Flameless Fluid Heater Using Shear Pump and Multi-Source Heat Recovery
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Solution Overview
Problem
In the energy industry, particularly in oilfield fracture stimulation treatments, large volumes of water need to be heated efficiently and safely without using open flames, as traditional diesel or propane-fired burners are inefficient, hazardous, and lead to environmental and safety issues.
Innovation Solution
A trailer-mounted system utilizing a prime mover connected to a fluid shear pump and multiple heat exchangers to transfer heat from various sources to water, eliminating the need for open flames by using a closed-loop system with liquid and air-to-liquid heat exchangers, ensuring efficient and safe heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If open flame burners are used to heat water, then heating capability is achieved, but safety hazards and fuel inefficiency increase
Solution Approach 1:
The patent replaces the thermal-mechanical combustion system (open flame burners) with a mechanical energy conversion system. The fluid shear pump converts mechanical energy from the prime mover directly into thermal energy through viscous dissipation and shear heating of the heater fluid, eliminating the need for combustion and associated safety hazards while maintaining heating capability
Solution Approach 2:
The patent introduces a heater fluid as an intermediary substance between the prime mover and the water to be heated. The heater fluid receives mechanical energy conversion in the fluid shear pump and transfers thermal energy to water through heat exchangers, mediating the energy transfer process without requiring direct combustion contact with water or atmospheric oxygen
2Temperature
If open flame burners are used to heat water, then heating capability is achieved, but fuel consumption increases
Solution Approach 1:
The patent replaces inefficient combustion-based heating with direct mechanical-to-thermal energy conversion in the fluid shear pump. This conversion process is significantly more efficient as it directly transforms prime mover output into useful thermal energy without the energy losses inherent in combustion processes, thereby reducing fuel consumption while maintaining heating capability
Solution Approach 2:
The heater fluid serves itself by being circulated through the fluid shear pump where it automatically receives mechanical energy conversion and becomes heated. The system uses its own circulating fluid as both the working medium and the heat transfer medium, eliminating the need for external fuel sources and achieving self-sufficient heating
3Temperature
If water is transported to heating tanks, then heating can be performed, but transportation time and complexity increase
Solution Approach 1:
The patent performs preliminary heating action by integrating the heating function into the water delivery system itself. Water is heated during the pumping and delivery process through the heat exchangers, rather than being transported first and then heated separately. This preliminary heating eliminates the need for separate heating tanks and reduces overall process time
Solution Approach 2:
The patent merges the water transportation and water heating functions into a single integrated system. The prime mover simultaneously drives both the main pump for water delivery and the fluid shear pump for heating, combining what were previously separate operations into one unified process that reduces time and system complexity
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 water, reducing fuel consumption and minimizing hazards, allowing for the transportation of warm water via pipelines and further heating at the site, addressing the inefficiencies and safety concerns of traditional open-flame heating methods.
Implementation Method 1
The pump shears a heater fluid such as oil. 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 2
transfers its heat energy to the water through a liquid to liquid heat exchanger
Implementation Method 3
A second heat exchanger is also a liquid to liquid heat exchanger, which transfers heat generated in the engine coolant 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
Implementation Method 5
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
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.