Power compounder

Abstract

A power compounder system and method is disclosed, wherein the system includes a prime mover producing waste heat and a power compounder coupled to the prime mover. The power compounder includes a. working fluid configured to receive thermal energy from the waste heat, a working fluid collector to hold the working fluid, an evaporator fluidly coupled to the working fluid collector for transferring the waste heat to the working fluid to change the working fluid to a vapor working fluid, a feed pump to cause the working fluid to flow between the working fluid collector and the evaporator, a double screw expander fluidly coupled to the evaporator to receive the vapor working fluid to create rotational mechanical energy, where the double screw expander is associated with the prime mover via at least one of a mechanical clutch, an electrical clutch and a sprag clutch.

1 . A power compounder system comprising:
 a prime mover producing waste heat; and   a power compounder coupled_to said prime mover, said power compounder comprising:
 a working fluid configured to receive thermal energy from said waste heat from said prime mover; 
 a working fluid collector configured to hold said working fluid as a liquid working fluid; 
 an evaporator fluidly coupled to said working fluid collector, said evaporator configured to transfer said waste heat to said working fluid to change said working fluid from said liquid working fluid to a vapor working fluid; 
 a feed pump configured to cause said working fluid to flow between said working fluid collector and said evaporator; 
 a double screw expander fluidly coupled to said evaporator, said expander configured to receive said vapor working fluid to create rotational mechanical energy from expansion of said vapor working fluid through said double screw expander, said double screw expander transfers said rotational mechanical energy via a shaft to said prime mover, wherein said double screw expander is further coupled to said prime mover via at least one of a mechanical clutch, an electrical clutch and a sprag clutch; and 
   a condenser fluidly coupled to said double screw expander, said condenser configured to receive said vapor working fluid and change said vapor working fluid to said liquid working fluid, wherein said condenser is fluidly coupled to said working fluid collector.   
     
     
         2 . The power compounder system of  claim 1 , wherein said prime mover has an increase of net power of about 10% from addition of said rotational mechanical energy. 
     
     
         3 . The power compounder system of  claim 1 , wherein said working fluid flows by force of gravity from said condenser to said working fluid collector. 
     
     
         4 . The power compounder system of  claim 1 , wherein said feed pump is configured to control a flow rate of said working fluid from said working fluid collector to said evaporator. 
     
     
         5 . The power compounder system of  claim 1 , further comprising:
 a pump configured to supply said working fluid to said evaporator.   
     
     
         6 . The power compounder system of  claim 1 , wherein said prime mover is selected from the group consisting of engines, pumps, external combustion engines, internal combustion engines, turbines, and compressors. 
     
     
         7 . The power compounder system of  claim 1 , wherein said rotational mechanical energy is synchronized to a rotational mechanical energy of said prime mover. 
     
     
         8 . The power compounder system of  claim 1 , further comprising:
 a timing belt coupled to a pulley on said double screw expander and to a pulley on said prime mover, wherein a combination of said timing belt and said pulleys transfers said rotational mechanical energy to said prime mover.   
     
     
         9 . The power compounder system of  claim 1 , further comprising:
 a system cabinet comprising said working fluid collector, said evaporator, said condenser and a cooling tower coupled to said condenser.   
     
     
         10 . A method of using a power compounder system, comprising:
 directing waste heat produced in a prime mover to a power compounder;   transferring thermal energy from said waste heat to a liquid working fluid;   transforming said liquid working fluid to a vapor working fluid in an evaporator;   directing said vapor working fluid through a double screw expander fluidly coupled to said evaporator, wherein said double screw expander is further coupled to said prime mover via a belt, powered take-off shaft and at least one of a mechanical clutch, an electrical clutch and a sprag clutch;   creating rotational mechanical energy in said double screw expander when said vapor working fluid flows through said double screw expander;   transferring said rotational mechanical energy via a shaft of said double screw expander to said prime mover; and   directing said vapor working fluid to a condenser for transforming to said liquid working fluid, said condenser fluidly coupled to said expander.   
     
     
         11 . The method of  claim 10 , further comprising:
 increasing a net power of said prime mover by about 10%.   
     
     
         12 . The method of  claim 10 , further comprising:
 flowing said working fluid by force of gravity from said condenser to a working fluid collector fluidly coupled to said evaporator; and   controlling a flow rate of said working fluid from said working fluid collector to said evaporator using a feed pump.   
     
     
         13 . The method of  claim 10 , further comprising:
 supplying said working fluid to said evaporator using a pump.   
     
     
         14 . The method of  claim 10 , wherein said prime mover is selected from the group consisting of engines, pumps, external combustion engines, internal combustion engines, turbines, and compressors. 
     
     
         15 . The method of  claim 10 , further comprising:
 synchronizing said rotational mechanical energy of said power compounder to a rotational mechanical energy of said prime mover.   
     
     
         16 . The method of  claim 10 , further comprising:
 coupling a timing belt to a pulley on said double screw expander and to a pulley on said prime mover, wherein a combination of said timing belt and said pulleys transfers said rotational mechanical energy to said prime mover.   
     
     
         17 . The method of  claim 10 , further comprising:
 coupling a timing belt to a gear on said double screw expander and to a gear on said prime mover, wherein a combination of said timing belt and said gears transfers said rotational mechanical energy to said prime mover.   
     
     
         18 . The method of  claim 10 , further comprising:
 positioning a working fluid collector, said evaporator, said condenser and a cooling tower in a system cabinet, said cooling tower coupled to said condenser.