Patent Publication Number: US-9897385-B2

Title: Helical coil heating apparatus and method of operation

Description:
TECHNICAL FIELD 
     This invention relates generally to a heating apparatus and specifically to a helical coil heating apparatus and method of operation. 
     BACKGROUND OF THE INVENTION 
     In many industries it is often necessary to heat liquids that exist in cold environments. Usually, these liquids are stored in tanks or other large reservoirs or they exist naturally in the environment. It is desirable to keep these liquids from freezing or to thaw these liquids if they do freeze. This is typically achieved by using heating mechanisms that are bulky, inefficient, and difficult to use. 
     SUMMARY OF THE INVENTION 
     According to embodiments of the present disclosure, disadvantages and problems associated with previous heating mechanisms may be reduced or eliminated. 
     In one embodiment, a heating apparatus comprises an exposed tube formed into an outer coil and an inner coil. In the apparatus, each coil is formed of a plurality of rings that are arranged to extend in a longitudinal direction. The outer coil is formed around the inner coil with a gap separating the outer coil and the inner coil. The tube has a first end that terminates the outer coil and a second end that terminates the inner coil. The apparatus also comprises support frame comprising a base portion, a body portion, and a top portion. The top portion of the support frame is arranged transverse to the longitudinal direction of the plurality of rings. The body portion of the support frame has a first end that is coupled to the top portion and a second end that is coupled to the base portion. The base portion comprises a plurality of legs and is arranged transverse to the longitudinal direction of the plurality of rings. The heating apparatus also comprises a spacer frame that extends from the top portion of the support frame to the base portion of the support frame. The spacer frame has a plurality of apertures formed therein, each aperture operable to support a corresponding ring of the outer coil such that at least one ring of the outer coil is separated from at least one other ring of the outer coil. The spacer frame has a vertex positioned between the inner coil and the outer coil. The apparatus also comprises a spacer rod having a first end that couples to the top portion of the support frame and a second end that couples to the base portion of the support frame, wherein the spacer rod is threaded through the spacer frame between the outer coil and the vertex of the spacer frame. 
     Certain embodiments may provide one or more advantages. One advantage of one embodiment may include the ability to heat toxic, corrosive, or any other type of contents safely. Another advantage may include the ability to use the same heating apparatus to heat contents of multiple different types of natural and artificial reservoirs. Yet another advantage may be the ability to heat contents quickly and through minimal heat loss. 
     Various embodiments of the invention may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To provide a more complete understanding of the present disclosure and the features and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  illustrates a perspective view of a system for heating fluids using a helical coil heating apparatus; 
         FIG. 2  illustrates one embodiment of a helical coil heating apparatus; 
         FIG. 3  illustrates one embodiment of a support frame and four spacer frames and spacer rods; 
         FIG. 4  illustrates one embodiment of a spacer frame and a spacer rod used in the helical coil heating apparatus of  FIG. 2 ; and 
         FIG. 5  illustrates a top down view of one embodiment of a helical coil heating apparatus. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a perspective view of a helical coil heating apparatus  10  connected to a heater  12  by a supply line  32  and a return line  34 . According to this embodiment, heating apparatus  10  comprises an exposed tube  16 , support frame  22 , and spacer frames  24   a  and  24   b . Tube  16  is formed into an outer helical coil  18  and an inner helical coil  20 . Spacer frames  24   a  and  24   b  are attached to outer helical coil  18 . In this embodiment, heating apparatus  10  is heated by using fluid that is heated by heater  12 . Here, tube  16  is supported by support frame  22 . Support frame  22  has a hook  26 . A crane  28  uses hook  26  to lower heating apparatus  10  into reservoir  14  through an opening  30 . As heating apparatus  10  is lowered into reservoir  14 , heating apparatus  10  comes in contact with the contents of reservoir  14  and heats those contents. In one embodiment, the contents of reservoir  14  may be frozen and heating apparatus  10  may be placed on top of the frozen contents to melt the frozen contents. 
     Heater  12  may be any system, device, or apparatus for heating a fluid. In various embodiments, heater  12  may be mobile or stationary. Heater  12  may be powered by any power source including generators, solar panels, batteries, the power grid, hydro-electric power, wind turbines, geothermal energy or any other power source. In some embodiments, heater  12  has multiple connections to connect multiple lines and is operable to heat fluids for multiple heating apparatuses  10 . In the various embodiments, heater  12  may heat fluids to any suitable temperature. Heater  12  may also include or be coupled to a pump for pumping the heated fluid into the heated supply and return lines  32  and  34 , respectively. In one embodiment, heater  12  may be connected to supply line  32  and return line  34  and heater  12  may both supply heated fluid and receive heated fluid. In another embodiment, heater  32  may only supply heated fluid. 
     Reservoir  14  may be any natural formation or artificial container including tanks, ponds, lakes, etc. Reservoir  14  may have an inlet or an outlet for fluid to enter or exit reservoir  14 . In different embodiments, reservoir  14  may or may not be enclosed. Reservoir  14  may or may not be deep enough to submerge the entire heating apparatus  10 . In one embodiment, reservoir  14  includes an opening  30  for accessing reservoir  14 . Opening  30  may be large enough to insert heating apparatus  10 . Reservoir  14  may be submerged, partially submerged, underground, partially underground, elevated off the ground, at ground level or in any other location. At different times of operation, reservoir  14  may be full, partially filled, or empty. Reservoir  14  may contain any substance in any form including any combination of liquids, solids, and gasses. For example, reservoir  14  may contain substances that are toxic, corrosive, flammable, edible, or potable. In one embodiment, reservoir  14  may contain frozen liquids. In various embodiments, reservoir  14  may be of any shape including a shape that may vary depending upon the contents of reservoir  14 . 
     Crane  28  may be any system, device, or apparatus for moving any component of heating apparatus  10 . In operation, crane  28  may couple with a hook  26  to lift any component of heating apparatus  10  and place it in any suitable location. Crane  28  may be mobile or stationary. Crane  28  may be powered by any power source including generators, engines, solar panels, batteries, gasoline, diesel, or any other power source. In some embodiments, crane  28  may be able to couple with multiple heating apparatuses  10  or may be able to couple with multiple portions of heating apparatus  10 . Crane  28  may interact with heating apparatus  10  by any means for lifting any component of heating apparatus  10  including, for example, by hooks, a magnetic plate, a sack, a platform, or any other suitable mechanism or feature. 
     Supply line  32  and return line  34  may be made of any material and may have any suitable dimensions for transporting heated fluid. Lines  32  and  34  may be made of a flexible or a malleable material. At various times of operation, lines  32  and  34  may be partially filled with fluid, fully filled with fluid, or be empty. Lines  32  and  34  may carry glycol, water, oil, or any other suitable fluid that is heated by heater  12 . 
     As discussed in greater detail below with respect to  FIG. 2 , heating apparatus  10  may comprise a tube  16  that is formed into an outer helical coil  18  and an inner helical coil  20 . Tube  16  may be supported by a support frame  22 . Spacer frames  24   a  and  24   b  may be attached to outer helical coil  18 . In other embodiments, as discussed in greater detail below, additional spacer frames may be attached to inner helical coil  20 . 
     In operation, heating apparatus  10  may heat the contents of reservoir  14  through a series of heat transfers. First, heater  12  may heat any fluid, for example, glycol, to a suitable temperature. Heater  12  may then pump that heated fluid into supply line  32 . In one embodiment, supply line  32  may be coupled to outer helical coil  18 . In another embodiment, supply line  32  may be coupled to a non-corrosive, thermally conductive extender that is coupled to outer helical coil  18  so that supply line  32  does not come in contact with contents of reservoir  14 . The heated fluid may flow from heater  12  through supply line  32  into outer helical coil  18 . Once the heated fluid is inside outer helical coil  18 , heat energy may transfer from the heated fluid to outer helical coil  18 . Because outer helical coil  18  may be in thermal contact with the contents of reservoir  14 , heat energy may transfer from outer helical coil  18  to the contents of reservoir  14 . As the contents closest to outer helical coil  18  are heated, they may become less dense and rise. The cooler contents of reservoir  14  may then flow towards outer helical coil  18  thereby heating the contents of entire reservoir  14  instead of just the contents adjacent to outer helical coil  18 . The heated fluid inside outer helical coil  18  flows from outer helical coil  18  to inner helical coil  20 . The heated fluid may continue to heat inner helical coil  20  in a similar manner. Inner helical coil  20  may also continue to heat the contents of reservoir  14 . The heated fluid may become less hot as heat energy transfers from the heated fluid to helical coils  18  and  20 . In one embodiment, inner helical coil  20  may be coupled to one end of return line  34 . In another embodiment, return line  34  may be coupled to a non-corrosive, thermally conductive extender that is coupled to inner helical coil  20  so that return line  34  does not come in contact with contents of reservoir  14 . The other end of return line  34  may be coupled to heater  12 . The heated fluid may flow from inner helical coil  20  back to heater  12  through return line  34 . Heater  12  may reheat the heated fluid and pump the heated fluid into supply line  32  to continuously heat the contents of reservoir  14 . 
       FIG. 2  illustrates one embodiment of helical coil heating apparatus  10  coupled to supply line  32  and return line  34 . In this embodiment, exposed tube  16  is formed into an outer helical coil  18  and an inner helical coil  20 . In other embodiments, tube  16  may have any number of coils. Outer helical coil  18  and inner helical coil  20  may be formed of a plurality of rings that are arranged to extend in a longitudinal direction. As shown, outer helical coil  18  is substantially cylindrical. It will be appreciated, however, that outer helical coil  18  may be of any shape. Similarly, as shown, inner helical coil  20  is substantially cylindrical. As with outer helical coil  18 , inner helical coil  20  may be of any shape. As discussed below in relation to  FIG. 5 , in one embodiment, outer helical coils  18  and  20  may have one or more planar surfaces and may be shaped substantially as a “D.” In the present embodiment, outer helical coil  18  is formed around inner helical coil  20  and there is a gap between outer helical coil  18  and inner helical coil  20 . Outer helical coil  18  may be separated from inner helical coil  20  by any suitable means. In this embodiment, tube  16  has a first end  40  and a second end  42 . First end  40  of tube  16  terminates outer helical coil  18 . Second end  42  of tube  16  terminates inner helical coil  20 . First end  40  and second end  42  may be next to each other and may face substantially the same direction. For example, in one embodiment, ends  40  and  42  may terminate in a position that is parallel to the longitudinal direction of the plurality of rings. Tube  16  may be made of any material including any thermally conductive material. In some embodiments, tube  16  may be made of a non-corrosive material such as stainless steel. Tube  16  may be of any shape. Tube  16  may be made of a flexible or malleable material. It may be possible to change the shape of tube  16  depending upon the intended use of heating apparatus  10 . In the present embodiment, spacer frames  24   a  and  24   b  are used in conjunction with outer helical coil  18 , and spacer frames  24   c  and  24   d  are used in conjunction with inner helical coil  20  as discussed in greater detail with respect to  FIG. 4  below. Here spacer frames  24   a  and  24   b  are positioned on different portions of outer helical coil  18 . Similarly, spacer frames  24   c  and  24   d  are positioned on different portions of inner helical coil  20 . Although spacer frames  24   a  and  24   b  and spacer frames  24   c  and  24   d  are all illustrated herein, it should be understood that any number and combination of spacer frames  24  can be used depending on the particular needs of the heating apparatus  10 . For example, in one embodiment, spacer frames  24   a  and  24   b  are used but not spacer frames  24   c  and  24   d . In another embodiment, spacer frames  24   c  and  24   d  are used but not spacer frames  24   a  and  24   b . In still another embodiment, one of spacer frames  24   a  and  24   b  is used along with one of spacer frames  24   c  and  24   d . In still other embodiments, additional spacer frames  24  can be used in conjunction with outer coil  18  and/or additional spacer frames  24  can be used in conjunction with inner coil  20 . As discussed in greater detail with respect to  FIGS. 3 and 4  below, spacer frames  24   a - d  are additionally held in place on heating apparatus  10  by spacer rods  52   a - d.    
     Support frame  22  may be any structure or apparatus for supporting tube  16 . Support frame  22  may be made of any material including a thermally conductive material. In one embodiment, support frame  22  may be made of a non-corrosive material such as stainless steel. Different portions of support frame  22  may be made of different materials. In one embodiment, support frame  22  may comprise a top portion  44 , a body portion  46 , and a base portion  48 . In another embodiment, support frame  22  may only comprise a top portion  44  and a base portion  48 . 
     Top portion  44  may be any structure that forms one portion of support frame  22 . Top portion  44  may be of any shape. Top portion  44  may be made of any material. In one embodiment, top portion  44  may be made of a non-corrosive, thermally conductive material such as stainless steel. Top portion  44  may comprise one or more hooks  26 . In one embodiment, hooks  26  may be permanently attached to top portion  44 . In another embodiment, hooks  26  may be removably coupled to top portion  44 . In the various embodiments, hooks  26  may be attached near the middle of top portion  44 , near the ends of top portion  44 , or at any other part of top portion  44 . 
     In one embodiment where support frame  22  has a body portion  46 , body portion  46  may have a first end and a second end. The first end of body portion  46  may be coupled to top portion  44 . The second end of body portion  46  may be coupled to base portion  48 . Body portion  46  may be coupled to top portion  44  in any manner. In one embodiment, body portion  46  may be rotatably coupled to top portion  44  so that top portion  44  may be able to rotate around the axis of body portion  46  to increase the maneuverability of support frame  22 . In another embodiment where support frame  22  does not have a body portion  46 , top portion  44  may be connected to base portion  48  using spacer rods  52  as described in greater detail with respect to  FIG. 3  below. 
     Base portion  46  may be any structure on which tube  16  can be placed. In one embodiment, base portion  48  may be attached to body portion  46 . Base portion  48  may have any suitable number of legs  50 . In some embodiments, base portion  48  may be a rectangular or disk shaped plate. Base portion  48  may have any suitable dimensions. In one embodiment, the dimensions of base portion  48  may be different from the dimensions of top portion  44 . Base portion  48  may be made of any material. In one embodiment, base portion  48  may be made of a non-corrosive, thermally conductive material such as stainless steel. 
     In this example embodiment, outer helical coil  18  and inner helical coil  20  of tube  16  are placed upon base portion  48  of support frame  22 . In other embodiments, base portion  48  may only support inner helical coil  20  and not outer helical coil  18 . In the present embodiment, top portion  44  is arranged transverse to the longitudinal direction of the plurality of rings forming outer coil  18  and inner coil  20 . Here, both outer helical coil  18  and inner helical coil  20  come in thermal contact with base portion  48 . In this embodiment, base portion  48  comprises legs  50   a ,  50   b ,  50   c , and  50   d  ( 50   d  is not shown) and base portion  48  is also arranged transverse to the longitudinal direction of the plurality of rings forming outer coil  18  and inner coil  20 . In this embodiment, outer helical coil  18  and inner helical coil  20  are placed around body portion  46  of support frame  22 . In other embodiments, support frame  22  may not have a body portion  46  and outer coil  18  and inner coil  20  may be placed on support frame  22  using spacer rods  52  as described below with respect to  FIG. 3 . In the present embodiment, both first end  40  and second end  42  of tube  16  face substantially the same direction and terminate adjacent to top portion  44 . Ends  40  and  42  may be attached to top portion  44  of support frame  22 . In this embodiment, first end  40  and second end  42  are both positioned parallel to the longitudinal direction of the plurality of rings to aid with connecting ends  40  and  42  to lines  32  and  34  when heating apparatus  10  is lowered into a reservoir  14  in a longitudinal position. In other embodiments, first end  40  and second end  42  may be attached to different portions of support frame  22  or may remain unattached. 
     In operation, one end of supply line  32  is coupled to heater  12  and the other end of supply line  32  is coupled to first end  40  of outer helical coil  18 . Here, supply line  32  may be coupled to outer helical coil  18  in any manner including by using quick couplers so that supply line  32  may be easily coupled and decoupled from outer helical coil  18 . In other embodiments, supply line  32  may be coupled to a non-corrosive, thermally conductive extender that is coupled to outer helical coil  18  in any manner including by using quick couplers. Outer helical coil  18  runs substantially the entire length of tube  16  and forms the outer surface of tube  16 . Outer helical coil  18  then connects with inner helical coil  20 . In some embodiments, outer helical coil  18  and inner helical coil  20  may be two distinct coils that are connected together in any suitable manner. In other embodiments, outer helical coil  18  and inner helical coil  20  may be formed of one tube  16 . Inner helical coil  20  also runs substantially the entire length of tube  16  and forms the inner surface of tube  16 . Second end  42  of inner helical coil  20  is coupled to one end of return line  34 . Here, return line  34  may be coupled to inner helical coil  20  in any manner including by using quick couplers so that return line  34  may be easily coupled and decoupled from inner helical coil  20 . In other embodiments, return line  34  may be coupled to another non-corrosive, thermally conductive extender that is coupled to inner helical coil  20  in any manner including by using quick couplers. The other end of return line  34  is coupled to heater  12 . It will be appreciated that in other embodiments, heating apparatus  10  may only have one coil  18  and this coil  18  may be connected to both supply line  32  and return line  34 . Similarly, in some embodiments, return line  34  may not connect to heater  12  but may instead remain unattached, may connect to a tank, a well, or any other container or reservoir. 
       FIG. 3  illustrates one embodiment of a support frame  22 , four spacer frames  24   a ,  24   b ,  24   c , and  24   d , and four spacer rods  52   a ,  52   b ,  52   c , and  52   d . In this illustration, inner coil  20  and outer coil  18  are not depicted so as to more clearly show the other elements of heating apparatus  10 . In this embodiment, support frame  22  is a frame comprising a top portion  44 , a body portion  46 , and a base portion  48 . Here, top portion  44  is a rectangular beam. 
     Body portion  46  may be attached to top portion  44  and may be substantially transverse to top portion  44 . In one embodiment, body portion  46  may be attached near the middle of top portion  44 . In one such embodiment, body portion  46  and top portion  44  form a substantially “T” shape. In some embodiments, body portion  46  may be aligned with one or more hooks  26 . Body portion  46  is made of any material. In one embodiment, body portion  46  may be made of a non-corrosive, thermally conductive material such as stainless steel. Body portion  46  may be extendable. In one embodiment, body portion  46  may be made of layered beams so that body portion  46  may be extended by sliding the layered beams. 
     In one embodiment, base portion  48  may be attached to body portion  46 . As one example, base portion  48  may be substantially transverse to body portion  46  and substantially parallel to top portion  44 . In this example embodiment, base portion  46  has four legs  50   a ,  50   b ,  50   c , and  50   d  that are evenly spaced apart from each other. In other embodiments, base portion  46  may have more or less than four legs. Legs  50   a ,  50   b ,  50   c , and  50   d  may be of any width or of any length. In other embodiments, support frame  22  may not have a body portion  46  and base portion  48  may be connected to top portion  44  by coupling one end of a spacer rod  52  to top portion  44  and the other end of spacer rod  52  to base portion  48  of support frame  22  as described below. 
     Spacer rods  52   a - d  may be any rods that keep spacer frames  24   a - d  from sliding off of tube  16  and for connecting top portion  44  to base portion  48 . Spacer rods  52   a - d  may be bald or partially or entirely threaded. Spacer rods  52   a - d  may be made of any material including any thermally conductive non-corrosive material such as stainless steel. In the present embodiment, one end of spacer rods  52   a - d  is coupled to top portion  44  and the other end of spacer rods  52   a - d  is coupled to base portion  48  of support frame  22 . In the present embodiment, spacer frames  24   a - d  are placed so that they are substantially aligned with legs  50   a - d  of base portion  48 . In this manner, spacer rods  52   a  and  52   b  can be placed between outer coil  18  and spacer frame  24   a  and  24   b  and be coupled to top portion  44  as well as legs  50   a  and  50   c  of base portion  48 . Similarly, spacer rods  52   c  and  52   d  can be placed between inner coil  20  and spacer frame  24   c  and  24   d  and be coupled to top portion  44  as well as legs  50   a  and  50   c  of base portion  48 . Spacer rods  52   a - d  may thus prevent coils  18  and  20  from sliding out of spacer frames  24 . In other embodiments, where base portion  48  is not comprised of legs  50 , spacer rod  52  may be connected to any part of base portion  48 . 
       FIG. 4  illustrates one embodiment of a spacer frame  24  and a spacer rod  52 . Spacer frame  24  may be made of any material including any thermally conducting, non-corrosive material such as stainless steel. In this embodiment, spacer frame  24  is a rectangular sheet having a width  152  and a length  154 . Apertures  150  are formed in a line along length  154  of spacer frame  24 . Each aperture  150  is of a rounded rectangular shape with two linear sides and two rounded sides. In other embodiments, apertures  150  may be of any shape. Each aperture is big enough to hold a corresponding ring of helical coil  18  or  20 . In some embodiments, apertures  150  may be larger than the rings of helical coils  18  or  20 . In other embodiments, apertures  150  may be smaller than the rings of helical coil  18  or  20  and may need to be deformed to hold the rings of coils  18  or  20  more tightly. Spacer frame  24  is bent near the middle of width  152  of spacer frame  24  to form a substantially “v” shape with vertices  156 . Vertices  156  may be substantially aligned along the center of each apertures  150 . In other embodiments, spacer frame  24  may be rounded to form a substantially “u” shape with the curved portion. The curved portion of that embodiment may by substantially aligned along the center of each aperture  150 . 
     In operation, spacer frame  24  may be attached to outer helical coil  18  and/or inner helical coil  20  as shown above in  FIG. 2 . When attached to outer helical coil  18 , each ring of outer helical coil  18  may be placed in each aperture  150  so that each ring of outer helical coil  18  is separated from at least one other ring of outer helical coil  18 . Here, vertices  156  may be placed in between outer helical coil  18  and inner helical coil  20 . Spacer rod  52  may be threaded through outer helical coil  18  and vertices  156  of spacer frame  24 . When attached to inner helical coil  20 , each ring of inner helical coil  20  may be placed in each aperture  150  so that each ring of inner helical coil  20  is separated from at least one other ring of inner helical coil  20 . Here, vertices  156  may be placed in between outer helical coil  18  and inner helical coil  20 . Spacer rod  52  may be threaded through inner helical coil  20  and vertices  156  of spacer frame  24 . In both situations, spacer frame  24  may extend from the top portion  44  of support frame  22  to the base portion  48  of support frame  22 . Similarly, in both situations, one end of spacer rod  52  may be coupled to top portion  44  and the other end of spacer rod  52  may be coupled to base portion  48  of support frame  22 . 
       FIG. 5  illustrates a top-down view of an example embodiment of heating apparatus  10  where outer coil  18  and inner coil  20  have substantially planar surfaces  200   a  and  200   b . In the present embodiment, outer coil  18  is formed around inner coil  20  and both coils  18  and  20  are substantially “D” shaped. In other embodiments, outer coil  18  and inner coil  20  may be of different shapes. Although outer coil  18  and inner coil  20  each have one planar surface in the present embodiment, it will be appreciated that in other embodiments, coils  18  and  20  may have multiple planar surfaces. 
     In operation, heating apparatus  10  may be placed on its side so that planar surface  200   a  of heating apparatus  10  is in thermal contact with the contents that need to be heated. Placing the planar surface  200   a  of outer helical coil  18  in thermal contact with the contents may maximize the surface area of tube  16  that comes in contact with the contents. Maximizing the surface area of contact between tube  16  and the contents to be heated may reduce heat loss and increase heat transfer from the heating apparatus  10  to the contents. This embodiment may also prevent heating apparatus  10  from rolling when it is placed horizontally on a frozen surface. 
     Modifications, additions, or omissions may be made to the systems and apparatuses described herein without departing from the scope of the disclosure. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. The methods may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. Additionally, operations of the systems and apparatuses may be performed using any suitable logic. As used in this document, “each” refers to each member of a set or each member of a subset of a set. 
     Although several embodiments have been illustrated and described in detail, it will be recognized that substitutions and alterations are possible without departing from the spirit and scope of the present disclosure, as defined by the appended claims. To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims to invoke 35 U.S.C. §112(f) as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.