Diesel Engine Heat Transfer System for Produced Fluid Separation

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Solution Overview

Problem

Existing methods for heating produced fluids from oil or gas wells often result in direct heat transfer between engine exhaust and hydrocarbons, leading to potential explosions and inefficient separation of hydrocarbons from water, as they do not effectively control temperature and can cause hydrocarbons to flash.

Innovation Solution

A heat transfer system that uses a non-combustible heat transfer fluid to separate the direct heat from a diesel engine and transfer it to produced fluids, preventing direct heat transfer between the engine exhaust and hydrocarbons, thereby safely increasing the temperature of the produced fluids for effective hydrocarbon separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If direct heat transfer from engine exhaust to produced fluids is used, then heating efficiency is improved, but safety deteriorates due to potential hydrocarbon explosions

Engineering Contradiction:

Improveheating efficiencyVSAvoidexplosion risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

A heat transfer fluid is introduced as an intermediary substance between the engine exhaust and the produced fluids. The heat transfer fluid absorbs heat from the engine exhaust through a first heat exchanger and transfers it to the produced fluids through a second heat exchanger, preventing direct contact between hydrocarbons and ignition sources while maintaining efficient heat transfer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If produced fluid temperature is increased to improve hydrocarbon separation, then separation efficiency is improved, but safety deteriorates due to hydrocarbon flashing

Engineering Contradiction:

Improveseparation efficiencyVSAvoidhydrocarbon flashing

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The heat transfer fluid serves as a mediator that allows controlled temperature increase of produced fluids without direct exposure to high-temperature engine exhaust. This intermediate heat transfer mechanism enables reaching separation-optimized temperatures while preventing hydrocarbon flashing that would occur with direct heating.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces direct thermal contact (mechanical/physical mixing) with indirect heat transfer through heat exchangers. This substitution allows precise temperature control of produced fluids, achieving optimal separation conditions without the uncontrolled temperature spikes that cause hydrocarbon flashing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a heat transfer system with multiple heat exchangers is used to prevent direct heat transfer, then safety is improved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heat transfer fluid performs multiple functions: it acts as a thermal mediator between engine exhaust and produced fluids, serves as a heat storage medium, and provides a safety barrier preventing hydrocarbon ignition. This multi-functionality justifies the added system complexity by consolidating several protective and operational roles into a single fluid system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach allows for efficient and safe separation of hydrocarbons from produced fluids by raising their temperature, reducing hydrocarbon content and preventing explosions, while ensuring compliance with safety standards for offshore oil platforms.

Implementation Method 1

Energy (heat) from the engine is exchanged with a non-combustible heat transfer fluid that then transfers heat to the produced fluids

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

heats the produced fluids, e.g., so that hydrocarbons can be separated from produced water by helping break a hydrocarbon/water emulsion

Methodology Applied

Scientific EffectEmulsion breaking: Emulsion

Data Source

PatentUS9469552B2Produced fluid heating and separation

Publication Date: 2016.10.18 AMCOL INTERNATIONAL CORP

AI summary

An apparatus and method for heating produced fluid from a well, the heating apparatus comprising a produced fluid pathway; a heat generation system comprising a diesel engine, a heated hydraulic fluid pathway, and an engine coolant pathway; and a heat transfer system disposed between the produced fluid pathway and the heat generation system to transfer thermal energy from the heat generation system to a produced fluid contained within the produced fluid pathway.