Internal-combustion engines – Charge forming device – Gaseous fuel and air mixer
Reexamination Certificate
2003-02-10
2004-06-15
Wolfe, Willis R. (Department: 3747)
Internal-combustion engines
Charge forming device
Gaseous fuel and air mixer
C137S484200
Reexamination Certificate
active
06748932
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fuel regulators for engines in co-generation units; and, more particularly, natural gas regulators for internal combustion engine driven co-generation units.
2. Description of Related Art
Electric energy generation in this country has lagged behind demand. There are a number of reasons for this, but chief among them is failure of traditional energy producers to replace spent units and capitalize new plants. This has been, in part, due to increased air quality regulations. In addition, new challenges face electric generation-security. Events of Sep. 11, 2001 showed this nation its vulnerability to terrorist attack. Vital operations, such as police, medical and civil defense that relied upon the electric power “grid” for service, realized that their needs were susceptible to disruption and viewed stand-alone units as well as micro grids as a possible solution. These alternatives are fraught with their own problems. Chief among the reasons is a drastic increase in demand. Thus, while energy demand has increased, generating capabilities have not.
One reason for the growth in demand is the increased use of computers and other technology for industrial and business purposes, as well as personal use. As computer usage continues to grow, the use of power-consuming peripheral technologies, such as printers, cameras, copiers, photo processors, servers, and the like, keep pace and even expand. As business use of computer based equipment continues to rise, as do the number of in-house data servers, outsourced data storage facilities, financial systems, and Internet-related companies requiring constant electrical uptime and somewhat reducing traditional peak demand times, requirement for reliable, cheap, environmentally compliant electrical power, continues to grow.
Other technological advances have also increased electrical energy demand. Increased use of power consuming devices in every aspect of life from medical to industrial manufacturing robots, as well as innovations in almost every research and industrial field, are supported by increasingly complex technology, which requires more electrical power to function. CAT scans, NMRs, side looking X-rays, MRIs and the like, all take electrical power.
As a result, the Federal Government deregulated power generation, and a number of states have begun to establish competitive retail energy markets. Unfortunately, the deregulation process has not provided adequate incentives for industry entities to construct generating facilities, upgrade the transmission grid, or provide consumers with price signals to enable intelligent demand-side management of energy consumption. With the deregulation in the utility market, energy (kWh) has become a commodity item that can be bought or sold. However, swings in supply and demand leave end users open to fluctuations in the cost of electricity.
According to the ETA, to meet projected increases in demand over the next 20 years, at least 393 GW of additional generating capacity must be added. In some areas, the growth in demand is much higher than the projected two percent average (e.g., California's peak electricity demand grew by 18 percent between 1993 and 1999, while generating capacity increased by only 0.3 percent.) Despite California's highly publicized energy situation, a similar problem exits for other states as well; the New York Independent System Operator recently stated that 8600 MW of additional generating capacity (a 25 percent increase) must be added by 2005 to avoid widespread shortages that may lead to blackouts.
In addition to the mismatch between demand and generating capacity, the physical transmission infrastructure necessary to deliver power from geographically remote generating facilities to the consumer's location is unable to support the increased load. Even under today's operating conditions, the transmission grid is subject to stress and occasional failure.
Further, security and reliability of source has become of increasing concern. Grid system vulnerability and blackouts have become more commonplace. Strategic industries are looking to cut energy costs, increase reliability, and assure security. This has lead to an interest in distributed market technologies. The potential market for distributed generation has become vast without adequate means for fulfilling this need. Again, inefficiency, reliability, and environmental concerns are major barriers. The compelling economics are made on engine efficiency without the financial benefit of waste heat usage, yet with all of the same customer reluctance to accept hassles. Industry estimates indicate that the existing market for distributed generation is $300 billion in the United States and $800 billion worldwide.
The need to leverage existing technology while transitioning to alternative energy sources is an important consideration for meeting this challenge. Although most existing distributed generation sites use small gas turbine or reciprocating engines for generation, there are many alternatives that are being considered over the longer term. Technologies, such as micro turbines, are currently available, but only used at a relatively small number of sites. These newer generators offer some inherent advantages, including built-in communications capabilities. It is anticipated that fuel cells will be available in the next five years, which will provide some highly appealing, environmentally friendly options.
As it stands today however, small gas turbine and reciprocating engines comprise a substantial proportion of existing generator technology in the market and will for some time to come for a number of reasons. Engines provide the best conversion efficiency (40%), and they can operate using non-pressurized gas. Micro turbines, on the other hand, require compressed gas and conversion efficiency is lower (approximately 30%). These latter generators tend to be used in wastewater and landfill and other specialty sites, where a conventional prime mover is unable to stand up to poor fuel quality. Therefore, for utilities to truly benefit from a distributed generation scheme over the short term, they must look to the existing generator technology to provide a sustainable and affordable solution.
Waste heat utilization or co-generation is one way to meet this challenge. In the case of power generation, the waste heat is not used, and the economics are based largely on the cost of the electricity produced (i.e. heat rate is paramount), with little consideration for improved reliability or independence from the electric grid. The anticipated fluctuation in energy costs, reduced reliability, and increasing demand has led end users to consider maximizing efficiency through use of heat from generation of on-site generating-heat capture systems, i.e. co-generation, or “Combined Heating and Power” (CHP).
Co-generation of electricity and client service heat to provide space heating and/or hot water from the same unit is one solution. Cogeneration provides both electricity and usable process or utility heat from the formerly wasted energy inherent in the electricity generating process. With cogeneration, two problems are solved for the price of one. In either case, the electricity generation must meet stringent local air quality standards, which are typically much tougher than EPA (nation wide) standards.
On-site co-generation represents a potentially valuable resource for utilities by way of distributed generation. A utility can increase capacity by turning to a “host” site (e.g. industrial user) with an existing generator, and allow them to parallel with the grid and use their generator capacity to handle peak volumes. From the utility's point of view, the key advantages to a distributed generation solution are twofold: improved system reliability and quality; and the ability to defer capital costs for a new transformer station.
For customers who can use the process/utility waste heat, the economics of cogeneration are compel
Dorn Gerald H.
Sorter Richard L.
Chapeau, Inc.
Myers, Esq. Lee G.
Wolfe Willis R.
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