Dual-chamber slurry condenser and methods of delivering slurry

Abstract

Disclosed herein are components, systems, and methods to deliver dense-phase slurry to a cutting head of a fluid jet cutting system to form a slurry jet. A slurry condenser receives lean-phase slurry in a first chamber. The lean-phase slurry gathers in a lower portion of the first chamber. A slurry valve and a bypass fluid valve that are both positioned between the first chamber and a second chamber along two separate flow paths of the slurry condenser may be opened to transfer the slurry from the first chamber to the second chamber. The slurry exits the second chamber and is then delivered to the fluid jet cutting head where the slurry is combined with a fluid jet to form the slurry jet.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of Provisional Application No. 63 / 764,892, filed Feb. 28, 2025, the disclosure of which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] This disclosure relates to fluid jet systems and related methods, and more particularly, to the use of abrasive fluid jet systems that process workpieces.

[0003] Fluid jet cutting systems, such as waterjet or abrasive waterjet cutting systems, are used for cutting a wide variety of materials, including stone, glass, ceramics and metals. Referring to FIG. 1, a known fluid jet cutting system 10 generates and delivers a high-pressure fluid 11 to a cutting head 12. The cutting head 12 forces the high-pressure fluid 11 through an orifice unit 14 with a reduced lumen. Passage of the high-pressure fluid 11 through the orifice unit 14 generates a fluid jet 16, which is directed toward a workpiece 18. The fluid jet 16 is a “pure” fluid jet. As used herein a “pure” fluid jet is devoid of any solid particles (e.g., abrasive particles) added to enhance the cutting power of the fluid jet.

[0004] Referring to FIG. 2, some known fluid jet cutting systems 20 may draw or feed abrasive media 32 into a fluid jet 34 to form an abrasive fluid jet 36. As used herein, an abrasive fluid jet is formed when a “pure” fluid jet entrains solid particles (e.g., abrasive particles) into the “pure” fluid jet at a location downstream of an orifice unit that generated the “pure” fluid jet. The abrasive fluid jet then accelerates the entrained solid particles toward a workpiece, such that the entrained solid particles enhance the cutting power of the fluid jet. Abrasive fluid jets include “dry” abrasive fluid jets, in which dry abrasive (carried by a gas, such as air) with minimal (ideally close to zero) moisture content is entrained into the fluid jet. Abrasive fluid jets also include wet abrasive fluid jets, in which wet abrasive (carried by a fluid, such as water) with a higher (e.g., non-zero) moisture content is entrained into the wet fluid jet.

[0005] Similar to FIG. 1, a high-pressure fluid 22 is delivered to a cutting head 24. The cutting head 24 includes an orifice unit 26 through which the high-pressure fluid 22 is moved to generate the “pure” fluid jet 34. As shown, the abrasive media 32 may be entrained upstream of a mixing chamber 38 or nozzle and downstream of the orifice unit 26 that forms the fluid jet 34. The abrasive media 32 entrained into the abrasive fluid jet 36 enhances the cutting power of the abrasive fluid jet 36. This enables the cutting head 24 to process workpieces 28 made of harder materials compared to a “pure” fluid jet (e.g., the fluid jet 16 of FIG. 1), that is devoid of the abrasive media 32.

[0006] The source for the abrasive media 32 (e.g., a hopper, chamber, or pallet), is typically positioned remote from the cutting head 24. The cutting head 24 often moves relative to the workpiece 28 during processing, and the added mass / weight of the source of abrasive media 32 could negatively impact performance of the cutting head 24. Thus, the abrasive media 32 is usually delivered over some distance from the source to the cutting head 32. It is often easier to deliver the abrasive media when a ratio of the abrasive media 32 to the fluid carrying the abrasive media 32 (i.e., carrying fluid) is lower compared to when the ratio is higher. However, delivering abrasive media 32 with a lower ratio may result in inconsistent flow rate of the abrasive media 32 to the fluid jet 34. This inconsistency may impact the cutting power of the abrasive fluid jet 36 (e.g., increasing and decreasing as the amount of the abrasive media 32 being delivered spikes and dips). The amount of the abrasive media 32 delivered to the fluid jet 34 may vary, resulting in the fluctuating cutting power of the abrasive fluid jet 36 (e.g., increased water content may reduce cutting power by reducing the energy available to be transferred to the abrasive media 32).

[0007] Referring to FIG. 3, other known fluid jet cutting systems 40 supply a concentrated mixture of abrasives and a fluid (e.g., water), referred to herein as a “slurry”42 or a “suspension,” directly to an orifice unit 44 of a cutting head 46. The slurry 42 (including the abrasive particles therein) pass through the orifice unit 44 to generates a slurry jet 48 for cutting or processing a workpiece 50. As used herein the term slurry jet refers to a fluid jet that is formed by moving / forcing a mixture of fluid and solid / abrasive particles through an orifice unit that generates a resulting jet with the solid / abrasive particles embedded in the jet.

[0008] One disadvantage to some known slurry jets (e.g., the known fluid jet cutting system 40) is that they operate on a batch system. The fluid jet cutting system 40 is filled with a batch of the slurry 42, which is sealed, pressurized, and then fed / delivered to the cutting head 46 wherein the slurry 42 passes through the orifice unit 44 to generate the slurry jet 48. In these known batch systems the feed is not continuous, resulting in the known fluid jet cutting system 40 needing to be shut down, depressurized, unsealed, and refilled with additional slurry 42. This reduces the effectiveness and economic viability of the known fluid jet cutting system 40 for many high-pressure fluid jet operations, which require a continuous run time for a number of hours.

[0009] Additionally, the production of the slurry jet 48 of the known fluid jet cutting system 40 increases material, maintenance, and operating costs compared to the production of the abrasive fluid jet 36 generated by the abrasive fluid jet cutting system 20. To produce the abrasive fluid jet 36, the abrasive particles 32 are entrained into the already formed fluid jet 34 (e.g., downstream of the orifice unit 26). To produce the slurry jet 48, the slurry 42, which includes abrasive particles carried in a fluid (e.g., water) must be pressurized to a high-pressure (e.g., above 20,000 psi) and delivered to the orifice unit 44. Generating and delivering a high-pressure fluid (e.g., above 20,000 psi) involves specialized conduits (e.g., tubes, pipes, etc.) made of hard materials with thick walls. These specialized conduits are often heavy and expensive. Abrasive particles delivered to an already formed fluid jet (downstream of the orifice unit) may be kept at a much lower pressure (e.g., below 100 psi).

[0010] Abrasive particles, by their nature, abrade material that they contact. This includes the conduits used to deliver the abrasive particles (e.g., to the cutting head 46). Additional wear and tear on the specialized, high-pressure conduits reduces the operational lifetime of the high-pressure conduits and greatly increases costs associated with operation of the known high-pressure system 40 (e.g., compared to the known high-pressure system 20). Further, moving the high-pressure slurry 42, which includes suspended abrasive particles, through the orifice unit 44 may result in faster deterioration and a shorter lifespan for the orifice unit 44.BRIEF SUMMARY

[0011] Embodiments described herein provide a fluid jet cutting system that delivers wet abrasive (e.g., abrasive particles suspended in / carried by a liquid) to form an abrasive waterjet used to process a workpiece. Also described herein are embodiments of components of fluid jet cutting systems that produce and deliver a steady stream of wet abrasive particles. For example, a condenser is described that receives wet abrasive at a lower ratio of abrasive media to fluid / liquid carrying the abrasive media (referred to herein as “lower density”), condenses the wet abrasive to have a higher ratio of abrasive media to fluid / liquid carrying the abrasive media (referred to herein as “higher density”), and delivers the higher density wet abrasive to a component of a high-pressure system, such as a cutting head. Additional embodiments described herein include components of the fluid jet cutting system and methods of use and assembly of the fluid jet cutting system, and components of those systems including wet abrasive production and delivery devices.

[0012] One of the limiting factors in the use of wet abrasive in the formation of a fluid jet used to process workpieces is the flow rate of the wet abrasive particles that can be reliably and consistently delivered to the fluid jet. When using abrasive to increase cutting power of a fluid jet, different applications may have different optimal flow rates. Delivering a higher density of wet abrasive particles to the fluid jet may increase the cutting power of the resulting abrasive fluid jet, whereas delivering a lower density of wet abrasive (with a higher fluid / water content) may decrease the cutting power of the resulting abrasive fluid jet.

[0013] Referring to FIGS. 4 and 5, a slurry as referred to herein includes “wet” abrasive particles 80 carried by / suspended within a liquid 82 (e.g., such as water). As shown in FIG. 4, the abrasive particles 80 and the liquid 82 may form a lean-phase slurry 84 in which some, optionally a majority, and up to all of the individual abrasive particles 80 within the lean-phase slurry 84 are suspended in / surrounded by the liquid 82. The lean-phase slurry 84 may include spacing between adjacent ones of the abrasive particles 80.

[0014] As shown in FIG. 5, reference herein to a dense-phase slurry 86 includes a condition in which the density of the abrasive particles 80 (ratio of abrasive particles 80 to liquid 82) is increased compared to the lean-phase slurry 84. The density of the dense-phase slurry 86 includes up to a condition in which the liquid 82 content is limited to interstitial spaces between adjacent ones of the abrasive particles 80. The terms “lean-phase slurry” and “dense-phase slurry” may also be used comparatively. For example, a “lean-phase slurry” within a fluid jet system may have a lower density than a “dense-phase slurry” within the same fluid jet system. In some embodiments, the lean-phase slurry may have a higher fluid (e.g., water) content and a lower abrasive content than the dense-phase slurry, which has a lower fluid content and a higher abrasive content.

[0015] For use in high-pressure systems (e.g., fluid jet cutting heads), the lean-phase slurry 84 is typically easier to transport than the dense-phase slurry 86. This may be due, in part, to the lean-phase slurry 84 having flow characteristics of a fluid. Thus, the lean-phase slurry 84 may be easier to move via a pump and / or easier to transport along a tube / pipe. A path from the source of the slurry to the cutting head may include tight curves / bends, and may move / change during operation of the cutting head. The less dense arrangement of abrasive particles 80 in the lean-phase arrangement is less likely to clog or get stuck along the delivery path. However, the lean-phase arrangement may result in inconsistent delivery of abrasive to the cutting head. Additionally, the lean-phase arrangement may be less efficient, due to the high pressure water (fluid jet) needing to accelerate a greater amount of carrying fluid, which does not increase cutting power.

[0016] As shown in FIG. 4, a clump 88 of abrasive particles 80 may form (e.g., due to static electricity buildup). Additionally, a gap 90 (e.g., volume devoid of the abrasive particles 80 or having very few abrasive particles 80) may be present within the lean-phase slurry 84. Inconsistent delivery of the abrasive particles 80 (e.g., in the form of the clumps 88 and the gaps 90) may result in inconsistent cutting power of the resulting abrasive fluid jet. Some conventional systems attempt to improve consistency by using thickeners (e.g., Xanthan gum) within the slurry. However, these thickeners can result in problems such as a frothy water jet tank, or abrasive material that does not settle. Additionally, the thickened fluid may be harder to filter than pure water without added thickeners. Further challenges include controlling the ratio of thickener agent to pure water (both an immediate dosage and an overall concentration in the total volume). These two variables involve constant monitoring / control / intervention to maintain functionality, and they are avoided by the embodiments of the fluid jet cutting system described herein.

[0017] Embodiments of the fluid jet cutting system described herein receive lean-phase slurry (e.g., recycled from a catcher tank of the fluid jet cutting system), transition / condense the lean-phase slurry into a dense-phase slurry, and deliver the dense-phase slurry to a fluid jet cutting head to be combined with a fluid jet (downstream of an orifice unit that generates the fluid jet) to form an abrasive fluid jet that is used to process a workpiece. The dense-phase slurry may be pressurized (e.g., between atmospheric pressure and about 50 psi, between atmospheric pressure and about 100 psi, or even higher such up to the pressure at which air liquifies) prior to delivery to the fluid jet cutting head. These embodiments may provide improved performance (e.g., consistent cutting power, increased cutting power) of the abrasive fluid jet compared to other known fluid jet cutting systems that use suction (e.g., generated by the venturi effect of a fluid jet) or other mechanisms to draw abrasive particles (e.g., dry abrasive, or lean-phase slurry) into the fluid jet. Embodiments of the fluid jet cutting systems described herein may also generate and combine unpressurized (e.g., similar to ambient / atmospheric pressure) slurry with the fluid jet to form the abrasive fluid jet.

[0018] According to one embodiment, a slurry condenser includes a first chamber, a second chamber, and a slurry inlet fluidly connected to the first chamber. The slurry condenser further includes a slurry transfer valve positioned between the first chamber and the second chamber. The slurry transfer valve is transitionable from an open configuration in which the first chamber and the second chamber are connected (e.g., fluidly) along a first path to a closed configuration in which flow from the first chamber to the second chamber along the first path is blocked. The slurry condenser further includes a bypass positioned between the first chamber and the second chamber, and fluidly connects the first chamber to the second chamber along a second path that is separate from the first path. A fluid (e.g., gas, liquid, or both) inlet of the slurry condenser fluidly connects a fluid source to the first chamber.

[0019] According to one embodiment, a slurry condenser includes a first chamber, a second chamber, and a slurry inlet fluidly connected to the first chamber. The slurry condenser further includes a slurry transfer valve positioned between the first chamber and the second chamber. The slurry transfer valve is transitionable from an open configuration in which the first chamber and the second chamber are fluidly connected along a first path to a closed configuration in which flow from the first chamber to the second chamber along the first path is blocked. The slurry condenser further includes a bypass positioned between the first chamber and the second chamber, and fluidly connects the first chamber to the second chamber along a second path that is separate from the first path. A fluidizer of the slurry condenser injects fluid into the first chamber at a location closer to the slurry transfer valve than the location is from the slurry inlet.

[0020] An embodiment of a method of delivering slurry to a fluid jet cutting head includes adding slurry to a first chamber of a slurry condenser. The method further includes maintaining a slurry valve in a closed configuration while the slurry delivered to the first chamber condenses in a lower portion of the first chamber. The slurry valve is positioned between the first chamber and a second chamber along a first flow path. The method further includes transitioning the slurry valve from the closed configuration to an open configuration, and transitioning a bypass fluid valve from a closed configuration to an open configuration. The bypass fluid valve positioned along a bypass fluidly connecting the first chamber and a second chamber along a second flow path that is separate from the first flow path. The slurry gathered in the lower portion of the first chamber is transferred through the open slurry valve and into a second chamber of the slurry condenser. The method further includes maintaining a first portion of a pocket of gas within an upper portion of the first chamber and removing the slurry from the second chamber and delivering the slurry to the fluid jet cutting head.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0021] In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements and may have been solely selected for ease of recognition in the drawings. The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

[0022] FIG. 1 is a schematic view of a known fluid jet cutting system including a fluid jet cutting head that generates a pure fluid jet.

[0023] FIG. 2 is a schematic view of a known fluid jet cutting system including a fluid jet cutting head that generates an abrasive fluid jet.

[0024] FIG. 3 is a schematic view of a known fluid jet cutting system including a fluid jet cutting head that generates a slurry jet.

[0025] FIG. 4 is a schematic view of a lean-phase slurry.

[0026] FIG. 5 is a schematic view of a dense-phase slurry.

[0027] FIG. 6 is a schematic view of a fluid jet cutting system including a fluid jet cutting head and a slurry condenser.

[0028] FIG. 7 is a schematic view of the slurry condenser illustrated in FIG. 6, in a closed configuration, according to an embodiment.

[0029] FIG. 8 is a schematic view of the slurry condenser illustrated in FIG. 7, in an open configuration, according to an embodiment.

[0030] FIG. 9 is a schematic view of the slurry condenser illustrated in FIG. 6, in the open configuration, according to another embodiment.

[0031] FIG. 10 is a flow chart illustrating a method of operation of a slurry condenser, according to one embodiment.

[0032] FIG. 11 is a flow chart illustrating a portion of the method illustrated in FIG. 10, according to one embodiment.

[0033] FIG. 12 is a flow chart illustrating a portion of the method illustrated in FIG. 10, according to one embodiment.

[0034] FIG. 13 is a flow chart illustrating a portion of the method illustrated in FIG. 10, according to one embodiment.DETAILED DESCRIPTION

[0035] As noted above, conventional fluid jet cutting systems are known and used to process workpieces with a fluid jet generated from pressurized fluid. Because the efficacy of an abrasive fluid jet formed by entraining a slurry into a formed fluid jet is dependent, at least in part, on the consistency and / or the density of the slurry being delivered to and entrained into the fluid jet, a device that produces and delivers a dense-phase slurry to the fluid jet may improve the performance of a fluid jet cutting system that includes the device.

[0036] Referring to FIGS. 6 to 9, a fluid jet cutting system 100 generates a fluid jet 102 formed by a high-pressure fluid 104 flowing through an orifice unit 106 of a cutting head 108. The fluid jet cutting system 100 may include a slurry condenser 120 that receives a lean-phase slurry 122 as an input, condenses the lean-phase slurry 122 into a dense-phase slurry 124, and delivers the dense-phase slurry 124 to the cutting head 108 (e.g., to the fluid jet 102 downstream of the orifice unit 106) to be combined with the fluid jet 102 to form an abrasive fluid jet 126. The cutting head 108 may include a nozzle 110 (and / or a mixing chamber) that the abrasive fluid jet 126 passes through while following a flow path that exits the cutting head 108 (e.g., via a distal opening in the nozzle 110) and processes (e.g., cuts, treats, alters a surface of) a workpiece 112 positioned along the flow path.

[0037] Dry abrasive is known for use in the formation of an abrasive fluid jet. However, delivering the dry abrasive is difficult to do consistently. The source (e.g. container, hopper, etc.) is typically positioned remote from the cutting head. Delivery of the dry abrasive may generate static electricity, which can result in clumping / clogging of the conduit used to deliver the dry abrasive, especially around curves and at locations where the internal diameter of the conduit changes (e.g., a metering device). Wet abrasive remedies some of the issues associated with dry abrasive (e.g., no static electricity is generated). However, wet abrasive may clump while being delivered from a source (e.g., container, hopper, catcher tank, etc.). Typically, a lower density slurry is easier to deliver, but is more prone to inconsistent results.

[0038] When a slurry is entrained into a fluid jet, both the fluid in the slurry (e.g., water) and the abrasive particles are rapidly accelerated by the fluid jet. Energy of the fluid jet used to accelerate other fluid carrying the abrasive particles (referred to herein as “carrying fluid”) is suboptimal or “wasted” as it is the accelerated abrasive particles that provide the desired cutting power. Thus, embodiments of the slurry condenser 120 disclosed herein are capable of receiving the lean-phase slurry 122 as an input and condensing the lean-phase slurry 122 to form the dense-phase slurry 124, which is then delivered to a tool (e.g., the cutting head 108). The dense-phase slurry 124 may then be entrained into the fluid jet 102 to form the abrasive fluid jet 126.

[0039] According to one embodiment, the slurry condenser 120 is capable of delivering slurry (e.g., the dense-phase slurry 124) to the cutting head 108 while simultaneously refilling itself (e.g., from a remote source 128 of the lean-phase slurry 122 that may (or may not) be in fluid communication with a catcher tank 114 of the fluid jet cutting system 100). The slurry condenser 120 enables the use of easy-to-deliver lean-phase slurry 122, while still providing the consistent-performing, dense-phase slurry 124 to the cutting head 108. Some embodiments of the slurry condenser 120 provide a continuous flow of the dense-phase slurry 124, which avoids the downtime associated with known, batch-fed systems.

[0040] The slurry condenser 120 may include a first chamber 130 and a second chamber 132. As shown, the first chamber 130 and the second chamber 132 may be stacked vertically (e.g., such that the first chamber 130 is above the second chamber 132). According to some embodiments, the first chamber 130 and the second chamber 132 may be arranged horizontally (e.g., such that the first chamber 130 is at about the same elevation as the second chamber 132), or at other relative heights and positions. The vertically stacked arrangement may improve transfer of the material from the first chamber 130 to the second chamber 132 due to gravity assistance.

[0041] The first chamber 130 and the second chamber 132 may be fluidly connected / connectable along at least one path. As shown, the slurry condenser 120 may include a slurry transfer valve 136 positioned along a first path 134 between the first chamber 130 and the second chamber 132. The slurry transfer valve 136 may be positioned so as to fluidly connect a lower portion 138 (e.g., a bottom, a lower half, a lower third) of the first chamber 130 to an upper portion 140 (e.g., a top, an upper half, an upper third) of the second chamber 132.

[0042] Additionally, some embodiments of the slurry condenser 120 may define a second path 142 that follows a bypass 117 and fluidly connects an upper portion 144 (e.g., a top, an upper half, an upper third) of the first chamber 130 to the upper portion 140 of the second chamber 132 without passing through the slurry transfer valve 136. Some embodiments of the condenser 120 may be devoid of the bypass 117, and the second path 142 may extend through the transfer valve 136 along a path (e.g., through a tube, conduit, or passage) that is fluidly isolated from the first path 134 through the transfer valve 136). The slurry condenser 120 may include a bypass fluid valve 146 positioned along the second path 142 (e.g., between the upper portion 144 of the first chamber 130 and the upper portion 140 of the second chamber 132).

[0043] Transitioning the slurry transfer valve 136 to an open configuration allows passage of a slurry 123 (e.g., formed from a settled and / or fluidized volume of the lean-phase slurry 122 entering the first chamber 130) from the first chamber 130 to the second chamber 132. Transitioning both the slurry transfer valve 136 and the bypass fluid valve 146 to the open configuration may result in an improved (e.g., faster, smoother, less turbulent) passage of the slurry 123 from the first chamber 130 to the second chamber 132.

[0044] The slurry transfer valve 136 may be sized to optimize a flow rate of the slurry 123 from the first chamber 130 to the second chamber132. According to one embodiment, the slurry transfer valve 136 may include a lumen 148 extending therethrough when the slurry transfer valve is in the open configuration (as shown in FIGS. 8 and 9). While a larger opening / volume of the lumen 148 between the first chamber 130 and the second chamber 132 will generally result in a higher maximum flow rate between the chambers, the slurry transfer valve 136 may be sized with other considerations in mind.

[0045] For example, if a volume of the lumen 148 changes by a large enough amount (referred to herein as a volume delta) when transitioning between the open configuration and a closed configuration (as shown in FIG. 7), in which the flow of the slurry 123 from the first chamber 130 to the second chamber 132 is prevented, pressure dips and spikes in the second chamber 132 may result that negatively impact performance of the slurry condenser 120. Some embodiments of the slurry transfer valve 136 may define a volume delta of less than 5 cubic inches, for example about 2 cubic inches to avoid the aforementioned pressure dips and spikes. However, the slurry condenser 120 is not limited to slurry transfer valves with a volume delta of any particular size.

[0046] Additional factors to be considered may include a minimum cross-sectional dimension of the lumen 148. Between cycles of transition of the slurry transfer valve 136 from the closed configuration to the open configuration the slurry 123 may gather within the lower portion 138 (e.g., at the bottom / adjacent the slurry transfer valve 136) of the first chamber 130. For example, gathered / settled slurry may not fall or may not fall fast enough through a lumen of a valve with a cross-sectional dimension less than 0.5 inches to meet demands of the cutting head 108. Accordingly, some embodiments of the lumen 148 of the slurry transfer valve 136 of the slurry condenser 120 may include a minimum cross-sectional dimension (e.g., diameter) of 0.5 inches or greater. For some embodiments of the slurry condenser 120 the slurry transfer valve 136 may be in the form of a flexible pinch valve (e.g., with one or more fingers 147 or other movable members that close the lumen 148 to transition the slurry transfer valve 136 from the open configuration to the closed configuration). Other embodiments of the slurry transfer valve 136 may be air actuated.

[0047] To promote / improve flow of the slurry 123 into the slurry transfer valve 136, some embodiments of the slurry condenser 120 may include a vibrator 149 (e.g., coupled to and / or supported by the first chamber 130) that vibrates the first chamber 130. Depending on the construction of the slurry condenser 120, the vibrator 149 may vibrate additional components of the slurry condenser 120 (e.g., up to an entirety of the slurry condenser 120 if it is rigidly constructed). The vibrator 149 may improve the density of the slurry 123 that settles in the lower portion 138 of the first chamber 130 when the slurry transfer valve 136 is in the closed configuration, and / or may facilitate movement of the slurry 123 from the first chamber 130 through the slurry transfer valve 136 to the second chamber 132 when the slurry transfer valve 136 is in the open configuration. Some embodiments of condenser 120 may be devoid of the vibrator 149.

[0048] The first chamber 130 may enclose a volume (or pocket) of gas 150 (e.g., air) within an interior of the first chamber 130. As shown, the volume of gas 150 may be less dense than the fluid 152 that forms the slurry 123 resulting in the volume of gas 150 residing within the upper portion 144 of the first chamber 130. Thus, the volume of gas 150 may be more compressible than the fluid 152. Thus, the volume of gas 150 may act as a dampening medium that improves performance of the slurry condenser 120 by smoothing out sudden pressure increases and / or decreases within the first chamber 130 (e.g., during operation of the slurry condenser 120, such as transition of the slurry transfer valve 136 from the closed configuration to the open configuration, or vice versa). Compared to a chamber that is filled with liquid and is devoid of a pocket of gas, the volume of gas 150 within the first chamber 130 may reduce the occurrence of inconsistencies in the flow rate, which in turn may have a negative impact on performance (e.g., cutting power) of the abrasive fluid jet 126. Additionally, a reduction of inconsistency in flow rate of slurry may improve safe operation of high-pressure systems by helping prevent spiking of pressure values to dangerous levels.

[0049] The slurry condenser 120 may include a gas delivery system 154 that provides an entry and / or exit for the pocket of gas 150 to / from the first chamber 130. The gas delivery system 154 may include tubing 156 that is coupled to a source 158 of the gas and a gas valve 160 that transitions between an open configuration (as shown in FIG. 7), in which gas can enter / exit the first chamber 130 via the tubing 156 and a closed configuration (as shown in FIG. 8) in which the entry / exit of the gas 150 via the tubing 156 is prevented. The source 158 may be located outside of the first chamber 130 (e.g., external of the slurry condenser 120).

[0050] The gas delivery system 154 may be used to pressurize the first chamber 130 (e.g., up to about 100 psi). According to some embodiments, opening the gas valve 160 and increasing the volume of gas 150 (e.g., a density of the pocket of gas 150) within the first chamber 130 increases the pressure within the first chamber 130 and closing the gas valve 160 maintains the volume of gas 150 within the first chamber 130 and maintains the pressure within the first chamber 130. The gas valve 160 may also be opened allowing an amount of the volume of gas 150 to exit the first chamber 130, lowering the pressure within the first chamber 130 (e.g., to atmospheric pressure, to 0 psi, etc.).

[0051] Some embodiments of the slurry condenser 120 may include a fluidizer 170 that facilitates movement of the slurry 123 from the first chamber 130 to the second chamber 132 (e.g., through the slurry transfer valve 136 when the slurry transfer valve 136 is in the open configuration). According to one embodiment, the fluidizer 170 delivers (e.g., injects) a fluid 152 (e.g., the fluid of the slurry 123, which according to one embodiment may be water) to the gathered / settled slurry 123 in the lower portion 138 of the first chamber 130. As shown, the fluidizer 170 may be fluidly connected to a source 172 of the fluid 152 located outside of the first chamber 130 (e.g., external of the slurry condenser 120). The fluidizer 170 may include a fluid conduit 174 (e.g., tubing, piping, etc.) fluidly coupled to the source 172, the fluid conduit 174 having one or more outlets 176 that direct the fluid 152 into the gathered / settled slurry 123 improving the flow characteristics of the gathered / settled slurry 123.

[0052] The slurry condenser 120 may include one or more sensors that detect fluid and / or slurry levels within components of the slurry condenser 120. For example, the slurry condenser 120 may include a first chamber fill sensor 180 and a first chamber stop sensor 182 that each detect the presence of the slurry 123 within respective portions of the first chamber 130. As shown, the first chamber fill sensor 180 may be located closer to the slurry transfer valve 136 (e.g., within the lower portion 138) than the first chamber stop sensor 182 is from the slurry transfer valve 136. The first chamber stop sensor 182 may be located in the upper portion 144 of the first chamber 130, according to some embodiments.

[0053] The first chamber fill sensor 180 and the first chamber stop sensor 182 may be contact sensors or non-contact (e.g., optical) sensors. According to one embodiment, at least a portion of components (e.g., the first chamber 130, the second chamber 132, the bypass 117, etc.) may be transparent such that the first chamber fill sensor 180 and the first chamber stop sensor 182 may be positioned externally with respect to the first chamber 130. Some embodiments of the slurry condenser 120 may be devoid of any sensors, and other embodiments of the slurry condenser 120 may include a single sensor that determines the amount of slurry 123 present within the first chamber 130. For example, a sensor of the slurry condenser 120 may determine an amount of the slurry 123 within the first chamber 130 based on a weight of the first chamber 130. Some embodiments of the slurry condenser 120 may include one or more timers that work in conjunction with or in the absence of the one or more sensors to automate operation of the slurry condenser 120.

[0054] Some embodiments of the slurry condenser 120 deliver the dense-phase slurry 124 in a pressurized state that is below the pressure of the fluid 104 that passes through the orifice unit 106 to form the fluid jet 102. For example, the dense-phase slurry 124 may be between 0 psi and about 100 psi, whereas the fluid 104 may be between about 12,000 psi and about 200,000 psi. The relatively low pressures of the slurry condenser 120 may enable the use of transparent materials referenced above. The transparent materials enable the use of optical sensors to detect levels of fluid and abrasive within components of the slurry condenser 120.

[0055] In some embodiments, the slurry condenser 120 may be mounted on the cutting head 108. During operation of the fluid jet cutting system 100 the cutting head 108 may move as it processes the workpiece 112. The capability of the slurry condenser 120 to operate a lower pressure (e.g., between atmospheric pressure and about 100 psi) enables the use of lower weight components (e.g., plastic for the first chamber 130 and the second chamber 132) that reduce the mass carried by the cutting head 108 or a gantry / robotic arm supporting the cutting head 108. Another benefit of the relatively low pressures within the first chamber 130 is that the volume of gas 150 remains in a gaseous phase, whereas the gas may liquify at significantly higher pressures (e.g., such as those used to generate the fluid jet 102).

[0056] The slurry condenser 120 may include a second chamber fill sensor 184 (e.g., similar to the first chamber fill sensor 180 as described herein) but positioned to determine the amount of the slurry 123 within the second chamber 132. According to one embodiment, when the second chamber fill sensor 184 detects an absence of the slurry 123, an instruction / signal may be generated to open the slurry transfer valve 136 and move an amount of the slurry 123 from the first chamber 130 into the second chamber 132 (e.g., along the first path 134).

[0057] Although not shown in the illustrated embodiment, some embodiments of the slurry condenser 120 may include a second chamber stop sensor (e.g., similar to the first chamber stop sensor 182 as described herein). According to one embodiment, when the second chamber stop sensor detects the presence of the slurry 123, an instruction / signal may be generated to close the slurry transfer valve 136 and prevent additional slurry 123 from entering the second chamber 132. Similar to the first chamber 130, the second chamber fill sensor 184 may be located closer to an exit 188 of the slurry condenser 120 than the second chamber stop sensor is from the exit 188. The exit 188 of the slurry condenser 120, where the dense-phase slurry 124 exits the slurry condenser 120, may be downstream from a slurry inlet 189, where the lean-phase slurry 122 enters the slurry condenser 120.

[0058] The slurry condenser 120 may include a bypass sensor 190. As shown, the bypass sensor 190 may be positioned proximate to (e.g., supported by) the bypass 117 to determine how much of the fluid 152 is present within the bypass 117. The bypass sensor 190 may detect the presence or absence of the fluid 152, and in response an instruction / signal may be generated to open or close a bypass inlet / outlet valve 192 that adds fluid 152 to, or removes fluid 152 from, the bypass 117 (e.g., via a fluid source 194 that may be the same as, fluidly connected to, or separate from the fluid source 172).

[0059] During operation of the cutting head 108, the dense-phase slurry 124 is delivered from the second chamber 132 to the cutting head 108 to be entrained into the fluid jet 102 to form the abrasive fluid jet 126. When the slurry transfer valve 136 is in the closed configuration, the amount of the fluid 152 within the second chamber 132 decreases over time. To supplement the lost fluid 152, the condenser 120 may add additional fluid 152 to the second chamber 132, without that additional fluid 152 passing through the slurry transfer valve 136. If the additional fluid 152 was not added, air, gas, or a vacuum may form in the second chamber 132 that could impede transfer of the slurry 123 to the second chamber 132 when the slurry transfer valve 136 is transitioned to the open configuration. According to one embodiment, the bypass sensor 190 may detect a low level of fluid within the bypass 117 (or another feeder tube fluidly connected to the second chamber 132). Upon detection of the low level of fluid, the bypass sensor 190 may send a signal that transitions the bypass inlet / outlet valve 192 from a closed configuration to an open configuration, enabling flow of the fluid 152 into the second chamber 132 (e.g., via the bypass 117).

[0060] As shown, the bypass 117 may contain two different fluids along the second path 142 between the first chamber 130 and the second chamber 132. For example, the two different fluids may include a liquid (e.g., water) and a gas (e.g., air). When the slurry transfer valve 136 is transitioned from the closed configuration to the open configuration mass transfer between the first chamber 130 and the second chamber 132 occurs. As the slurry 123 enters the second chamber 132, the fluid 152 within the second chamber 132 is displaced. The bypass 117 provides a route (e.g., the second path 142) for the displaced fluid 152 to follow toward (and all the way back to, in some instances) the first chamber 130. The two different fluids may have two different densities. These different densities create a layered shock absorption that helps dissipate pressure surges / spikes / dips during the mass transfer between the first chamber 130 and the second chamber 132.

[0061] As shown in FIG. 9, the condenser 120 may be devoid of the bypass 117. In embodiments devoid of the bypass 117, the second path 142 may also pass through the slurry transfer valve 136 (e.g., in the opposite direction of the first path 134). If the first path 134 and the second path 142 are not fluidly isolated from one another, transfer of the slurry 123 from the first chamber 130 to the second chamber 132 may take longer and be more turbulent, and the slurry 123 may take longer to settle within the second chamber 132.

[0062] Referring to FIGS. 6 to 13, a method of operation 200 of the slurry condenser 120 may include at 202 adding the lean-phase slurry 122 to the first chamber 130. According to one embodiment, the lean-phase slurry 122 is delivered to the slurry condenser 120 (e.g., from the source 128, which may be the catcher tank 114 of the fluid jet cutting system 100). The lean-phase slurry 122 may flow through a slurry entry valve 196 positioned between the source 128 and the first chamber 130 when the slurry entry valve 196 is in an open configuration. The lean-phase slurry 122 may be dispersed after entering the first chamber 130 (e.g., by a diffuser 198 of the slurry condenser 120 positioned within the first chamber 130).

[0063] According to the method 200, at 204 the lean-phase slurry 122 may be added to the first chamber 130 until the first chamber 130 is “filled.” Filling the first chamber 130 may not include filling an entirety of the first chamber 130, but rather filling a portion (e.g., the lower portion 138, or up to the first chamber stop sensor 182). Alternatively, an entirety of the first chamber 130 may be filled with the lean-phase slurry 122 at 204. During and / or after the lean-phase slurry 122 enters the first chamber 130, a portion of the lean-phase slurry 122 may condense / settle / gather (e.g., at the lower portion 138). At 206 the method 200 may include emptying the second chamber 132. Emptying the second chamber 132 may not include emptying an entirety of the second chamber 132, but rather emptying a portion (e.g., down to the second chamber fill sensor 184).

[0064] After either of the conditions at 204 or 206 are met, the method 200 may include at 208 transferring the slurry 123 from the first chamber 130 to the second chamber 132. Prior to and / or during transfer, the slurry 123 may be condensed to form the dense-phase slurry 124. The transfer of the slurry 123 may continue until the first chamber 130 is emptied at 210 and / or a set amount of time passes at 212. Emptying the first chamber 130 may not include emptying an entirety of the first chamber 130, but rather emptying a portion (e.g., the lower portion 138, or down to the first chamber fill sensor 180). The set amount of time may be selected based on operating characteristics of the slurry condenser 120 and may be adjusted from one operation to another. Operating characteristics may include, but are not limited to, operating pressure within the first chamber 130, the type / density of the abrasive / slurry, flowrate of the slurry 123 to the cutting head 108, etc.

[0065] When an amount of the dense-phase slurry 124 is present within the second chamber 132 (e.g., prior to adding the lean-phase slurry at 202 or after emptying the chamber 130 at 210 or the set amount of time passes at 212), the method may include delivering the dense-phase slurry 124 to the cutting head 108 at 214. According to one embodiment, delivery of the dense-phase slurry 124 may occur concurrently with any of 202 through 212. In some embodiments, the method 200 includes continuously delivering the dense-phase slurry 124 through the exit 188 (e.g., to the cutting head 108).

[0066] As shown in FIG. 9, the delivery of the dense-phase slurry 124 at 214 may include pressurizing the bypass 117 and the second chamber 132 (e.g., via the volume of gas 150). Additionally, the delivery at 214 may include maintaining a level of the fluid 152 within the bypass 117 (e.g., through the bypass inlet / outlet valve 192 via the source 194). As the dense-phase slurry 124 is delivered, an amount of fluid 152 within the second chamber 132 may decrease, resulting in additional fluid 152 being provided via the bypass 117. The decreasing amount of fluid 152 may be include carrying fluid that forms a part of the dense-phase slurry 124.

[0067] Additional fluid 152 may exit the condenser 120 (e.g., via the first chamber 130, the second chamber 132, or both) that is not delivered to the cutting head 108 (referred to herein as excess fluid 153). This excess fluid 153 may result from the flow rate of the fluid 152 of the lean-phase slurry 122 being higher than the flow rate of the abrasive particles of the dense-phase slurry 124. Removing this excess fluid 153 from the delivery path to the cutting head 108 prevents energy of the fluid jet 102 being wasted to accelerate the excess fluid 153. The excess fluid 153 may be directed along a path that bypasses the catcher tank 114 (e.g., back toward the condenser 120 for entry into the first chamber 130). At 220 the dense-phase slurry 124 in the second chamber 132 is delivered to the cutting head 108 (e.g., after leaving the slurry condenser 120 via the exit 188).

[0068] As shown in FIG. 12, adding the lean-phase slurry 122 to the first chamber 130 until the first chamber 130 is filled at 204 may include closing the bypass fluid valve 146 at 222 and depressurizing the first chamber 130 at 224. After the first chamber 130 is depressurized, the lean-phase slurry 122 may be added to the first chamber 130 at 226 (e.g., via the slurry entry valve 196). After the lean-phase slurry 122 enters the first chamber 130, the slurry 123 settles in the lower portion 138 of the first chamber 130 at 228. Excess fluid 152 (e.g., entering the first chamber 130 along with / as part of the lean-phase slurry 122) may be removed from the first chamber 130 (e.g., via the tubing 156).

[0069] According to one embodiment, adding the lean-phase slurry 122 to the first chamber 130 until the first chamber 130 is filled at 204 may include detecting that the first chamber 130 is full at 232. For example, the first chamber stop sensor 182 may detect when the amount / level of slurry 123 is sufficient for transfer to the second chamber 132. At 234 the method 200 may include blocking the flow of additional lean-phase slurry 122 into the first chamber 130. For example, in response to an instruction / signal from the first chamber stop sensor 182, the slurry entry valve 196 may transition to the closed configuration blocking the flow of additional lean-phase slurry 122 into the first chamber 130 and blocking the flow of gas, liquid, or solid material within the first chamber 130 from exiting the first chamber 130.

[0070] As shown in FIG. 13, transferring the slurry 123 from the first chamber 130 to the second chamber 132 at 208 may include closing the gas valve 160 at 236. The method 200 may further include pressurizing the first chamber 130 at 238 to match closely with the pressure of the second chamber 132 (e.g., ranging from about 0 psi to 25 psi, ranging from about 0 psi to about 100 psi). If the pressure of the first chamber 130 matches the pressure of the second chamber 132, it may be unnecessary to perform the pressurization at 238. The method 200 may also include fluidizing the settled slurry 123 in the lower portion 138 at 240. The settled slurry 123 may be fluidized via the fluidizer 170 injecting the fluid 152 into the lower portion 138 (e.g., directly into the settled slurry 123). The slurry 123 may be fluidized before, during, and / or after pressurization of the first chamber 130 at 238.

[0071] At 242 the method 200 may include opening the bypass fluid valve 146 and opening the slurry transfer valve 136 (e.g., simultaneously, or one after the other). When both the bypass fluid valve 146 and the slurry transfer valve 136 are both in the open configuration, the slurry 123, which may be fluidized, dense-phase slurry 124, is moved from the first chamber 130 to the second chamber 132 at 244. As shown, the fluidized, dense-phase slurry 124 may follow the first path 134 through the slurry transfer valve 136 as the fluidized, dense-phase slurry 124 is transferred from the first chamber 130 to the second chamber 132.

[0072] The method 200 may include raising a level of the fluid 152 within the bypass 117 at 246 when both the bypass fluid valve 146 and the slurry transfer valve 136 are both in the open configuration. As the fluidized, dense-phase slurry 124 is transferred to the second chamber 132, the amount of fluid 152 in the second chamber 132 may increase, resulting in the level of the fluid 152 in the bypass 117 increasing. The increasing level of the fluid 152 in the bypass 117 may push a portion of the volume of gas 150 that is in the bypass 117 into the first chamber 130. This displaced portion of the volume of gas 150 may fill a void left by the transferred slurry 123, resulting in a more efficient, smoother transfer of the slurry 123.

[0073] Moving the fluidized, dense-phase slurry 124 into the second chamber 132 at 244 may continue until the first chamber fill sensor 180 detects an absence of the slurry 123 at 248 (i.e., indicating a low level or “empty” condition in the first chamber 13) or until a set amount of time passes at 250 (e.g., a pre-programed cycle duration based on one or more operating characteristics of the fluid jet cutting system 100, the cutting head 108, the slurry condenser 120, or any combination thereof). Upon either of the conditions at 248 or 250 being met, the method 200 may include closing both the bypass fluid valve 146 and the slurry transfer valve 136 at 252.

[0074] The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. The various embodiments described above can be combined to provide further embodiments.

[0075] Many of the methods described herein can be performed with variations. For example, many of the methods may include additional acts, omit some acts, and / or perform acts in a different order than as illustrated or described.

[0076] These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

1. A slurry condenser comprising:a first chamber;a second chamber;a slurry inlet fluidly connected to the first chamber;a slurry transfer valve positioned between the first chamber and the second chamber, the slurry transfer valve transitionable from an open configuration in which a slurry is movable between the first chamber and the second chamber along a first path and a closed configuration in which movement of the slurry between the first chamber and the second chamber along the first path is blocked;a bypass fluidly connecting the first chamber and the second chamber along a second path that is separate from the first path; anda gas inlet fluidly connecting a gas source to the first chamber.

2. The slurry condenser of claim 1, further comprising a gas valve between the gas source and the first chamber transitionable from an open configuration in which gas from the gas source can flow through the gas valve and into the first chamber and vice versa and a closed configuration in which a flow of gas from the gas source to the first chamber and vice versa is blocked.

3. The slurry condenser of claim 1, further comprising a bypass fluid valve positioned between the first chamber and the second chamber along the second path, wherein the bypass fluid valve is transitionable from an open configuration in which fluid can flow through the bypass fluid valve and a closed configuration in which the flow of fluid through the bypass is blocked.

4. The slurry condenser of claim 3 wherein the bypass is coupled to a source of fluid that is pressurized below 100 psi.

5. The slurry condenser of claim 4, further comprising a bypass inlet / outlet valve positioned between the source of fluid and the bypass, wherein the bypass inlet / outlet valve is transitionable from an open configuration in which fluid from the source of fluid can flow through the inlet / outlet fluid valve and into the bypass and a closed configuration in which the flow of fluid from the source of fluid to the bypass is blocked.

6. The slurry condenser of claim 1 wherein the second path bypasses the slurry transfer valve.

7. The slurry condenser of claim 1, further comprising a bypass sensor positioned to detect fluid within the bypass.

8. The slurry condenser of claim 1, further comprising a first chamber fill sensor positioned to detect the slurry within the first chamber.

9. The slurry condenser of claim 8, further comprising a first chamber stop sensor positioned to detect absence of the slurry at a location within the first chamber.

10. The slurry condenser of claim 9, further comprising a slurry inlet valve transitionable from an open configuration in which slurry can flow through the slurry inlet valve into the first chamber to a closed configuration in which flow of the slurry into the first chamber is blocked.

11. The slurry condenser of claim 10 wherein the slurry inlet valve is communicatively coupled to the first chamber fill sensor, the first chamber stop sensor, or both, and transitions from the closed configuration to the open configuration, or vice versa, in response to an instruction from the first chamber fill sensor or the first chamber stop sensor.

12. The slurry condenser of claim 9, further comprising a fluidizer that injects fluid into the first chamber at a location between the first chamber fill sensor and the first chamber stop sensor.

13. The slurry condenser of claim 1, further comprising a fluidizer that injects fluid into a lower portion of the first chamber.

14. The slurry condenser of claim 13 wherein the fluidizer injects fluid into the slurry that has gathered within the lower portion of the first chamber.

15. The slurry condenser of claim 1 wherein the first chamber receives lean-phase slurry through the slurry inlet, and the second chamber outputs dense-phase slurry.

16. A fluid jet cutting system comprising:the slurry condenser of claim 1; anda fluid jet cutting head that generates a fluid jet,wherein the slurry condenser is fluidly connected to the fluid jet cutting head such that slurry from the slurry condenser is delivered to the fluid jet to form an abrasive fluid jet.

17. A slurry condenser comprising:a first chamber;a second chamber;a slurry inlet fluidly connected to the first chamber;a slurry transfer valve positioned between the first chamber and the second chamber, the slurry transfer valve transitionable from an open configuration in which a slurry is movable between the first chamber and the second chamber along a first path and a closed configuration in which movement of the slurry between the first chamber and the second chamber along the first path is blocked; anda fluidizer that injects fluid into the first chamber.

18. The slurry condenser of claim 17 wherein the fluidizer is positioned such that fluid is injected into the first chamber at a location closer to the slurry transfer valve than the location is from the slurry inlet.

19. The slurry condenser of claim 17, further comprising a gas inlet fluidly connecting a gas source to the first chamber.

20. The slurry condenser of claim 19, further comprising a gas valve between the gas source and the first chamber transitionable from an open configuration in which gas from the gas source can flow through the gas valve and into the first chamber and a closed configuration in which the flow of gas from the gas source to the first chamber is blocked.

21. The slurry condenser of claim 17, further comprising a bypass fluidly connecting the first chamber to the second chamber along a second path that is separate from the first path.

22. The slurry condenser of claim 21, further comprising a bypass fluid valve positioned between the first chamber and the second chamber along the second path, wherein the bypass fluid valve is transitionable from an open configuration in which gas from the first chamber can flow through the bypass fluid valve and toward the second chamber and a closed configuration in which the flow of gas from the first chamber toward the second chamber via the bypass is blocked.

23. The slurry condenser of claim 22 wherein the bypass is coupled to a source of fluid that is pressurized below 100 psi.

24. The slurry condenser of claim 23, further comprising a bypass inlet / outlet valve positioned between the source of fluid and the bypass, wherein the bypass inlet / outlet valve is transitionable from an open configuration in which fluid from the source of fluid can flow through the fluid inlet / outlet valve and into the bypass and a closed configuration in which the flow of fluid from the source of fluid to the bypass is blocked.

25. The slurry condenser of claim 24, further comprising a bypass sensor positioned to detect the fluid within the bypass between the location where the fluid enters the bypass and the bypass fluid valve.

26. The slurry condenser of claim 17, further comprising a first chamber fill sensor positioned to detect the slurry within the first chamber.

27. The slurry condenser of claim 26, further comprising a first chamber stop sensor positioned to detect absence of a dense-phase slurry at a location within the first chamber.

28. The slurry condenser of claim 26, further comprising a slurry inlet valve transitionable from an open configuration in which slurry can flow through the slurry inlet valve into the first chamber to a closed configuration in which the flow of slurry into the first chamber is blocked.

29. The slurry condenser of claim 28 wherein the slurry inlet valve is communicatively coupled to the first chamber fill sensor, the first chamber stop sensor, or both, and transitions from the closed configuration to the open configuration, or vice versa, in response to an instruction from the first chamber fill sensor or the first chamber stop sensor.

30. The slurry condenser of claim 17 wherein the first chamber receives lean-phase slurry through the slurry inlet, and the second chamber outputs dense-phase slurry.

31. A fluid jet cutting system comprising:the slurry condenser of claim 17; anda fluid jet cutting head that generates a fluid jet,wherein the slurry condenser is fluidly connected to the cutting head such that slurry from the slurry condenser is delivered to the fluid jet to form a slurry jet.

32. A method of delivering slurry to a fluid jet cutting head, the method comprising:adding slurry to a first chamber of a slurry condenser;maintaining a slurry valve in a closed configuration while the slurry delivered to the first chamber gathers in a lower portion of the first chamber, the slurry valve positioned between the first chamber and a second chamber along a first flow path;transitioning the slurry valve from the closed configuration to an open configuration;transitioning a bypass fluid valve positioned along a bypass fluidly connecting the first chamber and a second chamber along a second flow path that is separate from the first flow path;transferring the slurry gathered in the lower portion of the first chamber through the open slurry valve and into a second chamber of the slurry condenser;maintaining a first portion of a pocket of gas within an upper portion of the first chamber; andremoving the slurry from the second chamber and delivering the slurry to the fluid jet cutting head.

33. The method of claim 32, further comprising increasing a density of the slurry after the slurry is added to the first chamber and before the slurry is removed from the second chamber.

34. The method of claim 32, further comprising injecting a fluid into the slurry gathered in the lower portion of the first chamber.

35. The method of claim 32, further comprising increasing a level of fluid within the bypass thereby decreasing an amount of the pocket of gas in the bypass and increasing the amount of the pocket of gas within the first chamber.

36. The method of claims 32, further comprising monitoring an amount of slurry present within the first chamber, the second chamber, or both the first chamber and the second chamber via one or more sensors.

37. The method of claim 36 wherein the slurry valve and the bypass fluid valve are communicatively coupled to the one or more sensors, and the slurry valve and the bypass fluid valve transition from the open configuration to the closed configuration, and vice versa, in response to an instruction received from the one or more sensors.

38. The method of claim 32 wherein the slurry valve and the bypass fluid valve transition from the open configuration to the closed configuration, and vice versa, after a set amount of time passes.

39. The method of claim 32, further comprising pressurizing the first chamber to a maximum of 100 psi or less.

40. The method of claim 32, further comprising pressurizing the second chamber to a maximum of 100 psi or less.

41. The method of claim 32 wherein pressurizing the first chamber includes adding gas to the first portion of the pocket of gas within the upper portion of the first chamber.

42. The method of claim 32, further comprising:maintaining a second portion of the pocket of gas within the bypass.

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