[특허]Oil-fired frac water heater

Chandler, Ronald L.

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Oil-fired frac water heater

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	F24H-003/06 F28D-015/00
미국특허분류(USC)	122/276; 237/019; 126/116R; 165/104.34
출원번호	US-0352505 (2009-01-12)
등록번호	US-8534235 (2013-09-17)
발명자 / 주소	Chandler, Ronald L.
출원인 / 주소	Chandler, Ronald L.
대리인 / 주소	Degenfelder, Jeffrey G.
인용정보	피인용 횟수 : 26 인용 특허 : 44

초록
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The present invention overcomes many of the disadvantages of prior art mobile oil field heat exchange systems by providing an oil-fired heat exchange system. The present invention is a self-contained unit which is easily transported to remote locations. The present invention includes a single-pass tubular coil heat exchanger contained within a closed-bottom firebox having a forced-air combustion and cooling system. The rig also includes integral fuel tanks, hydraulic and pneumatic systems for operating the rig at remote operations in all weather environments. In a preferred embodiment, the oil-fired heat exchanger system is used to heat water on-the-fly (i.e., directly from the supply source to the well head) to complete hydraulic fracturing operations. The present invention also includes systems for regulating and adjusting the fuel/air mixture within the firebox to maximize the combustion efficiency. The system includes a novel hood opening mechanism attached to the exhaust stack of the firebox.

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1. A portable system for heating treatment fluids at a remote work site, comprising: a closed-bottom firebox having an exhaust stack configured near the top of said firebox;a heat exchanger contained within said firebox, said heat exchanger comprising a tubular coil having a single inlet and a single outlet, wherein said tubular coil includes an upper portion oriented about a first axis and a lower portion oriented about a second axis, said lower portion comprising a helical coil oriented about a horizontal axis so as to define a chamber for receiving a substantially horizontal combustion flow, said chamber being substantially enclosed by said helical tubular coil on all but one opened side;a fluid supply system including a fluid supply pump connected to said inlet of said tubular coil;three or more burner assemblies configured in said firebox, each of said burner assemblies comprising a nozzle that projects an atomized fuel-air spray into said chamber though said opened side, which when combusted results in a substantially horizontal combustion flow into said chamber,a primary air system for supplying a first pressurized air flow to each of said burner assemblies, wherein said primary air system comprises a blower pump fluidly connected to a primary air inlet of each of said plurality of burner assemblies, said blower pump comprising a positive displacement rotary blower; anda secondary air system for supplying a second pressurized air flow to said firebox,wherein said helical tubular coil includes a plurality of traversing lateral tubes which substantially enclose said chamber on side opposing said opened side, wherein at least one of said traversing lateral tubes is configured directly in line with said substantially horizontal combustion flow; andwherein said second pressurized air flow increases the convective heat transfer of thermal energy from said combustion flow to said treatment fluid as said fluid is pumped through said heat exchanger by said supply pump. 2. The system of claim 1, wherein said inlet is configured substantially near the top of the heat exchanger and said outlet is configured substantially near the bottom of the heat exchanger to minimize back pressure on said fluid supply pump. 3. The system of claim 1, wherein said upper portion comprises a plurality of stacked horizontal rows of tubing faked down in a series of reversing loops oriented about a vertical axis. 4. The system of claim 1, wherein said primary air system further comprises an intake air filter in fluid communication with said blower pump. 5. The system of claim 1, wherein said primary air system further comprises an air silencer mechanism in fluid communication with said blower pump and said plurality of burner assemblies. 6. The system of claim 1, wherein said secondary air system comprises a plurality of centrifugal fan mechanisms aligned in a parallel configuration and having a common driveshaft, wherein each of said plurality of centrifugal tin mechanisms includes a housing in fluid communication with ductwork that is fluidly connected to a plurality of vents in said firebox. 7. The system of claim 6, wherein said blower pump is rotatively coupled to said driveshaft. 8. The system of claim 7, wherein the blower pump and said plurality of centrifugal fan mechanisms are powered by a motor attached to said driveshaft. 9. The system of claim 8, wherein said motor is hydraulically powered. 10. The system of claim 1, wherein said plurality of burner assemblies comprises a first and second set of burner assemblies, wherein each set comprises more than one burner assembly;said primary air system comprises a first primary blower system which includes a first blower pump fluidly connected to a primary air inlet of each of said first set of burner assemblies, anda second primary blower system which includes a second blower pump fluidly connected to a primary air inlet of each of said second set of burner assemblies;said secondary air system comprises a first secondary blower system which includes a first plurality of centrifugal fan mechanisms aligned in a parallel configuration and having a common first driveshaft, wherein each of said first plurality of centrifugal fan mechanisms includes a housing in fluid communication with a first ductwork that is fluidly connected to a first plurality of vents in said firebox, anda second secondary blower system which includes a second plurality of centrifugal fan mechanisms aligned in a parallel configuration and having a common second driveshaft, wherein each of said second plurality of centrifugal fan mechanisms includes a housing in fluid communication with a second ductwork that is fluidly connected to a second plurality of vents in said firebox;wherein said first blower pump is rotatively coupled to said first driveshaft and said second blower pump is rotatively coupled to said second driveshaft. 11. The system of claim 10, wherein said first blower pump and said first plurality of centrifugal fan mechanisms are powered by first motor rotatively coupled to said first driveshaft; andsaid second blower pump and said second plurality of centrifugal fan mechanisms are powered by second motor rotatively coupled to said second driveshaft. 12. A system of claim 1, further comprising a fuel supply system, which includes a fuel pressure control motor valve that controls the volume of pressurized fuel supplied to each set of burner assemblies. 13. The system of claim 12, wherein said fuel pressure control motor valve is pneumatically actuated. 14. The system of claim 12, further comprising a temperature controller mechanism, which controls the temperature of the treatment fluid exiting said heat exchanger outlet by adjusting a control signal to said fuel pressure control motor valve to increase or decrease the volume of pressurized fuel supplied to each set of burner assemblies. 15. The system of claim 14, wherein said temperature controller mechanism automatically adjusts said control signal in response to a comparison between the temperature of the treatment fluid exiting said heat exchanger outlet and a set point temperature setting on said temperature controller mechanism. 16. The system of claim 15, wherein said temperature controller mechanism senses the temperature of said treatment fluid at said heat exchanger outlet, compares said temperature to a set-point temperature, and adjusts said control signal to said fuel pressure control motor valve to increase or decrease the volume of pressurized fuel supplied to each set of burner assemblies so that said temperature will equal said set-point temperature. 17. The system of claim 1, further including a hood door assembly, which comprises a first door, which is pivotally mounted to one side of said exhaust stack; and a second door, which is pivotally mounted to an opposing side of said exhaust stack. 18. The system of claim 17, further including a mechanism for opening said hood door assembly, comprising a piston having a one end pivotally attached to a side of said firebox and a piston rod protruding from an opposing end;a first bell crank pivotally attached to said piston rod and having a first pivot point, which is pivotally attached to a tapered hood assembly;a first pushrod linkage having one end pivotally attached to said first bell crank;a second bell crank, which is pivotally attached to an opposing end of said first pushrod linkage, and fixably attached said first door, said second bell crank having a second pivot point, Which is co-aligned with said pivotal mount of said first door;a second pushrod linkage having one end pivotally attached to said second bell crank;a third bell crank which is pivotally attached to an opposing end of said second pushrod linkage, and fixably attached said second door, said third bell crank having a third pivot point, which is co-aligned with said pivotal mount of said second door;wherein, when said piston is actuated, said piston rod extends from said piston simultaneously causing said first and second doors to pivot open. 19. The system of claim 18, wherein said piston is a pneumatic piston. 20. The system of claim 1, wherein said fluid supply pump comprises a hydraulically-powered centrifugal fluid pump. 21. A portable system for heating treatment fluids at a remote work site, comprising: a closed-bottom firebox having an exhaust stack configured near the top of said firebox;a heat exchanger contained within said firebox, said heat exchanger comprising a tubular coil having a single inlet and a single outlet, wherein said tubular coil includes an upper portion oriented about a first axis and a lower portion oriented about a second axis, said lower portion comprising a helical coil oriented about a horizontal axis so as to define a chamber for receiving a substantially horizontal combustion flow, said chamber being substantially enclosed by said helical tubular coil on all but one opened side;a fluid supply system including a fluid supply pump connected to said inlet of said tubular coil;three or more burner assemblies configured in said firebox, each of said burner assemblies comprising a nozzle that projects an atomized fuel-air spray into said chamber though said opened side, which when combusted results in a substantially horizontal combustion flow into said chamber,a primary air system for supplying a first pressurized air flow to each of said burner assemblies, wherein said primary air system comprises a blower pump fluidly connected to a primary air inlet of each of said plurality of burner assemblies, and an intake air filter in fluid communication with said blower pump; anda secondary air system for supplying a second pressurized air flow to said firebox,wherein said helical tubular coil includes a plurality of traversing lateral tubes which substantially enclose said chamber on side opposing said opened side, wherein at least one of said traversing lateral tubes is configured directly in line with said substantially horizontal combustion flow; andwherein said second pressurized air flow increases the convective heat transfer of thermal energy from said combustion flow to said treatment fluid as said fluid is pumped through said heat exchanger by said supply pump. 22. A portable system for heating treatment fluids at a remote work site, comprising: a closed-bottom firebox having an exhaust stack configured near the top of said firebox;a heat exchanger contained within said firebox, said heat exchanger comprising a tubular coil having a single inlet and a single outlet, wherein said tubular coil includes an upper portion oriented about a first axis and a lower portion oriented about a second axis, said lower portion comprising a helical coil oriented about a horizontal axis so as to define a chamber for receiving a substantially horizontal combustion flow, said chamber being substantially enclosed by said helical tubular coil on all but one opened side;a fluid supply system including a fluid supply pump connected to said inlet of said tubular coil;three or more burner assemblies configured in said firebox, each of said burner assemblies comprising a nozzle that projects an atomized fuel-air spray into said chamber though said opened side, which when combusted results in a substantially horizontal combustion flow into said chamber,a primary air system for supplying a first pressurized air flow to each of said burner assemblies, wherein said primary air system comprises a blower pump fluidly connected to a primary air inlet of each of said plurality of burner assemblies, and an air silencer mechanism in fluid communication with said blower pump and said plurality of burner assemblies; anda secondary air system for supplying a second pressurized air flow to said firebox,wherein said helical tubular coil includes a plurality of traversing lateral tubes which substantially enclose said chamber on side opposing said opened side, wherein at least one of said traversing lateral tubes is configured directly in line with said substantially horizontal combustion flow; andwherein said second pressurized air flow increases the convective heat transfer of thermal energy from said combustion flow to said treatment fluid as said fluid is pumped through said heat exchanger by said supply pump.

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