Hybrid fuel and electric fluid heating system and methods of manufacture thereof

Abstract

A hybrid fluid heating system for heating a production fluid using fuel and/or electric energy sources, the production fluid being contained in a pressure vessel includes a fuel-fired furnace heating subsystem, comprising: a furnace configured provide a thermal transfer fluid; and a heat exchanger configured to receive the thermal transfer fluid from the furnace and configured to be in thermal communication with the production fluid to provide convective heat exchange from the thermal transfer fluid to the production fluid; an electrical heating subsystem comprising one or more electrical heating elements disposed at least partially within the pressure vessel and being in contact with the production fluid; and wherein the fuel-fired furnace heating subsystem and the electrical heating subsystem are each configured to be individually controlled such that the production fluid is selectively heated by at least one of the fuel-fired furnace heating subsystem and the electrical heating subsystem.

What is claimed is: 
     
         1 . A hybrid fuel and electric fluid heating system for heating a production fluid using fuel and/or electric energy sources, the production fluid being contained in a pressure vessel, comprising:
 a fuel-fired furnace heating subsystem, comprising:
 a blower disposed in the first conduit configured to receive ambient air and electrical input power and to provide output source air; 
 a furnace configured to receive the output source air from the blower and to receive fuel and to provide the thermal transfer fluid; and 
 a heat exchanger configured to receive the thermal transfer fluid from the furnace and configured to be in thermal communication with the production fluid to provide convective heat exchange from the thermal transfer fluid to the production fluid and the heat exchanger configured to produce output exhaust gas; 
   an electrical heating subsystem comprising one or more electrical heating elements disposed at least partially within the pressure vessel and at least a portion of the heating elements within the pressure vessel being in contact with the production fluid; and   wherein the fuel-fired furnace heating subsystem and the electrical heating subsystem are each configured to be individually controlled such that the production fluid is selectively heated by at least one of the fuel-fired furnace heating subsystem and the electrical heating subsystem.   
     
     
         2 . The hybrid fluid heating system of  claim 1 , further comprising a control system configured to control the operation of the fuel-fired furnace heating subsystem and control the operation of the electrical heating subsystem. 
     
     
         3 . The hybrid fluid heating system of  claim 1 , further comprising a control system configured to control the operation of the fuel-fired furnace heating subsystem, the operation of the electrical heating subsystem, and the concurrent operation of the fuel-fired furnace heating subsystem and the electrical heating subsystem. 
     
     
         4 . The hybrid fluid heating system of  claim 1 , wherein the fuel-fired furnace heating subsystem utilizes a combustible fuel. 
     
     
         5 . The hybrid fluid heating system of  claim 1 , wherein the hybrid fluid heating system is a steam boiler. 
     
     
         6 . The hybrid fluid heating system of  claim 1 , wherein the hybrid fluid heating system is a hydronic boiler. 
     
     
         7 . The hybrid fluid heating system of  claim 1 , wherein the hybrid fluid heating system is a thermal fluid boiler. 
     
     
         8 . The hybrid fluid heating system of  claim 1 , wherein at least one electrical heating element is approximately parallel to a longitudinal axis of the pressure vessel. 
     
     
         9 . The hybrid fluid heating system of  claim 1 , wherein at least one electrical heating element is approximately perpendicular to a longitudinal axis of the pressure vessel. 
     
     
         10 . The hybrid fluid heating system of  claim 1 , wherein a portion of at least one of the electrical heating elements mechanically attaches to an outside surface of the pressure vessel. 
     
     
         11 . The hybrid fluid heating system of  claim 10 , wherein the electrical heating subsystem further comprises a bolted flange subassembly having a nozzle that penetrates the pressure vessel, the flange subassembly being attached to a portion of at least one of the electrical heating elements. 
     
     
         12 . The hybrid fluid heating system of  claim 10 , wherein the electrical heating subsystem further comprises a a threaded conduit subassembly that penetrates said pressure vessel, the threaded conduit subassembly being attached to a portion of at least one of the electrical heating elements. 
     
     
         13 . The hybrid fluid heating system of  claim 1 , wherein the electrical heating elements are arranged in a staggered configuration. 
     
     
         14 . The hybrid fluid heating system of  claim 1 , wherein the heat exchanger comprises at least one of: a tubeless heat exchanger and a shell and tube heat exchanger. 
     
     
         15 . The hybrid fluid heating system of  claim 1 , wherein the thermal transfer fluid comprises liquid water, steam, or a combination thereof. 
     
     
         16 . The hybrid fluid heating system of  claim 1 , wherein the production fluid comprises water, a C1 to C10 hydrocarbon, air, carbon dioxide, carbon monoxide, or a combination thereof. 
     
     
         17 . The hybrid fluid heating system of  claim 1 , wherein the thermal transfer fluid comprises a gaseous or non-gaseous fluid. 
     
     
         18 . The hybrid fluid heating system of  claim 1 , wherein the furnace comprises a burner assembly and combustion chamber, which receives the fuel and produces the output exhaust gas. 
     
     
         19 . A method of heating a production fluid using fuel and/or electric energy sources, the production fluid being contained in a pressure vessel, the method comprising:
 providing a fuel-fired furnace heating subsystem, comprising:
 a blower disposed in the first conduit configured to receive ambient air and electrical input power and to provide output source air; 
 a furnace configured to receive the output source air from the blower and to receive fuel and to provide the thermal transfer fluid; and 
 a heat exchanger configured to receive the thermal transfer fluid from the furnace and configured to be in thermal communication with the production fluid to provide convective heat exchange from the thermal transfer fluid to the production fluid and the heat exchanger configured to produce output exhaust gas; 
   providing an electrical heating subsystem comprising one or more electrical heating elements disposed at least partially within the pressure vessel and at least a portion of the heating elements within the pressure vessel being in contact with the production fluid;   flowing the production fluid from an inlet of the pressure vessel to an outlet of the pressure vessel; and   controlling the fuel-fired furnace heating subsystem and the electrical heating subsystem such that the production fluid is selectively heated by at least one of the fuel-fired furnace heating subsystem and the electrical heating subsystem.   
     
     
         20 . The method of  claim 19 , further comprising providing a control system for performing the controlling of the fuel-fired furnace heating subsystem and the electrical heating subsystem. 
     
     
         21 . The method of  claim 19 , further comprising flowing electrical current through the electrical heating elements, when it is time for heating the production fluid. 
     
     
         22 . The method of  claim 19 , wherein the fuel-fired furnace heating subsystem utilizes a combustible fuel. 
     
     
         23 . The method of  claim 19 , wherein the hybrid fluid heating system is a steam boiler. 
     
     
         24 . The method of  claim 19 , wherein the hybrid fluid heating system is a hydronic boiler. 
     
     
         25 . The method of  claim 19 , wherein the hybrid fluid heating system is a thermal fluid boiler. 
     
     
         26 . The method of  claim 19 , wherein at least one electrical heating element is approximately parallel to a longitudinal axis of the pressure vessel. 
     
     
         27 . The method of  claim 19 , wherein at least one electrical heating element is approximately perpendicular to a longitudinal axis of the pressure vessel. 
     
     
         28 . The method of  claim 19 , wherein at least one electrical heating element mechanically attaches to an outside surface of the pressure vessel by a bolted flange subassembly including a nozzle that penetrates said pressure vessel. 
     
     
         29 . The method of  claim 19 , wherein at least one electrical heating element mechanically attaches to an outside surface of the pressure vessel by a threaded conduit subassembly that penetrates said pressure vessel. 
     
     
         30 . The method of  claim 19 , wherein the electrical heating elements are arranged in a staggered configuration. 
     
     
         31 . The method of  claim 19 , wherein the heat exchanger comprises at least one of: a tubeless heat exchanger and a shell and tube heat exchanger. 
     
     
         32 . The method of  claim 19 , wherein the thermal transfer fluid comprises liquid water, steam, or a combination thereof. 
     
     
         33 . The method of  claim 19 , wherein the production fluid comprises water, a C1 to C10 hydrocarbon, air, carbon dioxide, carbon monoxide, or a combination thereof. 
     
     
         34 . The method of  claim 19 , wherein the thermal transfer fluid comprises a gaseous or non-gaseous fluid. 
     
     
         35 . The method of  claim 19 , wherein the furnace comprises a burner assembly and combustion chamber, which receives the fuel and produces the output exhaust gas. 
     
     
         36 . A method of manufacturing an electrical heating subsystem for a hybrid fuel and electric fluid heating system, for heating a production fluid using fuel and/or electric energy sources, the production fluid being contained in a pressure vessel, the method comprising:
 providing a plurality of electrical heating elements at least partially contained in the pressure vessel;   attaching a portion of at least one of the electrical heating elements to the pressure vessel using a flange and gasket seal subassembly which are attached to a portion of the at least one of the electrical heating elements, to secure the at least one of the electrical heating elements to the pressure vessel; and   connecting the electrical heating elements to an electrical conduit for the provision of electrical energy to the electrical heating elements from a control system disposed outside the pressure vessel.   
     
     
         37 . The method of  claim 36 , further comprising arranging the electrical heating elements in a staggered configuration, the electrical heating elements being at least partially disposed inside the pressure vessel. 
     
     
         38 . A hybrid fluid heating system for heating a production fluid using fuel and/or electric energy sources, the production fluid being contained in a pressure vessel, comprising:
 a fuel-fired furnace heating subsystem, comprising:
 a furnace configured provide a thermal transfer fluid; and 
 a heat exchanger configured to receive the thermal transfer fluid from the furnace and configured to be in thermal communication with the production fluid to provide convective heat exchange from the thermal transfer fluid to the production fluid; 
   an electrical heating subsystem comprising one or more electrical heating elements disposed at least partially within the pressure vessel and being in contact with the production fluid; and   wherein the fuel-fired furnace heating subsystem and the electrical heating subsystem are each configured to be individually controlled such that the production fluid is selectively heated by at least one of the fuel-fired furnace heating subsystem and the electrical heating subsystem.