A device to prevent scale formation in plate heat exchangers using electromagnetic waves and ultrasound.

Abstract

This device has operational and field applications in various industries, especially refineries and petrochemicals. Plate heat exchangers are one of the most widely used types of heat exchangers that exchange heat between cold and hot fluids through thin metal surfaces. The challenge of clogging and clogging of plate exchangers leads to a decrease in the efficiency of these exchangers and their lack of proper (standard) functioning. Given the significant costs of purchasing and repairing these exchangers on the one hand and the negative impact of stopping operations in production units on the other hand, preventing the deposition of organic and mineral compounds inside plate exchangers is very important from an economic and technical point of view. In the current situation, one of the important priorities of the oil industry is to manage and reduce repair costs. In this regard, various methods are used. Among these methods are the use of chemical solvents and thermal methods. These methods remove organic and mineral deposits from plate exchangers through different mechanisms such as sediment dissolution. Considering the new approaches of the oil industry based on using economical methods with minimal environmental destruction and pollution, the need to use new technologies such as ultrasonic and electromagnetic waves in this industry is more and more important than ever. This invention attempts to present, for the first time, a device that prevents the formation of deposits in plate heat exchangers using electromagnetic and ultrasonic waves, using wave emitters. This device has no similar domestic or foreign counterparts. The positive effect of using electromagnetic and ultrasonic waves in removing blockages and clogging of pipelines containing hydrocarbon fluids has been proven in previous research. Radiation of electromagnetic waves and ultrasound can prevent the aggregation of organic and mineral compounds in crude oil by changing the properties of crude oil, fluid temperature and pressure conditions, and the interaction between fluids and surfaces, and also prevent the formation of organic and mineral deposits (clogging of exchanger plates). In this regard, the aforementioned device is presented in a size appropriate to the size of the selected plate exchanger and with capabilities such as withstanding fluid pressure and temperature, non-corrosion and abrasion in case of contact with the fluid.

Description

Description of the invention Title of the invention A device that prevents scale formation in plate heat exchangers using electromagnetic waves and ultrasound. Technical background of the relevant invention This device has operational and field applications in various industries, especially refineries and petrochemical plants. Plate heat exchangers are one of the most widely used types of heat exchangers that exchange heat between cold and hot fluids through thin metal surfaces. The challenge of clogging and clogging of plate heat exchangers leads to a decrease in the efficiency of these exchangers and their failure to function properly (standard). Considering the significant costs of purchasing and repairing these exchangers on the one hand and the negative impact of stopping operations in production units on the other hand, preventing the deposition of organic and inorganic compounds inside plate heat exchangers is very important from an economic and technical perspective. In the current situation, one of the important priorities of the oil industry is to manage and reduce repair costs. In this regard, various methods are used. Among these methods are the use of chemical solvents and thermal methods. These methods remove organic and inorganic deposits from plate heat exchangers through different mechanisms such as dissolution of deposits.Given the new approaches of the oil industry based on the use of economic methods with minimal environmental destruction and pollution, the need to use new technologies such as ultrasonic and electromagnetic waves in this industry is more and more important than ever. In this project, an attempt has been made to present, for the first time, a device that prevents the formation of deposits in plate exchangers using electromagnetic and ultrasonic waves, using wave emitters. In this regard, the aforementioned device has been presented in sizes appropriate to the size of the selected plate exchanger and with capabilities such as withstanding fluid pressure and temperature, non-corrosion and abrasion in case of contact with the fluid. By implementing this project, it is possible to manufacture this device industrially for any type of exchanger, and it is also possible to provide services to domestic and foreign companies active in the oil industry. Technical problem and stating the objectives of the invention One of the most important and main equipment used in cooling and heating systems are heat exchangers, whose function is to transfer temperature and heat between flowing fluids. Plate heat exchangers, as their name suggests, consist of a large number of metal plates that are separated by polymer gaskets. These devices are used in petrochemicals and refineries in the country to change the temperature of fluids containing oil and gas. In this regard, blockage and clogging of the plates of these exchangers by organic and mineral deposits leads to a sharp decrease in the efficiency of these exchangers. This blockage and clogging inside plate exchangers must be removed to ensure accurate management of fluid temperature. For this purpose, electromagnetic waves and ultrasound, by changing the physical properties of crude oil, the temperature and pressure conditions of the fluid, and the interaction between fluids and solid surfaces, prevent the accumulation of organic and mineral compounds in crude oil and prevent the formation of deposits (clogging of exchanger plates).In this regard, after carefully examining the results of this device and analyzing the sensitivity of important factors such as the flow rate of the fluid entering the exchanger, a device is designed to prevent the formation of deposits in plate exchangers by radiating electromagnetic and ultrasonic waves. The fluid entering the exchanger contains oil containing heavy organic compounds such as asphaltenes and water with high salinity (various ions) which precipitate due to changes in temperature and pressure conditions inside the exchanger plates. The precipitates formed, by blocking the exchanger plates, lead to a decrease in their efficiency. This blockage in the exchangers causes them to be out of service and requires repairs and even replacement of this equipment. The main objectives of building this device are: • Solving the problem of blockage and clogging in plate heat exchangers •Management and continuity of hydrocarbon fluid delivery in refineries and petrochemical plants •Reducing costs related to maintenance and repair of heat exchangers •Increasing the lifespan of heat exchangers and improving their performance within a certain period of time •Preventing reduction in fluid production due to heat exchangers being out of service A description of the state of the prior art and the history of developments related to the claimed invention. The presented device has no domestic or foreign analogues. The positive and practical effect of using electromagnetic waves and ultrasonic waves in removing blockages and clogging of pipelines and porous media containing hydrocarbon fluids caused by organic and mineral sediments has been proven in previous research. In this regard, the radiation of electromagnetic waves and ultrasonic waves can prevent the aggregation of organic and mineral compounds in crude oil by changing the properties of crude oil, the temperature and pressure conditions of the fluid, and the interaction between fluids and surfaces, and also prevent the formation of organic and mineral sediments (clogging of exchangers). According to research and experiments, the radiation of ultrasonic and electromagnetic waves to hydrocarbon fluids has an effective and significant role in improving fluid flow, with results such as: separation of asphaltene masses in crude oil, removal of wax sediments, desalination and dewatering of crude oil; however, this technology has not yet been applied in the field and in practice in Iran. Table 1: Examples of similar foreign patents for the presented device Patent Number Patent Title Application Difference from the Presented Design WO2024222129A1 WIPO (PCT) All-in-one plate heat exchanger, temperature control apparatus comprising same, energy storage device, and vehicle In this invention, a heat exchanger with temperature monitoring and control capability is provided. Electromagnetic waves and ultrasound are not used in this invention. Descaling of heat exchanger plates is not mentioned in this invention. EP3633301A1 European Patent Office Plate heat exchanger and heat pump hot water supply system In this invention, the design and construction of a type of plate heat exchanger containing a hot fluid flow system is mentioned. Electromagnetic waves and ultrasound are not used in this invention. Descaling of heat exchanger plates is not mentioned in this invention. US10962302B2 United States Heat exchangers in a petrochemical plant or refinery In this invention, a plate heat exchanger is designed that contains mechanical and digital sensors to record various parameters of the fluid inside the exchanger.This invention does not use electromagnetic waves or ultrasound. This invention does not refer to the descaling of heat exchanger plates. US10328408B2 United States Detecting and correcting fouling in heat exchangers In this invention, sensors are used to identify problems and challenges of plate heat exchangers such as leakage and corrosion. This invention does not use electromagnetic waves or ultrasound. This invention does not refer to the descaling of heat exchanger plates. US10663238B2 United States Detecting and correcting maldistribution in heat exchangers in a petrochemical plant or refinery In this invention, a plate heat exchanger is provided with the ability to detect leakage and equipment failure caused by mechanical esters. This invention does not use electromagnetic waves or ultrasound. This invention does not refer to the descaling of heat exchanger plates.KR101432954B1 South Korea A heat exchanger plate and a plate heat exchanger In this invention, a plate heat exchanger with two walls containing a sensor for evaluating the fluid flow within the exchanger is provided. Electromagnetic waves and ultrasound are not used in this invention. The descaling of the heat exchanger plates is not mentioned in this invention. Providing a solution to an existing technical problem along with an accurate, sufficient, and integrated description of the invention The radiation of waves to the converter leads to the phenomenon of cavitation in the fluid and changes the rheological (viscosity) properties of the fluid. Also, the waves, by vibrating the fluid, prevent the accumulation of organic and inorganic compounds inside the converter plates and prevent their deposition. For this purpose, in this invention, a device that prevents the formation of deposits inside plate converters by radiating electromagnetic and ultrasonic waves is presented. In this design, the simultaneous and combined use of magnetic waves and ultrasonic waves in preventing the deposition of organic and inorganic compounds inside plate converters is presented as a solution. Identifying the optimal conditions for this operation and analyzing the sensitivity to important parameters are the main questions of this design. A schematic diagram of this device is presented in Figure 1 of the invention drawing file. The parts used in different parts of this device are: As shown in Figure 1, the heat exchanger plates are shown in section 1 of the invention drawing. The hydrocarbon fluid enters the exchanger through a pipe (section 2 of the invention drawing). The fluid, which has undergone a temperature change by the heat exchanger, exits the exchanger through an outlet pipe and is sent to other parts of the refinery through flow lines (section 3 of the invention drawing). The ultrasonic wave emitters are located near the exchanger plates (section number 4 in the invention drawing) and the radiation of ultrasonic waves to the hydrocarbon fluid inside the exchanger is carried out continuously and simultaneously with the fluid flow. The frequency and power of these waves must be optimized. In this regard, the optimal conditions for the radiation of waves must be identified in the laboratory in accordance with the type of hydrocarbon fluid, the flow rate of the flow entering the exchanger, the material and dimensions of the exchanger plates, and the temperature and pressure conditions of the area. The radiation of these waves prevents the deposition of organic and inorganic compounds on the exchanger plates and the pipelines inside it. The electromagnetic wave emitters are located adjacent to the exchanger plates (section 5 in the invention drawing). The energy and frequency of these waves can be adjusted in proportion to the flow rate into the exchanger, the properties of the hydrocarbon fluid such as density and viscosity, and the temperature and pressure conditions of the area. The radiation of these waves prevents the deposition of organic and inorganic compounds on the exchanger plates and the pipelines inside it. Part number 6 in the invention drawing indicates the flow sensor (flow meter) on the exchanger that continuously records the fluid flow rate inside the exchanger. Part number 7 in the invention drawing indicates the pressure sensor (pressure gauge) on the exchanger that continuously records the fluid pressure inside the exchanger. Part number 8 in the invention drawing indicates the temperature sensor (thermometer) on the exchanger that continuously records the fluid temperature inside the exchanger. The parameters recorded by these sensors are used in the management and control of waves (electromagnetic and ultrasonic) radiated to the fluid inside the heat exchanger. Also, with these sensors, the efficiency of the exchangers can be checked online and continuously. Project service steps and description: Step 1: Measuring the characteristics of selected heat exchangers 1-1-The exact dimensions of the heat exchanger, the number and size of the plates used in it are measured. 1-2- The types of plates, tubes, and equipment used in the exchanger are identified. 1-3-The temperature and pressure conditions of the desired area are determined. Step 2: Measuring the characteristics of the hydrocarbon fluid entering the converter 1-4- The density and viscosity of the hydrocarbon fluid entering the heat exchanger are determined. 1-5- The composition of the fluid entering the exchanger, including the amount of organic compounds and salts present in the water, is determined. 1-6- The conditions for the precipitation of organic compounds, especially asphaltenes, and the conditions for the precipitation of minerals (salts with water) are identified in order to optimize the temperature and pressure of the fluid inside the exchanger. Step Three: Preparing electromagnetic and ultrasound wave emitters 1-7-Electromagnetic wave emitters are prepared according to the operating conditions of the selected converters. 1-8-Ultrasonic wave emitters are prepared according to the operating conditions of the selected transducers. Step Four: Installing equipment and identifying optimal radiation conditions 1-9-Ultrasonic and electromagnetic wave emitters are installed in the vicinity of the heat exchanger plates. 1-10- Temperature, pressure, and fluid flow sensors are installed at the fluid outlet from the heat exchanger. Step 5: Continuous online monitoring and evaluation of converter performance 1-11- The pressure, temperature, and flow rate data of the fluid within the fluid are recorded and analyzed continuously and online. 1-12- By recording and examining operating parameters such as temperature, pressure, and fluid flow rate inside the exchanger and analyzing the sensitivity to wave characteristics such as their power and frequency, the prevention of the formation of organic and mineral deposits inside the exchanger is optimized. Explanation of shapes, maps and diagrams The various parts of the invention are described in order according to the device drawing. According to the numbers in the invention drawing (to view the invention images, refer to the invention drawing file): Figure 1) Schematic image of the device from the front side Figure 2) Schematic image of the device from above Figure 3) Schematic image of the device from the left side Explanation of the various parts used in Figures 1 to 3 in the invention drawing: Part 1: Plate heat exchanger Part 2: Hydrocarbon fluid inlet pipe to the converter Part 3: Hydrocarbon fluid outlet pipe from the converter Part 4: Ultrasonic wave emitters to the fluid inside the transducer Part 5: Radiating electromagnetic waves to the fluid inside the exchanger Part 6: Flowmeter Part 7: Fluid Pressure Sensor (Manometer) Part 8: Fluid temperature sensor (thermometer) A clear and precise statement of the advantages of the claimed invention over prior inventions. The main advantages of this device in refineries and petrochemicals are: 1) Better management and control of the temperature of the fluid leaving the heat exchangers 2) Reducing the destruction and corrosion of equipment used in converters 3) Reduction of organic and mineral deposits in plate heat exchangers 4) Reducing costs related to heat exchanger replacement and repairs 5) No environmental pollution 6) No harm to employees and personnel 7) No need to stop the fluid flow during operation Description of at least one implementation method for implementing the invention 1) It is possible to use this device in heat exchangers used in desalination units of the Southern Iranian Oil Company. Currently, these plate exchangers face the significant challenge of organic and inorganic compound deposition, which has severely reduced the efficiency and effectiveness of these exchangers and has led to their accelerated destruction. This problem has imposed significant costs on these units of the National Iranian Oil Company. This challenge can be overcome by using the device presented in this invention. 2) Using this device in heat exchangers in refineries in southern Iran is also effective and practical and leads to solving the problem of clogging and blockage of the plates inside the heat exchangers. Explicit mention of the industrial application of the invention The main applications of this device in refineries and petrochemical plants are: 1) Preventing the deposition of organic and inorganic compounds inside heat exchangers 2) Optimal management of fluid temperature inside the heat exchanger 3) Reducing the time of destruction and corrosion of heat exchangers 4) Reducing the cost of replacing and repairing the converter 5) No interruption in the fluid flow during the wave radiation operation (wave radiation is simultaneous with the operation of the converter)

Claims

Claim What is claimed: Claim 1) A device that prevents the formation of deposits in plate heat exchangers by simultaneously radiating (combined) electromagnetic and ultrasonic waves; which consists of the following components: -Electromagnetic wave radiators -Ultrasonic wave radiators -Temperature sensor -Pressure sensor -Flow meter Claim 2) According to claim 1, electromagnetic waves and ultrasonic waves are simultaneously (combined) radiated to the fluid inside the plate heat exchanger. The sensors embedded in the device record instantaneously and continuously the pressure, temperature, and flow rate of the fluid entering and leaving the heat exchanger.

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