Modular Water Heating Pod for Portable High-Capacity Hot Water
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Solution Overview
Problem
Current water heating solutions for industrial applications, such as hydraulic fracturing, are inefficient due to the need for transporting large volumes of heated water and the inability to scale or reconfigure existing large units, leading to inefficiencies and logistical challenges, especially in remote locations where water sources are scarce.
Innovation Solution
A modular, portable hot water heating system comprising multiple water heating units connected within a containerized structure, utilizing a basin with baffle plates and spillways to optimize fluid communication and isolation, allowing for on-demand hot water production and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional large-scale water heating units are used to meet industrial hot water demand, then sufficient hot water supply is achieved, but the units become too large to transport in ready-to-use condition for field applications
Solution Approach 1:
The water heating system is divided into multiple modular heating units that can be independently transported and then combined to achieve the required hot water supply capacity. Each module contains its own heating elements and can be configured in different arrangements based on site requirements.
Solution Approach 2:
Multiple heating modules are nested within a common basin structure, with each module containing smaller heating elements within standardized module housings. This allows compact packaging for transport while maintaining full operational capacity when assembled.
2Quantity of substance
If single large-scale water heating units are deployed, then hot water demand is met, but the system cannot be re-scaled in case of malfunction, leading to complete system failure
Solution Approach 1:
The system consists of independent modular heating units that can be selectively activated or deactivated. If one module malfunctions, the remaining modules continue to operate and can be individually replaced without shutting down the entire system.
Solution Approach 2:
The modular configuration allows dynamic reconfiguration of the system capacity by adding or removing modules based on changing operational requirements or replacement needs, providing flexibility that fixed single-unit systems cannot offer.
3Adaptability or versatility
If multiple modular water heating units are used to improve portability and scalability, then transportability and adaptability are enhanced, but system complexity increases due to multiple units and connections
Solution Approach 1:
Multiple heating modules share a common basin and control system, merging their individual functions into a coordinated unified system. This reduces the operational complexity compared to completely independent units while maintaining the benefits of modularity.
Solution Approach 2:
Each modular unit is designed with standardized interfaces and universal mounting configurations, allowing the same module design to serve multiple positions and functions within the system, thereby reducing the variety of components needed and simplifying maintenance.
4Temperature
If conventional mobile boilers are used at drilling sites, then water heating is achieved, but thermal efficiency is poor due to transportation of large volumes of water and storage requirements
Solution Approach 1:
The system pre-heats water in a storage basin before it enters the heating modules, utilizing the basin as a pre-conditioning chamber. This preliminary action reduces the energy required in the main heating phase and eliminates the need for separate storage tanks.
Solution Approach 2:
The heating modules are directly integrated with the basin structure, eliminating separate storage tanks and reducing heat transfer losses between storage and heating components. The combined design minimizes thermal losses by reducing the number of interfaces and insulation requirements.
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, on-demand hot water production, optimizing thermal efficiency and minimizing pressure pulsations, enabling scalable and portable operation suitable for remote industrial applications like hydraulic fracturing, reducing transportation and operational costs.
Implementation Method 1
a basin for pressure pulsation modulation of a plurality of water heating units
Implementation Method 2
multiple water heating units that can be operated independently or together to meet hot water supply demands
Data Source
AI summary
A water heating pod includes at least one water heating module packaged within a container. The water heating module includes a plurality of water heating units in fluid communication with a basin. The basin is configured to support a first fluid communication between the water heating units and provide a second fluid isolation between the water heating units.