Pressure Exchanger Flow Adapter

Abstract

The pressure exchanger includes a rotor, an end cover, and a flow adaptor. The rotor is configured to exchange pressure between fluids. The end cover is disposed at a distal end of the rotor. The end cover defines an end cover low pressure port and an end cover high pressure port. The flow adaptor defines a planar surface, a distal end, and an upper surface. The planar surface defines a planar low pressure opening and a planar high pressure opening and is configured to seal against the end cover. The distal end defines a distal low pressure opening. Low pressure fluid flow exists between the end cover low pressure port and the distal low pressure opening via the planar low pressure opening. The upper surface defines an upper high pressure opening. High pressure fluid flow exists between the end cover high pressure port and the upper high pressure opening via the planar high pressure opening.

Description

[Technical field]

[0001] The present disclosure relates to pressure exchangers, and more particularly, to flow adapters for pressure exchangers. [Background technology]

[0002] Some systems use fluids at various pressures. Some systems use components to increase the pressure of the fluid.

[0003] The present disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings. [Brief description of the drawings]

[0004] [Figure 1A] 1 is a schematic diagram of a fluid processing system including a hydraulic energy transfer system, in accordance with certain embodiments. [Figure 1B] 1 is a schematic diagram of a fluid processing system including a hydraulic energy transfer system, in accordance with certain embodiments. [Figure 1C] 1 is a schematic diagram of a fluid processing system including a hydraulic energy transfer system, in accordance with certain embodiments. [Figure 1D] 1 is a schematic diagram of a fluid processing system including a hydraulic energy transfer system, in accordance with certain embodiments. [Figure 2A] FIG. 2 is an exploded perspective view of a pressure exchanger (PX) according to a particular embodiment. [Figure 2B] FIG. 2 is an exploded perspective view of a pressure exchanger (PX) according to a particular embodiment. [Figure 2C] FIG. 2 is an exploded perspective view of a pressure exchanger (PX) according to a particular embodiment. [Figure 2D] FIG. 2 is an exploded perspective view of a pressure exchanger (PX) according to a particular embodiment. [Figure 2E] FIG. 2 is an exploded perspective view of a pressure exchanger (PX) according to a particular embodiment. [Figure 3A] 1 illustrates components of a PX according to a specific embodiment. [Figure 3B] 1 illustrates components of a PX according to a specific embodiment. [Figure 3C] 1 illustrates components of a PX according to a specific embodiment. [Figure 3D] 1 illustrates components of a PX according to a specific embodiment. [Figure 3E] 1 illustrates components of a PX according to a specific embodiment. [Figure 3F] 1 illustrates components of a PX according to a specific embodiment. [Figure 3G] 1 illustrates components of a PX according to a specific embodiment. [Figure 3H] 1 illustrates components of a PX according to a specific embodiment. [Figure 3I] 1 illustrates components of a PX according to a specific embodiment. [Figure 3J] 1 illustrates components of a PX according to a specific embodiment. [Figure 3K] 1 illustrates components of a PX according to a specific embodiment. [Figure 3L] 1 illustrates components of a PX according to a specific embodiment. [Figure 3M] 1 illustrates components of a PX according to a specific embodiment. [Figure 3N] 1 illustrates components of a PX according to a specific embodiment. [Figure 4] FIG. 2 is a flow diagram illustrating a method associated with controlling pressure in a pressure exchanger, according to some embodiments. [Diagram 5] FIG. 1 is a block diagram illustrating a computer system in accordance with certain embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] SUMMARY OF THE DISCLOSURE The embodiments described herein relate to a flow adapter for a pressure exchanger.

[0006] A system may use fluids at different pressures. A fluid may be supplied to a system at a lower pressure and one or more portions of the system may operate at a higher pressure. A system may include a closed loop where different fluid pressures are maintained in different portions of the loop. Such systems may include hydraulic fracturing (e.g., fracking or fracing) systems, desalination systems, refrigeration systems, heat pump systems, energy generation systems, mud pump systems, slurry pump systems, industrial fluid systems, wastewater systems, fluid transport systems, etc. Pumps or compressors may be used to increase the pressure of the fluids in such systems.

[0007] Traditionally, systems (e.g., refrigeration systems, heat pump systems, reversible heat pump systems, water systems, etc.) use pumps or compressors to increase the pressure of a fluid (e.g., refrigeration fluids such as carbon dioxide (CO2), R-744, R-134a, hydrocarbons, hydrofluorocarbons (HFCs), hydrochlorofluorocarbons (HCFCs), ammonia (NH3), refrigerant mixtures, R-407A, R-404A, etc.). Traditionally, separate pumps or compressors mechanically coupled to a motor are used to increase the pressure of the fluid in any part of the system, including increasing the fluid pressure. Pumps and compressors, especially those that operate with large pressure differentials (e.g., causing large pressure increases in the fluid), require large amounts of energy. Thus, traditional systems consume large amounts of energy to increase the pressure of the fluid (through the pump or compressor driven by the motor). Additionally, traditional fluid transfer systems reduce the pressure of the fluid through an expansion valve. Traditional systems inefficiently increase the pressure of the fluid and reduce the pressure of the fluid when operating in a loop. This is wasteful in terms of the energy used to run conventional systems (e.g., the energy used to repeatedly increase the pressure of a refrigerated fluid to raise or lower the temperature of the surrounding environment).

[0008] Traditionally, systems (e.g., refrigeration systems, heat pump systems, reversible heat pump systems, water systems, etc.) have large components that undergo a process of machining at certain locations on the component. The bores take up a lot of space on the component and limit the types of applications the component can be used in. These traditional components waste material, limit applications, and increase production time, for example.

[0009] The systems, apparatus, and methods of the present disclosure provide solutions to these and other shortcomings of conventional systems. The present disclosure provides a PX for use in a system (e.g., a fluid processing system, a heat transfer system, a refrigeration system, a heat pump system, a cooling system, a heating system, etc.). In the system, the PX may include a rotor and an end cover disposed at a distal end of the rotor. In the system, the PX may be configured to exchange pressure between a first fluid (e.g., a high-pressure portion of the refrigeration fluid in a refrigeration cycle) and a second fluid (e.g., a low-pressure portion of the refrigeration fluid in a refrigeration cycle). The PX receives the first fluid (e.g., a portion of the high-pressure refrigeration fluid) via a first inlet (e.g., a high-pressure inlet) and receives the second fluid (e.g., a portion of the low-pressure refrigeration fluid) via a second inlet (e.g., a low-pressure inlet). The first fluid may be at a higher pressure than the second fluid when it enters the PX. The PX exchanges pressure between the first fluid and the second fluid. A first fluid exits the PX through a first outlet (e.g., a low pressure outlet) and a second fluid exits the PX through a second outlet (e.g., a high pressure outlet). The second fluid may be at a higher pressure than the first fluid when it exits the PX (e.g., pressure has been exchanged between the first and second fluids).

[0010] In some embodiments, the PX further comprises a flow adaptor. The flow adaptor may comprise a planar surface (e.g., a bottom surface abutting the upper surface of the end cover), a distal end (e.g., opposite the planar surface), and an upper surface. The planar surface defines a planar low pressure opening and a planar high pressure opening. In some embodiments, a face seal is disposed between the planar surface and the end cover for sealing the flow adaptor to the end cover. In some embodiments, a radial seal is used to seal the flow adaptor (e.g., to the end cover, sleeve, housing, etc.). The end cover may define at least two end cover low pressure ports and at least two end cover high pressure ports. The distal end of the flow adaptor may define a distal low pressure opening. Low pressure fluid flow is between the end cover low pressure port and the distal low pressure opening via the planar low pressure opening. The upper surface of the flow adaptor defines an upper high pressure opening. High pressure fluid flow is between the end cover high pressure port and the upper high pressure opening via the planar high pressure opening.

[0011] The disclosed systems, devices, and methods provide advantages over conventional solutions. The disclosed systems reduce energy consumption compared to conventional systems. For example, the use of the disclosed PX can recover energy stored as pressure and transfer that energy back to the system, reducing the energy costs of operating the system. The disclosed systems can reduce wear on components (e.g., pumps, compressors) compared to conventional systems. The disclosed PX can waste less material (e.g., by not having a bore), reduce production time, have more applications, and / or the like compared to conventional systems.

[0012] Although some embodiments of the present disclosure are described in relation to pressure exchangers, energy recovery devices, and hydraulic energy transmission systems, the present disclosure may be applied to other systems and devices (e.g., non-isobaric pressure exchangers, rotating components that are not pressure exchangers, non-rotary pressure exchangers, systems that do not include a pressure exchanger, etc.).

[0013] Although some embodiments of the present disclosure are described in the context of pressure exchange between fluids used in fracking, desalination, heat pump and / or refrigeration systems, the present disclosure may also be applied to other types of systems. Fluids may refer to liquids, gases, transcritical fluids, supercritical fluids, subcritical fluids and / or combinations thereof.

[0014] 1A-1D show schematic diagrams of a fluid treatment system 100 including a hydraulic energy transfer system 110, according to certain embodiments.

[0015] In some embodiments, the hydraulic energy transfer system 110 includes a pressure exchanger (e.g., a PX). The PX may include one or more of the features (e.g., a flow adapter) described in one or more of Figures 3A-5 to provide improved performance over conventional systems.

[0016] The hydraulic energy transfer system 110 (e.g., PX) receives a low pressure (LP) in fluid 120 (e.g., a low pressure inlet flow) from an LPin system 122. The hydraulic energy transfer system 110 also receives a high pressure (HP) in fluid 130 (e.g., a high pressure inlet flow) from an HPin system 132. The hydraulic energy transfer system 110 (e.g., PX) exchanges pressure between the HPin fluid 130 and the LPin fluid 120 to provide an LPout fluid 140 (e.g., a low pressure outlet flow) to an LPout fluid system 142 and an HPout fluid 150 (e.g., a high pressure outlet flow) to an HPout fluid system 152.

[0017] In some embodiments, the hydraulic energy transfer system 110 includes a PX that exchanges pressure between the HPin fluid 130 and the LPin fluid 120. The PX may be a device that transfers fluid pressure between the HPin fluid 130 and the LPin fluid 120 with an efficiency of about 50%, 60%, 70%, 80%, 90% or more (e.g., without using centrifugal techniques). High pressure (e.g., HPin fluid 130, HPout fluid 150) refers to a pressure higher than low pressure (e.g., LPin fluid 120, LPout fluid 140). The LPin fluid 120 in the PX is pressurized and discharged from the PX at high pressure (e.g., HPout fluid 150 at a pressure higher than the pressure of the LPin fluid 120), and the HPin fluid 130 is depressurized and discharged from the PX at low pressure (e.g., LPout fluid 140 at a pressure lower than the pressure of the HPin fluid 130). The PX may operate with the HPin fluid 130 exerting a direct force to pressurize the LPin fluid 120, with or without a fluid separator between the fluids. Examples of fluid separators that may be used in the PX may include, but are not limited to, pistons, bladders, diaphragms, and the like. In some embodiments, the PX may be a rotary device. Rotary PXs, such as those manufactured by Energy Recovery Inc. of San Leandro, California, may not have any separate valves, as the relative motion of the rotor to the end cover achieves effective valving within the device. Rotary PXs may be designed to operate with internal pistons to separate the fluids and transfer pressure with relatively little mixing of the inlet fluid streams. Reciprocating PXs may have pistons that move back and forth within a cylinder to transfer pressure between the fluid streams. The present disclosure may use any PX or multiple PXs, such as, but not limited to, rotary PXs, reciprocating PXs, or any combination thereof. Additionally, the PX may be located on a separate skid from other components of fluid treatment system 100 (eg, if the PX is being added to an existing fluid treatment system).

[0018] In some embodiments, the motor 160 is coupled to the hydraulic energy transmission system 110 (e.g., PX). In some embodiments, the motor 160 controls the speed of a rotor of the hydraulic energy transmission system 110 (e.g., to increase the pressure of the HPout fluid 150 or decrease the pressure of the LPout fluid 140). In some embodiments, the motor 160 generates energy (e.g., functions as a generator) based on pressure exchanges in the hydraulic energy transmission system 110.

[0019] The hydraulic energy transfer system 110 may be a hydraulic protection system (e.g., hydraulic buffer system, hydraulic isolation system) that exchanges work and / or pressure with another fluid while blocking or limiting contact between the fluid containing solid particles (e.g., fracking fluid) and various equipment (e.g., hydraulic fracturing equipment, high pressure pumps). By blocking or limiting contact between the fluid containing solid particles and various equipment (e.g., fracturing equipment) the hydraulic energy transfer system 110 increases the life and performance of the various equipment (e.g., fracturing equipment, high pressure fluid pumps) while reducing wear and tear. The use of equipment (e.g., high pressure fluid pumps) that is not designed for abrasive fluids (e.g., fracking fluids and / or corrosive fluids) may reduce the cost of equipment that may be used in the fluid treatment system 100.

[0020] The hydraulic energy transfer system 110 may include a hydraulic turbocharger or hydraulic pressure exchange system, such as a rotary PX. The PX may include one or more chambers (e.g., 1-100) that facilitate pressure transfer and pressure equalization between volumes of a first fluid and a second fluid (e.g., gas, liquid, multiphase fluid). In some embodiments, the PX may transfer pressure between a first fluid (e.g., a pressure exchange fluid, such as a proppant-free or substantially proppant-free fluid) and a second fluid that may be highly viscous and / or contain solid particles (e.g., fracking fluids containing sand, proppant, powder, debris, ceramic). The solid particle fluid causes wear and / or erosion of parts of the PX, such as the rotor and end covers of the PX. The fluid (e.g., abrasive particles within the fluid) may cause wear at the interface between the rotor and each end cover as the rotor rotates relative to the end cover. Replacement of worn parts of the PX may be costly.

[0021] The hydraulic energy transfer system 110 may be used in various types of systems, such as fracking systems, desalination systems, and refrigeration systems.

[0022] 1A shows a schematic diagram of a fluid treatment system 100A including a hydraulic energy transfer system 110, according to certain embodiments. The fluid treatment system 100A may include a control module 180 including one or more controllers 185.

[0023] 1B shows a schematic diagram of a fluid treatment system 100B including a hydraulic energy transfer system 110, according to certain embodiments. Fluid treatment system 100B may be a fracking system. In some embodiments, fluid treatment system 100B includes more components, fewer components, the same routing, different routing, etc. than those shown in FIG. 1B.

[0024] The LPin fluid 120 and the HPout fluid 150 may be fracking fluids (e.g., fluids containing solid particles, proppant-containing fluids, etc.). The HPin fluid 130 and the LPout fluid 140 may be fluids that are substantially free of solid particles (e.g., proppant-free fluids, water, filtered fluids, etc.).

[0025] The LPin system 122 may include one or more low pressure fluid pumps for supplying the LPin fluid 120 to the hydraulic energy transmission system 110 (e.g., PX). The HPin system 132 may include one or more high pressure fluid pumps 134 for supplying the HPin fluid 130 to the hydraulic energy transmission system 110.

[0026] A hydraulic energy transfer system 110 exchanges pressure between LPin fluid 120 (e.g., low pressure fracking fluid) and HPin fluid 130 (e.g., high pressure water) to provide HPout fluid 150 (e.g., high pressure fracking fluid) to an HPout system 152, which provides LPout fluid 140 (e.g., low pressure water). The HPout system 152 may include a rock formation 154 (e.g., a well) that includes cracks 156. Solid particles (e.g., proppant) from the HPout fluid 150 may be provided into the cracks 156 in the rock formation.

[0027] In some embodiments, the LPout fluid 140, the high pressure fluid pump 134, and the HPin fluid 130 are part of a first loop (e.g., a fluid loop that does not include a proppant). The LPout fluid 140 may be fed to the high pressure fluid pump to produce the HPin fluid 130, which becomes the LPout fluid 140 upon exiting the hydraulic energy transfer system 110.

[0028] In some embodiments, the LPin fluid 120, the HPout fluid 150, and the low pressure fluid pump 124 are part of a second loop (e.g., a proppant-containing fluid loop). The HPout fluid 150 may be fed into the rock formation 154 and then pumped out of the rock formation 154 by the low pressure fluid pump 124 to produce the LPin fluid 120.

[0029] In some embodiments, the fluid treatment system 100B is used in well completion operations in the oil and gas industry to perform hydraulic fracturing (e.g., fracking, fracing) to increase the release of oil and gas in a rock formation 154. The HPout system 152 may include a rock formation 154 (e.g., a well). Hydraulic fracturing may include pumping an HPout fluid 150, including a combination of water, chemicals, and solid particles (e.g., sand, ceramic, proppant), at high pressure into the well (e.g., rock formation 154). The LPin fluid 120 and the HPout fluid 150 may include fluids containing particles that increase the release of oil and gas in the rock formation 154 by propagating and increasing the size of cracks 156 in the rock formation 154. The high pressure of the HPout fluid 150 causes cracks 156 to initiate, expand in size, and propagate through the rock formations 154, releasing more oil and gas, while solid particles (e.g., powder, debris, etc.) enter the cracks 156 and keep them open (e.g., preventing the cracks 156 from closing once the HPout fluid 150 is depressurized).

[0030] To pump the particle-laden fluid into the rock formation 154 (e.g., a well), the fluid treatment system 100B may include one or more high pressure fluid pumps 134 and one or more low pressure fluid pumps 124 coupled to a hydraulic energy transfer system 110. For example, the hydraulic energy transfer system 110 may be a hydraulic turbocharger or PX (e.g., a rotary PX). In operation, the hydraulic energy transfer system 110 transfers pressure without implementing any substantial mixing between a first fluid (e.g., HPin fluid 130, a proppant-free fluid) pumped by the high pressure fluid pump 134 and a second fluid (e.g., LPin fluid 120, a proppant-containing fluid, a fracking fluid) pumped by the low pressure fluid pump 124. In this manner, the hydraulic energy transfer system 110 prevents or limits wear on the high pressure fluid pump 134 while simultaneously enabling the fluid treatment system 100B to pump the high pressure fracking fluid (e.g., HPout fluid 150) into the rock formation 154 to release oil and gas. To operate in corrosive and abrasive environments, the hydraulic energy transmission system 110 may be made from materials that are resistant to the corrosive and abrasive substances contained in either the first fluid or the second fluid. For example, the hydraulic energy transmission system 110 may be made from a ceramic (e.g., a cermet such as alumina, carbide, oxide, nitride, or boride hard phase) in a metal matrix (e.g., Co, Cr, or Ni or any combination thereof), such as tungsten carbide in a matrix of CoCr, Ni, NiCr, or Co.

[0031] In some embodiments, the hydraulic energy transfer system 110 comprises a PX (e.g., a rotary PX) where an HPin fluid 130 (e.g., a first fluid, a fluid that does not contain solid particles at high pressure) flows into a first side of the PX. Here, the HPin fluid 130 contacts an LPin fluid 120 (e.g., a second fluid, a low-pressure fracking fluid) that flows into the PX on a second side. The contact between the fluids allows the HPin fluid 130 to increase the pressure of the second fluid (e.g., the LPin fluid 120), which then pushes a second out fluid (e.g., the HPout fluid 150) of the PX into the well (e.g., the rock formation 154) for fracturing operations. The first fluid (e.g., the LPout fluid 140) also exits the PX, but at a lower pressure after exchanging pressure with the second fluid. As previously mentioned, the second fluid may be a low-pressure fracking fluid that may contain abrasive particles that may wear down the interface between the rotor and each end cover as the rotor rotates against each end cover.

[0032] 1C shows a schematic diagram of a fluid treatment system 100C including a hydraulic energy transfer system 110, according to certain embodiments. Fluid treatment system 100C may be a desalination system (e.g., removing salt and / or other minerals from water). In some embodiments, fluid treatment system 100C includes more components, fewer components, the same routing, different routing, etc. than those shown in FIG. 1C.

[0033] The LPin system 122 may include a feed pump 126 (e.g., low pressure fluid pump 124) that receives in seawater 170 (e.g., a reservoir feed or a direct ocean feed) and supplies the LPin fluid 120 (e.g., low pressure seawater, feed) to the hydraulic energy transfer system 110 (e.g., PX). The HPin system 132 may include a membrane 136 that supplies the HPin fluid 130 (e.g., high pressure brine) to the hydraulic energy transfer system 110 (e.g., PX). The hydraulic energy transfer system 110 exchanges pressure between the HPin fluid 130 and the LPin fluid 120 to supply the HPout fluid 150 (e.g., high pressure seawater) to the HPout system 152 and the LPout fluid 140 (e.g., low pressure brine) to the LPout system 142 (e.g., a geological mass, ocean, sea, wastewater, etc.).

[0034] The membrane 136 may be a membrane separator configured to separate fluids passing through the membrane, such as a reverse osmosis membrane. The membrane 136 may provide a concentrated feedwater or concentrate (e.g., brine) HPin fluid 130 to the hydraulic energy transfer system 110. The pressure of the HPin fluid 130 may be used to compress a low pressure feedwater (e.g., LPin fluid 120) to a high pressure feedwater (e.g., HPout fluid 150). For simplicity and explanation, the term feedwater is used. However, fluids other than water may be used in the hydraulic energy transfer system 110.

[0035] A circulation pump 158 (e.g., a centrifugal pump) delivers HPout fluid 150 (e.g., high pressure seawater) to the membrane 136. The membrane 136 filters the HPout fluid 150 to deliver LP drinking water 172 and HPin fluid 130 (e.g., high pressure brine). The LPout system 142 delivers out brine 174 (e.g., to a geological body, ocean, sea, wastewater, etc.).

[0036] In some embodiments, a high pressure fluid pump 176 is disposed between the feedwater pump 126 and the membrane 136. The high pressure fluid pump 176 increases the pressure of the low pressure seawater (e.g., LPin fluid 120, providing the high pressure feedwater) that is mixed with the high pressure seawater provided by the circulation pump 158.

[0037] In some embodiments, use of the hydraulic energy transfer system 110 reduces the load on the high pressure fluid pump 176. In some embodiments, the fluid treatment system 100C provides the LP potable water 172 without the use of the high pressure fluid pump 176. In some embodiments, the fluid treatment system 100C provides the LP potable water 172 using the high pressure fluid pump 176 intermittently.

[0038] In some examples, a hydraulic energy transfer system 110 (e.g., PX) receives an LPin fluid 120 (e.g., low pressure feedwater) at about 30 pounds per square inch (PSI) (about 207 kPa) and an HPin fluid 130 (e.g., high pressure brine or concentrate) at about 980 PSI (about 6757 kPa). The hydraulic energy transfer system 110 (e.g., PX) transfers pressure from the high pressure concentrate (e.g., HPin fluid 130) to the low pressure feedwater (e.g., LPin fluid 120). The hydraulic energy transfer system 110 (e.g., PX) outputs an HPout fluid 150 (e.g., high pressure (compressed) feedwater) at about 965 PSI (about 6653 kPa) and outputs an LPout fluid 140 (e.g., low pressure concentrate) at about 15 PSI (about 103 kPa). Because of this, the hydraulic energy transmission system 110 (e.g., PX) can be approximately 97% efficient because the input volume is approximately equal to the output volume of the hydraulic energy transmission system 110 (e.g., PX) and 965 PSI (approximately 6653 kPa) is approximately 97% of 980 PSI (approximately 6757 kPa).

[0039] 1D shows a schematic diagram of a fluid treatment system 100D including a hydraulic energy transfer system 110, according to certain embodiments. Fluid treatment system 100D may be a refrigeration system. In some embodiments, fluid treatment system 100D includes more components, fewer components, the same routing, different routing, etc. than those shown in FIG. 1D.

[0040] A hydraulic energy transfer system 110 (e.g., PX) receives LPin fluid 120 from an LPin system 122 (e.g., low pressure lift device 128, low pressure fluid pump, etc.) and receives HPin fluid 130 from an HPin system 132 (e.g., condenser 138). The hydraulic energy transfer system 110 (e.g., PX) may exchange pressure between the LPin fluid 120 and the HPin fluid 130 to provide HPout fluid 150 to the HPout system 152 (e.g., high pressure lift device 159) and provide LPout fluid 140 to the LPout system 142 (e.g., evaporator 144). The evaporator 144 may provide fluid to the compressor 178 and the low pressure lift device 128. The condenser 138 may receive fluid from the compressor 178 and the high pressure lift device 159.

[0041] Fluid treatment system 100D may be a closed system. LPin fluid 120, HPin fluid 130, LPout fluid 140 and HPout fluid 150 may all be fluids (eg, refrigerants) that circulate in the closed system of fluid treatment system 100D.

[0042] In some embodiments, the fluid of the fluid treatment system 100D may include solid particles. For example, solid particles (e.g., solid particles from welding) may be entrained in the fluid in the fluid treatment system 100D due to piping, equipment, connections (e.g., welding of pipes, soldering of pipes), etc. Solid particles in the fluid and / or high pressure of the fluid may cause wear and / or erosion of the PX components (e.g., rotors, end covers) of the hydraulic energy transfer system 110.

[0043] 2A-2E are exploded perspective views of a rotary PX 40 (eg, a rotary pressure exchanger, a rotary liquid piston compressor (LPC)) according to certain embodiments. The PX 40 may include a motor 92 and / or a control module 94.

[0044] In some embodiments, the PX40 includes one or more of the features described in one or more of Figures 3A-5 (e.g., a flow adapter) to provide improved performance over conventional systems.

[0045] The PX 40 is configured to transfer pressure and / or work between a first fluid (e.g., a proppant-free fluid or supercritical carbon dioxide, HPin fluid 130) and a second fluid (e.g., fracking fluid or superheated carbon dioxide gas, LPin fluid 120) with minimal fluid mixing. The rotary PX 40 may include a generally cylindrical body portion 42 including a sleeve 44 (e.g., rotor sleeve) and a rotor 46. The rotary PX 40 may also include two end caps 48 and 50 including manifolds 52 and 54, respectively. The manifold 52 includes respective inlet and outlet ports 56 and 58, and the manifold 54 includes respective inlet and outlet ports 60 and 62. In operation, the inlet ports 56, 60 allow the first and second fluids to enter and exchange pressure with the rotary PX 40, while the outlet ports 58, 62 allow the first and second fluids to exit the rotary PX 40. In operation, the inlet port 56 may receive a first fluid (e.g., HPin fluid 130) at high pressure and, after exchanging pressure, the outlet port 58 may be used to pump the first fluid (e.g., LPout fluid 140) at low pressure out of the rotary PX 40. Similarly, the inlet port 60 may receive a second fluid (e.g., LPin fluid 120) at low pressure and the outlet port 62 may be used to pump the second fluid (e.g., HPout fluid 150) at high pressure out of the rotary PX 40. The end caps 48 and 50 are disposed within the respective manifolds 52 and 54 and include respective end covers 64 and 66 (e.g., end plates) that enable fluid-sealing contact with the rotor 46.

[0046] As noted above, one or more components of PX 40, such as rotor 46, end cover 64 and / or end cover 66, may be constructed from a wear-resistant material (e.g., carbide, cemented carbide, silicon carbide, tungsten carbide, etc.) having a hardness greater than a predetermined threshold (e.g., a Vickers Hardness number of at least 1000, 1250, 1500, 1750, 2000, 2250 or more). For example, tungsten carbide may provide increased durability and improved wear resistance to abrasive fluids compared to other materials, such as alumina ceramic.

[0047] The rotor 46 may be cylindrical and disposed within the sleeve 44, which allows the rotor 46 to rotate about an axis 68. The rotor 46 may have a number of channels 70 (e.g., ducts, rotor ducts) that run generally longitudinally through the rotor 46, with openings 72 and 74 (e.g., rotor ports) at each end symmetrically disposed about the longitudinal axis 68. The openings 72 and 74 of the rotor 46 are disposed to be in fluid communication with the inlet and outlet apertures 76 and 78 (e.g., end cover inlet and end cover outlet ports) and 80 and 82 (e.g., end cover inlet and end cover outlet ports) of the end covers 64 and 66, respectively, in such a way that the channels 70 are exposed to high and low pressure fluids during rotation. As shown, the inlet and outlet apertures 76 and 78, 80 and 82 may be designed in the shape of an arc or a portion of a circle (e.g., C-shaped).

[0048] In some embodiments, a controller using sensor feedback (e.g., revolutions per minute measured via a tachometer or optical encoder, or volumetric flow rate measured via a flow meter) may control the degree of mixing of the first and second fluids in the rotary PX 40. This controller may be used to improve the operability of a fluid treatment system (e.g., fluid treatment systems 100A-100D of FIGS. 1A-1D). For example, by varying the volumetric flow rates of the first and second fluids entering the rotary PX 40, a plant operator (e.g., a system operator) can control the amount of fluid mixing in the PX 40. Additionally, by varying the rotational speed of the rotor 46, an operator can also control the mixing. Three characteristics of the rotary PX 40 that affect mixing include (1) the aspect ratio of the rotor channel 70, (2) the exposure time between the first and second fluids, and (3) the creation of a fluid barrier (e.g., an interface) between the first and second fluids in the rotor channel 70. First, the rotor channel 70 (e.g., a duct) is generally long and narrow, which stabilizes the flow in the rotary PX 40. Furthermore, the first and second fluids may move through the channel 70 in a plug-flow manner with minimal axial mixing. Second, in certain embodiments, the speed of the rotor 46 reduces the contact between the first and second fluids. For example, the speed of the rotor 46 (e.g., a rotor speed of about 1200 RPM) may reduce the contact time between the first and second fluids to less than about 0.15 seconds, 0.10 seconds, or 0.05 seconds. Third, a small portion of the rotor channel 70 is used to exchange pressure between the first and second fluids. Thus, a certain amount of fluid remains in the channel 70 as a barrier between the first and second fluids. Any of these mechanisms may limit mixing in the rotary PX 40. Additionally, in some embodiments, the rotary PX40 may be designed to operate with all or part of an internal piston or other barrier that isolates the first and second fluids while allowing pressure transmission.

[0049] 2B-2E are exploded views of one embodiment of the rotary PX 40, showing the sequence of positions of a single rotor channel 70 in the rotor 46 as the channel 70 rotates through a complete cycle. It should be noted that FIGS. 2B-2E are simplified views of the rotary PX 40, showing one rotor channel 70, which is depicted as having a circular cross-sectional shape. In other embodiments, the rotary PX 40 may include multiple channels 70 having the same or different cross-sectional shapes (e.g., circular, elliptical, rectangular, polygonal). Thus, FIGS. 2B-2E are simplified views for illustrative purposes, and other embodiments of the rotary PX 40 may have different configurations than those shown in FIGS. 2A-2E. As described in more detail below, the rotary PX 40 facilitates pressure exchange between the first and second fluids by allowing the first and second fluids to come into slight contact with each other within the rotor 46. In certain embodiments, this exchange occurs at a rate that results in limited intermixing of the first and second fluids. The speed of the pressure wave traveling through the rotor channel 70 (once the channel is exposed to the aperture 76), the rate of diffusion of the fluids, and the rotational speed of the rotor 46 govern whether and to what extent intermixing occurs.

[0050] FIG. 2B is an exploded perspective view of one embodiment of a rotary PX 40 (e.g., a rotary LPC) according to certain embodiments. In FIG. 2B, the channel opening 72 is in a first position. In the first position, the channel opening 72 is in fluid communication with an aperture 78 in the end cover 64 and thus the manifold 52, while the opposite channel opening 74 is in fluid communication with an aperture 82 in the end cover 66 and extends therefrom into the manifold 54. As discussed below, the rotor 46 may rotate in a clockwise direction as indicated by arrow 84. In operation, a low pressure second fluid 86 passes through the end cover 66 and into the channel 70 where it contacts the first fluid 88 at a dynamic fluid interface 90. The second fluid 86 then pushes the first fluid 88 out of the channel 70, through the end cover 64, and out of the rotary PX 40. However, due to the short contact time, there is minimal mixing between the second fluid 86 and the first fluid 88.

[0051] 2C is an exploded perspective view of one embodiment of a rotating PX 40 (e.g., a rotating LPC) in accordance with certain embodiments. In FIG. 2C, the channel 70 has been rotated clockwise through an arc of approximately 90 degrees. In this position, the opening 74 (e.g., outlet) is not in fluid communication with the apertures 80 and 82 in the end cover 66, and the opening 72 is not in fluid communication with the apertures 76 and 78 in the end cover 64. Thus, a low pressure second fluid 86 is temporarily contained within the channel 70.

[0052] FIG 2D is an exploded perspective view of one embodiment of a rotating PX 40 (e.g., a rotating LPC) according to certain embodiments. In FIG 2D, the channel 70 has been rotated through an arc of approximately 60 degrees from the position shown in FIG 2B. The opening 74 is now in fluid communication with the aperture 80 in the end cover 66, and the opening 72 in the channel 70 is now in fluid communication with the aperture 76 in the end cover 64. In this position, a first fluid 88 at high pressure flows in and pressurizes a second fluid 86 at low pressure, forcing the second fluid 86 out of the rotor channel 70 and through the aperture 80.

[0053] FIG 2E is an exploded perspective view of one embodiment of a rotary PX 40 (e.g., a rotary LPC) in accordance with certain embodiments. In FIG 2E, the channel 70 has rotated through an arc of approximately 270 degrees from the position shown in FIG 2B. In this position, the opening 74 is no longer in fluid communication with the apertures 80 and 82 in the end cover 66, and the opening 72 is no longer in fluid communication with the apertures 76 and 78 in the end cover 64. Thus, the first fluid 88 is no longer pressurized and is temporarily retained within the channel 70 until the rotor 46 rotates another 90 degrees to begin the cycle again.

[0054] Abrasion and / or erosion damage to the PX can occur when suspended matter is induced and mixed with the fluid entering the PX. Abrasion damage can occur when particles enter the gaps of the PX (e.g., become trapped between the stationary end cover and the rotating rotor). Erosion damage can occur due to the presence of suspended matter (e.g., erosion) in high-velocity fluid jets (e.g., slurry jets) that are formed due to high pressure differentials inside the PX. When high-velocity jets impinge on components of the PX, they can damage such components. Damage (e.g., erosion damage) can occur when high-pressure rotor ports (e.g., rotor ducts) open to low-pressure end cover ports (e.g., kidneys) or when low-pressure rotor ports (e.g., rotor ducts) open to high-pressure end cover ports (e.g., kidneys) creating high pressure differentials.

[0055] Figures 3A-N show components of a PX 300, according to some embodiments. One or more of the hydraulic energy transmission systems 110 of Figures 1A-D and / or one or more of the PX 40 of Figures 2A-E may include one or more of the same or similar features, materials, functionality, etc. as those of Figures 3A-N. The PX 300 depicted in Figures 3A-N may include one or more of the features, materials, functionality, etc. described in connection with one or more of Figures 1A-2E.

[0056] FIG. 3A shows a front cross-sectional view of a PX 300 including a flow adapter 330 (e.g., an adapter plate) according to certain embodiments. FIG. 3B shows a front perspective view of the flow adapter 330 according to certain embodiments. FIG. 3C shows a top perspective view of the flow adapter 330 according to certain embodiments. FIG. 3D shows a bottom perspective view of the flow adapter 330 according to certain embodiments. FIG. 3E shows a side view of the flow adapter 330 according to certain embodiments. FIG. 3F shows a front view of the flow adapter 330 according to certain embodiments. FIG. 3G shows a plan view of the flow adapter 330 according to certain embodiments. FIG. 3H shows a bottom view of the flow adapter 330 according to certain embodiments. FIG. 3I shows a front perspective view of the flow adapter 330 according to certain embodiments. FIG. 3J shows a front perspective view of the PX 300 including the flow adapter 330 according to certain embodiments. FIG. 3K shows a plan view of the PX 300 including the flow adapter 330 according to certain embodiments. FIG. 3L shows a partial cross-sectional front perspective view of a PX 300 including a flow adapter 330, according to certain embodiments.

[0057] Referring to FIG. 3A, PX 300 may include rotor 310, end covers 320A-B, flow adapters 330A-B, seal plates 340A-B, end caps 350A-B, shaft 360, sleeve 370, housing 380, and external ports 382 (e.g., low pressure and high pressure ports).

[0058] The rotor 310 may be configured to exchange pressure between a first fluid and a second fluid. An end cover 320 may be disposed at a distal end of the rotor 310. Each end cover 320 defines one or more end cover low pressure ports 322A and one or more end cover high pressure ports 332B. In some embodiments, the end cover 320 defines at least two low pressure ports and at least two high pressure ports (e.g., multi-cycle PX 300).

[0059] The flow adaptor 330 may include a planar surface 332, a distal end 334, and an upper surface 336. The planar surface 332 may form planar openings 333 (e.g., planar low pressure opening 333A and planar high pressure opening 333B). The planar surface 332 is configured to seal against the end cover 320 (e.g., via a face seal 338, via a radial seal). The distal end 334 forms a distal low pressure opening 335. Low pressure fluid flow is between the end cover low pressure port 332A and the distal low pressure opening 335 via the planar low pressure opening 333A. The flow adaptor 330 may form low pressure paths from the planar low pressure opening 333A that merge into a single path toward the distal low pressure opening 335. The upper surface 336 forms an upper high pressure opening 337. The flow adapter 330 can form a high pressure path (e.g., a separate high pressure path for each planar high pressure opening 333B) from the planar high pressure opening 333B to the corresponding upper high pressure opening 337. High pressure fluid flow is between the end cover high pressure port and the upper high pressure opening 337 via the planar high pressure openings 333B.

[0060] In some embodiments, the flow adapter 330 is configured to direct a flow path between the end cover 320 and external ports 382 (eg, low pressure and high pressure ports) of the PX 300.

[0061] In some embodiments, the flow adapter 330 is configured to set the pressure distribution on the end cover 320 .

[0062] In some embodiments, the flow adapter 330 is configured to seal against the end cover 320 and provide a sealed pathway between the end cover 320 and external ports 382 (e.g., low pressure and high pressure ports) of the PX 300.

[0063] In some embodiments, the flow adapter 330 has a substantially uniform wall thickness (see, e.g., Figures 3B-H), and in some embodiments, the flow adapter is injection molded (e.g., has ribs that have a substantially uniform thickness, see Figure 3I).

[0064] In some embodiments, the end cover 320 forms at least two low pressure ports 322A and at least two high pressure ports 322B. The flow adapter 330 is configured to mix the fluid flows from the at least two low pressure ports 322A (e.g., at a distal low pressure opening 335) and provide the mixed fluid flow to a low pressure external port 382 (e.g., a low pressure port).

[0065] In some embodiments, the flow adapter 330 mixes the fluid flow from the end cover low pressure port 322A of the end cover 320 proximate the center of the end cover 320 and reduces deflection of the end cover 320 relative to the rotor 310 (e.g., reducing high pressure proximate the center of the end cover 320).

[0066] In some embodiments, the planar surface 332 of the flow adapter 330 is configured to seal against the end cover 320 via a face seal 338 (eg, a gasket, an O-ring) or a radial seal.

[0067] In some embodiments, the flow adapter 330 comprises an overmolded construction (eg, an overmolded steel construction or an overmolded ceramic construction).

[0068] In some embodiments, the flow adapter 330 is the interface between the PX cartridge (e.g., rotor 310, end cover 320, and sleeve 370) and the housing (e.g., seal plate 340, housing 380, end cap 350) to direct the flow path and set the pressure distribution.

[0069] The PX cartridge (e.g., rotor 310, sleeve 370, and two end covers 320 that govern the HP and LP flows entering rotor 310) has a sealed passage (e.g., via flow adapter 330) that routes the HP and LP flows from housing 380 and external ports 382 (e.g., low and high pressure ports) into end covers 320. Flow adapter 330 provides a sealed passage with performance and cost advantages and increased design flexibility over conventional solutions.

[0070] Flow adapter 330 is sealed against the rear of end cover 320 (e.g., the surface of end cover 320 opposite the surface of the end cover adjacent rotor 310). Flow adapter 330 mixes the fluid flows from the LP ports and routes the fluid flows from the LP ports (e.g., toward low pressure external port 382). Flow adapter 330 mixes the fluid flows from the HP ports and routes the fluid flows from the HP ports (e.g., toward high pressure external port 382).

[0071] The flow adapter 330 can avoid expensive machining (e.g., forming bores therein) of the ceramic end cover 320. Complex geometries can be transferred from a conventional end cover to the flow adapter 330 (e.g., instead of machining complex geometries into a ceramic end cover, a flow adapter 330 having complex geometries can be produced more cheaply via injection molding).

[0072] In some embodiments, end cover 320 has two HP ports and two LP ports (e.g., there may be more than two or less than two each of the HP and LP ports). Flow adapter 330 seals against the rear side of end cover 320. The geometry of flow adapter 330 allows the LP flow to mix with the LP flow and the HP flow to mix with the HP flow, and seals therebetween (e.g., prevents the LP fluid flow from mixing with the HP fluid flow).

[0073] In some embodiments, the two LP ports of the end cover 320 mix toward the center / inner portion of the flow adapter 330, and the HP ports mix at the outer portion of the flow adapter 330. By mixing the LP fluids toward the center of the flow adapter 330, this can reduce the amount of pressure force on the center of the end cover 320. This can reduce deflection of the end cover 320 toward the rotor 310.

[0074] By varying the diameter of the LP outlet port at the top (eg, distal end 334) of the flow adapter 330, the amount of pressure exerted on the end cover 320 can be varied.

[0075] The PX 300 with flow adapter 330 can avoid the use of interconnects and bores that are machined into the rear of the end cover in conventional systems. Machining the interconnects and bores increases the cost of conventional systems. Also, in conventional systems, the bores may take up a significant amount of space in the end cover. By using the flow adapter 330 (e.g., as well as face seal 338 and / or radial seal), the PX 300 may have a smoother flow path with more flexibility in how to shape the path through the end cover 320.

[0076] In some embodiments, complex geometries are transferred to the flow adapter 330, allowing for simplification of the end cover 320.

[0077] The flow adapter 330 allows for greater design flexibility (e.g., it may no longer be necessary to provide an interconnecting bore) and the ports in the end cover 320 can be located closer to the outer diameter (e.g., of the end cover 320). This allows the PX 300 to have a center post design (e.g., a sleeveless design).

[0078] Overmolded features (e.g., made of steel or ceramic) may be covered by the flow adapter 330 to increase strength and rigidity as needed. In some embodiments, the use of the flow adapter 330 may enable the PX to have a thinner (e.g., very thin) end cover 320 compared to conventional solutions. Conventionally, the end cover 320 is made of thick ceramic (e.g., stiff, less deformable, good bearing material). By using the flow adapter 330 to have a design that properly compensates for pressure (e.g., equal pressure forces from the front to the back of the end cover 320), the end cover 320 can become thinner and thinner to the point where the end cover 320 can be a thin slab with all the complex flow geometries and the sealing surfaces molded into the flow adapter 330 or the flow adapter 330 can simply interface directly with the rotor 310.

[0079] In some embodiments, the flow adapter 330 can balance the pressure distribution on the end cover 320, which can minimize deflection (e.g., of the end cover 320) and leakage (through the interface between the end cover 320 and the rotor 310), leading to improved performance of the PX 300.

[0080] The flow adapter 330 may be injection molded to provide a hydraulically smooth flow path to minimize differential pressure (DP) losses and improve the efficiency of the PX 300.

[0081] In some embodiments, the flow adapter 330 reduces and / or eliminates several expensive parts in the PX design, resulting in reduced cost, materials, time, and waste.

[0082] In some embodiments, the flow adapter 330 is used with a PX having a single cycle PX design (e.g., a single LP port and a single HP port in the end cover 320) or a multi-cycle PX design (e.g., two or more LP ports, two or more HP ports). In some embodiments, the end cover 320 has the same number of LP ports as HP ports (e.g., two LP ports and two HP ports).

[0083] In some embodiments, the flow adapter 330 is used with a PX that has a sleeve. In some embodiments, the flow adapter 330 is used with a PX that does not have a sleeve (e.g., a center post type PX).

[0084] The flow adapter 330 may simplify the design of the end cover 320 and may reduce the manufacturing complexity of the end cover 320 .

[0085] The flow adapter 330 may be used to reduce the height, weight, and / or footprint of the PX 300.

[0086] In some embodiments, the flow adapter 330 is made from a metal (e.g., aluminum, steel). In some embodiments, the flow adapter 330 is made from a plastic (e.g., injection molded plastic).

[0087] In some embodiments, the flow adapter 330 is configured to distribute high and low pressure regions behind the end cover 320 in a specific ratio that substantially matches the pressure distribution that exists in front of the end cover 320 facing the rotor 310. In some embodiments, this is done by using a groove at the interface between the flow adapter 330 and the end cover 320 and a gasket (e.g., an O-ring) in the groove (e.g., the planar surface 332 of the flow adapter 330 forms a groove and a gasket is placed in the groove; e.g., the end cover surface adjacent to the flow adapter 330 forms a groove and a gasket is placed in the groove). This minimizes deflection of the end cover in the axial direction, which avoids using a large axial bearing clearance (e.g., between the rotor 310 and the end cover 320) to accommodate deflection of the end cover. A shorter and more spatially uniform axial bearing clearance may allow for reduced leakage and increased efficiency of the PX. Mixing through the bearing gap may also be reduced.

[0088] 3M-N show a system 301 including a PX 300, according to certain embodiments. System 301 may include a pump 390 (e.g., a lube pump), a regulator 392 (e.g., a hydraulic regulator), a controller 394, and a sensor 396 (e.g., a lube flow sensor).

[0089] This pressure distribution may work well through the flow adapter 330 (e.g., a flow adapter 330 configured to passively control the end cover 320 pressure) when the PX 300 is configured to operate in one condition. This may not always be met, and HP / LP differential pressures may change the resulting differential pressure distribution and the interface between the end cover 320 and the rotor 310. The pressure of the center bore fluid supply may vary by design (e.g., by switching the center bore due to fluid composition or other considerations) or may naturally vary over time due to wear, erosion, deposition, etc. in the pressure equalization channels, etc. Similarly, the pressure in the circumferential grooves may vary by design (e.g., outer bearing fluid supply) or may naturally vary due to contamination, wear, etc.

[0090] In some embodiments, an active end cover pressure balance system is used to match the changing pressure distribution on the rotor end surface of the end cover 320. In this way, the deflection of the end cover is kept controlled to create optimal flow (e.g., optimal leakage flow). This can be achieved by creating a chamber 398 (e.g., area, volume enclosed by a gasket) between the flow adapter 330 and the end cover 320. The pressure inside can be regulated by a regulator 392 (e.g., hydraulic regulator) driven by a controller 394 (see, e.g., FIG. 3M). A pump 390 (e.g., lubricant pump) or a pressurized fluid source can be connected to the channel through the regulator 392 (e.g., hydraulic regulator). The controller 394 senses the lubricant flow (leakage and loss of compressibility) of the PX 300 (via sensor data from sensor 396) and adjusts the regulator 392 (e.g., hydraulic regulator). Adjusting regulator 392 adjusts the pressure in chamber 398, which in turn adjusts the deflection of the end cover that results in reverse lubricant flow (e.g., for optimal performance) within limits.

[0091] Another common cause of increased lubricant flow can be axial eccentricity of the rotor 310. A rotor 310 that is not axially centered can have a larger (e.g., much larger) lubricant flow than a well-centered rotor 310. Even if the rotor 310 and end cover 320 are configured to provide near-zero axial thrust on the rotor 310 at the designed point and the axial bearings are designed to provide adequate stiffness, rotor eccentricity can still occur. Rotor axial eccentricity can occur due to unequal pressure differentials on the HP and LP sides across the rotor 310 during operation. Eccentricity can also occur due to changing operating conditions, e.g., dirty bearings, center bore pressure changes. To overcome this, an active rotor balancing system (e.g., FIG. 3N) can be used.

[0092] 3N, system 301 may include an active rotor balancing system. Pressure within one or more circumferential grooves 399 may be adjusted (e.g., see FIG. 3N) using regulator 392 (e.g., a hydraulic regulator) to axially center rotor 310. Controller 394 senses (e.g., via sensor data from sensor 396) an increase in lubricant flow (e.g., above a threshold) and adjusts pressure within one or more circumferential grooves 399 (e.g., varying rotor thrust and bearing stiffness) to return rotor 310 to a centered position and to bring lubricant flow within limits.

[0093] The present disclosure has application to pressure exchangers in refrigeration systems, such as transcritical carbon dioxide (CO2) refrigeration systems, although the present disclosure may be used in any area of ​​pressure exchanger applications.

[0094] The present disclosure may enable the use of high pressure and / or high velocity gas or multi-phase fluids in a pressure exchanger by providing a flow adapter 330.

[0095] The present disclosure (eg, one or more of the embodiments of FIGS. 3A-N) may have improvements over conventional solutions in one or more of pressure range, efficiency, volume, cost reduction, and the like.

[0096] FIG. 4 is a flow diagram illustrating a method 400 associated with controlling pressure in a pressure exchanger (e.g., one or more PXs 300 of FIGS. 3A-N), according to certain embodiments. In some embodiments, the method 400 is performed by processing logic including hardware (e.g., circuits, dedicated logic, programmable logic, microcode, a processing device, etc.), software (e.g., instructions running on a processing device, a general purpose computer system, or a dedicated machine), firmware, microcode, or a combination thereof. In some embodiments, the method 400 is performed, at least in part, by a controller (e.g., one of the control modules 180 or the controller 185 of FIGS. 1A-D, the control module 94 of FIGS. 2A-E, the controller 394 of FIGS. 3M-N). In some embodiments, a non-transitory storage medium stores instructions that, when executed by a processing device (e.g., one of the control modules 180 or the controller 185 of FIGS. 1A-D, the control module 94 of FIGS. 2A-E, the controller 394 of FIGS. 3M-N), cause the processing device to perform the method 400.

[0097] For simplicity of explanation, method 400 is depicted and described as a series of operations, although operations in accordance with the present disclosure may occur in various orders and / or simultaneously, together with other operations not shown and described herein. Moreover, in some embodiments, not all of the illustrated operations are performed to implement method 400 in accordance with the subject matter of the present disclosure. In addition, those skilled in the art will understand and appreciate that method 400 may alternatively be represented as a series of interrelated states via a state diagram or events.

[0098] At block 402, processing logic (e.g., a controller) receives sensor data from a sensor. The sensor data can be pressure data between the end cover and the flow adapter or between the end cover and the rotor. In some embodiments, the sensor data can be lubricant flow rate of PX (e.g., flow rate difference between HPin and HPout).

[0099] At block 404, processing logic determines an active adjustment of the pressure provided at the end cover based on the sensor data. The active adjustment may increase or decrease the pressure between the end cover and the flow adapter or between the end cover and the rotor.

[0100] At block 406, processing logic causes active adjustment of pressure at the end cover based on the sensor data. Processing logic may repeat method 400 periodically.

[0101] In some embodiments, the processing logic causes active regulation of pressure via the lubricant pump (e.g., between the flow adapter 330 and the end cover 320). In some embodiments, the processing logic causes active regulation of pressure at the surface of the end cover (e.g., between the end cover and the adapter plate, between the end cover and the rotor). In some embodiments, the processing logic causes active regulation of pressure in a circumferential groove between the rotor and the end cover.

[0102] 5 is a block diagram illustrating a computer system 500 according to some embodiments. In some embodiments, computer system 500 may be a controller, a controller device, a client device, a server, control module 180 or controller 185 of FIGS. 1A-D, control module 94 of FIGS. 2A-E, controller 394 of FIGS. 3M-N, etc.

[0103] In some embodiments, computer system 500 is connected to other computer systems (e.g., via a network such as a local area network (LAN), an intranet, an extranet, or the Internet). Computer system 500 operates in the capacity of a server or client computer in a client-server environment, or as a peer computer in a peer-to-peer or distributed network environment. In some embodiments, computer system 500 is provided by a personal computer (PC), a tablet PC, a set-top box (STB), a personal digital assistant (PDA), a mobile phone, a web appliance, a server, a network router, switch or bridge, or any device capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that device. Furthermore, the word "computer" is intended to include any collection of computers that individually or cooperatively execute a set (or sets) of instructions to implement any one or more of the methods described herein.

[0104] In some embodiments, computer system 500 includes a processing unit 502, volatile memory 504 (e.g., Random Access Memory (RAM)), non-volatile memory 506 (e.g., Read-Only Memory (ROM) or Electrically Erasable Programmable ROM (EEPROM)), and / or data storage device 516, which communicate with each other via a bus 508.

[0105] In some embodiments, processing unit 502 comprises one or more processors, such as a general purpose processor (e.g., a Complex Instruction Set Computing (CISC) microprocessor, a Reduced Instruction Set Computing (RISC) microprocessor, a Very Long Instruction Word (VLIW) microprocessor, a microprocessor that executes other types of instruction sets, or a combination of multiple types of instruction sets, etc.) or a specialized processor (e.g., an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a Digital Signal Processor (DSP), a PID controller, or a network processor, etc.). In some embodiments, processing unit 502 comprises one or more of a single processor, multiple processors, a single processor with multiple processing cores, and / or the like.

[0106] In some embodiments, computer system 500 further comprises a network interface device 522 (e.g., coupled to network 574). In some embodiments, computer system 500 comprises one or more input / output (I / O) devices. In some embodiments, computer system 500 also includes a video display unit 510 (e.g., a liquid crystal display (LCD)), an alphanumeric input device 512 (e.g., a keyboard), a cursor control device 514 (e.g., a mouse), and / or a signal generating device 520. Computer system 500 may comprise a signal input device 515, e.g., for receiving signals from other devices. For example, signal input device 515 facilitates receipt by computer system 500 of measurement data from sensors associated with the fluid processing system. Signal generating device 520 may be utilized to generate and / or transmit control signals for transmitting commands to one or more components of the fluid processing system.

[0107] In some implementations, data storage 518 (e.g., disk drive storage, fixed and / or removable storage devices, fixed disk drives, removable memory cards, optical storage, network attached storage (NAS), and / or storage area networks (SAN)) comprises a non-transitory computer readable storage medium 524 that stores instructions 526 that encode any one or more of the methods or functions described herein and are for performing the methods described herein. A control module 527 (e.g., including any of the controllers and / or control modules of the present disclosure) may include instructions 526.

[0108] In some embodiments, the instructions 526 also reside, completely or partially, within the volatile memory 504 and / or the processing unit 502 during execution thereof by the computer system 500. Thus, the volatile memory 504 and the processing unit 502 also constitute machine-readable storage media in some embodiments.

[0109] Although computer-readable storage medium 524 is shown as a single medium in the illustrative example, the term "computer-readable storage medium" is intended to include single or multiple media (e.g., centralized or distributed databases and / or associated caches and servers) that store one or more sets of executable instructions. The term "computer-readable storage medium" is also intended to include any tangible medium that can store or encode a set of instructions for execution by a computer that causes the computer to perform one or more of the methods described herein. The term "computer-readable recording medium" is also intended to include, but is not limited to, solid-state memories, optical media, and magnetic media.

[0110] The methods, components, and features described herein may be performed by individual hardware components or may be integrated into the functionality of other hardware components, such as an ASIC, FPGA, DSP, or similar device. Additionally, the methods, components, and features may be performed by firmware modules or functional circuits within a hardware device. Furthermore, the methods, components, and features may be implemented in any combination of hardware and computer program components, or in a computer program.

[0111] Unless otherwise specified and unless otherwise clear from the context, words such as "receive," "transmit," "determine," "generate," "cause," "operate," "regulate," "control," "identify," "provide," and similar words refer to acts or processes performed or carried out by a computer system that manipulate and transform data represented as physical quantities (electrical quantities) in a register or memory of the computer system into other data also represented as physical quantities in the memory or register of the computer system, or other such information storage, transmission, or display device. Also, as used herein, words such as "first," "second," "third," "fourth," and the like are meant as labels to distinguish different elements and do not necessarily have a hierarchical meaning according to their numerical designations.

[0112] The embodiments described herein also relate to an apparatus for performing the methods described herein. The apparatus may be specially configured to perform the methods described herein, or may comprise a general-purpose computer system selectively programmed by a computer program stored in the computer system. Such a computer program may be stored on a computer-readable tangible storage medium.

[0113] The methods and illustrative examples described herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may be used in accordance with the teachings described herein, or it may prove convenient to construct more specialized apparatus to perform the methods described herein and / or each of their individual functions, routines, subroutines or operations. Examples of structures for various such systems are set forth in the description above.

[0114] Although the operations of the methods herein are shown and described in a particular order, the order of the operations of each method may be changed such that certain operations may be performed in reverse order, or such that certain operations may be performed at least in part concurrently with other operations. In other embodiments, instructions of separate operations or sub-operations may be intermittent and / or interleaved.

[0115] In the above description, numerous specific details are described, such as examples of specific systems, components, methods, etc., to fully understand some embodiments of the present disclosure. However, it will be apparent to one skilled in the art that at least some embodiments of the present disclosure may be practiced without such specific details. In other instances, well-known components or methods are not described in detail or are presented in simple block diagram form to avoid unnecessarily obscuring the present disclosure. Thus, the specific details described are merely exemplary. A particular implementation may vary from such example details and still be considered within the scope of the present disclosure. The description of the system herein may include a description of one or more optional components. Components may be included in combinations not specifically discussed in the present disclosure, and such components may still be within the scope of the present disclosure.

[0116] References throughout this specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the appearances of the phrase "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or". When the terms "about", "substantially" or "approximately" are used herein, this is intended to mean that the stated nominal value is accurate to within 10%. In addition, the terms "first", "second", "third", "fourth", etc., used herein are intended as labels to distinguish different elements and do not necessarily have an ordinal meaning according to their numerical designations.

[0117] As used herein, the terms "throughout," "under," "between," "disposed on," "before," "after," and "on" refer to the location of a layer of material or component relative to another layer or component. For example, a layer that is disposed over, through, or under another layer may be in direct contact with the other layer or there may be one or more intervening layers. Further, a layer that is disposed between two layers may be in direct contact with the two layers or there may be one or more intervening layers. Similarly, unless expressly stated otherwise, a feature that is disposed between two features may be in direct contact with the adjacent feature or there may be one or more intervening layers or components.

[0118] It is to be understood that the above description is intended to be illustrative, and not limiting. Many other embodiments will be apparent to those skilled in the art upon reading and understanding the above description. Thus, the scope of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which each claim is entitled.

Claims

1. A pressure exchanger, comprising: a rotor configured to exchange pressure between a first fluid and a second fluid; an end cover disposed at a first distal end of the rotor, the end cover defining an end cover low pressure port and an end cover high pressure port; A flow adapter, the flow adapter comprising: a planar surface forming a planar low pressure opening and a planar high pressure opening, the planar surface configured to seal against the end cover; a distal end defining a distal low pressure opening, wherein low pressure fluid flow exists between the end cover low pressure port and the distal low pressure opening through the planar low pressure opening; a flow adapter having an upper surface forming an upper high pressure opening, wherein high pressure fluid flow exists between the end cover high pressure port and the upper high pressure opening through the planar high pressure opening.

2. The pressure exchanger of claim 1 , wherein the flow adapter is configured to direct a flow path between the end cover and an external port of the pressure exchanger.

3. 2. The pressure exchanger of claim 1, wherein the flow adaptor is configured to set a pressure distribution on the end cover to reduce deflection of the end cover relative to the rotor.

4. The pressure exchanger of claim 1 , wherein the flow adapter is configured to seal against the end cover to provide a sealed path between the end cover and an external port of the pressure exchanger.

5. The pressure exchanger of claim 1 , wherein the flow adapter is injection molded.

6. 2. The pressure exchanger of claim 1, wherein the end cover defines at least two low pressure ports and at least two high pressure ports, and the flow adapter mixes fluid flows from the at least two low pressure ports and delivers the mixed fluid flow to a low pressure external port.

7. 2. The pressure exchanger of claim 1, wherein the flow adapter mixes fluid flow from the end cover low pressure ports of the end cover proximate a center of the end cover to reduce deflection of the end cover relative to the rotor.

8. The pressure exchanger of claim 1 , wherein the planar surface of the flow adapter is configured to seal against the end cover via a face seal or a radial seal.

9. The pressure exchanger of claim 1 , wherein the flow adapter comprises an overmolded steel construction or an overmolded ceramic construction.

10. A flow adapter for a pressure exchanger, the flow adapter comprising: a planar surface forming a planar low pressure opening and a planar high pressure opening, a face seal disposed between the planar surface and an end cover for sealing the flow adapter to the end cover, the end cover forming at least two end cover low pressure ports and at least two end cover high pressure ports; a distal end defining a distal low pressure opening, wherein low pressure fluid flow is between the end cover low pressure port and the distal low pressure opening through the planar low pressure opening; a top surface defining an upper high pressure opening, high pressure fluid flow being between the end cover high pressure port and the upper high pressure opening through the planar high pressure opening.

11. The flow adaptor of claim 10 , wherein the flow adaptor is configured to direct a flow path between the end cover and an external port of the pressure exchanger.

12. The flow adaptor of claim 10 , wherein the flow adaptor is configured to set a pressure distribution on the end cover.

13. The flow adaptor of claim 10 , wherein the flow adaptor is configured to seal against the end cover to provide a sealed path between the end cover and an external port of the pressure exchanger.

14. The flow adapter of claim 10 , wherein the flow adapter is injection molded.

15. 11. The flow adapter of claim 10, wherein the flow adapter is configured to mix fluid flow from the end cover low pressure ports of the end cover proximate a center of the end cover and reduce deflection of the end cover relative to a rotor of the pressure exchanger.

16. The flow adapter of claim 10 , wherein the flow adapter comprises an overmolded steel construction or an overmolded ceramic construction.

17. 1. A system comprising: A pressure exchanger, comprising: A rotor; an end cover disposed at a distal end of the rotor; a flow adapter configured to passively control pressure at the end cover; and A controller, the controller comprising: receiving sensor data from the lubricant flow sensor; a controller configured to cause active adjustment of the pressure at the end cover based on the sensor data.

18. The system of claim 17 , wherein the controller causes active regulation of the pressure via a lubricant pump.

19. The system of claim 17 , wherein the controller causes active regulation of the pressure at a surface of the end cover.

20. The system of claim 17 , wherein the controller causes active regulation of the pressure in a circumferential groove between the rotor and the end cover.

Images