Pressure exchanger

Abstract

A pressure exchanger comprises: a rotor which exchanges pressure between a first and a second fluid; a first sealing plate which has a first sealing plate surface which is substantially planar and an opposite second sealing plate surface; a piston structure which extends from the first sealing plate surface to form a substantially planar piston surface which has a first surface area and is substantially parallel to the first sealing plate surface; wherein the first sealing plate and the piston structure form a first hydraulic chamber which passes from a first opening formed on the piston surface to a second opening formed on the second sealing plate surface; the first hydraulic chamber is configured to guide a first fluid at a first pressure to flow between the piston surface and the second sealing plate surface; and a first sealing structure which is configured to connect the second sealing plate surface to a corresponding surface; the first sealing structure forms a first boundary of a first region of the second sealing plate surface; the first region of the second sealing plate surface has a second surface area; a second opening is formed in the first region; and the second surface area is greater than the first surface area.

Description

[0001] This application is a divisional application of a patent application with an application date of February 15, 2022, application number 202280006212.3 (international application number PCT / US2022 / 016483), and invention name “Motorized pressure exchanger with a low-pressure center hole”. Technical Field

[0002] Some embodiments of the present disclosure are generally directed to a motorized pressure exchanger having a low pressure center bore. Background Art

[0003] Well completion in the oil and gas industry typically involves hydraulic fracturing (often referred to as "fracking" or "fracing") to increase the release of oil and gas in a rock formation, thereby providing an oil or gas well. . Hydraulic fracturing involves pumping a fluid (e.g., a fracturing fluid) containing a composition of water, chemicals, and proppants (e.g., sand, ceramics) into a well at high pressure. The high pressure of the fluid increases the size of the cracks and the expansion of the cracks in the rock formation, thereby releasing oil and gas, while the proppants prevent the cracks from closing once the fluid is depressurized. Hydraulic fracturing operations use high-pressure pumps to increase the pressure of the fracturing fluid. Unfortunately, the proppants in the fracturing fluid may interfere with the operation of rotating equipment. In some cases, the solids may slow down or prevent the rotating parts from rotating. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The present disclosure is illustrated in the accompanying drawings by way of example and not by way of limitation, wherein like reference numerals indicate like elements. It should be noted that different references to "one" or "an" embodiment in the present disclosure are not necessarily references to the same embodiment, and such references mean at least one.

[0005] Figure 1 A schematic diagram of a fluid handling system is shown according to some embodiments.

[0006] Figure 2 A perspective view of a hydraulic energy transfer system is shown, according to certain embodiments.

[0007] Figure 3 A cross-sectional view of a hydraulic energy transfer system is shown, according to certain embodiments.

[0008] Figure 4 A perspective view of a cartridge assembly of a hydraulic energy transfer system is shown, according to certain embodiments.

[0009] Figure 5 An exploded view of a cartridge assembly of a hydraulic energy transfer system is shown, according to certain embodiments.

[0010] Figure 6 A cross-sectional view of a cartridge assembly of a hydraulic energy transfer system is shown, according to certain embodiments.

[0011] Fig. 7A -B illustrates a sealing plate of a cartridge assembly according to certain embodiments.

[0012] Fig. 8A -B illustrates an end cap of a cartridge assembly according to certain embodiments.

[0013] Fig. 9A -B illustrates an end cap of a cartridge assembly according to certain embodiments.

[0014] Fig. 10A -B illustrates a sealing plate of a cartridge assembly according to certain embodiments. DETAILED DESCRIPTION

[0015] Embodiments described herein relate to powered hydraulic power transfer systems.

[0016] Many industrial processes operate at high pressure and have high pressure waste streams. One way to provide high pressure to an operation that requires high pressure is to transfer pressure from a high pressure fluid (e.g., a high pressure waste fluid) to a usable fluid (e.g., a fracturing fluid) for the high pressure operation. A particularly effective type of pressure exchange is a rotary pressure exchanger. A rotary pressure exchanger uses a cylindrical rotor with longitudinal channels aligned parallel to the axis of rotation. The rotor rotates in a sleeve enclosed by two end caps. Pressure energy is directly transferred from the high pressure stream to the low pressure stream in the channels of the rotor. Some of the fluid retained in the channels acts as a barrier to prevent mixing between the streams. As the pressure transfer process is repeated, the channels of the rotor are also filled and discharged.

[0017] High pressure fluid entering a pressure exchanger causes components of the pressure exchanger (e.g., seals) to be under high pressure. Conventional pressure exchangers are limited in the amount of pressure that can be transferred between fluids. In some conventional pressure exchangers, the seals limit the amount of pressure that can be transferred (e.g., the pressure of the high pressure fluid cannot be higher than the pressure that the seals can support). In some conventional pressure exchangers, one or more additional components (e.g., pressure compensators, canned motors, etc.) are used to help compensate for the seals. The manufacture of the additional components and the coupling of the additional components to the pressure exchanger are additional costs, are additional components that may fail, and are not readily available.

[0018] The devices and systems disclosed herein provide a hydraulic energy transfer system (e.g., a rotary isobaric exchanger (IPX)) that is capable of operating with a high pressure influent fluid (e.g., above 15 kilopounds per square inch (ksi), or up to the pressure of the influent fluid) while maintaining a central bore at a low pressure (e.g., below 150 pounds per square inch (psi), or as low as the outfluent fluid). The hydraulic energy transfer system may include a low pressure port designed to receive a first fluid at a first pressure. The hydraulic energy transfer system may further include a rotor fluidly coupled to (e.g., in a flow path of the low pressure port). The rotor may form a group of rotating longitudinal channels designed to receive and exchange pressure between a first fluid and a second fluid. The hydraulic energy transfer system may also include an axis passing through the central bore formed by the hydraulic energy transfer system. The axis may be attached to the rotor. The hydraulic energy transfer system may form a low pressure passage from the low pressure port to an opening of one of the channels in the channel group of the rotor. The hydraulic energy transfer system may further form a fluid passage from the low pressure passage to the central bore. The fluid passage may result in the central bore and the shaft being at a low pressure (eg, lower than the pressure of the first inflowing fluid which is at a high pressure).

[0019] In some embodiments, a hydraulic energy transfer system (e.g., a rotary IPX) may include an assembly (e.g., a cartridge assembly) having a first sealing plate that forms a first hydraulic chamber (e.g., a hydraulic chamber structure) to receive a first fluid at a first pressure. The assembly may also include a first end cap connected to the first sealing plate, the first end cap forming a first set of orifices configured to direct a first fluid flow from the first hydraulic chamber into a first side of a rotor via the first set of orifices. The assembly may further include a rotor connected to the first end cap, the rotor may form a set of rotating longitudinal channels to receive a first fluid from the first end cap on one side of the rotor, receive a second fluid on a second side of the rotor, and exchange pressure between the first fluid and the second fluid. The assembly may also include a shaft passing through a central hole formed by the assembly. The shaft may be attached to the rotor. The assembly may form a fluid passage from the first hydraulic chamber to the central hole. The first pressure of the first hydraulic chamber may be transmitted to the central hole formed by the first sealing plate, the first end cap, and the rotor via the fluid passage. The first pressure may be a low pressure (e.g., 150 psi) to maintain the central hole at a low pressure when the rotor is running.

[0020] The devices and systems disclosed herein have advantages over conventional solutions. The hydraulic energy transfer system can have a low-pressure center hole (e.g., less than 150psi, or substantially equivalent to the low-pressure fluid entering the system) in a rotary IPX, which operates with an inflow of high-pressure fluid (e.g., 15ksi, or substantially equivalent to the inflow of high-pressure fluid). The low-pressure center hole allows the use of easy-to-procure, compact, reliable shaft seals without the need for custom manufacturing or design of conventional pressure compensators and / or shielded motor system combinations. The low-pressure center hole allows for more diverse shaft seals and / or motor systems that can be coupled to the rotary IPX, such as sealing systems and motor systems designed for various operations and functionality. The low-pressure center hole can also allow instruments to pass through the low-pressure center hole, which is impossible in the high-pressure center hole. This can include real-time measurements in the rotary IPX. For example, diagnostic measurements can be performed while the rotary IPX is running.

[0021] Figure 1A schematic diagram of a fluid handling system 110 including a hydraulic energy transfer system 102 (e.g., a rotary IPX) and a motor system 104 is shown according to certain embodiments. The fluid handling system 100 (e.g., a fracturing system or a hydraulic fracturing system) includes the hydraulic energy transfer system 102, the motor system 104 coupled to the hydraulic energy transfer system 102, a first fluid pump 106, and a second fluid pump 108. The hydraulic energy transfer system 102 transfers work and / or pressure between a first fluid (e.g., a pressure exchange fluid, such as a proppant-free fluid) and a second fluid (e.g., a fracturing fluid, such as a proppant-laden fluid). The first fluid may include: a low pressure (LP) proppant-free fluid output 116, which is directed from the hydraulic energy transfer system 102; and a high pressure (HP) proppant-free fluid input 114, which is directed from the first fluid pump 106 to the hydraulic energy transfer system 102. The second fluid may include: a low pressure (LP) fracturing fluid input 118, which is directed to the hydraulic energy transfer system 102; and a high pressure (HP) fracturing fluid output 120, which is directed from the hydraulic energy transfer system 102 to the fracturing site (e.g., the rock formation 110). These fluids may be multiphase fluids, such as gas / liquid flows, gas / solid particle flows, liquid / solid particle flows, gas / liquid / solid particle flows, or any other multiphase flows. For example, the multiphase fluid may also be a non-Newtonian fluid (e.g., a shear thinning fluid), a high viscosity fluid, a non-Newtonian fluid containing a proppant, or a high viscosity fluid containing a proppant. In addition, the first fluid may be at a pressure of about 5000 kPa to 25000 kPa, 20000 kPa to 50000 kPa, 40000 kPa to 75000 kPa, 75000 kPa to 100000 kPa, and / or greater than the second pressure of the second fluid. The hydraulic energy transfer system 102 may or may not completely equalize the pressure between the first fluid and the second fluid. Therefore, the hydraulic energy transfer system 102 may operate isobarically or substantially isobarically.

[0022] The hydraulic energy transfer system 102 may also be described as a hydraulic protection system, a hydraulic buffer system, or a hydraulic isolation system because the hydraulic energy transfer system 102 can block or limit contact between the fracturing fluid and various hydraulic fracturing equipment (e.g., a high pressure pump, a second fluid pump 108) while still exchanging work and / or pressure between the first fluid and the second fluid. By blocking or limiting contact between various hydraulic fracturing equipment and the second fluid (e.g., a fluid containing a proppant). In addition, the hydraulic energy transfer system 102 is capable of enabling a hydraulic fracturing system, for example, a high pressure pump that is not designed for abrasive fluids (e.g., fracturing fluids and / or corrosive fluids). In some embodiments, the hydraulic energy transfer system may be a rotary isobaric pressure exchanger (e.g., a rotary PX). A rotary isobaric pressure exchanger may generally be defined as a device that transfers fluid pressure between a high pressure inlet flow and a low pressure inlet flow at an efficiency of more than about 50%, 60%, 70%, 80%, or 90% without using centrifugal technology. Centrifugal technology may include a device that rotates a fluid at high speed to separate fluids of different densities. The fluid is forced outward in a radial direction around a central axis of rotation. The notations for the "first" fluid and the "second" fluid are exemplary only and are not intended to identify or limit each fluid to any particular limitation herein.

[0023] In some embodiments, the hydraulic energy transfer system 102 may include or be part of a refrigeration system that uses a fluid in a supercritical state (eg, a transcritical carbon dioxide refrigeration system). For example, the first and / or second fluid may include a refrigerant (eg, carbon dioxide).

[0024] To facilitate rotation, the hydraulic energy transfer system 102 can be connected to a motor system 104 (e.g., an off-board motor system), or can include a motor system 104 in a housing of a hydraulic energy transfer system (e.g., an onboard motor system). For example, the motor system may include an electric motor, a hydraulic motor, a pneumatic motor, another rotary drive, or any combination thereof. In operation, the motor system 104 enables the hydraulic energy transfer system 102 to rotate with high viscosity and / or fluids with solid particles, powders, debris, etc. For example, the motor system 104 can help start with a high viscosity or particle-laden fluid, which enables the hydraulic energy transfer system 102 to be started quickly. The motor system 104 can also provide additional force that enables the hydraulic energy transfer system 102 to wear through the particles to maintain an appropriate operating speed (e.g., rpm) with a high viscosity / particle-laden fluid. In addition, the motor system 104 can also substantially expand the operating range of the hydraulic energy transfer system 102. For example, the motor system 104 can enable the hydraulic energy transfer system 102 to operate with good performance at lower or higher flow rates than a "freewheel" hydraulic energy transfer system without a motor system because the motor system 104 can help control the speed (e.g., rotational speed) of the hydraulic energy transfer system 102 and control the degree of mixing between the first fluid and the second fluid. For example, during a well completion operation, the fluid treatment system 100 pumps a pressurized particle-laden fluid that increases the release of hydrocarbons in the rock formation 110 by propagating and increasing the size of the fractures 112. In order to prevent the fractures 112 from closing once the fluid treatment system 100 is depressurized, the fluid treatment system 200 uses a fluid with solid particles, powders, debris, etc., which enter the fractures 112 and keep them open.

[0025] To pump the particle-laden fluid into the well, the fluid handling system 100 may include one or more first fluid pumps 106 and one or more second fluid pumps 108, the first fluid pumps and the second fluid pumps being coupled to the hydraulic energy transfer system 102. For example, the hydraulic energy transfer system 102 may be a rotary IPX. In operation, the hydraulic energy transfer system 102 transfers pressure between a first fluid (e.g., a fluid without proppant) pumped by the first fluid pump 106 and a second fluid (e.g., a fluid containing proppant or a fracturing fluid) pumped by the second fluid pump 108 without any substantial mixing between the two. In this way, the hydraulic energy transfer system 102 blocks or limits wear on the first fluid pump 106 (e.g., a high-pressure pump) while enabling the fluid handling system 100 to pump a high-pressure fracturing fluid into the well (e.g., a rock formation 110) to release oil and gas. To operate in a corrosive and abrasive environment, the hydraulic energy transfer system 102 may be made of a material that is resistant to corrosive and abrasive substances in the first fluid and the second fluid. For example, the hydraulic energy transfer system 102 may be made of a ceramic (e.g., alumina, a cermet such as a carbide, oxide, nitride, or boride hard phase) within a metal matrix (e.g., Co, Cr, or Ni, or any combination thereof), such as tungsten carbide in a CoCr, Ni, NiCr, or Co matrix.

[0026] The hydraulic energy transfer system 102 may include a low pressure port configured to receive a first fluid at a first pressure. The hydraulic energy transfer system 102 may further include a rotor (eg, Figure 3 The hydraulic energy transfer system 102 may further include a shaft (eg, a rotor 304) extending through a central hole formed by the hydraulic energy transfer system 102. Figure 3 The shaft 302 can be attached to the rotor. The hydraulic energy transfer system 102 can form a low pressure passage from the low pressure port to the rotor. The hydraulic energy transfer system 102 can further form a fluid passage from the low pressure passage to the central hole. The fluid passage can cause the central hole and the shaft to be at a low pressure (e.g., lower than the pressure of the first inflow fluid at a high pressure).

[0027] Figure 2 A perspective view of a hydraulic energy transfer system 200 (eg, a rotary IPX) is shown according to certain embodiments. Figure 2The number of some elements of the other figures may be the same, and these elements may be substantially similar to those elements having the same number in the other figures. The hydraulic energy transfer system 200 may include a rotor enclosed by a central container 208. The central container 208 may be coupled to (e.g., connected, adhered to, or in contact with) the housing 210A and the housing 210B through seals 206A-B. The hydraulic energy transfer system 200 may also include ports 204A-D and a motor system 202.

[0028] like Figure 2 As shown, the hydraulic energy transfer system 200 may include ports 204A-D. In some embodiments, a first pair of ports 204A-B are disposed on a first side of the hydraulic energy transfer system 200, and a second pair of ports 204C-D are disposed on a second side of the hydraulic energy transfer system. In some embodiments, a first fluid (e.g., a proppant-free fluid) and / or a second fluid (e.g., a proppant-containing fluid or a fracturing fluid) are received and output on the same side of the hydraulic energy transfer system 200. For example, port 204B may receive a first fluid and port 204A may output the first fluid. Port 204C may input a second fluid and port 204D may output the second fluid. In some embodiments, a high-pressure first fluid enters a port (e.g., ports 204A-B) on a first side of the hydraulic energy transfer system 200 and transfers pressure to a second fluid that enters a port (e.g., ports 204C-D) on a second side of the hydraulic energy transfer system 200. The high-pressure second fluid may be output through a port (e.g., ports 204C-D) on a second side of the hydraulic energy transfer system 200. It should be noted that the role of each port 204A-D may be interchangeable based on the desired flow paths of the first and second fluids.

[0029] In some embodiments, ports 204A-B can be integrated into housing 210A, while ports 204C-D can be integrated into housing 210B. Pressure from the first fluid and the second fluid enclosed by hydraulic energy transfer system 200 can be applied to the housing. For example, the housing can experience compressive forces generated by the pressurized first fluid and the pressurized second fluid entering and exiting ports 204A-D.

[0030] like Figure 2 As shown, the housing 210A-B is coupled to the central container 208 via a seal. The seals 206A-B may include fluid seals (e.g., piston seals, rod seals, wiper seals, wear rings, clamps, washers, etc.) that prevent the first fluid and the second fluid from flowing through the contact surface provided between the housing 210A-B and the central container 208. In some embodiments, the central container 208 is selectively coupled to the housing 210A-B so that the central container 208 can be easily removed, replaced, repaired, and / or reinstalled.

[0031] like Figure 2 As shown, the motor system 202 is coupled to the housing 210A. As further discussed in other embodiments, the motor system 202 facilitates operation of the rotor enclosed by the center housing 208 by providing torque for grinding through particles, maintaining the operating speed of the rotor, controlling fluid mixing within the hydraulic energy transfer system 200 (e.g., changing the rotational speed of the rotor enclosed within the center container 208), or starting the rotor with a high viscosity or particle laden fluid.

[0032] In some embodiments, one of the ports 204A-D may be a low pressure port designed to receive a first fluid at a first pressure. The hydraulic energy transfer system 200 may further include a rotor (e.g., disposed in the central reservoir 208) fluidly coupled to (e.g., in a flow path of the low pressure port). The hydraulic energy transfer system 200 may also include a shaft (e.g., disposed in the central reservoir 208) extending through a central bore formed by the hydraulic energy transfer system 200. Figure 3 The shaft 302 can be attached to the rotor. The hydraulic energy transfer system 200 can form a low pressure passage from the low pressure port to the rotor. The hydraulic energy transfer system 200 can further form a fluid passage from the low pressure passage to the central hole. The fluid passage can cause the central hole and the shaft to be at a low pressure (e.g., lower than the pressure of the first inflow fluid at a high pressure).

[0033] In some embodiments, the hydraulic energy transfer system 200 can be a fracturing system. However, it should be understood that the hydraulic energy transfer system 200 can be any suitable system capable of handling abrasive (e.g., particle-laden) fluids. For example, the hydraulic energy transfer system 200 can be configured for fluid delivery for water injection, for well recovery, and for use of the hydraulic energy transfer system 200 as a pump. In embodiments where the fluid handling system is a fracturing system, the fracturing system pumps pressurized particle-laden fluids that increase hydrocarbon release in a formation by propagating and increasing the size of fractures.

[0034] Figure 3 A hydraulic energy transfer system 300 (eg, Figure 2 Hydraulic energy transmission system 200, Figure 1 A cross-sectional view of a hydraulic energy transmission system 102, etc. Figure 3 The number of some elements of the hydraulic energy transfer system 300 may be the same as that of the other figures, and these elements may be substantially similar to those elements having the same number in the other figures. The hydraulic energy transfer system 300 may include the motor system 202 coupled to the housing end cap 312A via a shaft 302. The shaft 302 may be disposed in a central bore formed by the hydraulic energy transfer system 300. The central bore (in Figure 3, enclosed with shaft 302) may include a shaft seal 308 that seals fluid from the motor side of the center bore and fluid from the rotor side of the center bore. The hydraulic energy transfer system includes a housing end cap 312A that integrates ports 204A-B and a housing end cap 312B that integrates ports 204C-D. The hydraulic energy transfer system may also include a central container 208 disposed between the housing end caps 312A-B. The central container 208 may enclose a cartridge assembly 310. In some embodiments, the housing end caps 312A-B are integrated together to form a single housing that encloses the cartridge assembly 310. Alternatively or additionally, the housing end caps 312A-B may be integral with the central container 208 (e.g., to completely enclose the cartridge assembly).

[0035] like Figure 3 As shown, the hydraulic energy transfer system 300 may include one or more adapter plates 362A-B. One or more adapter plates 362A-B may be coupled to (e.g., connected, adhered to, or in contact with) one or more housing end caps 312A-B. For example, the adapter plates 362A-B and the housing end caps 312A-B may be coupled together using fasteners, adhesives, or other bonding techniques known in the art (e.g., welding, brazing, riveting, etc.). Alternatively, the adapter plates 362A-B may be integral with the housing end caps 312A-B. One or more adapter plates 362A-B may include a recess or hole configured to receive the cartridge assembly 310. For example, the cartridge assembly may include one or more pistons (e.g., piston 324) that allow the cartridge assembly 310 to move axially relative to the housing end caps 312A-B within the center container 208.

[0036] like Figure 3As shown, and as will be discussed in more detail in conjunction with other figures, the hydraulic energy transfer system 300 includes a cylinder assembly 310. The cylinder assembly 310 may include a piston 324. In some embodiments, the hydraulic energy transfer system 300 may include more pistons in addition to the piston 324. The piston 324 may be coupled to one or more sealing plates 314A-B. For example, the piston 324 may be coupled to, combined with, or integrated into the sealing plate 314A. The sealing plate 314A may be coupled to an end cap 316A. The end cap 316A may be coupled to a sleeve 360. The sleeve 360 ​​may be coupled to the end cap 316B. The end cap 316B may be coupled to the sealing plate 314B. The sleeve 360 ​​may enclose the rotor 304. In some embodiments, the cartridge assembly 310 is adapted to receive a first fluid from ports 204A-B (e.g., a high-pressure first fluid may enter through port 204A and a low-pressure first fluid may exit from port 204B) and a second fluid from ports 204C-D (e.g., a low-pressure second fluid may enter through port 204D and a high-pressure second fluid may exit through port 204B). The cartridge assembly is also used to transfer pressure from one of the high-pressure first fluids to the low-pressure second fluid or to transfer the high-pressure second fluid to the high-pressure first fluid. It should be noted that the flow paths of the high-pressure and low-pressure fluids and the first and second fluids may be generalized to any port 204A-D and any hydraulic chamber 326A-B, without being limited to the specific flow paths identified herein. It should also be noted that the use of "first" and "second" is exemplary, and the limitations described for the first fluid may apply to the second fluid.

[0037] In some embodiments, the hydraulic energy transfer system 300 includes a piston 324. The piston can be coupled to the adapter plates 362A-B and / or the seal plates 314A-B. The piston can be adapted to allow the cartridge assembly to move axially relative to the adapter plates 312A-B while maintaining a seal between the cartridge assembly 310 and the adapter plates 362A-B. For example, the piston 324 can be moved toward or away from the adapter plates 362A-B axis to increase the compressive force on the cartridge assembly 310 and to move the cartridge assembly 310 laterally between the housing end caps 312A-B.

[0038] like Figure 3 As shown, the hydraulic energy transfer system 300 forms a passage 330 (e.g., a low pressure passage). The passage 330 can be disposed between the port 204B and the sealing plate 314A. For example, the passage 330 can transfer fluid from the port 204B to the hydraulic chamber 326A. In another example, the passage 330 can transfer fluid from the hydraulic chamber 436A to the port 204B. In some embodiments, the passage 330 transfers high pressure fluid (e.g., the pressure of the highest pressure fluid entering the system) or low pressure fluid (e.g., the pressure of the lowest pressure fluid entering the system).

[0039] like Figure 3 As shown, the hydraulic energy transfer system 300 forms a fluid passage 306 disposed between the passage 330 and the central bore 352. For example, the fluid passage 306 can allow fluid to pass between the passage 330 and the central bore 352 (e.g., on the rotor side of the shaft seal 308 or the motor side of the shaft seal 308). The fluid passage 306 can be formed by one or more of the housing end caps 312A-B, the piston 324, the seal plates 314A-B, the end covers 316A-B, and / or the rotor 304. The fluid passage 306 allows fluid to flow between the passage 330 and the central bore 352 (e.g., on the rotor side of the shaft seal 308 or the motor side of the shaft seal 308). The fluid passage 330 can be disposed between one of the ports 204A-D and the rotor 304. In some embodiments, the pressure of the fluid disposed in the fluid passage 306 is transmitted to the shaft and flows through the orifices in the seal plate 314A, the end cover 316A, and / or the rotor 304. In some embodiments, the fluid passage 306 is formed between the center hole 352 formed by the system and the piston 324, the port 204B and / or the passage 330. The center hole 352 may include a passage formed by one or more components of the hydraulic energy transfer system 300. The center hole 352 may include substantially the same diameter. The center may be designed to receive the shaft 302. There may be a gap between the surface of the shaft 302 and the center hole 352. For example, the shaft 302 may be designed to rotate, and the center hole 352 may provide enough space to eliminate contact between the shaft 302 and the surface of the center hole 352.

[0040] like Figure 3 As shown, the hydraulic energy transfer system 300 includes the motor system 202. As shown, the motor system 202 includes a shaft 302, which is coupled to the rotor 304 through a housing end cap 312A. Specifically, the shaft 302 can pass through an aperture in the housing end cap 312A, an aperture in the sealing plate 314A, an aperture in the end cover 316A, and enter the aperture of the rotor 304. The aperture formed by one or more of the housing end cap 312A, the sealing plate 314A, the end cover 316A, the rotor 304, the end cover 316B, the sealing plate 314B and / or the housing end cap 312B can form a central hole 352 of the system. The sealing plate 314A and the end cover 316A can form corresponding portions of the central hole 352 formed by the hydraulic energy transfer system 300. To facilitate the rotation of the shaft 302, the motor system 202 can also include one or more bearings 320A-B supporting the shaft 302. The bearing 320A may be disposed within or outside the housing end caps 312A-B. In some embodiments, the shaft 302 may extend completely through the rotor 304 and the end cap 316B. This may enable the shaft 302 to be supported on the opposite side of the rotor 304 by the end cap 316B and / or the seal plate 314B.

[0041] In operation, the motor system 202 facilitates the operation of the rotor 304 by providing torque for grinding through particles, maintaining the operating speed of the rotor 304, controlling the mixing of fluids within the hydraulic energy transfer system 300 (e.g., changing the rotational speed of the rotor 304), and / or starting the rotor 304 with a high viscosity or particle-laden fluid. The motor can be coupled to a controller (not shown) that uses feedback from sensors to control the motor system. The controller can include a processor and a memory (not shown) that stores non-transitory computer instructions that can be executed by the processor. For example, when the controller receives feedback from one or more sensors, the processor executes instructions stored in the memory to control the power output from the motor system.

[0042] In some embodiments, a controller using sensor feedback can control the degree of mixing between the first fluid and the second fluid in the hydraulic energy transfer system 300, which can be used to improve overall operability. For example, changing the ratio of the first fluid and the second fluid entering the hydraulic energy transfer system 300 allows the operator to control the amount of fluid mixing that occurs within the system. Three features of the rotary IPX that affect mixing are: (1) the aspect ratio of the rotor channel 322, (2) the short exposure duration between the first fluid and the second fluid, and (3) the formation of a fluid barrier (e.g., an interface) between the first fluid and the second fluid within the rotor channel 322. First, the rotor channel 322 is generally long and narrow, which stabilizes the flow within the rotary IPX. In addition, the first fluid and the second fluid can move through the channel 322 in a plug flow state with minimal axial mixing. Second, in some embodiments, the speed of the rotor 304 reduces the contact between the first fluid and the second fluid. For example, the speed of the rotor 304 can reduce the contact time between the first fluid and the second fluid to less than about 0.15 seconds, 0.10 seconds, or 0.05 seconds. Third, a small portion of the rotor passage 322 is used for pressure exchange between the first fluid and the second fluid. A certain volume of fluid is retained in the passage 322 as a barrier between the first fluid and the second fluid. All these mechanisms can limit the mixing in the barrel assembly 310. In addition, in some embodiments, the barrel assembly 310 can be designed to operate with one or more internal pistons, which isolate the first fluid and the second fluid and achieve pressure transmission simultaneously.

[0043] Figure 4 A hydraulic energy transfer system (eg, Figure 2-3 A stereoscopic view of a cylinder assembly 400 of a hydraulic energy transfer system 200-300, or a rotary IPX). Figure 4The number of some elements of the cylinder assembly 400 may be the same as that of the other figures, and the elements may be substantially similar to those elements having the same number in the other figures. The cylinder assembly 400 transfers pressure and / or work between a first fluid and a second fluid (e.g., a proppant-free fluid and a proppant-containing fluid) with minimal mixing between the fluids. In some embodiments, the cylinder assembly 400 is a hydraulic energy transfer system (e.g., Figure 2-3 A selectively removable element of a hydraulic energy transfer system 200-300).

[0044] As shown in FIG. Figure 4 As shown, the barrel assembly may have a cylindrical body including a rotor sleeve 402, a pair of end caps 404A-B, and a pair of sealing plates 406A-B. The barrel assembly 400 may include a rotor sleeve 402. The rotor sleeve 402 includes a generally cylindrical structure. In some embodiments, the rotor sleeve 402 may include a recess or inlet disposed along the periphery of the cylindrical structure to receive a fixing device (e.g., compression rods 430A-C). The rotor sleeve 402 may enclose a rotor device (e.g., Figure 5 502 of the rotor). The rotor sleeve 402 may contact the first end cap 404A on a first side and the second end cap 404B on a second side. The end caps may include a cylindrical structure. In some embodiments, the diameter of the end caps 404A-B is substantially equal to the diameter of the rotor sleeve 402. The rotor sleeve 402 may include one or more substantially flat surfaces to contact the end caps 404A-B. For example, the rotor sleeve may be coupled to and held together by a friction fit at the contact surface between the rotor sleeve 402 and the end caps 404A-B. The contact surface between the rotor sleeve 402 and the end caps 404A-B may include a coating or abrasive texture that promotes friction between the rotor sleeve 402 and the end caps 404A-B. The contact surface between the rotor sleeve and the end caps may form a seal to prevent the first fluid and the second fluid from leaving the barrel assembly between the rotor sleeve 402 and the end caps 404A-B. In some embodiments, the rotor sleeve 402 and the end caps 404A-B may be coupled together using fasteners, adhesives, or other bonding techniques known in the art (e.g., welding, brazing, riveting, etc.). In some embodiments, the contact surfaces between the sealing plates 406A-B and the end caps 404A-B and the contact surfaces between the end caps and the housing (e.g., Figure 3 The contact surface between the adapter plates 362A-B or the housing end caps 312A-B).

[0045] In some embodiments, the end caps 404A-B are configured or adapted to direct the first fluid and the second fluid into and out of the rotor enclosed by the rotor sleeve 402. As will be discussed further, the end caps 404A-B may each include a surface adapted to couple with the rotor enclosed by the rotor sleeve 402. The end caps may have a cylindrical shape (e.g., similar to the rotor sleeve). The end caps 404A-B are coupled to the sealing plates 406A-B. The coupling of the end caps 404A-B and the sealing plates 406A-B may include similar coupling techniques disclosed with respect to the coupling between the rotor sleeve 402 and the end caps 404A. In addition, the sealing plates 406A-B may form a seal between the end caps 404A-B and the sealing plates 406A-B. The sealing plates 406A-B may also include a cylindrical structure.

[0046] like Figure 4 As shown, the barrel assembly 400 may include one or more seals 408 (e.g., face seals, barrel seals, radial shaft seals, O-rings, etc.) disposed on one or more ends of the barrel assembly. The one or more seals 408 may couple or connect the barrel assembly 400 to a hydraulic energy transfer system (e.g., Figure 2-3 4. In some embodiments, the one or more seals 408 may couple the cartridge assembly 400 to the housing of the hydraulic energy transfer system 200-300 using a friction fit. For example, the pressure of the first fluid and the second fluid may apply a force (e.g., a compressive force) on the housing of the hydraulic energy transfer system and / or the cartridge assembly to create a friction interface between the hydraulic energy transfer system and the cartridge assembly that creates a seal and holds the cartridge assembly 400 in place. For example, pressurizing the first fluid and pressurizing the second fluid may result in a compressive force toward the longitudinal center of the cartridge assembly 400.

[0047] In some embodiments, the cartridge assembly 400 is designed to generate a net force in the longitudinal direction of the assembly. For example, the cartridge assembly 400 may include Figure 4406A, and the second side of the sealing plate 406B depicted in the figure. The compression force may be suitable for providing a net force pointing to the first side or the second side of the barrel assembly. This may cause sealing plate 406A, end cap 404A, rotor sleeve 402, end cap 406B and / or sealing plate 406B to be subjected to the force from adjacent elements, so that each element is compressed and forms a seal with each adjacent element. For example, due to the net force, sealing plate 406 may form a seal to the end cap. In certain embodiments, the net force generated on barrel assembly 400 causes friction fit between elements (e.g., sealing plate 406A, end cap 404A, rotor sleeve 402, end cap 406B and sealing plate 406B). For example, the friction force generated by the net force applied by barrel assembly 400 may keep each of these elements in place. In certain embodiments, alignment pins may be used to hold these elements together.

[0048] In some embodiments, the sealing plates 406A-B, the end caps 404A-B, and the sleeve are held together by a compression force based on the pressurized fluid flowing through the barrel assembly 400. In some embodiments, the barrel assembly 400 may include one or more compression rods 430A-C. The compression rods 430A-C may include fasteners that are fixed to one or more ends of the compression rods 430A-C and are coupled to the sealing plates 403A-C, the end caps 404A-B, and / or the rotor sleeve 402. The compression rods 430A-C may be suitable for compressing the barrel assembly 400 together. For example, a central compression force is applied to the sealing plates 406A-B against the end caps 404A-B, and a compression force is applied to the end caps 404A-B against the rotor sleeve 402. In some embodiments, the barrel assembly is held together by a combination of fluid compression force and external compression force (e.g., using compression rods 430A-C). The rotor sleeve 402 enables the enclosed rotor to rotate about the central axis when the barrel assembly 400 is compressed together.

[0049] In some embodiments, the cartridge assembly 400 is enclosed by a fluid disposed in a cavity formed between the housing of the hydraulic energy transfer system and the cartridge assembly 400. The fluid may include a fluid carrier including a thin layer of pressurized liquid and / or gas rapidly moving between a surface of the cartridge assembly 400 and the housing of the hydraulic energy transfer system.

[0050] like Figure 4 As shown, one or more of the sealing plates 406A-B may be a piston 412 disposed on the distal end of the radial surface of the cylindrical protruding structure of the sealing plate 406A. As discussed in other embodiments, the sealing plates 406A-B include a surface for applying pressure. The piston 412 is configured to slide axially through a connection point (e.g., an adapter plate (e.g., Figure 3The adapter plate 362A may include a recess or hole to allow the cartridge assembly 400 to be coupled to a hydraulic energy transfer system (e.g., Figure 2-3 The housing of the hydraulic energy transfer system 200-300 (e.g., Figure 3 relative movement between the housing end caps 312A-B).

[0051] In some embodiments, the sealing plate 406A can form a high-pressure hydraulic chamber (e.g., 410B) and a low-pressure hydraulic chamber (e.g., 410A). The high-pressure hydraulic chamber (e.g., 410B) can enclose one of the first fluid or the second fluid at a high pressure (e.g., about 15000 ksi), while the low-pressure hydraulic chamber (e.g., 410A) can contain one of the first fluid or the second fluid at a low pressure (e.g., 150 psi). In some embodiments, the high-pressure hydraulic chamber and the low-pressure hydraulic chamber enclose the same fluid, however, in other embodiments, the high-pressure hydraulic chamber can contain one of the first fluid or the second fluid, while the low-pressure hydraulic chamber can contain the first fluid or the other of the first fluid that is not contained in the high-pressure hydraulic chamber.

[0052] As further discussed in other embodiments, the seal plates 406A-B can be designed so that the pressurized fluid in the hydraulic chambers 410A-B generates a force substantially similar to the opposing internal cylinder force (e.g., to reduce the net force on the end caps 404A-B). Reducing the net force on the end caps can reduce the deflection of the bearing surface of the rotor disposed within the rotor sleeve 402. It should be noted that as a result of the low pressure center hole 416 (e.g., provided by the fluid passage 418), forces can be generated that can change the seal and contact points between the seal plates 406A-B, the end caps 404A-B, and the rotor sleeve 402. The seal plates are designed to resist these forces to minimize the net force on the end caps 404A-B. The efficiency of pressure transfer between the first fluid and the second fluid can be improved by minimizing the deflection caused by the net force (e.g., pressure imbalance) on the end caps 404A-B.

[0053] The cartridge assembly 400 may further include a central bore 416 and a shaft seal 420. In some embodiments, the shaft seal 420 is disposed within the housing (e.g., Figure 3416A). In some embodiments, the barrel assembly 400 can form a fluid passage 418 (e.g., a fluid passage structure) that is hydraulically connected to the shaft and the hydraulic chamber 410A. In other embodiments, the fluid passage 418 can be formed by one or more of the housing end caps 312A-B, the piston 324, the sealing plates 314A-B, the end caps 316A-B, and / or the rotor 304. The fluid passage 418 allows fluid to flow between the hydraulic chamber 410A and the center hole 416. In some embodiments, the pressure of the fluid disposed in the fluid passage 418 is communicated to the center hole 416 and flows through an orifice in one of the sealing plate 406A, the end cap 404A, the rotor 430C, the end cap 404B, and the sealing plate 406B. In some embodiments, the fluid passage 418 is formed between the center hole 416 formed by the barrel assembly 400 and the piston 412 and / or the hydraulic chamber 410A. The fluid passage 418 transmits the pressure from the sealing plate (e.g., the pressure of the fluid in one of the hydraulic chambers 410A-B) to the central hole 416 disposed along the central axis of the barrel assembly 400. The fluid passage 418 may be formed by machining or drilling through a recess of one of the piston 412, the sealing plate 406A, the end cap 404A, the rotor disposed within the rotor sleeve 402, the end cap 404B, the sealing plate 406B, or any combination thereof. In some embodiments, the diameter of the fluid passage 418 may be within 1-3 cm.

[0054] In some embodiments, the diameter of the fluid passage 418 is substantially uniform. In some embodiments, the diameter of the fluid passage is smaller than one of the fluid passages between the hydraulic chamber 410A and the rotor disposed within the rotor sleeve 402. In some embodiments, the hydraulic chamber 410A encloses a first or second fluid and transmits the pressure of the fluid enclosed in the hydraulic chamber to the center hole 416. For example, the hydraulic chamber 410A can enclose a low pressure (150psi) fluid. The fluid transmits the low pressure to the center hole 416. The barrel assembly can form a center hole 416 that encloses the shaft. The center hole 416 can pass through the sealing plate 406A, the end cover 404A, and the rotor enclosed within the rotor sleeve 402. The center hole 416 can be suitable for receiving a motor system (e.g., Figure 1 The central bore 416 may further include a shaft seal 420 that seals and separates a portion of the central bore 416 that is enclosed by the barrel assembly 400 and a portion of the central bore 416 that is disposed outside the barrel assembly 400 (e.g., Figure 3 For example, the shaft seal can isolate a first area of ​​the central bore 416 proximate to the rotor enclosed by the rotor sleeve 402 from a second area of ​​the central bore 416 outside the barrel assembly 400 .

[0055] In operation, hydraulic chambers 410A-B enable a first fluid and a second fluid (e.g., a proppant-free fluid) to enter and exit the barrel assembly. One of hydraulic chambers 410A-B can receive a high-pressure first fluid, and after exchanging pressures, the other hydraulic chamber 410A-B can be used to discharge a low-pressure fluid out of the barrel assembly 400. The barrel assembly can also include a hydraulic chamber (not shown) on the lower side (near seal 308) opposite hydraulic chambers 410A-B. The hydraulic chamber on the lower side can be configured to receive one of the first fluid or the second fluid.

[0056] Figure 5 A hydraulic energy transfer system (eg, Figure 1 Hydraulic energy transmission system 120, Figure 2-3 An exploded view of a cylinder assembly 400 of a hydraulic energy transfer system 200-300, or a rotary IPX, etc. Figure 5 The number of some elements of the other figures may be the same, and these elements may be substantially similar to those elements having the same number in the other figures. The barrel assembly 400 may include a rotor sleeve 402 enclosing a rotor 502, end caps 404A-B, and seal plates 406A-B.

[0057] The rotor 502 may include a cylindrical structure adapted to rotate within the rotor sleeve 402. The rotor 502 may also include one or more channels 504 extending substantially longitudinally through the rotor 502, with an opening at each end. The channels 504 may be arranged symmetrically about the central axis. The openings of the channels 504 may be arranged for hydraulic communication between the two end covers 404A-B. For example, the rotor 502 is designed to rotate, and during rotation, the channels 504 are exposed to high-pressure fluids and low-pressure fluids, which are directed to the channels through the orifices 506A-D formed by the end covers 404A-B. The orifices 506A-D may be in the form of circular arcs or circular segments (e.g., C-shaped).

[0058] like Figure 5 As shown, the end caps 404A-B may include a flat surface that contacts the rotor sleeve 402, and another flat surface that contacts the sealing plate 406A. As described in other embodiments, the end caps 404A, the sealing plates 406A-B, and the rotor sleeve 402 can all be coupled with a friction fit interface. For example, a compressive force external to the barrel assembly 400 can hold the end caps 404A, the sealing plates 406A-B, the rotor sleeve 402, and the rotor 502 in place and maintain a hydraulic seal at each contact point. In some embodiments, the rotor 502 rotates on a bearing surface formed by the surfaces of the rotor sleeve 402 and the end caps 404A-B.

[0059] Figure 6 A hydraulic energy transfer system (eg, Figure 1 Hydraulic energy transmission system 120, Figure 2-3 A cross-sectional view of a cylinder assembly 400 of a hydraulic energy transfer system 200-300, rotary IPX, etc. Figure 6 The number of some elements of the drawings may be the same as that of other drawings, and these elements may be substantially similar to those elements having the same number in other drawings. Figure 6 As shown, cartridge assembly 400 may include seal plate 406A coupled to end cap 404A. End cap 404A may be coupled to rotor sleeve 402 and rotor 502. Rotor sleeve 402 and rotor 502 may be coupled to second end cap 404B. Second end cap may be coupled to second seal plate 406B.

[0060] like Figure 6 As shown, the barrel assembly 400 may include a center hole 416 that is suitable for receiving a motor system (e.g., a motor shaft, a crank, a rotating element, etc.). The barrel assembly 400 may form a center hole 416 that passes through the sealing plate 406A, the end cap 404A, and the rotor 502. In some embodiments, the system may further form a center hole 416 that passes through the end cap 404B and the sealing plate 406B. In another embodiment, 416 can be arranged along the central axis of the barrel assembly 400. The barrel assembly may form a center hole 416 that passes through both ends of the barrel assembly 400 (e.g., above the piston 412 and through the hydraulic chambers 410C-D). The center hole 416 can receive a shaft that can be coupled to the rotor via a shaft coupling 508.

[0061] In some embodiments, the central hole 416 can form a through-path (e.g., a hole, a slot, a gap, a central hole, etc.) through the sealing plate 406A, the end cap 404A, and the rotor 502. The through-path can transmit a pressure (e.g., a low pressure, 150 psi) to the central hole 416 of the rotor 502. In some embodiments, the cartridge assembly 400 includes a through-path external to the cartridge assembly 400 that hydraulically communicates between the central hole 416 and a low pressure fluid flow of the first fluid or the second fluid disposed external to the cartridge assembly.

[0062] In some embodiments, in order to compensate for the smaller pressure distribution on the inside of the barrel assembly 400 due to the low-pressure center hole 416, there is a larger low-pressure distribution on the outside of the barrel to balance the force (i.e., minimize deflection). In one embodiment, the force balance is adjusted by changing the diameter of the piston 412. The piston 412 may include a booster 363A-B, which is suitable for resisting the force generated by the low-pressure center hole 416 by applying a compressive force generated by the pressurized fluid disposed in the hydraulic chamber 410A. For example, there is a low-pressure booster 363A and a high-pressure booster 323B above the piston 412. By changing the diameter of the piston 412, the area of ​​the relative booster 363A-B changes, which can adjust the net force. For example, the size of the low-pressure booster 363A can be increased (by increasing the diameter of the piston 412), which corresponds to a reduction in the size of the high-pressure booster 363B. In some embodiments, the top sealing plate (e.g., sealing plate 406A) can set the pressure balance by applying a compressive force on the barrel assembly 400. The sealing plate 406A may include two hydraulic chambers 410A-B and a piston 412. The piston 412 may include one or more radial seals (e.g., radial O-rings) that seal into one or more receiving holes of the housing (e.g., housing end caps 312A-B). The sealing plate 406A may include one or more face seals to seal the sealing plate to the end cap 404A. In some embodiments, the sealing plate 406A and the end cap 404A are used in combination to connect the hydraulic chambers 410A-B (e.g., high pressure chambers and low pressure chambers) on the cartridge assembly 400 with the hydraulic energy transfer system (e.g., Figure 2-3 A separate sealed flow path is established between ports on a housing (eg, a casing) of the hydraulic energy transfer system 200-300).

[0063] In some embodiments, piston 412 includes a radial seal (e.g., a radial O-ring) that maintains pressure containment of barrel assembly 400 by moving axially under pressure. In some embodiments, piston 412 allows relative movement between the housing and barrel assembly 400. In some embodiments, piston 412 accommodates changes in barrel height. For example, barrel height may be variable due to standard machine tolerances and material removal during repair, replacement, resurfacing (resurfacing) of barrel assembly 400 or components associated with barrel assembly 100.

[0064] In some embodiments, the bottom sealing plate (e.g., sealing plate 406B) is omitted. For example, one or more face seals of sealing plate 406B are integrated into the housing and coupled to end cap 404B. For example, the seal created at the contact surface between the housing and end cap 404B can be created by increasing the compressive force generated by plenum 363A-B.

[0065] Fig. 7A -B shows a cartridge assembly according to certain embodiments (e.g., Figure 4 The sealing plates 700A-B of the cartridge assembly 400). Fig. 7A -B may have the same number of elements as in the other figures, and these elements may be substantially similar to those elements having the same number in the other figures. The sealing plate 700A-B may be a hydraulic energy transfer system (e.g., Figure 3 The upper sealing plate (eg, Figure 4 Sealing plate 406A). Fig. 7A The upper surface of the sealing plate 700A is shown, and Figure 7B The lower surface of the sealing plate 700B can be shown. The upper surface of the sealing plate can be designed to be connected to or contact the housing (e.g., Figure 3 The housing end cap 312A in FIG. Fig. 7A The top surface of the sealing plate 700A is shown. Fig. 7A As shown, the seal plate 700A may include a first surface (eg, a top surface) that includes one or more hydraulic chambers 410A-B, a piston 412 , a fluid passage 418 , a central bore 416 , and a shaft seal 420 .

[0066] In some embodiments, the sealing plate 700A forms a central hole 416 that passes through the center of the sealing plate 700B adapted to receive a shaft. In other embodiments, the sealing plate forms an eccentrically disposed hole adapted to receive a shaft. In some embodiments, the central hole 416 is disposed within the hydraulic chamber 410A or through the piston 412. In other embodiments, the central hole 416 is disposed outside the piston 412 so as not to pass through the piston 412.

[0067] In some embodiments, the first hydraulic chamber 410A contains one of a first fluid or a second fluid (e.g., a proppant-free fluid or a proppant-containing fluid) having a first pressure, and the second hydraulic chamber 410B contains the first fluid or the second fluid having a second pressure greater than the first pressure. For example, both hydraulic chambers 410A-B may include the same fluid but have different pressures.

[0068] As previously described, the hydraulic chambers 410A-B can input and / or output the first fluid and / or the second fluid. The hydraulic chambers 410A-B are fluidly coupled to a hydraulic energy transfer system (e.g., Figure 2-3 Ports on a housing (e.g., a shell) of a hydraulic energy transfer system 200-300). For example, hydraulic chamber 410A may be an inlet port for transferring fluid into a cartridge assembly, while hydraulic chamber 410B may be an outlet port for transferring fluid out of the cartridge assembly.

[0069] In some embodiments, a fluid passage 418 (e.g., a fluid passage structure) is in hydraulic communication with the central bore 416 and the sealing plate 406. For example, the fluid passage 418 can transmit fluid from one of the hydraulic chambers 410A or the piston 412 to the central bore 416. For example, the hydraulic chamber 410A can enclose the fluid at a low pressure (e.g., 150 psi) and transmit the pressure to the central bore 416. The central bore 416 of the sealing plate can transmit the pressure to the central bore 414 of the rotor, thereby causing the pressure of the central bore 416 to be less than the pressure of the housing of the hydraulic energy transfer system, which can enclose the cartridge assembly (e.g., Figure 4 of the cartridge assembly 400).

[0070] In some embodiments, the seals 704A-B are designed to be disposed between the sealing plates 700A-B and the corresponding end caps (e.g., Figure 4 A hydraulic seal is formed between the end caps 404A-B). Figure 7B As shown, the second surface (e.g., bottom surface) of the sealing plate 700B may include one or more seals 704A-B. The seals 704A-B may include shaft seals or face seals (e.g., O-rings, washers, end face mechanical seals, etc.) to couple the second surface of the sealing plate 700B to the end cap (e.g., Figure 4 The face seal may be shaped to enclose a surface that contacts the end cap. The enclosed surface may create high pressure areas and low pressure areas that result in force applied to the end cap due to the pressurized fluid enclosed in the sealing plate 700. In another example, seal 704B may form a high pressure area enclosed by seal 704A, and seal 704 may form a low pressure area enclosed by seal 704B. In some embodiments, the relative size and geometry of the areas formed by seals 704A-B may be designed to ensure that the contact pressure between the sealing plates 406A-B and their respective adjacent end caps 404A-B is sufficient to achieve a proper seal between the components. In some embodiments, the sealing plates 700A-B may form a fluid passage 418 from the center hole 416 to one of the hydraulic chambers 410A-B.

[0071] Fig. 8A -B shows a cartridge assembly according to certain embodiments (e.g., Figure 4 The end caps 800A-B of the cartridge assembly 400). Fig. 8A -B may have the same number of elements as those in other drawings, and these elements may be substantially similar to those elements having the same number in other drawings. Fig. 8A A first surface (eg, top surface) of end cap 800A is shown including one or more apertures 506A-B and central hole 416. The top surface may be configured to couple, connect, or be integral with one of seal plates 700A-B. Figure 8BA second surface (eg, bottom surface) of the end cap 800B is shown. The bottom surface may be configured to be coupled, connected, or integral with the rotor.

[0072] One or more ports 506A-B may be formed by the end cap and adapted to transfer fluid from a sealing plate (eg, Figure 4 The sealing plates 406A-B) are directed to the rotor (e.g., Figure 5 The rotor 502) has a channel (e.g., Figure 5 In some embodiments, the orifices 506A-B are larger than the channels (e.g., Figure 5 For example, the orifices 506A-D may be designed in the form of an arc or a circular segment (eg, a C-shape).

[0073] Fig. 9A -B shows a cartridge assembly according to certain embodiments (e.g., Figure 4 The end caps 900A-B of the cartridge assembly 400). Fig. 9A -B may have the same number of elements as in other figures, and these elements may be substantially similar to those elements having the same number in other figures. Fig. 9A As shown, the end cap 900A may define one or more apertures 506A-B and a central hole 416. Fig. 9B As shown, end cap 900B may include central hole 416 and apertures 506A-B. Fig. 9A -The embodiments and corresponding elements shown in B may include or be similar to the combination of Fig. 8A -B discloses features of end caps 800A-B. In some embodiments, end caps 900A-B form one or more fluid passages. For example, a fluid passage can be formed from central hole 416 to orifices 506A-B.

[0074] Fig. 9A A first surface (eg, top surface) of end cap 900A is shown, which includes one or more apertures 506A-B and central hole 416. The top surface can be configured to mate with a rotor (eg, Figure 5 The rotor 502) is connected, connected or integrated. Fig. 9B A second surface (e.g., bottom surface) of end cap 900B is shown. The bottom surface can be configured to be coupled, connected, or integral with a sealing plate (e.g., sealing plate 1000A-B). End cap 900A-B can be a hydraulic energy system (e.g., Figure 3 The bottom end cover (e.g., Figure 3 end cap 316B).

[0075] Fig. 10A -B shows a cartridge assembly according to certain embodiments (e.g., Figure 4The sealing plates 1000A-B of the cartridge assembly 400). Fig. 10A -B may have the same number of elements as in other figures, and these elements may be substantially similar to those elements having the same number in other figures. Fig. 10A As shown, the sealing plate 1000A may include one or more seals 704A-B, one or more hydraulic chambers 410A-B, and a central hole 416. Fig. 10B As shown, the seal plate 1000B may include a central bore 416 and one or more hydraulic chambers 410A-B. Fig. 10A -The embodiments and corresponding elements shown in B may include or be similar to the combination of Fig. 7A -B discloses features of the sealing plates 700A-B. In some embodiments, the sealing plates 1000A-B form one or more fluid passages. For example, a fluid passage can be formed from the central hole 416 to one of the hydraulic chambers 410A-B.

[0076] Fig. 10A A first surface (eg, top surface) of seal plate 1000A is shown, including one or more seals 704A-B, hydraulic chambers 410A-B, and central aperture 416. The top surface may be configured to couple, connect, or be integral with one of end caps 900A-B. Fig. 10B The second surface (eg, bottom surface) of the sealing plate 1000B is shown. The bottom surface can be configured to be aligned with the housing (eg, Figure 3 The sealing plates 1000A-B may be a hydraulic energy system (e.g., Figure 3 The bottom sealing plate (e.g., Figure 3 Sealing plate 314B).

[0077] The foregoing description presents many specific details, such as examples of specific systems, components, methods, etc., in order to provide a good understanding of several embodiments of the present disclosure. However, it will be apparent to those skilled in the art that at least some embodiments of the present disclosure may be implemented without these specific details. In other cases, well-known components or methods are not described in detail, or are presented in a simple block diagram format to avoid unnecessary confusion of the present disclosure. Therefore, the specific details set forth are merely exemplary. Specific embodiments may differ from these exemplary details and may still be expected to be within the scope of the present disclosure.

[0078] References throughout this specification to "an embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic associated with the description of the embodiment is included in at least one embodiment. Therefore, the phrases "in one embodiment" or "in an embodiment" appearing in various places throughout this specification do not necessarily refer to the same embodiment. In addition, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or". When the terms "approximately", "substantially" or "approximately" are used herein, this means that the nominal value presented is accurate to within ±10%.

[0079] Although the operations of the methods herein are shown and described in a particular order, the order of operations of each method can be changed so that certain operations can be performed in reverse order, or so that certain operations can be performed at least partially simultaneously with other operations. In another embodiment, instructions or sub-operations of different operations can be performed in an intermittent and / or alternating manner. In one embodiment, multiple metal bonding operations are performed as a single step.

[0080] It should be understood that the above description is intended to illustrate rather than to limit. After reading and understanding the above description, many other embodiments will be apparent to those skilled in the art. Therefore, the scope of the present disclosure should be determined with reference to the attached claims and the full range of equivalents covered by each claim.

Claims

1. A pressure exchanger, comprising: a rotor configured to exchange pressure between a first fluid and a second fluid; a first sealing plate having a first substantially planar sealing plate surface and a second substantially planar sealing plate surface disposed opposite the first substantially planar sealing plate surface, wherein a piston structure extends from the first substantially planar sealing plate surface to form a substantially planar piston surface, the substantially planar piston surface having a first surface area and being substantially parallel to the first substantially planar sealing plate surface, wherein the first sealing plate and the piston structure form a first hydraulic chamber, the first hydraulic chamber passing from a first opening formed by the substantially planar piston surface to a second opening formed by the second substantially planar sealing plate surface, and wherein the first hydraulic chamber is configured to direct the first fluid at a first pressure to flow between the substantially planar piston surface and the second substantially planar sealing plate surface; and A first sealing structure, wherein the first sealing structure is configured to connect the sealing plate surface of the second basic plane to the corresponding surface of the pressure exchanger, wherein the first sealing structure forms a first boundary of a first region of the sealing plate surface of the second basic plane, wherein the first region of the sealing plate surface of the second basic plane has a second surface area, wherein the second opening is formed within the first region, and wherein the second surface area is larger than the first surface area.

2. The pressure exchanger according to claim 1, characterized in that The first area of ​​the second substantially planar sealing plate surface and the substantially planar piston surface are configured to induce a first force of the first fluid on the substantially planar piston surface and a second force on the second substantially planar sealing plate surface, and wherein the first force is greater than the second force.

3. The pressure exchanger according to claim 1, characterized in that Also included is a first end cap, wherein: The corresponding surface is a substantially planar end cap surface coupled to the second substantially planar seal plate surface via the first seal structure; the first end cap forming a first set of apertures configured to direct the first fluid to flow between the first hydraulic chamber and the rotor; and The rotor forms a plurality of rotational longitudinal channels configured to: receive the first fluid from the first end cap via a first distal end of the rotor; receive the second fluid via a second distal end of the rotor; and exchange pressure between the first fluid and the second fluid.

4. The pressure exchanger according to claim 3, characterized in that The first seal plate forms a second hydraulic chamber configured to direct the first fluid at a second pressure to flow between the first substantially planar seal plate surface and the second substantially planar seal plate surface, the pressure exchanger further comprising: A second sealing structure, wherein the second sealing structure is arranged between the first sealing plate and the first end cover, wherein the second sealing structure forms a second boundary of a second area of ​​the sealing plate surface of the second basic plane, wherein the second area of ​​the sealing plate surface of the second basic plane has a third surface area, and wherein the third opening of the second hydraulic chamber is formed in the second area of ​​the sealing plate surface of the second basic plane.

5. The pressure exchanger according to claim 4, characterized in that The second region of the second substantially planar sealing plate surface is disposed within the first region of the second substantially planar sealing plate surface.

6. The pressure exchanger according to claim 4, characterized in that The second surface area is greater than a combined surface area including the first surface area and the third surface area.

7. The pressure exchanger according to claim 4, characterized in that The second pressure is greater than the first pressure.

8. The pressure exchanger according to claim 3, characterized in that Also included is a second end cap and a sleeve, wherein the pressure exchanger is configured to receive a third fluid at a second pressure greater than the first pressure, the third fluid forming a fluid bearing between the rotor and the sleeve, between the rotor and the first end cap, and between the rotor and the second end cap.

9. The pressure exchanger according to claim 3, characterized in that Also includes: A housing structure forming an interior volume, wherein the first sealing plate, the first end cap and the rotor are disposed within the interior volume, and wherein the piston structure is configured to move within a recess formed by respective surfaces to allow the combination of the first sealing plate, the first end cap and the rotor to move relative to the housing structure.

10. The pressure exchanger according to claim 3, characterized in that Also includes: A shaft is coupled to the rotor and passes through a central aperture formed by the first seal plate and the first end cap, wherein the central aperture passes through the first region of the second substantially planar seal plate surface.

11. The pressure exchanger according to claim 2, characterized in that Also includes: a second sealing plate, the second sealing plate having a third substantially planar sealing plate surface and a fourth substantially planar sealing plate surface disposed opposite to the third substantially planar sealing plate surface, wherein the third substantially planar sealing plate surface is coupled to a corresponding surface via a second sealing structure forming a third boundary of a third region of the third substantially planar sealing plate surface, wherein the third region of the third substantially planar sealing plate surface has a third surface area, wherein the second sealing plate forms a second hydraulic chamber configured to guide the second fluid at a second pressure to flow between the third substantially planar sealing plate surface and the fourth substantially planar sealing plate surface; and A second end cap, the second end cap having a substantially planar end cap surface, the substantially planar end cap surface being coupled to the fourth substantially planar sealing plate surface via a third sealing structure, wherein the third sealing structure forms a fourth boundary of a fourth region of the fourth substantially planar sealing plate surface, wherein the fourth region of the fourth substantially planar sealing plate surface has a fourth surface area greater than the third surface area, wherein a third opening of the second hydraulic chamber is formed within the third region of the third substantially planar sealing plate surface, and wherein the second end cap forms a second set of orifices, the second set of orifices being configured to direct the flow of the second fluid between the second hydraulic chamber and the rotor via the second set of orifices.

12. A pressure exchanger configured to exchange pressure between a first fluid and a second fluid, wherein: The pressure exchanger comprises: a first sealing plate having a first substantially planar sealing plate surface and a second substantially planar sealing plate surface disposed opposite the first substantially planar sealing plate surface, wherein a piston structure extends from the first substantially planar sealing plate surface to form a substantially planar piston surface, the substantially planar piston surface having a first surface area and being substantially parallel to the first substantially planar sealing plate surface, wherein the first sealing plate and the piston structure form a first hydraulic chamber, the first hydraulic chamber extending from a first opening formed by the substantially planar piston surface to a second opening formed by the second substantially planar sealing plate surface, and wherein the first hydraulic chamber is configured to direct the first fluid at a first pressure to flow between the substantially planar piston surface and the second substantially planar sealing plate surface; a first sealing structure configured to couple the second substantially planar sealing plate surface to a corresponding surface of the pressure exchanger, wherein the first sealing structure forms a first boundary of a first region of the second substantially planar sealing plate surface, wherein the first region of the second substantially planar sealing plate surface has a second surface area, wherein the second opening is formed within the first region, and wherein the second surface area is greater than the first surface area; and A second sealing structure, the second sealing structure is configured to connect the second basically planar sealing plate surface to the corresponding surface of the pressure exchanger, wherein the second sealing structure forms a second boundary of a second area of ​​the second basically planar sealing plate surface, wherein the second area of ​​the second basically planar sealing plate surface has a third surface area, and wherein a third opening of the second hydraulic chamber is formed within the second area of ​​the second basically planar sealing plate surface.

13. The pressure exchanger according to claim 12, characterized in that Also included is a rotor configured to exchange pressure between the first fluid and the second fluid.

14. The pressure exchanger according to claim 13, characterized in that Also included is a first end cap, wherein: The corresponding surface is a substantially planar end cap surface coupled to the second substantially planar seal plate surface via the first seal structure; the first end cap forming a first set of apertures configured to direct the first fluid to flow between the first hydraulic chamber and the rotor; and The rotor forms a plurality of rotational longitudinal channels configured to: receive the first fluid from the first end cap via a first distal end of the rotor; receive the second fluid via a second distal end of the rotor; and exchange pressure between the first fluid and the second fluid.

15. The pressure exchanger according to claim 12, characterized in that The first area of ​​the second substantially planar sealing plate surface and the substantially planar piston surface are configured to induce a first force of the first fluid on the substantially planar piston surface and a second force on the second substantially planar sealing plate surface, and wherein the first force is greater than the second force.

16. The pressure exchanger according to claim 12, characterized in that The first seal plate forms the second hydraulic chamber configured to direct the first fluid at a second pressure to flow between the first substantially planar seal plate surface and the second substantially planar seal plate surface.

17. A pressure exchanger configured to exchange pressure between a first fluid and a second fluid, wherein: The pressure exchanger comprises: a first component having a first substantially planar component surface and a second substantially planar component surface disposed opposite the first substantially planar component surface, wherein a piston structure extends from the first substantially planar component surface to form a substantially planar piston surface, the substantially planar piston surface having a first surface area and being substantially parallel to the first substantially planar component surface, wherein the first component and the piston structure form a first hydraulic chamber extending from a first opening formed by the substantially planar piston surface to a second opening formed by the second substantially planar component surface, and wherein the first hydraulic chamber is configured to direct the first fluid at a first pressure to flow between the substantially planar piston surface and the second substantially planar component surface; a second component having a third substantially planar component surface; and A first sealing structure, the first sealing structure being configured to couple the second substantially planar component surface to the third substantially planar component surface, wherein the first sealing structure forms a first boundary of a first region of the second substantially planar component surface, wherein the first region of the second substantially planar component surface has a second surface area, wherein the second opening is formed within the first region, and wherein the second surface area is greater than the first surface area.

18. The pressure exchanger according to claim 17, characterized in that Also included is a rotor configured to exchange pressure between the first fluid and the second fluid, wherein the first component is a first sealing plate and the second component is a first end cap, and wherein the first sealing plate directs the first fluid through the first end cap and into the rotor.

19. The pressure exchanger according to claim 18, characterized in that the first end cap forming a first set of apertures configured to direct the first fluid to flow between the first hydraulic chamber and the rotor; and The rotor forms a plurality of rotational longitudinal channels configured to: receive the first fluid from the first end cap via a first distal end of the rotor; receiving the second fluid via a second distal end of the rotor; and exchanging pressure between the first fluid and the second fluid.

20. The pressure exchanger according to claim 17, characterized in that The first area of ​​the second substantially planar component surface and the substantially planar piston surface are configured to induce a first force of the first fluid on the substantially planar piston surface and a second force on the second substantially planar component surface, and wherein the first force is greater than the second force.

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