Non-axial flow pressure exchanger

Abstract

The pressure exchanger includes a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first fluid and the second fluid, a sleeve disposed around the rotor such that the first fluid enters the rotor radially through the sleeve, and a post disposed inside the rotor.

Description

[Technical Field]

[0001] The present disclosure relates to pressure exchangers, and more particularly to non-axial flow pressure exchangers. [Background technology]

[0002] The system uses fluids at different pressures. The system uses components to increase the pressure of the fluids.

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

[0004] [Figure 1A] FIG. 1A shows a schematic diagram of a fluid treatment system including a hydraulic energy transfer system, according to certain embodiments. [Figure 1B] FIG. 1B shows a schematic diagram of a fluid treatment system including a hydraulic energy transfer system, according to certain embodiments. [Figure 1C] FIG. 1C shows a schematic diagram of a fluid treatment system including a hydraulic energy transfer system, according to certain embodiments. [Figure 1D] FIG. 1D shows a schematic diagram of a fluid processing system including a hydraulic energy transfer system, according to certain embodiments. [Figure 2A] FIG. 2A is an exploded perspective view of a pressure exchanger (PX), according to some embodiments. [Figure 2B] FIG. 2B is an exploded perspective view of a pressure exchanger (PX), according to some embodiments. [Figure 2C] FIG. 2C is an exploded perspective view of a pressure exchanger (PX), according to some embodiments. [Figure 2D] FIG. 2D is an exploded perspective view of a pressure exchanger (PX), according to some embodiments. [Figure 2E] FIG. 2E is an exploded perspective view of a pressure exchanger (PX), according to some embodiments. [Figure 3A]FIG. 3A shows a perspective view of the components of a PX according to some embodiments. [Figure 3B] FIG. 3B shows a cross-sectional view of components of a PX according to some embodiments. [Figure 3C] FIG. 3C shows a top or bottom view of the rotor of a PX according to some embodiments. [Figure 4A] FIG. 4A shows a perspective view of the components of a PX, according to some embodiments. [Figure 4B] FIG. 4B shows a cross-sectional view of components of a PX according to some embodiments. [Figure 4C] FIG. 4C shows a cross-sectional view of components of a PX according to some embodiments. [Figure 4D] FIG. 4D shows a perspective view of the components of a PX according to some embodiments. [Figure 4E] FIG. 4E shows a cross-sectional view of components of a PX according to some embodiments. [Figure 4F] FIG. 4F shows a cross-sectional view of components of a PX according to some embodiments. [Figure 4G] FIG. 4G shows a perspective view of the components of a PX according to some embodiments. [Figure 5A] FIG. 5A shows components of a PX according to some embodiments. [Figure 5B] FIG. 5B illustrates components of a PX according to some embodiments. [Figure 6A] FIG. 6A shows components of a PX according to some embodiments. [Figure 6B] FIG. 6B illustrates components of a PX according to some embodiments. [Figure 7A] FIG. 7A illustrates components of a PX according to a specific embodiment. [Figure 7B] FIG. 7B illustrates components of a PX according to a specific embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0005] The embodiments described herein relate to non-axial flow pressure exchangers (eg, pressure exchangers with non-axial fluid flow into and / or fluid flow out of a rotor).

[0006] A system may use fluids at different pressures. One supply of fluid to a system may be at low pressure, while one or more portions of the system operate at higher pressures. A system may include a closed loop, with various fluid pressures maintained in different portions of the loop. These systems may include hydraulic fracturing (e.g., fracking or fracing) systems, desalination systems, refrigeration systems, heat pump systems, power generation systems, mud pump systems, slurry pump systems, industrial fluid systems, waste fluid systems, fluid transport systems, etc. Pumps or compressors may be used to increase the pressure of fluids in such systems.

[0007] Traditionally, systems (e.g., refrigeration systems, heat pump systems, reversible heat pump systems, water-based systems, etc.) use pumps or compressors to increase the pressure of a fluid (e.g., a refrigerant fluid such as carbon dioxide (CO), R-744, R-134a, hydrocarbons, hydrofluorocarbons (HFCs), hydrochlorofluorocarbons (HCFCs), ammonia (NH), refrigerant mixtures, R-407A, R-404A, etc.). Traditionally, a separate pump or compressor mechanically coupled to a motor has been used to increase the fluid pressure in any part of the system, including the part where the fluid pressure is increased. Pumps and compressors, especially those operating at large pressure differentials (e.g., causing large pressure increases in the fluid), require a large amount of energy. Therefore, traditional systems consume a large amount of energy to increase the fluid pressure (via a pump or compressor driven by a motor). Furthermore, traditional heat transfer systems reduce the fluid pressure through an expansion valve and / or a heat exchanger (e.g., a condenser and / or evaporator, etc.). Conventional systems raise and lower fluid pressure inefficiently, which is wasteful in terms of the energy used to operate the conventional system (e.g., the energy used to repeatedly raise the pressure of the refrigerant fluid to raise or lower the temperature of the surrounding environment). Conventional systems have unintended leaks and mixing within the PX.

[0008] The systems, apparatus, and methods of the present disclosure provide solutions to these and other drawbacks 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 can be configured to exchange pressure between a first fluid (e.g., a high-pressure portion of a refrigerant fluid in a refrigeration cycle) and a second fluid (e.g., a low-pressure portion of a refrigerant fluid in a refrigeration cycle). The PX can receive the first fluid (e.g., a portion of the high-pressure refrigerant fluid) via a first inlet (e.g., a high-pressure inlet) and the second fluid (e.g., a portion of the low-pressure refrigerant fluid) via a second inlet (e.g., a low-pressure inlet). The first fluid can be at a higher pressure than the second fluid upon entering the PX. The PX can exchange pressure between the first fluid and the second fluid. A first fluid may exit the PX through a first outlet (e.g., a low-pressure outlet), and a second fluid may exit the PX through a second outlet (e.g., a high-pressure outlet). Upon exiting the PX, the second fluid may be at a higher pressure than the first fluid (e.g., pressure has been exchanged between the first and second fluids).

[0009] In some embodiments, the PX includes a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. The PX may further include a sleeve disposed about the rotor, such that the first fluid enters the rotor radially through the sleeve. The PX may further include a stationary post disposed within the rotor.

[0010] In some embodiments, the second fluid may enter the rotor radially through a post. The post may define either a first low pressure in (LPIN) port and a first low pressure out (LPOUT) port, or a first high pressure in (HPIN) port and a first high pressure out (HPOUT) port. The post may further define either a second LPIN port and a second LPOUT port, or a second HPIN port and a second HPOUT port. The sleeve may define either a first LPIN port and a first LPOUT port, or a first HPIN port and a first HPOUT port. The sleeve may further define either a second LPIN port and a second LPOUT port, or a second HPIN port and a second HPOUT port.

[0011] In some embodiments, the rotor may be configured to rotate about an axis of rotation, and the sleeve may define angled ports disposed about a port axis, where the port axis does not intersect the axis of rotation.

[0012] In some embodiments, the posts may form angled ports arranged about a port axis, where the port axis does not intersect the axis of rotation.

[0013] In some embodiments, the rotor defines multiple ducts, and at least one of the first fluid and the second fluid enters the rotor radially through the multiple ducts. In some embodiments, the multiple ducts may be flute-shaped. A flute-shaped duct may refer to a duct formed by the surface of the rotor. The surface of the rotor may form substantially parallel grooves or channels (the flute-shaped ducts). The flute-shaped ducts may be oriented along the length of the rotor. The flute-shaped ducts may have a uniform shape and depth, forming a consistent pattern across the surface of the rotor. In some embodiments, the flute-shaped ducts may be covered by a sleeve that surrounds the rotor, thereby sealing the flute-shaped ducts. In some embodiments, the flute-shaped ducts may be formed by the rotor (e.g., grooves or channels on the outer surface of the rotor). The flute-shaped ducts may vary in depth, width, and shape. The flute-shaped ducts may be passages (conduits) used to control fluid or gas flow, improve heat transfer, and increase pressure exchange efficiency. The rotor has a planar top surface, a planar bottom surface, a curved inner surface (where the posts are located), and a curved outer surface. The curved outer surface may form a fluted duct. The rotor and sleeve form a passage or conduit between the fluted duct and the inner surface of the sleeve. In some embodiments, the sleeve (e.g., disposed around the rotor) may seal the flutes (e.g., to retain a fluid). The sleeve may be a cylindrical casing that encloses the rotor and covers the fluted duct. This seal causes (e.g., ensures) the fluid or gas within the fluted duct is retained and directed according to a desired flow pattern, reducing (e.g., preventing) unintended leakage or mixing compared to conventional systems.

[0014] In some embodiments, the PX includes a rotor configured to exchange pressure between a first fluid and a second fluid, the rotor defining a rotor cavity. In some embodiments, the rotor includes an outer surface, the first fluid radially entering the rotor through the outer surface. The rotor further includes an inner surface defining the rotor cavity, the second fluid radially entering the rotor through the inner surface.

[0015] In some embodiments, the PX further includes a post disposed within the rotor cavity, the post forming a post cavity, such that the second fluid enters the post cavity axially, exits the post cavity radially, and enters the rotor radially. The rotor may define ducts, such that at least one of the first fluid or the second fluid enters the rotor radially and enters at least one of the ducts. The ducts may be fluted. In some embodiments, the flutes of the fluted duct may open onto at least one of a sleeve or a post disposed around the rotor. The duct may extend across the rotor, beginning near a first distal end of the rotor and terminating near a second distal end of the rotor.

[0016] In some embodiments, the flutes of a flute-shaped duct may refer to individual grooves or channels (e.g., formed by a flute-shaped duct) on the outer surface of the rotor. In some embodiments, flutes may be concave features on the surface of the rotor. Flutes may vary in terms of their depth, width, and shape and may be pathways (conduits) for the flow of fluids or gases. In some embodiments, flutes may be channels or grooves formed by a flute-shaped duct.

[0017] In some embodiments, the ducts may be arranged in a helical path through the rotor. The helical ducts may be fluted and may be formed by the outer surface of the rotor or the inner surface of the rotor. The helical ducts may also be internal channels within the body of the rotor (e.g., surrounded by the rotor and not by the rotor / sleeve combination).

[0018] In some embodiments, the rotor may be configured to rotate about an axis of rotation, and the sleeve may form angled ports disposed about a port axis, where the port axis does not intersect the axis of rotation.

[0019] In some embodiments, the rotor may be configured to rotate about an axis of rotation, and the posts may form angled ports arranged about a port axis, where the port axis does not intersect the axis of rotation.

[0020] In some embodiments, PX includes a rotor forming a radial duct. The radial duct may be a duct arranged in a radial pattern. For example, the radial duct may extend outward from a center point or central axis of the rotor. The radial duct may be configured to extend directly from the central axis of the rotor's cross-sectional circle toward the outer periphery of the rotor's cross-sectional circle. The duct may be linear, emanating from the geometric center of the cross-sectional circle and reaching the outer surface of a cylindrical rotor.

[0021] The rotor may be configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. PX may include a post disposed within a cavity formed by the rotor, where the first fluid radially enters the rotor through a first port of a first pair of ports formed by a sleeve or post disposed around the rotor, enters one of the radial ducts, and radially exits the rotor through a second port of the first pair of ports.

[0022] In some embodiments, PX includes a second pair of ports formed by a sleeve or a post. The sleeve is disposed around the rotor and the post is disposed within the rotor cavity. In some embodiments, the second pair of ports includes either a low pressure in (LPIN) port and a high pressure out (HPOUT) port, or a high pressure in (HPIN) port and a low pressure out (LPOUT) port.

[0023] In some embodiments, the first pair of ports formed by the sleeve or post may include either an LPIN port and an HPOUT port, or an HPIN port and an LPOUT port.

[0024] In some embodiments, the rotor may be configured to rotate about an axis of rotation, and the sleeve may form angled ports disposed about a port axis, where the port axis does not intersect the axis of rotation.

[0025] In some embodiments, the rotor may be configured to rotate about an axis of rotation, and the posts may form angled ports arranged about a port axis, where the port axis does not intersect the axis of rotation.

[0026] In some embodiments, the PX includes a third pair of ports formed by a sleeve or a post. The third pair of ports may include either an LPIN port and an HPOUT port, or an HPIN port and an LPOUT port.

[0027] In some embodiments, the PX includes a fourth port pair formed by a sleeve or post. The fourth port pair may include either an LPIN port and an HPOUT port, or an HPIN port and an LPOUT port.

[0028] In some embodiments, the PX includes one or more of the features described in one or more of Figures 3A-7B.

[0029] The disclosed systems, devices, and methods offer advantages over conventional solutions. The disclosed systems reduce energy consumption compared to conventional systems. For example, the disclosed PX can be used to recover energy stored as pressure and return that energy to the system, thereby reducing the energy cost to operate the system and improving efficiency. The disclosed systems can reduce wear on components (e.g., pumps, compressors) compared to conventional systems. The disclosed systems prevent unintentional leakage or mixing.

[0030] Although some embodiments of the present disclosure are described in connection with 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, non-pressure exchanger rotating components, non-rotary pressure exchangers, systems that do not include pressure exchangers, etc.).

[0031] Although some embodiments of the present disclosure are described in the context of exchanging pressure between fluids used in fracing systems, desalination systems, heat pump systems, and / or refrigeration systems, the present disclosure may be applied to other types of systems. Fluids may refer to liquids, gases, transcritical fluids, supercritical fluids, subcritical fluids, and / or combinations thereof.

[0032] 1A-1D show schematic diagrams of a fluid treatment system 100 including a hydraulic energy transfer system 110, according to certain embodiments.

[0033] In some embodiments, hydraulic energy transfer system 110 includes a pressure exchanger (e.g., PX). The PX may include one or more of the features described in one or more of FIGS. 3A-7B. In some embodiments, the PX includes a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. The first fluid and / or the second fluid enter and / or exit the rotor in a non-axial direction.

[0034] The hydraulic energy transfer system 110 (e.g., PX) receives an LPin fluid 120 (e.g., a low-pressure inlet flow) from an LPin system 122. The hydraulic energy transfer system 110 also receives an HPin 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 and supplies an LPout fluid 140 (e.g., a low-pressure outlet flow) to an LPout system 142 and an HPout fluid 150 (e.g., a high-pressure outlet flow) to an HPout system 152.

[0035] In some embodiments, the hydraulic energy transfer system 110 includes a PX that exchanges pressure between the HP in fluid 130 and the LP in fluid 120. The PX can be a device that transfers fluid pressure between the HP in fluid 130 and the LP in fluid 120 with greater than about 50%, 60%, 70%, 80%, 90% efficiency, or greater (e.g., without utilizing centrifugal techniques). High pressure (e.g., HP in fluid 130, HP out fluid 150) refers to a pressure higher than low pressure (e.g., LP in fluid 120, LP out fluid 140). The LP in fluid 120 at the PX can be pressurized and exit the PX at a higher pressure (e.g., HP out fluid 150 at a higher pressure than the LP in fluid 120), while the HP in fluid 130 can be depressurized and exit the PX at a lower pressure (e.g., LP out fluid 140 at a lower pressure than the HP in fluid 130). The PX may operate in a configuration in which the HPin fluid 130 applies a force directly to the LPin fluid 120, with or without a fluid separator between the fluids. Examples of fluid separators that may be used with the PX include, but are not limited to, pistons, bladders, diaphragms, etc. 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 separate valves because effective valving is achieved internally through the relative motion of the rotor and end cover. Rotary PXs may be designed to operate with internal pistons to isolate fluids and transfer pressure with relatively little mixing of the inlet fluid streams. Reciprocating PXs may include a piston that moves back and forth within a rotor duct to transfer pressure between fluid streams. Any PX or multiple PXs may be used in the present disclosure, including, 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, in situations where the PX is being added to an existing fluid treatment system).

[0036] In some embodiments, a motor 160 is coupled to the hydraulic energy transfer system 110 (e.g., to PX). In some embodiments, the motor 160 controls the rotational speed of a rotor of the hydraulic energy transfer system 110 (e.g., to increase the pressure of the HPout fluid 150 or decrease the pressure of the HPin fluid 130). In some embodiments, the motor 160 generates energy based on pressure exchanges in the hydraulic energy transfer system 110 (e.g., functions as a generator).

[0037] Hydraulic energy transfer system 110 may be a hydraulic protection system (e.g., hydraulic buffer system, hydraulic isolation system) that may isolate or limit contact between solid particle-laden fluids (e.g., fracking fluids) and various equipment (e.g., hydraulic fracturing equipment, high-pressure pumps) while exchanging work and / or pressure with other fluids. By isolating or limiting contact between various equipment (e.g., fracturing equipment) and solid particle-laden fluids, hydraulic energy transfer system 110 reduces wear and tear while improving the life and performance of the various equipment (e.g., fracturing equipment, high-pressure fluid pumps). Less expensive equipment may be used in fluid treatment system 100 by using equipment (e.g., high-pressure fluid pumps) that are not designed for abrasive fluids (e.g., fracking fluids and / or corrosive fluids).

[0038] The hydraulic energy transfer system 110 may include a hydraulic turbocharger or hydraulic exchange system, such as a rotary PX. The PX may include one or more (e.g., 1-100) chambers to facilitate pressure transfer and 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, a proppant-free or substantially proppant-free fluid) and a high-viscosity and / or solid particle-containing fluid, such as a second fluid (e.g., a fracking fluid containing sand, proppant, powder, debris, or ceramic). The solid particle-containing fluid causes wear and / or erosion of PX components, such as the rotor and end covers of the PX. The fluid (e.g., abrasive particles in the fluid) may cause wear at the interface between the rotor and each end cover as the rotor rotates relative to the end cover. Replacing worn PX components can be expensive.

[0039] The hydraulic energy transfer system 110 may be used in different types of systems such as fracing systems, desalination systems, and refrigeration systems.

[0040] 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.

[0041] 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 frac system. In some embodiments, fluid treatment system 100B includes more components, fewer components, the same routing, different routing, and / or the like than those shown in FIG. 1B.

[0042] LPin fluid 120 and HPout fluid 150 may be fracking fluids (e.g., solid particle-containing fluids, proppant fluids, etc.). HPin fluid 130 and LPout fluid 140 may be substantially solid particle-free fluids (e.g., proppant-free fluids, water, filtered fluids, etc.).

[0043] 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.

[0044] The hydraulic energy transfer system 110 exchanges pressure between an LPin fluid 120 (e.g., low-pressure fracking fluid) and an HPin fluid 130 (e.g., high-pressure water) and supplies an HPout fluid 150 (e.g., high-pressure fracking fluid) and an LPout fluid 140 (e.g., low-pressure water) to an HPout system 152. The HPout system 152 includes a rock formation 154 (e.g., a wellbore) that includes cracks 156. Solid particles (e.g., proppant) from the HPout fluid 150 can be delivered to the cracks 156 in the rock formation.

[0045] 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 proppant-free fluid loop). The LPout fluid 140 is 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.

[0046] 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 supplied to the rock formation 154 and then pumped from the rock formation 154 by the low-pressure fluid pump 124 to produce the LPin fluid 120.

[0047] In some embodiments, the fluid treatment system 100B may be 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). The hydraulic fracturing may include pumping an HPout fluid 150, which includes 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 be particle-containing fluids that increase the release of oil and gas 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 and increase 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, keeping them open (e.g., preventing them from closing after the HPout fluid 150 is depressurized).

[0048] To pump this particle-laden fluid into the rock formation 154 (e.g., the wellbore), 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 hydraulic energy transfer system 110. For example, hydraulic energy transfer system 110 may be a hydraulic turbocharger or PX (e.g., a rotary PX). During operation, hydraulic energy transfer system 110 transfers pressure between a first fluid (e.g., HPin fluid 130, proppant-free fluid) pumped by high-pressure fluid pump 134 and a second fluid (e.g., LPin fluid 120, proppant-bearing fluid, fracking fluid) pumped by low-pressure fluid pump 124 without substantial mixing. In this manner, hydraulic energy transmission system 110 enables fluid treatment system 100B to pump high-pressure fracking fluid (e.g., HPout fluid 150) into rock formation 154 to release oil and gas while insulating or limiting wear on high-pressure fluid pump 134. To operate in a corrosive and abrasive environment, hydraulic energy transmission system 110 may be made from a material that is resistant to the corrosive and abrasive substances in the first or second fluids. For example, hydraulic energy transmission system 110 may be made from a ceramic (e.g., alumina, a cermet, such as a 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 CoCr, Ni, NiCr, or Co.

[0049] In some embodiments, hydraulic energy transfer system 110 includes a PX (e.g., a rotary PX) where an HPin fluid 130 (e.g., a first fluid, a high-pressure, solid-free fluid) enters a first side of the PX where it contacts an LPin fluid 120 (e.g., a second fluid, a low-pressure fracking fluid) entering a second side of the PX. The contact between the fluids causes the HPin fluid 130 to increase the pressure of the second fluid (e.g., the LPin fluid 120), enabling the second fluid to be driven from the PX (e.g., as an HPout fluid 150) into a wellbore (e.g., a rock formation 154) to perform fracturing operations. The first fluid (e.g., the LPout fluid 140) also exits the PX, but at a lower pressure after pressure exchange with the second fluid. As noted above, the second fluid may be a low-pressure fracking fluid and may include abrasive particles that may wear down the interface between the rotor and its respective end cover as the rotor rotates relative to the respective end cover.

[0050] 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, and / or the like than those shown in FIG. 1C.

[0051] The LPin system 122 may include a supply pump 126 (e.g., low-pressure fluid pump 124) that receives in seawater 170 (e.g., a reservoir or direct ocean feedwater) and supplies the LPin fluid 120 (e.g., low-pressure seawater, feedwater) 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 and supplies 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.).

[0052] Membrane 136 may be a membrane separator configured to separate fluids passing through the membrane, such as a reverse osmosis membrane. Membrane 136 may provide concentrated feedwater or a concentrate (e.g., brine) HPin fluid 130 to hydraulic energy transfer system 110. The pressure of HPin fluid 130 may be used to compress low-pressure feedwater (e.g., LPin fluid 120) into high-pressure feedwater (e.g., HPout fluid 150). For convenience and illustrative purposes, the term feedwater is used herein. However, fluids other than water may be used in hydraulic energy transfer system 110.

[0053] A circulation pump 158 (e.g., a centrifugal pump) supplies HPout fluid 150 (e.g., high-pressure seawater) to membrane 136. Membrane 136 filters HPout fluid 150 and provides LP drinking water 172 and HPin fluid 130 (e.g., high-pressure brine). LPout system 142 supplies out brine 174 (e.g., from a geological mass, ocean, sea, waste, etc.).

[0054] In some embodiments, a high-pressure fluid pump 176 is disposed between the supply 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) so that it mixes with the high-pressure seawater provided by the circulation pump 158.

[0055] In some embodiments, the use of hydraulic energy transfer system 110 reduces the load on high-pressure fluid pump 176. In some embodiments, fluid treatment system 100C provides LP potable water 172 without the use of high-pressure fluid pump 176. In some embodiments, fluid treatment system 100C provides LP potable water 172 using high-pressure fluid pump 176 intermittently.

[0056] In some examples, hydraulic energy transfer system 110 (e.g., PX) receives LPin fluid 120 (e.g., low-pressure feedwater) at approximately 30 PSI (approximately 0.207 MPa) and HPin fluid 130 (e.g., high-pressure brine or concentrate) at approximately 980 PSI (approximately 6.76 MPa). 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). Hydraulic energy transfer system 110 (e.g., PX) outputs HPout fluid 150 (e.g., high-pressure (compressed) feedwater) at approximately 965 PSI (approximately 6.65 MPa) and LPout fluid 140 (e.g., low-pressure concentrate) at approximately 15 PSI (approximately 0.103 MPa). Therefore, the hydraulic energy transmission system 110 (e.g., PX) may be approximately 97% efficient because the input volume of the hydraulic energy transmission system (e.g., PX) is approximately equal to the output volume, and 965 PSI (approximately 6.65 MPa) is approximately 97% of 980 PSI (approximately 6.76 MPa).

[0057] Figure 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, and / or the like than those shown in Figure 1D.

[0058] The hydraulic energy transfer system 110 (e.g., PX) may receive LPin fluid 120 from an LPin system 122 (e.g., low-pressure lift device 128, low-pressure fluid pump, etc.) and may receive 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 and supply HPout fluid 150 to an HPout system 152 (e.g., high-pressure lift device 159) and supply LPout fluid 140 to an LPout system 142 (e.g., evaporator 144). The evaporator 144 may supply 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.

[0059] 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 (e.g., refrigerants) that are circulated within the closed system of fluid treatment system 100D.

[0060] In some embodiments, the fluid in fluid treatment system 100D may contain solid particles. For example, piping, equipment, connections (e.g., pipe welds, pipe soldering), etc. may introduce solid particles (e.g., solid particles from welds) into the fluid in fluid treatment system 100D. Solid particles in the fluid and / or high pressure of the fluid may cause wear and / or erosion of PX components (e.g., rotors, end covers) of hydraulic energy transfer system 110.

[0061] 2A-2E are exploded perspective views of a rotary PX 40 (e.g., 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.

[0062] In some embodiments, the PX 40 includes one or more of the features described in one or more of Figures 3A-7B. In some embodiments, the PX includes a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. The first fluid and / or the second fluid enter and / or exit the rotor in a non-axial direction.

[0063] The PX 40 is configured to transfer pressure and / or work between a first fluid (e.g., proppant-free fluid or supercritical carbon dioxide, HPin fluid 130) and a second fluid (e.g., fracking fluid or superheated gaseous carbon dioxide, LPin fluid 120) with minimal fluid mixing. The rotary PX 40 may include a generally cylindrical body 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 an inlet port 56 and an outlet port 58, respectively, while the manifold 54 includes an inlet port 60 and an outlet port 62, respectively. During operation, the inlet ports 56, 60 allow the first and second fluids to enter the rotary PX 40 and exchange pressure, while the outlet ports 58, 62 allow the first and second fluids to subsequently exit the rotary PX 40. During operation, the inlet port 56 receives a high-pressure first fluid (e.g., HPin fluid 130), and after pressure exchange, the outlet port 58 can be used to route a low-pressure first fluid (e.g., LPout fluid 140) to exit the rotary PX 40. Similarly, the inlet port 60 receives a low-pressure second fluid (e.g., LPin fluid 120), and the outlet port 62 can be used to route a high-pressure second fluid (e.g., HPout fluid 150) to exit the rotary PX 40. The end caps 48 and 50 include respective end covers 64 and 66 (e.g., end plates) that provide fluid-sealing contact with the rotor 46 disposed within the respective manifolds 52 and 54.

[0064] 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 greater). For example, tungsten carbide may be more durable and provide improved wear resistance to abrasive fluids compared to other materials, such as alumina ceramic.

[0065] The rotor 46 may be cylindrical and disposed within the sleeve 44, allowing the rotor 46 to rotate about an axis 68. The rotor 46 may have a plurality of channels 70 (e.g., ducts, rotor ducts) extending substantially longitudinally through the rotor 46 with openings 72 and 74 (e.g., rotor ports) at each end symmetrically positioned about the longitudinal axis 68. The openings 72 and 74 in the rotor 46 are disposed in fluid communication with 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) in the end covers 64 and 66, respectively, such that the channels 70 are exposed to high- and low-pressure fluids during rotation. As shown, the inlet and outlet apertures 76 and 78 and 80 and 82 may be designed in the form of arcs or segments of a circle (e.g., C-shaped).

[0066] 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 between the first and second fluids in the rotary PX 40, which can be used to improve the operability of a fluid treatment system (e.g., fluid treatment systems 100A-D 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 within the PX 40. Additionally, the operator can control mixing by varying the rotational speed of the rotor 46. Three characteristics of the rotary PX 40 that affect mixing are: (1) the aspect ratio of the rotor channel 70; (2) the exposure time between the first and second fluids; and (3) the formation of a fluid barrier (e.g., an interface) between the first and second fluids within the rotor channel 70. First, the rotor channel 70 (e.g., a duct) is generally long and narrow, which stabilizes the flow within the rotary PX 40. Furthermore, the first and second fluids may move through the channel 70 in a plug flow regime with minimal axial mixing. Second, in certain embodiments, the speed of the rotor 46 reduces contact between the first and second fluids. For example, the speed of the rotor 46 (e.g., a rotor speed of about 1200 revolutions per minute (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 for pressure exchange between the first and second fluids. Therefore, a volume of fluid remains within the channel 70 as a barrier between the first and second fluids. All of these mechanisms may limit mixing within the rotary PX 40. Additionally, in some embodiments, the rotary PX40 may be designed to operate with an internal piston or other barrier, complete or partial, that separates the first and second fluids while still allowing pressure transmission.

[0067] 2B-2E are exploded views of one embodiment of the rotary PX 40, illustrating the sequence of positions of a single rotor channel 70 within the rotor 46 as it rotates through a complete cycle. FIGS. 2B-2E are simplified diagrams of the rotary PX 40, showing one rotor channel 70, with the channel 70 shown as having a circular cross-sectional shape. In other embodiments, the rotary PX 40 may include multiple channels 70 of the same or different cross-sectional shapes (e.g., circular, oval, square, rectangular, polygonal, etc.). Thus, FIGS. 2B-2E are simplified diagrams for illustrative purposes, and other embodiments of the rotary PX 40 may have configurations different from 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 briefly come into contact within the rotor 46. In certain embodiments, this exchange occurs at a rate that limits mixing of the first and second fluids. The velocity of the pressure wave through the rotor channel 70 (once the channel is exposed to the aperture 76), the rate of diffusion of the fluid, and the rotational speed of the rotor 46 determine whether and to what extent mixing occurs.

[0068] 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 therefore in fluid communication with the manifold 52, while the opposite channel opening 74 is in hydraulic communication with an aperture 82 in the end cover 66 and also in hydraulic communication with the manifold 54. As discussed below, the rotor 46 may rotate in a clockwise direction, as indicated by arrow 84. During operation, as a low-pressure second fluid 86 enters the channel 70 through the end cover 66, the second fluid 86 contacts the first fluid 88 at a dynamic fluid interface 90. The second fluid 86 then drives 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, mixing between the second fluid 86 and the first fluid 88 is minimal.

[0069] 2C is an exploded perspective view of one embodiment of a rotating PX 40 (e.g., a rotating LPC) according to certain embodiments. In FIG. 2C, channel 70 has been rotated clockwise through an arc of approximately 90 degrees. In this position, opening 74 (e.g., outlet) is no longer in fluid communication with apertures 80 and 82 in end cover 66, and opening 72 is no longer in fluid communication with apertures 76 and 78 in end cover 64. Thus, low-pressure second fluid 86 is temporarily retained within channel 70.

[0070] 2D is an exploded perspective view of one embodiment of a rotary PX 40 (e.g., a rotary LPC) according to certain embodiments. In FIG. 2D, the channel 70 has 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 of 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 enters and pressurizes a second fluid 86 at low pressure, driving the second fluid 86 out of the rotor channel 70 and through the aperture 80.

[0071] 2E is an exploded perspective view of one embodiment of a rotary PX 40 (e.g., a rotary LPC) according to certain embodiments. In FIG. 2E, channel 70 has rotated through an arc of approximately 270 degrees from the position shown in FIG. 2B. In this position, opening 74 is no longer in fluid communication with apertures 80 and 82 in end cover 66, and opening 72 is no longer in fluid communication with apertures 76 and 78 in end cover 64. Thus, first fluid 88 is no longer pressurized and is temporarily retained within channel 70 until rotor 46 rotates substantially another 90 degrees and the cycle begins again.

[0072] Abrasive and / or erosive damage to the PX can occur when suspended solids are introduced and mixed into the fluid entering the PX. Abrasive damage can occur when particles enter the interstices of the PX (e.g., become trapped between the stationary end cover and the rotor). Erosive damage can occur due to the presence of suspended solids (e.g., erodants) in high-velocity fluid jets (e.g., slurry jets) created by high pressure differentials inside the PX. When high-velocity jets impinge on PX components, they can damage those components. Damage (e.g., erosive 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) and high pressure differentials are created.

[0073] 3A-7B illustrate components of a PX according to some embodiments. A PX of the present disclosure may include one or more features of FIGS. 3A-7B. A PX of the present disclosure may have a non-axial fluid inflow into the rotor of the PX and / or a non-axial fluid outflow from the rotor of the PX. In some embodiments, the PX includes a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. The first fluid and / or the second fluid are configured to enter and / or exit the rotor non-axially.

[0074] The present disclosure can address the issue of axial contact (e.g., friction, rubbing, etc.) between the rotor and end cover of a PX, which may be caused (e.g., primarily caused) by the axial clearance between the rotor and end cover (e.g., very small axial clearance, approximately 10-25 microns (μm)). The closure of the axial clearance resulting in contact may be due to one or both of the following: deformation of the end cover due to pressure and / or a thrust load acting on the rotor that exceeds the existing thrust bearing capacity (e.g., excessive thrust load). The axial clearance on the load side may be approximately 5-10 microns (μm). The axial clearance on the non-load side should be kept to a minimum (approximately 20 microns (μm)) to minimize leakage, which may become excessive at high pressure.

[0075] 3A-C illustrate components of a PX according to some embodiments. FIG. 3A illustrates a perspective view of a PX component according to some embodiments (e.g., a PX with radial inflow, substantially straight ducts, and a post channel design), FIG. 3B illustrates a cross-sectional view of a PX component according to some embodiments (e.g., a PX with radial inflow, substantially straight ducts, and a post channel design), and FIG. 3C illustrates a top or bottom rotor view of a PX according to some embodiments. In some embodiments, two or more of FIGS. 3A-C may illustrate component views of the same PX (e.g., PX 300). In some embodiments, two or more of FIGS. 3A-C may illustrate component views of different PXs. In some embodiments, the PX of FIGS. 3A-C may have two cycles of pressure exchange per rotor revolution (e.g., each rotor duct is pressurized and depressurized twice per revolution) to balance radial loads (e.g., radial thrust) on the rotor 310. 3A-B may have a single cycle per rotation (e.g., each rotor duct is pressurized and depressurized once per rotation). For example, each complete rotation (e.g., 360 degree rotation) of the rotor accomplishes one complete cycle of pressure exchange. In a single rotation, the rotor may facilitate the process of pressure transfer from the HP fluid to the LP fluid. This may include the intake of HP fluid into the rotor, the transfer of pressure to the LP fluid, and the expulsion of the LP fluid, now at a different (higher) pressure.

[0076] In a single cycle, the HP ports (HPIN and HPOUT formed by the sleeve) and the LP ports (LPIN and LPOUT formed by the center post) may be clocked substantially 180 degrees apart (e.g., the HP ports are located diametrically opposite each other on the surface of the cylindrical sleeve, and the LP ports are located diametrically opposite each other on the surface of the cylindrical center post). To enable two-cycle operation, two additional ports may be formed on the sleeve substantially 180 degrees apart from each other and substantially 90 degrees apart from the single HP and LP ports. Furthermore, two additional ports are formed by the center post substantially 180 degrees apart from each other and substantially 90 degrees apart from the single HP and LP ports.

[0077] 3A-B may be that there is a larger sealing area between HPIN port 381 and LPOUT port 371, and between LPIN port 361 and HPOUT port 391, thereby reducing leakage. In some embodiments, the PX of Figures 3A-B may be used in low pressure applications such as brackish water desalination, wastewater treatment applications (e.g., potable water), etc.

[0078] FIG. 3A shows a PX 300 having radial inflow (e.g., via HPIN port 381, HPOUT port 391, LPIN port 361, and / or LPOUT port 371), a substantially straight duct 311, and a post flow path design (e.g., via post 330), according to some embodiments.

[0079] In some embodiments, the PX 300 may include a rotor 310 that may be configured to receive a first fluid, a second fluid, and exchange pressure between the first and second fluids. In some embodiments, the PX 300 may include a sleeve 320 that may be disposed around the rotor 310. In some embodiments, the first fluid enters the rotor 310 radially through the sleeve 320 (e.g., from the outer surface of the rotor into the rotor in the direction of arrow 302, through HPIN port 381, etc.). In some embodiments, the second fluid enters the rotor 310 radially (e.g., from the inner surface of the rotor into the rotor in the direction of arrow 302, through LPIN port 361, etc.). In some embodiments, the fluids enter the rotor radially rather than axially. In some embodiments, the PX 300 may include a post 330 disposed inside the rotor. In some embodiments, the post 330 forms a post cavity 350.

[0080] FIG. 3B shows a cross-sectional view of PX 300 having radial rotor inflow and outflow (e.g., via HPIN port 381, HPOUT port 391, LPIN port 361, and / or LPOUT port 371), a substantially straight duct 311, and a post flow path (e.g., via post 330) design.

[0081] In some embodiments, PX 300 may be substantially cylindrical. In some embodiments, the radial direction may be a direction substantially perpendicular to the central axis 309 of PX 300. For example, arrow 302 indicates the radial direction relative to the central axis 309 of PX 300. In some embodiments, the axial direction may be a direction substantially parallel to the central axis 309 of PX 300. For example, arrow 301 indicates the axial direction relative to the central axis 309 of PX 300.

[0082] In some embodiments, the second fluid enters the rotor 310 radially through the post 330 .

[0083] In some embodiments, the post 330 forms a first LPIN port 361 and a first LPOUT port 371.

[0084] In some embodiments, the sleeve 320 forms a first HPIN port 381 and a first HPOUT port 391 .

[0085] Alternatively, in some embodiments, the post 330 may form a first HPIN port and a first HPOUT port, and the sleeve 320 may form a first LPIN port and a first LPOUT port.

[0086] FIG. 3C shows a rotor 310 of a PX 300 according to some embodiments.

[0087] In some embodiments, the rotor is the same as or substantially similar to rotor 310 of Figures 3A and / or 3B.

[0088] In some embodiments, the PX 300 includes a rotor 310 configured to exchange pressure between a first fluid and a second fluid, the rotor forming a rotor cavity 360 .

[0089] In some embodiments, the rotor includes an outer surface 322, and the first fluid enters the rotor 310 radially through the outer surface 322. In some embodiments, the rotor 310 includes an inner surface 324 that defines a rotor cavity 360, and the second fluid enters the rotor 310 radially through the inner surface 324.

[0090] In some embodiments, PX 300 further includes a post 330 (see, e.g., FIGS. 3A and / or 3B ) disposed within rotor cavity 360, where post 330 forms post cavity 350. In some embodiments, the second fluid flows axially into post cavity 350, radially out of post cavity 350, and radially into rotor 310.

[0091] In some embodiments, the rotor 310 defines ducts 311 such that at least one of the first fluid or the second fluid radially enters the rotor 310 and into at least one of the ducts 311. In some embodiments, the ducts 311 may be fluted.

[0092] 4A-C show components of a PX according to some embodiments. In some embodiments, Figures 4A-C show a PX with a radial inflow (e.g., via HPIN ports 481 and 482, HPOUT ports 491 and 492, LPIN ports 461 and 462, and / or LPOUT ports 471 and 472), substantially straight duct 411, and centerbore (e.g., via centerbore 450) flow path design.

[0093] 4B-C show cross-sectional views of embodiments of the present disclosure. In some embodiments, a center bore 450 (e.g., formed by a post) is used as a flow path. This is done using a center post 430 with flow paths as shown in FIGS. 4A-C. Flow enters the PX 400 radially (through the sleeve 420 on the outside of the cartridge and through the center post 430 on the inside of the rotor 410) and makes a substantial 90 degree turn to enter the rotor 410. The LP fluid is shown within the center bore 450, and the HP is shown on the outside. In some embodiments, the HP and LP regions may be switched. The HP ports (e.g., 481-482 and 491-492) in sleeve 420 and the LP ports (e.g., 461-462 and 471-472) in rotor 410 are clocked substantially 90 degrees from one another (e.g., the HP and LP ports are positioned substantially 90 degrees from one another on the surface of cylindrical sleeve 420 or center post 430) to seal the high and low pressure regions and prevent direct communication or excessive leakage between the HP and LP ports. In some embodiments, the angular spacing of the ports is equal to or greater than the angular spacing of the ducts.

[0094] Providing two LP ports substantially 180 degrees apart (see, e.g., FIG. 4B) and two HP ports substantially 180 degrees apart (see, e.g., FIG. 4C) helps balance the radial loads on the rotor 410. The use of the center post 430 as a flow path in the radial inflow pressure exchanger 400 provides the advantage of simplifying the housing design and maintaining a similar exterior design to other PXs.

[0095] FIG. 4A shows a PX400 with a radial inflow, substantially straight duct, and post channel design, according to some embodiments.

[0096] In some embodiments, the PX 400 may include a rotor 410 that may be configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. In some embodiments, the PX 400 may include a sleeve 420 that may be disposed around the rotor 410. In some embodiments, the first fluid enters the rotor 410 radially (e.g., in the direction of arrow 402) through the sleeve 420. In some embodiments, the fluid enters the rotor radially rather than axially. In some embodiments, the PX 400 may include a post 430 disposed inside the rotor. In some embodiments, the post 430 fills a center bore of the rotor.

[0097] 4B-4C show cross-sectional views of a PX 400 with a radial inflow, substantially straight duct, and post channel design. In some embodiments, Figures 4B-4C show the same PX 400.

[0098] In some embodiments, PX400 may be substantially cylindrical. In some embodiments, the radial direction may be a direction substantially perpendicular to the central axis 405 of PX400. For example, arrow 402 indicates the radial direction relative to the central axis 405 of PX400. In some embodiments, the axial direction may be a direction substantially parallel to the central axis 405 of PX400. For example, arrow 401 indicates the axial direction relative to the central axis 405 of PX400.

[0099] In some embodiments, the second fluid enters the rotor 410 radially through the post 430 .

[0100] In some embodiments, the post 430 forms a first LPIN port 461 and a first LPOUT port 471. In some embodiments, the post 430 further forms a second LPIN port 462 and a second LPOUT port 472.

[0101] In some embodiments, sleeve 420 forms first HPIN port 481 and first HPOUT port 491. In some embodiments, sleeve 420 forms second HPIN port 482 and second HPOUT port 492.

[0102] Alternatively, in some embodiments, the post 430 may form a first HPIN port and a first HPOUT port. The post 430 may also form a second HPIN port and a second HPOUT port. The sleeve 420 may form a first LPIN port and a first LPOUT port. The sleeve 420 may also form a second LPIN port and a second LPOUT port.

[0103] In some embodiments, PX 400 may include a rotor 410 forming radial ducts (see, e.g., FIGS. 4A-B), where rotor 410 is configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. In some embodiments, PX 400 includes a post 430 disposed within a rotor cavity formed by rotor 410, such that the first fluid enters rotor 410 radially through a first one of the radial ducts, enters a second one of the radial ducts through a post cavity (e.g., centerbore 450) formed by post 430, and exits rotor 410 radially through the second radial duct.

[0104] In some embodiments, PX 400 further includes a first pair of ports formed by a sleeve 420 or a post 430. The sleeve 420 is disposed around the rotor 410, and the post 430 is disposed within the rotor cavity. In some embodiments, the first pair of ports includes an LPIN port and an LPOUT port. In some embodiments, the first pair of ports may include an HPIN port and an HPOUT port.

[0105] In some embodiments, PX 400 further includes a second pair of ports formed by sleeve 420 or post 430. In some embodiments, the second pair of ports includes an HPIN port and an HPOUT port. In some embodiments, the second pair of ports includes an LPIN port and an LPOUT port.

[0106] In some embodiments, PX 400 may include a third pair of ports formed by sleeve 420 or post 430. In some embodiments, the third pair of ports includes an LPIN port and an LPOUT port. In some embodiments, the third pair of ports includes an HPIN port and an HPOUT port.

[0107] In some embodiments, PX 400 may include a fourth port pair formed by sleeve 420 or post 430. In some embodiments, the fourth port pair includes an LPIN port and an LPOUT port. In some embodiments, the fourth post pair includes an HPIN port and an HPOUT port.

[0108] In some embodiments, the third pair of ports formed by posts 430 are positioned substantially 180 degrees away from the fourth pair of ports formed by posts 430 and are positioned substantially 90 degrees away from the first and second pair of ports formed by sleeve 420. In some embodiments, the first pair of ports formed by sleeve 420 and the second pair of ports formed by posts 430 are positioned substantially 180 degrees away from each other on sleeve 420.

[0109] In some embodiments, rotor 410 may be configured to rotate about axis of rotation 405. In some embodiments, sleeve 420 may form angled ports (e.g., angled ports 615 in FIGS. 6A-B) arranged about a port axis. In some embodiments, the port axis does not intersect with axis of rotation 405. See FIGS. 6A-B for a more detailed description.

[0110] In some embodiments, rotor 410 can be configured to rotate about axis of rotation 405. In some embodiments, posts 430 form angled ports disposed about a port axis. In some embodiments, the port axis does not intersect with axis of rotation 405 (see, e.g., FIGS. 6A-B and corresponding discussion).

[0111] 4D-F show components of a PX according to some embodiments. Figures 4D-F show a PX 400 with a fluted spiral design (instead of a 90-degree turn in the rotor 410). A fluted spiral duct may refer to a duct formed by the rotor surface. The rotor surface may form substantially parallel spiral grooves or channels (fluted ducts). The fluted ducts may spiral along the length of the rotor. The fluted ducts may have a uniform shape and depth, forming a consistent pattern across the rotor surface. In some embodiments, the fluted spiral ducts may be covered by a sleeve that surrounds the rotor, thereby enclosing the fluted ducts. This may result in a longer flow path within the rotor compared to a straight duct design, resulting in a more streamlined flow. For the same size skin dimensions, a pressure reduction may be required due to the greater stress on the solid portions of the rotor due to bending loads that are not present in a straight duct design. There may be applications where pressure is lower but mixing may be a greater concern. In some embodiments, the flutes may be any shape that increases the length of the duct. For example, the flutes may be partially helical, serpentine, partially serpentine, zigzag, partially zigzag, etc. (e.g., based on the application of the PX).

[0112] FIG. 4D shows the PX400 with radial inflow, flute-shaped ducts, and a spiral flow path design.

[0113] In some embodiments, the PX 400 may include a rotor 410 that may be configured to receive a first fluid, a second fluid, and exchange pressure between the first and second fluids. In some embodiments, the PX 400 may include a sleeve 420 that may be disposed around the rotor 410. In some embodiments, the first fluid enters the rotor 410 radially (e.g., in the direction of arrow 402) through the sleeve 420. In some embodiments, the fluid enters the rotor radially rather than axially. In some embodiments, the PX 400 may include a post 430 disposed inside the rotor. In some embodiments, the post 430 defines a center bore 450. The center bore 450 may be a hollow channel extending axially within the post 430. In some embodiments, the center bore 450 is a cylindrical hole formed in the center of the rotor 410 and extending the entire length of the rotor 410. The post 430 is a stationary piece disposed within the center bore 450 with clearance. The post 430 may form two cavities at opposite ends. For example, in some embodiments, the first cavity forms the LPIN plenum and the second cavity forms the LPOUT plenum. In some embodiments, the first cavity forms the HPIN plenum and the second cavity forms the HPOUT plenum.

[0114] In some embodiments, the rotor 410 of the PX400 defines a duct 411 such that at least one of the first fluid or the second fluid enters the rotor 410 radially through the duct 411. In some embodiments, the duct 411 is fluted.

[0115] In some embodiments, the flute-shaped ducts 411 may be formed by the rotor 410 (e.g., grooves or channels on the outer surface of the rotor). The flute-shaped ducts 411 may vary in depth, width, and shape. The flute-shaped ducts 411 may be passages (conduits) used to control fluid or gas flow, improve heat transfer, and increase pressure exchange efficiency. In some embodiments, a sleeve 420 (e.g., disposed around the rotor 410) may seal the flutes (e.g., to retain a fluid). The sleeve 420 may be a cylindrical casing that contains the rotor 410 and covers the flute-shaped ducts 411. This seal ensures that the fluid or gas within the flute-shaped ducts 411 is retained and directed according to a desired flow pattern and prevents unintended leakage or mixing.

[0116] In some embodiments, the flutes of the flute-shaped duct 411 refer to individual grooves or channels on the outer surface of the rotor 410 (e.g., formed by the flute-shaped duct). In some embodiments, the flutes may be concave features on the surface of the rotor 410. The flutes may vary in terms of their depth, width, and shape and may be paths (conduits) for the flow of fluids or gases. In some embodiments, the flutes are channels or grooves formed by the flute-shaped duct (e.g., of the flute-shaped duct 411).

[0117] In some embodiments, Figures 4E-F show cross-sectional views of a PX400 with radial inflow, flute-shaped ducts, and spiral flow path designs.

[0118] In some embodiments, the flutes of the duct 411 open into at least one of a sleeve 420 or a post 430 disposed around the rotor 410. In some embodiments, the duct 411 extends across the rotor 410, beginning near a first distal end 431 of the rotor 410 and ending near a second distal end 432 of the rotor 410. In some embodiments, the duct 411 is configured in a spiral path through the rotor 410.

[0119] In some embodiments, rotor 410 may be configured to rotate about axis of rotation 405. In some embodiments, sleeve 420 may form angled ports (e.g., angled ports 615 in FIGS. 6A-B) arranged about a port axis. In some embodiments, the port axis does not intersect with axis of rotation 405. See FIGS. 6A-B for a more detailed description.

[0120] In some embodiments, rotor 410 can be configured to rotate about axis of rotation 405. In some embodiments, posts 430 form angled ports arranged about a port axis, which in some embodiments does not intersect axis of rotation 405 (see, e.g., FIGS. 6A-B and corresponding discussion).

[0121] FIG. 4G shows components of a PX 400 according to some embodiments. FIG. 4G shows a PX that may not use a center bore for flow. All flow may enter and exit the sleeve 420. FIG. 4G shows a version of a fluted rotor design. In some embodiments, FIG. 4G may use straight ducts in the rotor shown in FIGS. 4A-C. FIG. 4G may eliminate the use of a center post (e.g., which may be desirable or required in certain applications).

[0122] In some embodiments, the PX in Figures 4A-C can have a straight duct as a slot on the rotor outer diameter (OD) that opens onto the sleeve inner diameter (ID). The duct can also be on the rotor ID and open onto the post OD. The benefit can be the option of not using end caps on the rotor (see, for example, Figures 6A-B). In some embodiments, the duct is angled rather than vertical.

[0123] Figures 5A-B show components of a PX according to some embodiments. Figures 5A-B show a PX 500 with a rotor with radial ducts. The LPIN fluid enters through the (outer diameter) OD sleeve and exits the OD sleeve as HPOUT. The HPIN fluid enters the rotor duct through the center post as HPIN, transfers its pressure energy, and then exits through the center post as LPOUT. In some embodiments, an advantage of this embodiment is that the HPOUT fluid receives a pressure boost due to the centrifugal head imparted by the rotor. Multiple rows of ducts can be arranged along the rotor axis to increase the flow capacity of the PX.

[0124] In some embodiments, the PX 500 includes a rotor 510 defining a radial duct 511, the rotor 510 configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. In some embodiments, the PX 500 includes a post 530 disposed within a rotor cavity defined by the rotor 510, such that the first fluid enters the rotor 510 radially through a first port 541 of a first pair of ports defined by a sleeve 520 or post 530 disposed on the outer periphery of the rotor 510, enters the radial duct of the radial duct 511, and exits the rotor 510 radially through a second port 552 of the first pair of ports. In some embodiments, the first pair of ports includes an HPIN port 551 and an LPOUT port 542. In some embodiments, the radial direction is indicated by arrow 502. Fluid radially entering the rotor may enter in the direction of arrow 502, for example.

[0125] In some embodiments, PX 500 further includes a second pair of ports, which are formed by sleeve 520 or post 530. Sleeve 520 is disposed around rotor 510, and post 530 is disposed inside post cavity 550. In some embodiments, the second pair of ports includes LPIN port 541 and HPOUT port 552. In some embodiments, the first pair of ports may include HPIN port 551 and LPOUT port 542.

[0126] In some embodiments, PX 500 may include a third pair of ports formed by sleeve 520 or post 530. In some embodiments, the third pair of ports includes LPIN port 561 and HPOUT port 572. In some embodiments, the third pair of ports includes HPIN port 571 and LPOUT port 562.

[0127] In some embodiments, PX 500 may include a fourth port pair formed by sleeve 520 or post 530. In some embodiments, the fourth port pair includes HPIN port 551 and LPOUT port 562. In some embodiments, the fourth port pair includes LPIN port 561 and HPOUT port 572.

[0128] In some embodiments, the third pair of ports formed by the posts 530 are positioned substantially 180 degrees away from the second pair of ports formed by the posts 530. The third pair of ports formed by the posts 530 are positioned substantially 180 degrees away from the first pair of ports disposed on the sleeve. The third pair of ports formed by the posts 530 and the fourth pair of ports formed by the sleeve 520 are positioned substantially 0 degrees away from each other on the posts 530 and the sleeve 520, respectively. In some embodiments, the first pair of ports formed by the sleeve 520 and the second pair of ports formed by the posts 530 are positioned substantially 0 degrees away from each other on the sleeve 520 and the posts, respectively.

[0129] In some embodiments, rotor 510 may be configured to rotate about axis of rotation 505. In some embodiments, sleeve 520 may form angled ports (e.g., angled ports 615 in FIGS. 6A-B) arranged about a port axis. In some embodiments, the port axis does not intersect with axis of rotation 505. See FIGS. 6A-B for a more detailed description.

[0130] In some embodiments, rotor 510 can be configured to rotate about axis of rotation 505. In some embodiments, posts 530 form angled ports arranged about a port axis. In some embodiments, the port axis does not intersect with axis of rotation 405 (see, e.g., FIGS. 6A-B and corresponding discussion).

[0131] FIGS. 6A-B show components of a PX according to some embodiments. FIGS. 6A-B may show components of the PX 600 used to generate torque on the rotor to initiate and maintain rotation. Generating torque on the rotor to rotate and exchanging pressure (e.g., functioning as a pressure exchanger) may include causing fluid to enter and exit at angles to the radial direction. In FIGS. 6A-B, the PX may have one cycle per revolution (e.g., that of FIGS. 3A-B) and / or may be applied to other embodiments of the present disclosure. To achieve greater control of the rotor RPM and minimize inlet losses, adjustable vanes can be incorporated into the ports (on the sleeve) through which fluid enters the rotor. In some embodiments, the adjustable vanes can be inserts that are installed within the ports and can be adjusted based on the application's flow rate. Adjustable vanes can be incorporated into sleeve ports and actuated mechanically, electrically, or hydraulically (e.g., when flow rates vary significantly over time). The adjustable vane may be part of another component upstream of the sleeve port. The adjustable vane may also be included in the HPIN port inside the center post.

[0132] In some embodiments, PX 600 may include a rotor 610 configured to receive a first fluid, receive a second fluid, and exchange pressure between the first and second fluids. In some embodiments, PX 600 may include a sleeve 620 that may be disposed around rotor 610. In some embodiments, the first fluid enters rotor 610 radially (e.g., in the direction of arrow 602) through sleeve 620. In some embodiments, the fluid enters the rotor radially rather than axially. In some embodiments, PX 600 may include a post 630 disposed inside the rotor.

[0133] In some embodiments, rotor 610 may be configured to rotate about a rotation axis 605. In some embodiments, sleeve 620 may form angled ports 615 disposed about a port axis 606. In some embodiments, port axis 606 does not intersect with rotation axis 605.

[0134] In some embodiments, rotor 610 can be configured to rotate about a rotation axis 605. In FIG. 6B, rotation axis 605 is depicted as a circle with a dot in the middle. This notation indicates that rotation axis 605 runs perpendicular to the 2D plane of the figure. In some embodiments, posts 630 form angled ports 615 arranged around port axis 606. In some embodiments, port axis 606 does not intersect with rotation axis 605. In some embodiments, this configuration causes fluid to enter rotor 610 at an angle, which helps rotor 610 rotate.

[0135] 7A-B are associated with a PX according to some embodiments. FIGS. 7A-B may show a layout of a PX including a cartridge inside a housing 701. In some embodiments, radial bearings 709 may be used to seal HP and LP fluids. Having bearings on the post and sleeve may provide a greater margin for allowable radial loads. FIGS. 7A-B also show axial bearings 708. Unlike conventional systems, these axial bearings may not function as seals, may not have the tight tolerances, and may not have the tight clearances of conventional systems. FIG. 7A shows an example of using a flow diverter insert 712 to help apply torque to the rotor to force fluid flow in a particular direction (e.g., clockwise in FIG. 7A).

[0136] To achieve high pressures and low leakage, conventional systems may use very small margins of error for manufacturing tolerances and inspections. Under high pressures, high thrust and / or end cover deflection always present a risk of contact between the rotor and end cover, causing the rotor to stall. The present disclosure aims to eliminate or mitigate this problem. The radial seal surface of the present disclosure allows for axial clearance (e.g., sufficient axial clearance) to prevent the end cover and rotor from contacting each other. The remaining thrust load can be absorbed by the bearing system (which does not rely on small clearances). Furthermore, the radial bearing surface (convex rotor against concave sleeve) may better accommodate unexpected operating loads, such as vibrations, that the PX may experience, compared to conventional systems.

[0137] In some embodiments of the present disclosure (e.g., FIGS. 4A-F, 3A-7B), the radial load of the PX may be balanced. In some embodiments, the radial load of the present disclosure may be greater than that of conventional systems. In some embodiments, the flow rate may be higher than that of conventional systems (e.g., for the same rotor and sleeve size outer shell). In some embodiments, one or more components of the PX may be manufactured using complex machining processes (e.g., components incorporating helical flutes).

[0138] The present disclosure (eg, one or more embodiments of FIGS. 3A-7B) may have improvements over conventional solutions in one or more of pressure range, efficiency, volume, and cost reduction.

[0139] The above description sets forth numerous specific details, such as examples of particular systems, components, methods, etc., to provide a thorough understanding of 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 can be practiced without these specific details. In other instances, well-known components or methods have been avoided from being described in detail or have been presented in simple block diagram form to avoid unnecessarily obscuring the present disclosure. Thus, the specific details described are merely exemplary. Particular implementations may vary from these illustrative details and still be considered within the scope of the present disclosure. The system description herein may include a description of one or more optional components. Components may be included in combinations not specifically described in the present disclosure and still be within the scope of the present disclosure.

[0140] Throughout this specification, a reference to "one embodiment" or "an embodiment" means 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 do not necessarily all refer 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%. Additionally, as used herein, the terms "first," "second," "third," "fourth," etc., are intended as labels to distinguish different elements and do not necessarily have an orderly meaning according to their numerical designations.

[0141] As used herein, the terms "above," "below," "between," "disposed on," "in front of," "behind," and "on" refer to the relative location of a layer of material or component with respect to another layer or component. For example, if a layer is disposed on, above, or below another layer, the layer may be in direct contact with the other layer or may have one or more intermediate layers. Furthermore, if a layer is disposed between two layers, the layer may be in direct contact with the two layers or may have one or more intermediate layers. Similarly, unless otherwise specified, if a feature is disposed between two features, the feature may be in direct contact with the adjacent feature or may have one or more intermediate layers or components.

[0142] It should be understood that the foregoing description herein is intended to be illustrative and not limiting. Many other embodiments will become apparent to those skilled in the art upon reading and understanding the foregoing description. Accordingly, the scope of the present disclosure should be determined with reference to the appended claims, including the full scope of equivalents to which each claim is entitled.

Claims

1. A pressure exchanger, the pressure exchanger comprising: a rotor configured to receive a first fluid, receive a second fluid, and exchange pressure between the first fluid and the second fluid; a sleeve disposed around the rotor, the first fluid passing radially through the sleeve and into the rotor; a post disposed inside the rotor.

2. The second fluid enters the rotor radially through the post, and the post comprises: forming a first low pressure in (LPIN) port and a first low pressure out (LPOUT) port; or 10. The pressure exchanger of claim 1 defining a first high pressure in (HPIN) port and a first high pressure out (HPOUT) port.

3. The sleeve is forming a first LPIN port and a first LPOUT port; or 3. The pressure exchanger of claim 2 defining a first HPIN port and a first HPOUT port.

4. The post further comprises: forming a second LPIN port and a second LPOUT port; or forming a second HPIN port and a second HPOUT port; and The sleeve further comprises: forming a second LPIN port and a second LPOUT port; or 4. The pressure exchanger of claim 3, defining a second HPIN port and a second HPOUT port.

5. The rotor is configured to rotate about a rotation axis, the sleeve defines an angled port disposed about a port axis; and The pressure exchanger of claim 1 , wherein said port axis does not intersect with said axis of rotation.

6. The rotor is configured to rotate about a rotation axis, the post defines an angled port disposed about a port axis; and 3. The pressure exchanger of claim 2, wherein said port axis does not intersect with said axis of rotation.

7. 2. The pressure exchanger of claim 1, wherein the rotor defines a plurality of ducts, at least one of the first fluid or the second fluid radially enters the rotor through the plurality of ducts, and the plurality of ducts are fluted.

8. A pressure exchanger, the pressure exchanger comprising: a rotor configured to exchange pressure between a first fluid and a second fluid, the rotor defining a rotor cavity, the rotor comprising: a pressure exchanger having an outer surface, the first fluid entering the rotor radially through the outer surface.

9. 9. The pressure exchanger of claim 8, wherein the rotor defines a plurality of flute-shaped ducts arranged in a helical path through the rotor, the plurality of flute-shaped ducts extending across the rotor beginning near a first distal end of the rotor and terminating near a second distal end of the rotor, at least one of the first fluid or the second fluid entering the rotor radially into at least one of the plurality of flute-shaped ducts, and the flutes of the plurality of ducts opening into a sleeve disposed around the rotor.

10. 9. The pressure exchanger of claim 8, further comprising a post disposed within the rotor cavity, the post defining a post cavity, the second fluid axially entering the post cavity and radially exiting the post cavity to radially enter the rotor, and the rotor further comprising an inner surface defining the rotor cavity, the second fluid radially entering the rotor via the inner surface.

11. 11. The pressure exchanger of claim 10, wherein the rotor defines a plurality of ducts, and at least one of the first fluid or the second fluid enters the rotor radially into at least one of the plurality of ducts, and the plurality of ducts are fluted.

12. 12. The pressure exchanger of claim 11, wherein the flutes of the ducts open into at least one of a sleeve or the post disposed around the rotor, and the ducts extend across the rotor beginning near a first distal end of the rotor and ending near a second distal end of the rotor.

13. 13. The pressure exchanger of claim 12, wherein the plurality of ducts are arranged in a helical path through the rotor.

14. The rotor is configured to rotate about a rotation axis, the sleeve defines an angled port disposed about a port axis; and 14. The pressure exchanger of claim 13, wherein the port axis does not intersect with the axis of rotation.

15. The rotor is configured to rotate about a rotation axis, the post defines an angled port disposed about a port axis; and 14. The pressure exchanger of claim 13, wherein the port axis does not intersect with the axis of rotation.

16. A pressure exchanger, the pressure exchanger comprising: a rotor defining a plurality of radial ducts, the rotor configured to receive a first fluid, to receive a second fluid, and to exchange pressure between the first fluid and the second fluid; a post disposed within a rotor cavity formed by the rotor, wherein the first fluid enters the rotor radially through a first port of a first pair of ports formed by a sleeve or post disposed around the rotor, enters one of the plurality of radial ducts, and exits the rotor radially through a second port of the first pair of ports.

17. The pressure exchanger further comprises a second pair of ports formed by the sleeve or the post, the second pair of ports comprising: a low pressure in (LPIN) port and a high pressure out (HPOUT) port; or a high pressure in (HPIN) port and a low pressure out (LPOUT) port, the first pair of ports formed by the sleeve or the post comprising: It has an LPIN port and an HPOUT port, or 17. The pressure exchanger of claim 16, comprising an HPIN port and an LPOUT port.

18. The rotor is configured to rotate about a rotation axis, the sleeve defines an angled port disposed about a port axis; and 18. The pressure exchanger of claim 17, wherein the port axis does not intersect with the axis of rotation.

19. The rotor is configured to rotate about a rotation axis, the post defines an angled port disposed about a port axis; and 18. The pressure exchanger of claim 17, wherein the port axis does not intersect with the axis of rotation.

20. The pressure exchanger comprises: a third pair of ports formed by the sleeve or the post, the third pair of ports comprising: It has an LPIN port and an HPOUT port, or a third port pair comprising an HPIN port and an LPOUT port; a fourth pair of ports formed by the sleeve or the post, the fourth pair of ports comprising: It has an LPIN port and an HPOUT port, or 20. The pressure exchanger of claim 17, comprising: a fourth pair of ports comprising an HPIN port and an LPOUT port.

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