Integrated intelligent condensing heating unit

Deskripsi

Key Features:

• Adaptive Temperature Control – Maintains ±1°C accuracy across 30–150°C range
• Energy Recovery Technology – Recovers 20–30% waste heat from gas turbines or engines
• Self-Cleaning Design – Automated descaling for prolonged heat exchanger efficiency
• Cloud-Connected Intelligence – Predictive analytics for hydrate risk mitigation
• Compact Modular Footprint – 50% smaller than conventional heating systems

Core Components:

Intelligent Heating Module:

• Multi-Pass Shell & Tube Heat Exchanger (ASME Section VIII certified)
• Electric/Combustion Hybrid Heater – Switchable between fuel types
• Phase-Change Thermal Storage – Maintains heat during power fluctuations

Smart Control System:

• IoT Sensors – Monitor gas dew point, pressure, temperature, and flow regime
• AI-Powered Controller – Predicts hydrate formation risks using reservoir models
• Digital Twin Integration – Simulates thermal performance under varying loads

Auxiliary Systems:

• Automatic Chemical Injection – Hydrate inhibitors (e.g., methanol, MEG)
• Explosion-Proof Enclosure – ATEX Zone 1/2 and IECEx certified
• Low-Emission Burner – NOx <30 mg/Nm³ (for combustion mode)

Working Principle:

1. Gas Inlet Analysis: Sensors detect gas composition, pressure, and temperature.

2. Risk Prediction: AI calculates hydrate formation potential using PVT data.

3. Adaptive Heating:

   • Electric Mode: Direct heating via resistance elements during low-demand periods.

   • Combustion Mode: Fuel-based heating for high-capacity requirements.

4. Heat Recovery: Waste heat from exhaust/flue gas is stored in phase-change materials.

5. Continuous Optimization: Digital twin adjusts parameters based on real-time pipeline conditions.

Performance Advantages:

• 40% Energy Savings vs. traditional line heaters
• Zero Hydrate Incidents – Predictive shutdowns prevent blockages
• 30% Lower Maintenance – Self-cleaning and corrosion-resistant materials
• 100% Remote Operability – Fully automated for unmanned stations

Applications:

• Gas condensate fields with high water content
• Subsea pipeline heating systems
• Shale gas well pads requiring intermittent heating
• LNG pre-cooling and boil-off gas management

Case Study: Arctic Gas Field Deployment:

• Challenge: Maintain 70°C in -40°C ambient for 20km pipeline
• Solution: Installed ICHS-5000 system with hybrid heating
• Results:
  ↗ Achieved 99.8% uptime over 3 winter seasons
  ↘ Reduced methanol consumption by 45%
  → Cut CO₂ emissions by 35% via energy recovery

Certifications & Standards:

• ASME BPVC Section VIII (Pressure Vessel Code)
• API 12K (Indirect-Type Oil Field Heaters)
• ISO 50001 (Energy Management Systems)
• SIL 2 (Safety Integrity Level)