
[00146] At step 314, detecting properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams via a plurality of sensors 122 and real-time sensor data is generated.
[00147] At step 316, receiving the sensor data from the plurality of sensors 122 via a data input module 130.
[00148] At step 318, processing the received sensor data and sending control instructions to the control valve 110 via a control module 132.
[00149] At step 320, regulating the flow of deionized water into the plurality of heat exchanger module (HEM) units 116 via a control valve 110.
[00150] At step 322, monitoring and adjusting the temperature of the deionized water and thermal oil streams via a temperature regulation module 134.
[00151] At step 324, evaluating the overall performance of the plurality of heat exchanger module (HEM) units 116 via a performance monitoring module 136.
[00152] At step 326, transmitting the data within the system via a communication module 138.
[00153] In one embodiment, the plurality of welded circular pipes 120 are welded by high-precision argon arc welding or tungsten inert gas (TIG) welding methods to form leak-proof joints that are strong enough to support the high temperatures and pressures involved in superheated steam and thermal oil circulation. This method of welding is used because it can make high-quality welds with less thermal distortion of the aluminium plates.
[00154] FIG. 4 illustrates an exemplary layout of a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[00155] At 402, the system starts with subcooled steam, which is low-energy exhaust steam returning from the turbine 418. This steam is directed to condenser, which is designed to allow the phase change of steam into liquid water.
[00156] At 404, the condenser utilizes either ambient air cooling or auxiliary cooling means such as forced air fans or circulating water loops in order to allow effective condensation. This condensation process optimizes system recovery effectiveness and readies the working fluid for recirculation.
[00157] At 406, the condensed water from the condenser is piped to a pump, which can be turbine-driven or electrically powered. The pump pressurizes the liquid water and pumps it into the main cold-water stream pipeline. Pressurization at this point secures proper flow through the downstream heat exchanger modules (HEM) and helps in producing superheated steam upon thermal exchange.
[00158] At 408, the main cold-water stream pipe is supplied with pressurized water from the pump and acts as the primary channel for delivering this water to the heat exchanger section. The pipe is fabricated to support high-pressure flow and ensure laminar delivery conditions for thermal exchange. The main pipe is an important connection between the pumping system and the distributed thermal transfer system and provides continuous, high-volume supply of water to downstream devices.
[00159] At 410, the primary cold-water stream pipeline splits into several sub cold-water stream pipelines, each running to a separate heat exchanger module (HEM). The sub-streams enable controlled or uniform distribution of the pressurized fluid, facilitating the system's capability to operate several HEM units in parallel. This modular design provides increased system scalability, allows load sharing among units, supports thermal load balancing, and offers redundancy to provide sustained operation in the case of partial subsystem failures.
[00160] At 412, the cold water is received by each heat exchanger module (HEM) and undergoes thermal exchange with circulating thermal oil contained in the thermal oil storage tank. The HEM units are precision-machined for optimum counterflow or crossflow heat transfer for rapid, uniform heating of the entering water stream. The exit product is superheated steam, usually well in excess of 100°C and atmospheric pressure, for maximum turbine efficiency.
[00161] At 414, the high-temperature steam produced by every heat exchanger module (HEM) is passed through specialized outlets to maximize the flow and facilitate efficient transfer of the thermal energy. This steam is then supplied through a main superheated steam pipe. The pipe is thermally insulated to maintain the steam quality high and reduce thermal losses during transport to the turbine so that the steam remains in the superheated condition for the highest efficiency of energy conversion when it arrives at the turbine.
[00162] At 416, the high-enthalpy steam is directed to the turbine, where it expands over blades or vanes to produce mechanical energy from thermal energy. The turbine shaft can be connected to an electric generator, giving either grid-quality or stand-alone power output depending on the deployment application.
[00163] At 420, expanded, the steam is discharged from the turbine 418 as low-pressure, subcooled exhaust steam. This is returned through a closed-loop pipe to 402, beginning the working cycle of the system again. This loop provides continuity, low fluid loss, and operational durability.
[00164] At 422, the input water stream to each HEM is controlled through a branching network of pipelines, allocating flow as needed by the system.
[00165] At 424, the control valves are provided at key junctions along this pipeline and are designed for electronic actuation. The control valves dynamically modulate the rate of water inflow in response to real-time sensor information, providing optimal thermal transfer, performance efficiency, and safety.
[00166] At 426, a plurality of DAQ lines are supplied, constituting the main data acquisition interface for all sensors and feedback loops embedded in the system. The DAQ lines are routed to constantly monitor and report critical operating parameters such as inlet and outlet temperatures of heat exchanger modules, superheated steam pressure, state of actuation of valves, and real-time flow rates of thermal oil and deionized water. The obtained data is transferred to the control unit for dynamic system control. These measurements are critical for performance diagnostics, system optimization, predictive maintenance, and safe operation under changing thermal and pressure conditions.
[00167] At 428, the control unit receives feedback from the DAQ lines, it processes a PID (proportional-integral-derivative) algorithm to control each control valve to ensure optimal heat exchange conditions and avoid instability of the system in the form of thermal overshoots, water hammer, or dry running of HEMs.
[00168] At 430, the thermal oil storage tank serves as a high-volume thermal buffer, holding heat-transfer oil that is preheated by external renewable or conventional energy sources. The thermal oil storage tank provides continuous supply of thermal energy to the heat exchanger module (HEM) despite transient input variations. The thermal oil storage tank can be mounted vertically or horizontally and made of corrosion-resistant, high-temperature materials.
[00169] At 432, the heat exchanger module (HEM) is connected in series inside the thermal oil storage tank and the arrangement is to increase the effective contact area between thermal oil and water-carrying channels, thus providing a higher thermal transfer rate. Serial connection provides staged temperature rises, enhancing thermal efficiency of the system.
[00170] At 434, hot oil comes into the thermal oil storage tank via the hot-oil inlet and after heat transfer to the heat exchanger module (HEM), departs via the cold-oil outlet. The external oil loop can be linked to solar parabolic troughs or fossil-fuel heaters to heat up the oil prior to recirculation.
[00171] FIG. 5 illustrates an exemplary visualization and the actual prototype representation of the heat exchanger module (HEM) used in a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant, in accordance with an exemplary embodiment of the present disclosure.
[00172] At 502, a section-cut perspective of one heat exchanger module (HEM) is shown emphasizing the internal flow dynamics and configuration. The heat exchanger module (HEM) consists of a serpentine configuration of internal channels to achieve the highest contact surface area between the flowing thermal oil and the integrated water pathways. The configuration is optimized for turbulent flow to achieve higher thermal conductivity and uniform heating. This perspective also helps in the determination of the orientation and position of the grooved plates and flow chambers.
[00173] At 504, a real visualisation of section-cut view of a single heat exchanger module (HEM) with geometric dimensions is shown marked for design purposes. The section-cut view illustrates important structural features like the depth (h), width (w), length (L), and pitch (p) between the neighboring channels. These specifications are crucial to determine the rate of heat transfer, flow velocity, and total effectiveness of the module. The cutaway aids in explaining the arrangement and spacing of alternating hot oil and water channels using grooved aluminum plates.
[00174] At 506, the actual constructed layout of the heat exchanger module (HEM) is illustrated. The prototype is assembled by using machined or cast aluminium plates that are bolted to provide sealed internal passageways. External connections that can be seen allow for inlet and outlet working fluid flow of the form of hot thermal oil and cold deionized water. The prototype confirms the crossover from CAD designs to operational hardware and proves manufacturability, compactness, and structural robustness appropriate for installation within the thermal oil storage tank.
[00175] In best mode of operation, a heat exchanger module system 100 for generating fixed temperature superheated steam in solar thermal power plant starts in a thermal storage tank 114, which establishes a fluid flow path for the two streams. Thermal oil is first pumped into the system 100 via the thermal oil inlet 106, where it is heated by solar thermal energy generated by parabolic troughs 102. The hot thermal oil enters the thermal storage tank 114, where it passes through a series of the plurality of heat exchanger module (HEM) units 116 made up of grooved aluminium plates 118 and welded circular pipes 120. The plurality of heat exchanger module (HEM) units 116 facilitate effective heat transfer between the hot thermal oil and the deionized water stream. At the same time, deionized water is fed into the tank via the deionized water inlet 108. The deionized water inlet 108 streams through the plurality of heat exchanger module (HEM) units 116 where it picks heat from the thermal oil and evolves into superheated steam as it is being converted. On the process of heat exchange, the thermal oil outlet 140 expels the cooled-down thermal oil out of the system 100. Meanwhile, the superheated steam exits the thermal storage tank 114 via a plurality of deionized water outlets 142, strategically placed to control steam flow and avoid thermal losses. During this process, the system 100 utilizes a plurality of sensors 122 that track important characteristics of both fluid streams, such as temperature, pressure, flow rate, and heat flux. The plurality of sensors 122 provide real-time sensor data, which is provided to the microcontroller 128 through the data input module 130. The control module 132 makes decisions based on sensor data and provides control commands to the control valve 110, which controls deionized water flow into the HEM units to maximize heat transfer. The temperature regulation module 134 maintains the deionized water and thermal oil streams at appropriate temperature levels. This ensures optimum thermal energy transfer and the creation of uniform superheated steam. The performance monitoring module 136 also continuously analyses the performance of the plurality of heat exchanger module (HEM) units 116, setting fluid flow rate and heat transfer rates to enhance energy efficiency to the highest degree. The system 100 is regulated by a control unit 124, having a proportional-integral-derivative (PID) controller 126 that adjusts the flow rate of deionized water according to real-time temperature readings from the plurality of deionized water outlets 142. The proportional-integral-derivative (PID) controller 126 reduces thermal response delay, avoiding system oscillations and providing a consistent steam output. Information is exchanged within the system 100 through a communication module 138, allowing real-time monitoring and performance monitoring. The system 100 also includes a display panel 144 that offers on-site visual output on operational parameters like thermal energy flow, storage capacity, and system performance, allowing for rapid adjustments and decisions. The system 100 is modular scalable and has the ability to have the plurality of heat exchanger module (HEM) units 116 connected in parallel or series with variable numbers of modules depending on steam temperature and flow rate needs. Additionally, the system 100 may be capable of storing surplus thermal energy in an energy storage unit 104, enabling uninterrupted running even during times of low demand. This smooth integration of components enables the system 100 to produce fixed-temperature superheated steam with high efficiency, while also facilitating flexible operation according to varying energy requirements. Through continuous fluid flow and temperature adjustment, and the use of real-time sensor information and sophisticated control logic, the system 100 provides optimal performance and energy efficiency in solar thermal power generation.
[00176] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it will be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[00177] A person of ordinary skill in the art may be aware that, in combination with the examples described in the embodiments disclosed in this specification, units and algorithm steps may be implemented by electronic hardware, computer software, or a combination thereof.
[00178] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present disclosure.
[00179] Disjunctive language such as the phrase “at least one of X, Y, Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.
[00180] In a case that no conflict occurs, the embodiments in the present disclosure and the features in the embodiments may be mutually combined. The foregoing descriptions are merely specific implementations of the present disclosure, but are not intended to limit the protection scope of the present disclosure. Any variation or replacement readily figured out by a person skilled in the art within the technical scope disclosed in the present disclosure shall fall within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
, Claims:I/We Claim:
1. A heat exchanger module system (100) for generating fixed temperature superheated steam in solar thermal power plant, the system (100) comprising:
a thermal storage tank (114) configured to define a fluid flow path for a thermal oil stream and a deionized water stream, the thermal storage tank (114) comprising:
a thermal oil inlet (106) configured to introduce thermal oil into the thermal storage tank (114);
a thermal oil outlet (140) configured to discharge thermal oil from the thermal storage tank (114) after heat exchange;
a deionized water inlet (108) configured to introduce deionized water into the thermal storage tank (114);
a plurality of deionized water outlets (142) configured to discharge superheated steam from the thermal storage tank (114);
a plurality of heat exchanger module (HEM) units (116) housed within the thermal storage tank (114), plurality of heat exchanger module (HEM) units (116) configured to facilitate thermal energy exchange between the thermal oil stream and the deionized water stream, thereby generating superheated steam.
a plurality of sensors (122) configured to detect properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams, generating real-time sensor data;
a control valve (110) operatively coupled to the deionized water inlet (108), the control valve (110) configured to regulate the flow of deionized water into the plurality of heat exchanger module (HEM) units (116);
a microcontroller (128) operatively connected to the control valve (110) and a plurality of sensors (122), the microcontroller (128) comprising:
a data input module (130) configured to receive sensor data from the plurality of sensors (122);
a control module (132) configured to process the received sensor data and send control instructions to the control valve (110);
a temperature regulation module (134) configured to monitor and adjust the temperature of the deionized water and thermal oil streams, ensuring efficient thermal energy exchange and maintain a constant superheated steam output;
a performance monitoring module (136) configured to evaluate the overall performance of the plurality of heat exchanger module (HEM) units (116), and adjust operational parameters for optimal energy efficiency;
a communication module (138) configured to transmit data within the system (100), enabling real-time monitoring and data exchange for system optimization.
2. The system (100) as claimed in claim 1, wherein the system (100) comprises a plurality of parabolic troughs (102) configured to capture solar irradiation and heat the thermal oil stream, thereby providing solar thermal energy to the thermal storage tank (104) via the thermal oil inlet (106).
3. The system (100) as claimed in claim 1, wherein the system (100) further comprises an energy storage unit (104) operatively connected to the plurality of heat exchanger module (HEM) units (116), the energy storage unit (104) configured to store excess thermal energy generated during periods of low demand and discharge the stored energy to the thermal oil stream, thereby ensuring continuous operation during periods of high demand.
4. The system (100) as claimed in claim 1, wherein the system (100) further comprises a control unit (124) configured to regulate the flow rate of deionized water through the control valve (110) based on sensor data, ensuring efficient thermal energy exchange.
5. The system (100) as claimed in claim 1, wherein the control unit (124) further comprises a proportional-integral-derivative (PID) controller (126) configured to locally regulate the flow rate of deionized water through the control valve (110) based on the temperature at the plurality of deionized water outlet (142), thereby minimizing thermal response delay and maintaining a constant superheated steam output by suppressing temperature oscillations.
6. The system (100) as claimed in claim 1, wherein the plurality of heat exchanger module (HEM) units (116) further comprises the plurality of grooved aluminium plates (118) configured to enhance thermal energy transfer between the thermal oil stream and the deionized water stream.
7. The system (100) as claimed in claim 1, wherein the plurality of heat exchanger module (HEM) units (116) is configured to enable modular arrangement in series or parallel, allowing for precise control over superheated steam temperature and flow rate by adjusting the number of heat exchanger module (HEM) units.
8. The system (100) as claimed in claim 1, wherein the thermal oil inlet (106), the thermal oil outlet (140), the deionized water inlet (108), and the plurality of deionized water outlet (142) each comprise the plurality of welded circular pipes (120) at interface points of the grooved aluminium plates (118), the plurality of welded circular pipes (120) configured to connect adjacent of the heat exchanger module (HEM) units (116) and integrate with a main fluid pipeline (112) of the system (100) to ensure structural integrity and efficient fluid transfer.
9. The system (100) as claimed in claim 1, wherein the system (100) further comprises a display panel (144) configured to provide real-time visual feedback on thermal energy flow, storage levels, and operational parameters of the system, thereby enabling on-site monitoring of the system (100).
10. A method (200) for a heat exchanger module system (100) for generating fixed temperature superheated steam in solar thermal power plant, the method (200) comprising:
defining a fluid flow path for a thermal oil stream and a deionized water stream within a thermal storage tank (114);
introducing thermal oil into the thermal storage tank (114) via a thermal oil inlet (106);
introducing deionized water into the thermal storage tank (114) via a deionized water inlet (108);
facilitating thermal energy exchange between the thermal oil stream and the deionized water stream via a plurality of heat exchanger module (HEM) units (116);
discharging thermal oil from the thermal storage tank (114) after heat exchange via a thermal oil outlet (140);
discharging superheated steam from the thermal storage tank (114) via a plurality of deionized water outlets (142);
detecting properties, including but not limited to temperature, pressure, flow rate, and heat flux, of the thermal oil and deionized water streams via a plurality of sensors (122), and generating real-time sensor data;
receiving sensor data from the plurality of sensors (122) via a data input module (130);
processing the received sensor data and sending control instructions to the control valve (110) via a control module (132);
regulating the flow of deionized water into the plurality of heat exchanger module (HEM) units (116) via control valve (110);
monitoring and adjusting the temperature of the deionized water and thermal oil streams via a temperature regulation module (134);
evaluating the overall performance of the plurality of heat exchanger module (HEM) units (116) via a performance monitoring module (136); and
transmitting data within the system (100) via a communication module (138).