Condensation type oil gas recovery heat exchanger bottom shell external heating device and control method thereof

Abstract

The invention relates to the technical field of oil gas recovery, and discloses a condensation type oil gas recovery heat exchanger bottom shell external heating device and a control method thereof.The condensation type oil gas recovery heat exchanger bottom shell external heating device comprises a curved surface shell attached to the outer surface of a bottom shell and an intelligent control unit, and an electromagnetic induction heating layer used for heating the bottom shell is arranged in the shell; the electromagnetic induction heating layer is composed of at least three sets of independent heating units, each set of heating unit comprises a high-heat-conduction ceramic substrate and an embedded electromagnetic coil, and the electromagnetic coils are evenly distributed on the inner side of the substrate. The heating device can be expanded into a multi-area independent temperature control structure, and each heating unit corresponds to a specific axial section of the bottom shell; the outer wall of the bottom shell and an internal condensate pipeline are subjected to multi-area monitoring through the intelligent control unit, the electromagnetic induction heating layer (divided into three sections) is installed on the outer wall of the bottom shell through the shell, multi-area independent temperature control is achieved, and energy is saved; non-contact uniform heating is achieved through the electromagnetic coil, and efficient and uniform bottom shell heating is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of oil and gas recovery, and more particularly, to an external heating device for the bottom shell of a heat exchanger in a condensing oil and gas recovery system and its control method. Background Art

[0002] In a condensing oil and gas recovery system, as the core heat transfer component, the operating stability and heat transfer efficiency of the heat exchanger directly affect the overall recovery effect. Traditional designs focus on optimizing the internal structure of the heat exchanger to improve the condensation efficiency, such as using shell-and-tube, plate, or finned-tube heat exchangers to achieve multi-stage cooling processes. However, under low-temperature conditions (such as -60°C to -110°C), the bottom shell of the heat exchanger is prone to frosting and accumulation of liquid hydrocarbon condensate due to the too low surface temperature, resulting in local corrosion or ice blockage that may be caused by the accumulated liquid. In extreme cases, it may cause equipment damage or the risk of oil and gas leakage.

[0003] Traditional solutions mostly adopt passive designs (such as optimizing the layout of heat exchange tubes) or temperature regulation of the refrigeration system, but they cannot dynamically adapt to complex working condition changes and do not effectively utilize the waste heat of the system. Existing active heating technologies (such as electric heating wires) have problems such as high energy consumption and uneven temperature distribution, which may cause local overheating and damage the equipment. Summary of the Invention

[0004] The purpose of the present invention is to provide an external heating device for the bottom shell of a heat exchanger in a condensing oil and gas recovery system and its control method, aiming to solve the problems of poor fluidity and freezing of condensate in the prior art.

[0005] The present invention is implemented as follows. The external heating device for the bottom shell of a heat exchanger in a condensing oil and gas recovery system includes a curved surface shell that fits the outer surface of the bottom shell and an intelligent control unit. The shell is detachably connected to the bottom shell. An electromagnetic induction heating layer for heating the bottom shell is provided in the shell. The intelligent control unit is electrically connected to the electromagnetic induction heating layer and the temperature sensing unit respectively. The temperature sensing units are distributed on the outer wall of the bottom shell and the internal condensate pipeline. The intelligent control unit is used to receive the sensor signals and adjust the heating power.

[0006] The electromagnetic induction heating layer is composed of at least 3 groups of independent heating units. Each group of heating units includes: a high thermal conductivity ceramic substrate and an embedded electromagnetic coil. The electromagnetic coils are evenly distributed on the inner side of the substrate. The heating device can be extended to a multi-region independent temperature control structure, and each heating unit corresponds to a specific axial segment of the bottom shell.

[0007] Furthermore, a thermal conductive silicone grease layer is filled between the high thermal conductivity ceramic substrate and the outer wall of the bottom shell, and an insulating layer is provided on the outer side of the high thermal conductivity ceramic substrate. The insulating layer is located between the high thermal conductivity ceramic substrate and the shell.

[0008] Furthermore, the intelligent control unit includes:

[0009] A PID controller for dynamically adjusting the output frequency according to the temperature deviation;

[0010] An environmental parameter sensor integrating humidity and air pressure detection functions;

[0011] A wireless communication unit supporting 4G / 5G or LoRa transmission protocols.

[0012] Furthermore, the PID controller executes the following control logic:

[0013] When the bottom shell temperature T ≥ 10°C, turn off the heating;

[0014] When 5°C ≤ T < 10°C, start low-power intermittent heating;

[0015] When T < 5°C, switch to continuous heating and trigger an alarm.

[0016] Furthermore, the temperature sensing unit includes a first temperature sensor group and a second temperature sensor group. The first temperature sensor group is arranged in a spiral distribution along the axial direction of the bottom shell; the second temperature sensor group is respectively embedded in the condensate outlet pipeline; the temperature sensing unit also includes an ambient temperature sensor installed outside the bottom shell.

[0017] Furthermore, it also includes: an overheat protection circuit that cuts off the power supply and sends a fault signal when the temperature exceeds 120°C;

[0018] A leakage protector with a response time ≤ 0.1 s.

[0019] Furthermore, the installation structure of the electromagnetic induction heating layer and the housing is a split-type buckle.

[0020] Furthermore, the bottom shell is provided with symmetrically arranged sliding rails along the length direction of the bottom shell. The sliding rails are embedded with guide grooves, and the two sides of the housing are provided with protruding sliders matching the guide grooves to achieve preliminary positioning of the electromagnetic induction heating layer;

[0021] Elastic clamping blocks are arranged on the bottom of the bottom shell, and a clamping groove is formed by inward depression on the housing; when the housing slides along the sliding rail to a preset position, the elastic clamping blocks automatically engage with the clamping groove to form secondary fixation.

[0022] Furthermore, quick-release bolts are provided on the side wall of the housing and are screwed into the fixing holes of the bottom shell through threads to achieve tertiary locking; the head of the quick-release bolt is a butterfly handle for easy manual operation;

[0023] On the outer periphery of the housing, an enclosing wall protrudes towards the bottom shell. The enclosing wall is arranged to surround the outer periphery of the housing in a circumferential direction, and the height of the enclosing wall is higher than the thickness of the electromagnetic induction heating layer.

[0024] Compared with the prior art, the external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery provided by the present invention monitors multiple regions of the outer wall of the bottom shell and the internal condensate pipeline through the intelligent control unit. The electromagnetic induction heating layer (divided into 3 sections) is installed on the outer wall of the bottom shell through the housing to achieve independent temperature control in multiple regions and save energy. Non-contact uniform heating is realized through the electromagnetic coil to achieve efficient and uniform heating of the bottom shell. This structural design integrates an external heating device with efficient heat source utilization, precise temperature control, and structural adaptability to improve the operating reliability and energy efficiency level of the heat exchanger bottom shell in extremely low temperature environments. Compared with the traditional built-in heating method, the energy consumption is reduced by more than 35%, the maintenance cost is reduced by 60%, and it has explosion-proof, anti-corrosion, and remote monitoring functions, and is applicable to the oil and gas recovery system in extreme environments. It solves the problems of poor fluidity and freezing of the condensate.

[0025] A control method for the external heating device of the bottom shell of the heat exchanger for condensing oil and gas recovery includes the steps of:

[0026] Real-time collect the data of the bottom shell temperature, ambient humidity, and oil and gas flow rate;

[0027] Calculate the target heating power through the fuzzy PID algorithm;

[0028] Dynamically adjust the working frequency and duty cycle of the electromagnetic coil;

[0029] When it is detected that the oil and gas flow rate drops by more than 30%, automatically switch to the energy-saving mode and reduce the heating power to 40%-60% of the rated value.

[0030] Compared with the prior art, the control method for the external heating device of the bottom shell of the heat exchanger for condensing oil and gas recovery provided by the present invention can collect the multi-region temperature of the bottom shell in real time through the temperature sensing unit, collect the oil and gas flow rate data by using the flow sensor, and collect the ambient humidity by using the ambient temperature sensor. Thus, the monitoring of the entire heat exchanger is optimized, the target heating power is calculated through the fuzzy PID algorithm, and precise heating of the local bottom shell is realized, saving energy. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 is a three-dimensional schematic diagram of the external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery provided by the present invention;

[0032] Figure 2 is a side-sectional structural schematic diagram of the heat exchanger and the housing provided by the present invention.

[0033] In the figure: housing 10, electromagnetic induction heating layer 20, temperature sensing unit 30, heat exchanger 40, intelligent control unit 50, raised slider 11, card slot 12, quick-release bolt 13, butterfly handle 14, enclosing wall 15, high thermal conductivity ceramic substrate 21, electromagnetic coil 22, insulating layer 23, thermal grease layer 24, first temperature sensor group 31, second temperature sensor group 32, bottom shell 41, sliding guide rail 42, guide groove 43, elastic latch 44, fixing hole 45. Detailed implementation mode

[0034] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0035] The implementation of the present invention will be described in detail below in conjunction with specific embodiments.

[0036] In the accompanying drawings of this embodiment, the same or similar reference numerals correspond to the same or similar components; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", etc. indicating the orientation or positional relationship, it is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the terms describing the positional relationship in the accompanying drawings are only for illustrative purposes and cannot be understood as a limitation of the present invention. For those of ordinary skill in the art, the specific meanings of the above terms can be understood according to specific circumstances.

[0037] Refer to Figure 1-2 As shown, it is a preferred embodiment provided by the present invention.

[0038] The external heating device of the bottom shell 41 of the heat exchanger 40 for condensing oil and gas recovery includes a curved housing 10 that fits on the outer surface of the bottom shell 41 and an intelligent control unit 50. The housing 10 is detachably connected to the bottom shell 41. An electromagnetic induction heating layer 20 for heating the bottom shell 41 is provided in the housing 10. The intelligent control unit 50 is electrically connected to the electromagnetic induction heating layer 20 and the temperature sensing unit 30 respectively. The temperature sensing unit 30 is distributed on the outer wall of the bottom shell 41 and the internal condensate pipeline. The intelligent control unit 50 is used to receive the sensor signal and adjust the heating power;

[0039] The electromagnetic induction heating layer 20 is composed of at least 3 groups of independent heating units. Each group of heating units includes: a high thermal conductivity ceramic substrate 21 and an embedded electromagnetic coil 22. The electromagnetic coils 22 are evenly distributed on the inner side of the substrate. The heating device can be extended to a multi-region independent temperature control structure, and each heating unit corresponds to a specific axial segment of the bottom shell 41.

[0040] The external heating device for the bottom shell 41 of the heat exchanger 40 in the above-provided condensing oil and gas recovery monitors multiple areas of the outer wall of the bottom shell 41 and the internal condensate pipeline through the intelligent control unit 50. The electromagnetic induction heating layer 20 (divided into 3 sections) is installed on the outer wall of the bottom shell 41 through the housing 10 to achieve multi-area independent temperature control and save energy. Non-contact uniform heating is achieved through the electromagnetic coil 22 to realize efficient and uniform heating of the bottom shell 41. This structural design integrates an external heating device with efficient heat source utilization, precise temperature control, and structural adaptability to improve the operation reliability and energy efficiency level of the bottom shell 41 of the heat exchanger 40 in extremely low-temperature environments. Compared with the traditional built-in heating method, the energy consumption is reduced by more than 35%, the maintenance cost is reduced by 60%, and it has explosion-proof, anti-corrosion, and remote monitoring functions, making it suitable for oil and gas recovery systems in extreme environments. It solves the problems of poor fluidity and freezing of the condensate.

[0041] In this embodiment, a thermal conductive silicone grease layer 24 is filled between the high thermal conductivity ceramic substrate 21 and the outer wall of the bottom shell 41. An insulating layer 23 is provided on the outside of the high thermal conductivity ceramic substrate 21, and the insulating layer 23 is located between the high thermal conductivity ceramic substrate 21 and the housing 10. The thickness of the thermal conductive silicone grease layer 24 is 0.5 - 1.2 mm.

[0042] The integrated design of the explosion-proof housing 10 and the insulating layer 23: Combining electromagnetic induction heating with high thermal conductivity insulating materials to improve safety and thermal efficiency.

[0043] The insulating layer 23 is made of fiberglass insulation cotton or nano-insulation cotton. These two materials have good heat insulation performance and high temperature resistance characteristics, which can effectively reduce heat dissipation, improve heating efficiency, and protect the equipment from high temperature damage.

[0044] In this embodiment, the intelligent control unit 50 includes:

[0045] A PID controller for dynamically adjusting the output frequency according to the temperature deviation;

[0046] An environmental parameter sensor integrating humidity and air pressure detection functions;

[0047] A wireless communication unit supporting 4G / 5G or LoRa transmission protocols.

[0048] Multi-parameter collaborative control: Optimizing the heating strategy by combining temperature, humidity, and flow data.

[0049] The PID controller executes the following control logic:

[0050] When the temperature T of the bottom shell 41 ≥ 10 °C, the heating is turned off;

[0051] When 5 °C ≤ T < 10 °C, start low-power intermittent heating (duty cycle 30% - 60%);

[0052] When T < 5°C, switch to continuous heating and trigger an alarm.

[0053] In this embodiment, the temperature sensing unit 30 includes a first temperature sensor group 31 and a second temperature sensor group 32. The first temperature sensor group 31 is arranged in a spiral distribution along the axial direction of the bottom shell 41; the second temperature sensor group 32 is respectively embedded in the condensate outlet pipeline. The temperature sensing unit 30 further includes an ambient temperature sensor, which is installed outside the bottom shell 41.

[0054] The temperature sensing unit 30 can monitor multiple regions of the bottom shell 41 in real time through the first temperature sensor group 31. When the temperature in a certain region is lower than the set value, the electromagnetic induction heating layer 20 can be controlled by the intelligent control unit 50 to heat this region, realizing local directional heating, saving energy, improving heating efficiency, and the uniformity of heat conduction.

[0055] The second temperature sensor group 32 can be used to monitor the condensate outlet pipeline in real time, so as to determine which region to perform heating control through the intelligent control unit 50.

[0056] In this embodiment, it further includes: an overheat protection circuit, which cuts off the power supply and sends a fault signal when the temperature exceeds 120°C; a leakage protector, with a response time ≤ 0.1 s.

[0057] Dual safety protection mechanism: automatic power-off in case of overheat (response time ≤ 0.1 s) and leakage isolation protection.

[0058] In this embodiment, the installation structure of the electromagnetic induction heating layer 20 and the housing 10 is a split-type buckle, which supports quick disassembly and maintenance.

[0059] Modular electromagnetic induction heating: The split-type electromagnetic induction heating layer 20 is designed to achieve non-contact uniform heating.

[0060] In this embodiment, the bottom shell 41 is provided with symmetrically arranged sliding rails 42. The sliding rails 42 are arranged along the length direction of the bottom shell 41. The sliding rails 42 are embedded with guide grooves 43. The two sides of the housing 10 are provided with convex sliders 11 that match the guide grooves 43 to realize the preliminary positioning of the electromagnetic induction heating layer 20.

[0061] Elastic clamping blocks 44 are arranged on the bottom of the bottom shell 41, and a clamping groove 12 is formed by inward depression on the housing 10; when the housing 10 slides along the sliding rail 42 to a preset position, the elastic clamping blocks 44 automatically engage with the clamping groove 12 to form secondary fixation.

[0062] Through the secondary fixation structure, the rapid disassembly and assembly of the electromagnetic induction heating layer 20 and the bottom shell 41 are realized, which is convenient for replacement or maintenance.

[0063] In this embodiment, a quick-release bolt 13 is provided on the side wall of the housing 10. By screwing it into the fixing hole 45 of the bottom case 41 through threads, three-stage locking is achieved. The head of the quick-release bolt 13 is a butterfly handle 14, which is convenient for manual operation.

[0064] On the outer periphery of the housing 10, an enclosing wall 15 protrudes towards the bottom case 41. The enclosing wall 15 is arranged to surround the outer periphery of the housing 10 circumferentially, and the height of the enclosing wall 15 is higher than the thickness of the electromagnetic induction heating layer 20.

[0065] Through a three-stage fixing structure (sliding guide 42, elastic buckle, quick-release bolt 13), the quick disassembly and assembly of the electromagnetic induction heating layer 20 and the bottom case 41 are realized, while taking into account the installation efficiency and the thermal conduction stability. The housing 10 encloses and closes the circumference of the electromagnetic induction heating layer 20 through the enclosing wall 15, reducing the heat dissipation and improving the heating effect.

[0066] A control method for the external heating device of the bottom case 41 of the heat exchanger 40 for condensing oil and gas recovery includes the steps of:

[0067] Real-time collecting the temperature of the bottom case 41, the environmental humidity and the oil and gas flow rate data;

[0068] Calculating the target heating power through a fuzzy PID algorithm;

[0069] Dynamically adjusting the working frequency and duty cycle of the electromagnetic coil 22;

[0070] When it is detected that the oil and gas flow rate drops by more than 30%, automatically switch to the energy-saving mode and reduce the heating power to 40%-60% of the rated value.

[0071] Control method:

[0072] Mode 1 (normal operation): When the temperature of the bottom case 41 > 5°C, enable intermittent low-power heating;

[0073] Mode 2 (anti-freezing mode): When the temperature ≤ 5°C, switch to continuous medium-power heating;

[0074] Mode 3 (emergency mode): When abnormal oil and gas flow rate is detected, trigger high-power heating and alarm.

[0075] The control method for the external heating device of the bottom case 41 of the heat exchanger 40 for condensing oil and gas recovery provided by the present invention can collect the multi-region temperature of the bottom case 41 in real time through the temperature sensing unit 30, collect the oil and gas flow rate data by using the flow sensor, and collect the environmental humidity by using the environmental temperature sensor; thereby optimizing the monitoring of the entire heat exchanger 40, calculating the target heating power through the fuzzy PID algorithm, realizing precise heating of the local part of the bottom case 41, and saving energy.

[0076] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. External heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery, characterized in that: It comprises a curved shell body that fits the outer surface of the bottom shell and an intelligent control unit, the shell body and the bottom shell are detachably connected, an electromagnetic induction heating layer for heating the bottom shell is arranged in the shell body, the intelligent control unit is electrically connected to the electromagnetic induction heating layer and a temperature sensing unit respectively, the temperature sensing unit is distributed on the outer wall of the bottom shell and the internal condensate pipeline, and the intelligent control unit is used to receive sensor signals and adjust the heating power; The electromagnetic induction heating layer is composed of at least 3 groups of independent heating units, each group of heating units includes: a high thermal conductivity ceramic substrate and an embedded electromagnetic coil, and the electromagnetic coil is evenly distributed on the inner side of the substrate; the heating device can be expanded into a multi-zone independent temperature control structure, and each heating unit corresponds to a specific axial segment of the bottom shell.

2. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to claim 1 is characterized in that: A thermally conductive silicone grease layer is filled between the high thermal conductivity ceramic substrate and the outer wall of the bottom shell, and an insulating layer is arranged on the outer side of the high thermal conductivity ceramic substrate, and the insulating layer is located between the high thermal conductivity ceramic substrate and the shell.

3. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to claim 2 is characterized in that: The intelligent control unit comprises: PID controller, used to dynamically adjust the output frequency according to temperature deviation; Environmental parameter sensor, integrated with humidity and air pressure detection functions; Wireless communication unit, supporting 4G / 5G or LoRa transmission protocol.

4. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to claim 3 is characterized in that: The PID controller implements the following control logic: When the bottom shell temperature T≥10℃, turn off the heating; When 5℃≤T<10℃, start low-power intermittent heating; When T<5℃, switch to continuous heating and trigger an alarm.

5. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to any one of claims 1 to 4, characterized in that: The temperature sensing unit comprises a first temperature sensor group and a second temperature sensor group. The first temperature sensor group is arranged in a spiral distribution along the axial direction of the bottom shell; and the second temperature sensor group is respectively embedded in the condensate outlet pipeline.

6. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to claim 5, characterized in that: Also includes: Overheat protection circuit, cuts off power and sends fault signal when the temperature exceeds 120℃; Leakage protector, response time ≤ 0.1s.

7. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to any one of claims 1 to 4, characterized in that: The mounting structure of the electromagnetic induction heating layer and the shell is a split buckle.

8. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to any one of claims 1 to 4, characterized in that: The bottom shell is provided with symmetrically arranged sliding guide rails, which are arranged along the length direction of the bottom shell, and the sliding guide rails are embedded with guide grooves, and both sides of the shell are provided with raised sliding blocks matching the guide grooves to achieve preliminary positioning of the electromagnetic induction heating layer; An elastic card block is arranged on the bottom of the bottom shell, and a card slot is formed on the shell inwardly recessed; when the shell slides to a preset position along the sliding guide rail, the elastic card block automatically engages with the card slot to form a secondary fixation.

9. The external heating device for the bottom shell of the heat exchanger for condensing oil and gas recovery according to claim 8, characterized in that: The side wall of the shell is provided with a quick-release bolt, which is screwed into the fixing hole of the bottom shell through a thread to achieve three-level locking; the head of the quick-release bolt is a butterfly handle, which is convenient for manual operation; An enclosure wall is protruded on the outer circumference of the shell toward the bottom shell, and the enclosure wall is arranged circumferentially along the outer circumference of the shell. The height of the enclosure wall is higher than the thickness of the electromagnetic induction heating layer.

10. The control method of the heating device according to any one of claims 1 to 9, characterized in that: Includes steps: Real-time collection of bottom shell temperature, ambient humidity and oil and gas flow data; Calculate the target heating power through fuzzy PID algorithm; Dynamically adjust the operating frequency and duty cycle of the electromagnetic coil; When it is detected that the oil and gas flow rate drops by more than 30%, it automatically switches to energy-saving mode and reduces the heating power to 40%-60% of the rated value.

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