Non-scaling efficient electromagnetic heating device for oil field

Abstract

The utility model provides a scaling-free high-efficiency electromagnetic heating device for an oil field. The scaling-free high-efficiency electromagnetic heating device comprises a tube bundle assembly, an electromagnetic heating unit, a mechanical vibration unit and a shell structure, the tube bundle assembly is formed by connecting a plurality of metal tubes, and a multi-channel fluid structure is formed. The electromagnetic heating unit is arranged outside the metal pipe and is used for heating the metal pipe so as to inductively heat fluid in the metal pipe; the mechanical vibration unit is fixedly connected to the tube bundle assembly and is used for applying mechanical vibration to the tube bundle assembly for descaling; the shell structure comprises an inlet end socket and an outlet end socket which are communicated with the two ends of the tube bundle assembly respectively and used for a fluid inlet and a fluid outlet in the tube bundle assembly. By means of the three-in-one design of efficient heating, active scale prevention and rapid overhauling, the industrial defects that in the prior art, energy consumption is high, scaling is prone to occurring, and maintenance is difficult are overcome, and the device has the advantages of being energy-saving, durable and economical and has wide application prospects in the fields of oil fields, chemical engineering and the like.

Description

Technical Field

[0001] This utility model relates to the technical field of oilfield produced fluid heating, and in particular to an electromagnetic heating device that can effectively prevent scaling, improve heating efficiency, and facilitate maintenance. Background Technology

[0002] Oilfield produced fluids require heating during transportation and processing to improve crude oil fluidity, reduce viscosity, and facilitate transport and subsequent processing. Traditional fuel oil and gas-fired heating furnaces pose environmental pollution problems, and with the advancement of the "dual-carbon" strategy, there is a need to seek more environmentally friendly heating methods. Electromagnetic heating technology, as an energy-efficient and high-performance heating method, has broad application prospects in the oilfield field.

[0003] However, existing electromagnetic heaters have the following problems in practical applications:

[0004] Scaling problem: Electromagnetic heating devices are prone to scaling during use. Impurities and polymers in the extracted fluid can easily form deposits on the inner wall of the heater, leading to problems such as decreased thermal efficiency, increased energy consumption, shortened equipment lifespan, increased maintenance costs, and increased safety hazards.

[0005] Low heating efficiency: Most existing electromagnetic heating devices adopt a pipe recirculation design with a large inner diameter, which leads to uneven temperature distribution of the fluid inside the pipe and the heating efficiency needs to be improved.

[0006] Inconvenient for maintenance: Existing electromagnetic heaters have a complex structure. Once scale forms, it cannot be quickly removed on-site using simple tools. Cleaning and maintenance are difficult on-site, requiring return to the factory for treatment, which increases maintenance time and costs. Utility Model Content

[0007] The purpose of this invention is to provide a non-scaling, high-efficiency electromagnetic heating device for oil fields, aiming to solve the problems of scaling, low heating efficiency, and inconvenient maintenance of existing electromagnetic heaters.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A non-scaling, high-efficiency electromagnetic heating device for oil fields includes a tube bundle assembly, an electromagnetic heating unit, a mechanical vibration unit, and a shell structure.

[0010] The tube bundle assembly is made of multiple metal tubes connected together to form a multi-channel fluid structure;

[0011] The electromagnetic heating unit is disposed outside the metal tube and is used to heat the metal tube, thereby inductively heating the fluid inside the metal tube.

[0012] The mechanical vibration unit is fixedly connected to the tube bundle assembly and is used to apply mechanical vibration to the tube bundle assembly for descaling.

[0013] The shell structure includes an inlet end cap and an outlet end cap that are respectively connected to both ends of the tube bundle assembly and are used for fluid inlet and outlet within the tube bundle assembly.

[0014] Preferably, the metal tube is a heating tube; the electromagnetic heating unit includes an electromagnetic coil and an electromagnetic controller, the electromagnetic coil is wound around the heating tube and connected to the electromagnetic controller, and is used to generate an electromagnetic field to heat the fluid inside the heating tube.

[0015] Preferably, the heating tube is wrapped with an insulation layer to provide high-temperature insulation; the electromagnetic coil is wound around the outside of the insulation layer.

[0016] Preferably, the shell structure includes a tube sheet, an inlet end cap, and an outlet end cap; two sets of tube sheets are respectively disposed at both ends of the tube bundle assembly, and the outer sides of the two sets of tube sheets are respectively connected to the inlet end cap and the outlet end cap. The inlet end cap is provided with a fluid inlet pipe, and the outlet end cap is provided with a fluid outlet pipe, and the tube bundle assembly is connected through the inlet end cap and the outlet end cap.

[0017] Preferably, the mechanical vibration unit includes an ultrasonic transducer, which is fixedly mounted on the tube sheet and connected to an ultrasonic controller for generating high-frequency mechanical vibration and transmitting it to the tube sheet and tube bundle assembly.

[0018] Preferably, the ultrasonic transducer is made of magnetostrictive material and is welded to the tube sheet, thus being tightly connected to the tube sheet.

[0019] Compared with the prior art, this utility model has the following advantages:

[0020] 1. This utility model significantly increases the heat transfer area through a parallel design of multiple metal tubes, and, in conjunction with an electromagnetic coil, directly and efficiently induction heats the tube wall, improving thermal efficiency by more than 30% compared to traditional heating methods. The external insulation layer effectively reduces heat loss, maximizing energy utilization and fully complying with current energy conservation and emission reduction policies, thus significantly reducing long-term operating energy costs.

[0021] 2. This invention utilizes an ultrasonic transducer made of magnetostrictive material, which generates high-frequency mechanical vibrations that are transmitted throughout the entire tube bundle system. This not only prevents the formation of new scale but also removes existing scale. This innovative design extends the continuous operating cycle of the equipment by 2-3 times and reduces maintenance frequency by more than 50%, making it particularly suitable for heating fluids with high scale content.

[0022] 3. The inlet and outlet end caps of this utility model adopt a flange-type detachable structure, eliminating the need for specialized equipment or factory repairs during maintenance. Tube bundle cleaning or replacement can be quickly completed on-site. This design reduces the average maintenance time from 3 days to less than 4 hours, significantly lowering maintenance costs and making it particularly suitable for the operation and maintenance needs of equipment in remote areas.

[0023] 4. This invention reduces fluid transport energy consumption by 15-20% through the synergistic effect of efficient heating and active scale prevention. Combined with a convenient maintenance design, it achieves a 1-2 year investment payback period. Its technological advantages perfectly align with the "dual-carbon" policy direction, and it has broad market application prospects and long-term economic value in oil fields, chemical industries, and other fields.

[0024] In summary, this utility model solves the industry pain points of high energy consumption, easy scaling, and difficult maintenance of traditional technologies through a three-in-one design of "high-efficiency heating + active scale prevention + rapid maintenance". It is energy-saving, durable and economical, and has broad application prospects in oil fields, chemical industry and other fields. Attached Figure Description

[0025] Figure 1 This is a front view structural diagram of a non-scaling, high-efficiency electromagnetic heating device for oil fields provided by this utility model.

[0026] Figure 2 This is a three-dimensional structural diagram of a non-scaling, high-efficiency electromagnetic heating device for oil fields provided by this utility model.

[0027] The serial numbers in the diagram are as follows:

[0028] 1. Heating element; 2. Insulation layer; 3. Electromagnetic coil; 4. Tube sheet; 5. Inlet end cap; 6. Outlet end cap; 7. Ultrasonic transducer; 8. Ultrasonic controller; 9. Electromagnetic controller. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0030] like Figure 1 and Figure 2 As shown, this embodiment illustrates a non-scaling, high-efficiency electromagnetic heating device for oil fields, comprising a tube bundle assembly, an electromagnetic heating unit, a mechanical vibration unit, and a shell structure.

[0031] Tube assembly: Consists of 24 parallel 304 stainless steel heating tubes 1, each 30mm in diameter and 2.5mm in wall thickness, with a tube length of 3 meters and both ends fixed by tube plates 4; the heating tubes 1 are wrapped with a 50mm thick aluminum silicate insulation layer 2. In this embodiment, each heating tube 1 and tube plate 4 are made of a corrosion-resistant and elastic metal material.

[0032] In this embodiment, the parallel connection of multiple heating tubes 1 increases the contact area between the fluid and the heating surface, thereby improving heating efficiency. Simultaneously, ultrasonic vibration promotes fluid mixing, resulting in a more uniform temperature distribution.

[0033] In addition, the tube bundle assembly has a simple structure, and once scale forms, the end caps can be disassembled on-site and cleaned using simple tools, without having to be transported back to the manufacturer for treatment, saving maintenance time and costs.

[0034] The electromagnetic heating unit includes an electromagnetic coil 3 and an electromagnetic controller 9. The electromagnetic coil 3 is made of copper wire evenly wound around the outer perimeter of the insulation layer 2. During the electromagnetic heating process, the weak current generated by the electromagnetic heating coil affects ions and molecules in the fluid, altering the electric field distribution and influencing the deposition behavior of dirt particles, thereby inhibiting scaling. Electromagnetic heating technology is energy-saving and environmentally friendly, aligning with the requirements of the "dual-carbon" strategy.

[0035] The mechanical vibration unit includes an ultrasonic transducer 7 and an ultrasonic controller 8. Six magnetostrictive ultrasonic transducers 7 are symmetrically welded to the tube sheets 4 at both ends. Ultrasonic vibration can disrupt the adhesion between dirt particles, making them easier for the fluid to carry away, thus preventing dirt deposition. More specifically, the long-pulse ultrasonic signal contains multiple small pulses that interfere with scale formation in its early stages, preventing scale crystals from depositing and growing on the metal surface. The continuous action of the long pulses maintains fluid dynamic conditions, reducing the conditions for scale formation, thereby achieving a long-term anti-scaling effect. The mechanical vibration generated by the ultrasound can effectively propagate on metal materials such as tube sheets and heating tubes, and can penetrate the liquid medium, directly acting on the scale layer, causing fatigue cracks, and generating shear force and peeling between the metal surface and the scale, leading to its detachment.

[0036] Furthermore, in this embodiment, the ultrasonic long-pulse vibration effectively prevents the formation of scale and removes existing deposits, ensuring the long-term stable operation of the heater and improving the service life and thermal efficiency of the equipment.

[0037] In addition, ultrasonic vibration can promote fluid mixing, making the fluid temperature and concentration distribution more uniform, preventing local overheating or oversaturation, thereby reducing the possibility of scaling.

[0038] The combination of weak current effect and ultrasonic scale prevention and removal can form a more effective scale prevention and removal mechanism, further improving the scale prevention and removal effect of the device of the present invention.

[0039] Through the above mechanisms, the device of the present invention can effectively prevent the formation of scale and remove existing scale, keeping the inner wall of the heating tube clean, thereby improving heating efficiency, extending the service life of the equipment, and reducing maintenance costs.

[0040] Shell structure: includes tube sheet 4, inlet end cap 5 and outlet end cap 6. The inlet end cap 5 and outlet end cap 6 are DN250 and are designed to be detachable through flange connection. The inlet end cap 5 is equipped with a DN80 fluid inlet pipe and the outlet end cap 6 is equipped with a DN80 fluid outlet pipe.

[0041] The application method of this embodiment is as follows:

[0042] The produced fluid enters the heating tube group 1 through the inlet end cap 5. The electromagnetic coil 3 generates an electromagnetic field to inductively heat the heating tube 1. Simultaneously, the ultrasonic transducer 7, driven by the ultrasonic controller 8, generates long-pulse high-frequency, low-amplitude fluctuations, causing the tube sheet 4 to vibrate synchronously, further driving each heating tube 1 to vibrate synchronously at high frequency. The high-frequency vibration generated by the ultrasonic transducer 7 produces cavitation bubbles in the fluid. When these bubbles burst, they generate a powerful impact force, causing the fluid in each heating tube 1 to undergo high-speed shearing and peeling motion, impacting and peeling off the scale on the tube wall of the heating tube 1, thereby producing an efficient scale prevention and removal effect and fluid mixing effect. This ensures that the electromagnetic heater has the functions of online scale prevention and removal and efficient heat exchange during actual operation. The heated produced fluid is discharged through the outlet pipe.

[0043] The beneficial effects of this embodiment are as follows:

[0044] Operating costs: The device in this embodiment inhibits scaling through ultrasonic and weak current effects, reducing the frequency of chemical cleaning and mechanical descaling, thereby significantly reducing operating costs.

[0045] Reduced maintenance costs: Because the device in this embodiment is simple to maintain, the long-term maintenance costs are low. Compared with traditional heating devices, the present invention can reduce a lot of maintenance costs.

[0046] Improved production efficiency: The device in this embodiment can ensure the continuity and stability of oilfield production, improve production efficiency, and thus indirectly increase the economic benefits of the oilfield.

[0047] Environmental Impact: The energy-saving effect of the device in this embodiment helps reduce carbon emissions, which is in line with the trend of green and environmentally friendly development and also plays a positive role in enhancing the corporate social responsibility image.

[0048] In summary, the device in this embodiment utilizes electromagnetic heating technology, which is more energy-efficient and environmentally friendly compared to traditional heating methods, aligns with policy guidelines, and has broad market prospects. This device can improve heating efficiency, reduce operating costs, and increase production efficiency, helping oilfield enterprises reduce costs and enhance competitiveness. This device can effectively prevent scaling, extend equipment lifespan, and reduce maintenance costs, resulting in significant economic benefits. This device employs ultrasonic anti-scaling and descaling technology, combined with a weak current effect, offering advantages such as scale prevention and removal, high heating efficiency, and convenient maintenance, demonstrating clear technological advantages. This device has a simple structure, low manufacturing cost, long service life, and low maintenance costs, resulting in significant cost advantages. This device can be widely used in the heating and transportation of produced fluids in oilfields, as well as in other applications requiring heated fluids, and has broad market prospects.

[0049] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A non-scaling, high-efficiency electromagnetic heating device for oil fields, characterized in that, Includes tube bundle assembly, electromagnetic heating unit, mechanical vibration unit and shell structure; The tube bundle assembly is made of multiple metal tubes connected together to form a multi-channel fluid structure; The electromagnetic heating unit is disposed outside the metal tube and is used to heat the metal tube, thereby inductively heating the fluid inside the metal tube. The mechanical vibration unit is fixedly connected to the tube bundle assembly and is used to apply mechanical vibration to the tube bundle assembly for descaling. The shell structure includes an inlet end cap (5) and an outlet end cap (6) that are respectively connected to both ends of the tube bundle assembly and are used for fluid inlet and outlet within the tube bundle assembly.

2. The oilfield non-scaling high-efficiency electromagnetic heating device according to claim 1, characterized in that, The metal tube is a heating tube (1); the electromagnetic heating unit includes an electromagnetic coil (3) and an electromagnetic controller (9). The electromagnetic coil (3) is wound around the heating tube (1) and connected to the electromagnetic controller (9) to generate an electromagnetic field to heat the fluid in the heating tube (1).

3. The oilfield non-scaling high-efficiency electromagnetic heating device according to claim 2, characterized in that, The heating tube (1) is wrapped with an insulation layer (2) to provide high-temperature insulation; the electromagnetic coil (3) is wound around the outside of the insulation layer (2).

4. The oilfield non-scaling high-efficiency electromagnetic heating device according to claim 1, characterized in that, The shell structure includes a tube sheet (4), an inlet end cap (5), and an outlet end cap (6); The tube sheet (4) is in two sets, respectively set at both ends of the tube bundle assembly. The outer sides of the two sets of tube sheets (4) are respectively connected to the inlet end cap (5) and the outlet end cap (6). The inlet end cap (5) is provided with a fluid inlet pipe, and the outlet end cap (6) is provided with a fluid outlet pipe. The tube bundle assembly is connected through the inlet end cap (5) and the outlet end cap (6).

5. The oilfield non-scaling high-efficiency electromagnetic heating device according to claim 4, characterized in that, The mechanical vibration unit includes an ultrasonic transducer (7), which is fixedly mounted on the tube sheet (4). The ultrasonic transducer (7) is connected to an ultrasonic controller (8) to generate high-frequency mechanical vibration and transmit it to the tube sheet (4) and the tube bundle assembly.

6. The oilfield non-scaling high-efficiency electromagnetic heating device according to claim 5, characterized in that, The ultrasonic transducer (7) is made of magnetostrictive material and is welded to the tube sheet (4) and is tightly connected to the tube sheet (4).

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