Flameless Fluid Heater Using Shear Pump and Multi-Stage Heat Recovery
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Solution Overview
Problem
Industrial applications, particularly in the energy sector, require large volumes of heated fluids without the use of open flames, as traditional open-flamed trucks for heating water in oilfield fracture stimulation treatments are inefficient, hazardous, and pose safety risks.
Innovation Solution
A trailer-mounted system utilizing a prime mover connected to a fluid shear pump and multiple heat exchangers to efficiently heat fluids without flames, using the energy from the prime mover to shear a heating fluid, which transfers heat to water through liquid-to-liquid and air-to-liquid heat exchangers, eliminating the need for open-flame heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If open-flamed trucks with diesel or propane fired burners are used to heat water, then heating capability is achieved, but fuel efficiency deteriorates and safety hazards worsen
Solution Approach 1:
The patent replaces the thermal field (open flame combustion) with a mechanical field (fluid shear pump). The fluid shear pump uses mechanical energy from the prime mover to directly shear and heat the heating fluid, eliminating the need for combustion-based thermal conversion. This substitution improves fuel efficiency by directly converting mechanical energy to heat without the energy losses associated with open-flame burners.
Solution Approach 2:
The patent introduces a heating fluid as an intermediary substance between the prime mover and the water to be heated. The heating fluid circulates through the system, absorbing heat from the fluid shear pump and transferring it to water through heat exchangers. This intermediary approach enables efficient heat transfer while eliminating direct flame contact with water, improving both fuel efficiency and safety.
2Temperature
If open-flamed trucks are used to heat water, then heating capability is achieved, but safety hazards worsen
Solution Approach 1:
The patent replaces the thermal field (open flame) with a mechanical field (fluid shear pump). By using mechanical energy to directly heat the heating fluid, which then transfers heat to water through heat exchangers, the system eliminates open flames entirely. This substitution removes fire hazards, burn risks, and other safety concerns associated with traditional open-flame heating equipment.
Solution Approach 2:
The heating fluid serves as a safe intermediary that transfers thermal energy without requiring open flames. The heating fluid circulates through sealed systems and heat exchangers, providing a controlled and safe method of heat transfer that eliminates the safety hazards of direct flame exposure while still achieving the required water temperature.
3Temperature
If water is transported by truck to heating tanks, then heating capability is achieved, but operational complexity worsens
Solution Approach 1:
The patent combines the heating function with the water transport system by integrating the fluid shear pump and heat exchangers directly into the water handling infrastructure. Water is heated as it flows through the system via the heated heating fluid, eliminating the need for separate truck-based heating units and reducing operational complexity.
Solution Approach 2:
The heated heating fluid acts as an intermediary that transfers thermal energy to water throughout the transport system. By circulating the heated heating fluid through heat exchangers positioned along the water transport path, the system provides continuous heating without requiring complex centralized heating operations or multiple handling steps.
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
The system provides efficient and safe heating of fluids, reducing fuel consumption and minimizing hazards, allowing for the transportation of warm water via pipelines and further heating at the site, addressing inefficiencies and safety concerns of traditional methods.
Implementation Method 1
This component utilizes the majority of the power available from the prime mover, and converts this energy into heat. The pump shears a heater fluid such as oil.
Implementation Method 2
This oil is contained in a separate system, and transfers its heat energy to the water through a liquid to liquid heat exchanger.
Implementation Method 3
A fourth heat exchanger is also an air to liquid heat exchanger, which transfers the heat generated in the engine exhaust of the prime mover to the water.
Implementation Method 4
A third heat exchanger is an air to liquid heat exchanger which transfers heat generated in the turbocharger intercooler on a diesel prime mover engine to the water.
Data Source
AI summary
Heat from a rotating prime mover(s) driving a fluid shear pump, heat from the prime mover and any exhaust heat generated by the prime mover is collected. The heat energy collected from all of these sources is transmitted through heat exchangers to a fluid where heat energy is desired. This fluid heating process is performed in the absence of an open flame.