Methods and devices for heating liquid for injection into a wellbore or pipeline system

Abstract

Super heater systems include self-contained units which are easily transported to remote locations. Such super heater systems include heat exchanger assemblies adapted to heat liquid on-the-fly (i.e., directly from the supply source to a wellbore or pipeline system. A heat exchange assembly may include a first header with a plurality of first header layers in alternating fluid communication, and a second header with a plurality of second header layers in alternating fluid communication. A plurality of heat exchange coils can be coupled between the first header and the second header such that the heat exchange coils are exposed to heat generated by a burner manifold. Other aspects, embodiments, and features are also claimed and described.

1 . A burner box, comprising:
 a plurality of heat exchange coils;   a first header coupled to a first longitudinal end of the plurality of heat exchange coils, the first header comprising a plurality of header layers in alternating direct fluid communication;   a second header coupled to an opposing second longitudinal end of the plurality of heat exchange coils, the second header comprising a plurality of header layers in alternating direct fluid communication; and   a burner manifold positioned to expose the plurality of heat exchange coils directly to a flame generated from the burner manifold when ignited.   
     
     
         2 . (canceled) 
     
     
         3 . The burner box of  claim 1 , wherein the plurality of heat exchange coils are adapted to expose a liquid flowing therethrough to heat generated by the burner manifold flame to increase a temperature of the liquid by between 30° and 85° at a rate of 30 barrels per minute or greater. 
     
     
         4 . The burner box of  claim 1  wherein the plurality of heat exchange coils are adapted to expose a liquid flowing therethrough to heat generated by the burner manifold flame to increase a temperature of the liquid by between 30° and 85° at a rate between 30 barrels per minute and 58 barrels per minute. 
     
     
         5 . The burner box of  claim 1 , wherein each header layer of the first header and the second header includes two sublayers of heat exchange coils coupled thereto. 
     
     
         6 . The burner box of  claim 1 , wherein each of the plurality of header layers of the first header and each of the plurality of header layers of the second header comprises a generally cuboid shape. 
     
     
         7 . The burner box of  claim 1 , wherein the alternating direct fluid communication of the plurality of header layers for the first header alternates with the alternating direct fluid communication of the plurality of header layers for the second header. 
     
     
         8 . The burner box of  claim 1 , wherein the first header comprises six header layers, and the second header comprises six header layers. 
     
     
         9 . A super heater system, comprising:
 a fuel storage and supply system;   a burner manifold in fluid communication with the fuel storage and supply system and adapted to generate heat in the form of a flame by combusting fuel received from the fuel storage and supply system;   at least one pump adapted to pump a fluid; and   a heat exchanger assembly in fluid communication with the pump to receive the pumped fluid, the heat exchanger assembly comprising:
 a first header at a first longitudinal end, the first header comprising a plurality of first header layers in alternating direct fluid communication; 
 a second header at a second longitudinal end, the second header comprising a plurality of second header layers in alternating direct fluid communication; and 
 a plurality of heat exchange coils extending between and coupled to the first header and the second header, wherein the plurality of heat exchange coils are directly exposed to the flame generated by the burner manifold. 
   
     
     
         10 . The super heater system of  claim 9 , wherein each header layer of the first header and the second header includes two sublayers of heat exchange coils coupled thereto. 
     
     
         11 . The super heater system of  claim 9 , wherein each of the first header layers and each of the second header layers comprises a generally cuboid shape. 
     
     
         12 . The super heater system of  claim 9 , wherein the alternating direct fluid communication of the plurality of first header layers alternates with the alternating direct fluid communication of the plurality of second header layers. 
     
     
         13 . The super heater system of  claim 9 , further comprising a housing at least substantially enclosing the heat exchanger assembly and the burner manifold, the housing comprising at least one rib disposed on a sidewall of the housing to run in a direction of a grain of the sidewall. 
     
     
         14 . The super heater system of  claim 9 , further comprising an outlet interface assembly in fluid communication with the heat exchanger assembly, the outlet interface assembly comprising:
 at least one on-the-fly outlet interface adapted to output heated liquid for use in hydraulic fracturing without prior storage; and   a plurality of preheat outlet interfaces adapted to output heated liquid for storage prior to use in hydraulic fracturing.   
     
     
         15 . A heat exchanger assembly, comprising:
 a plurality of heat exchange coils directly exposed to a flame;   a first header coupled to a first longitudinal end of the plurality of heat exchange coils, the first header comprising a plurality of header layers, wherein at least some of the header layers of the first header are in fluid communication with at least one other header layer of the first header; and   a second header coupled to an opposing second longitudinal end of the plurality of heat exchange coils, the second header comprising a plurality of header layers, wherein at least some of the header layers of the second header are in fluid communication with at least one other header layer of the second header.   
     
     
         16 . The heat exchanger assembly of  claim 15 , wherein:
 header layers of the first header in direct fluid communication correspond to header layers of the second header not in direct fluid communication; and   header layers of the second header in direct fluid communication correspond to header layers of the first header not in direct fluid communication.   
     
     
         17 . The heat exchanger assembly of  claim 15 , wherein the header layers of the first header and the second header are each coupled to two sublayers of heat exchange coils. 
     
     
         18 . The heat exchanger assembly of  claim 15 , wherein the header layers of the first header and the second header each comprises a generally cuboid shape. 
     
     
         19 - 26 . (canceled)