Fluid Shear Heater With Waste Heat Recovery for Flameless Heating
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Solution Overview
Problem
Industrial processes require efficient and safe heating solutions that do not involve open flames, particularly in environments like the energy industry where traditional boilers are inefficient, labor-intensive, and hazardous.
Innovation Solution
A trailer-mounted system utilizing a prime mover connected to a dynamic fluid shear heater, centrifugal pump, and heat exchangers to generate warm air and glycol, with a control system to manage heat distribution and safety, allowing for flameless heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional boilers are used for heating, then heating capability is provided, but the system becomes inefficient, labor-intensive, and hazardous due to open flames
Solution Approach 1:
The patent replaces the thermal combustion process with a mechanical energy conversion process. A prime mover (engine) converts chemical energy to mechanical energy, which then drives a dynamic heater to convert mechanical energy to thermal energy through fluid shear heating. This substitution eliminates open flames while providing the same heating function, resolving the contradiction between safety and heating capability.
Solution Approach 2:
The patent introduces a fluid medium (glycol or water) as an intermediary between the prime mover and the heating application. The fluid is pumped through a dynamic heater where mechanical energy is converted to thermal energy, and then circulated through heat exchangers to provide heat. This intermediary system eliminates direct flame contact while maintaining heating effectiveness, resolving the safety hazard contradiction.
2Productivity
If open flame heating systems are used, then heating is provided, but fuel efficiency decreases and labor requirements increase
Solution Approach 1:
The patent implements a continuous heating system where the prime mover continuously converts chemical energy to mechanical energy, which continuously drives the pump and dynamic heater to convert energy to heat. The heated fluid circulates continuously through heat exchangers, providing uninterrupted heating without the start-stop operations typical of traditional boilers, thereby improving productivity and reducing energy loss.
Solution Approach 2:
The system is designed to be self-regulating and automated. The control system monitors and adjusts the operation of the prime mover, pump, and heat exchangers automatically based on temperature sensors and system conditions. This eliminates the need for manual intervention and labor-intensive operations while optimizing fuel consumption, resolving the contradiction between productivity and energy efficiency.
3Reliability
If flameless heating is implemented, then safety is improved, but system complexity increases with multiple components
Solution Approach 1:
The patent designs the prime mover to serve multiple functions: it provides mechanical power to the dynamic heater for heat generation, drives the pump for fluid circulation, and can drive the fan for air movement. The heated fluid serves multiple purposes: direct heating, heat exchange with air, and circulation through various heat exchangers. This multi-functionality reduces the number of separate components needed, resolving the contradiction between safety and system complexity.
Solution Approach 2:
The patent combines multiple heating functions into a single integrated system. The prime mover, pump, dynamic heater, and heat exchangers are merged into one coordinated unit that provides both direct fluid heating and air heating capabilities. This consolidation achieves the flameless safety requirement while minimizing system complexity through integrated design rather than separate systems.
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, safe, and flexible heating capabilities, optimizing fuel use and eliminating the need for open flames, while ensuring a comfortable and safe work environment by generating warm air and glycol at user-specified ratios.
Implementation Method 1
This component utilizes the majority of the power available from the prime mover, and converts this energy into heat. The heater shears a heater fluid, typically glycol.
Implementation Method 2
One heat exchanger is a liquid to liquid heat exchanger which transfers heat from the engine coolant to the heating glycol. The remainder of the heat exchangers may be liquid to air or liquid to liquid
Implementation Method 3
The heater shears a heater fluid, typically glycol. This glycol is contained in a separate system, and may be heated by engine coolant, circulate through a heating hose, or to a liquid to air heat exchanger, or radiator, to provide warm air.
Implementation Method 4
Also connected to the drive of the prime mover is a centrifugal pump to move the glycol through the system.
Implementation Method 5
A fan, which may be driven by the prime mover, is utilized to move warm air through external ductwork to provide heat to equipment and/or personnel.
Data Source
AI summary
A dual heating process is performed in the absence of an open flame. Heat is created by a rotating prime mover(s) driving a fluid shear heater. Heat is also collected from a cooling system of the prime mover, and from any exhaust heat generated by the prime mover. The heat energy collected from all of these sources is transmitted through heat exchangers to a fluid where heat energy is desired. The fluid being heated may be glycol or air, depending on the type of heat desired.