Smart energy recovery device

Abstract

An energy recovery device (ERD) apparatus (200 / 300) and method for recovering pressure energy from a first liquid, such as high- pressure reverse osmosis (RO) brine, using a rotor (201 / 303). The rotor is configured to be driven by the first liquid (202) and / or a second liquid (203). The ERD includes a sensor (301) operatively coupled to the rotor, the sensor being electrically connected to a computer and / or an alarm system. The sensor is capable of measuring the rotational speed of the rotor to enable monitoring, such as real-time monitoring. The system further comprises a plurality of conduits for channeling the first liquid and a plurality of conduits for channeling the second liquid, facilitating the transfer of pressure energy between the fluids. The apparatus and method enable early detection of performance anomalies and support automated response to operational deviations.

Description

INTERNATIONAL PCT PATENT APPLICATION for SMART ENERGY RECOVERY DEVICE by Fayez Al Shehri Saudi Water Authority P.O. Box 5968 Riyadh 11432 KINGDOM OF SAUDI ARABIA and Yasir Hawsawi Saudi Water Authority P.O. Box 5968 Riyadh 11432 KINGDOM OF SAUDI ARABIACROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Kingdom of Saudi Arabia Patent Application No. SA 1020244050 filed July 16, 2024. The contents of the referenced patent application is incorporated into the present application by reference.BACKGROUND OF THE INVENTIONA. Field of the Invention

[0002] The present disclosure relates generally to energy recovery systems, and more particularly to a smart energy recovery device (ERD) apparatus and method for recovering pressure energy from a liquid stream.B. Description of Related Art

[0003] Reverse osmosis (RO) is a key technology in water desalination, and Energy Recovery Devices (ERDs) can play important roles in enhancing water desalination efficiency. Some ERDs operate on the principle of pressure exchange. They can help reduce energy consumption by capturing energy from high pressure streams and transferring the energy in the form of pressure exchange to a lower pressure stream. In some systems, the high pressure stream is a brine (waste stream) and the lower pressure stream is a feedwater. This process significantly reduces the system’s electrical energy consumption by reducing the need for pumps or the energy needed for the pumps to increase the pressure of lower pressure streams.

[0004] Some pressure exchange ERDs contain a moving or movable rotor. This rotor facilitates pressure exchange in part by rotation. However, during operation, fine impurities may enter the rotor chamber due to operational or environmental factors. These impurities can hinder or completely disrupt the pressure recovery process by slowing, hindering, or stopping the rotation of the rotor or any other moving parts in the ERDs. The slowing, hindering, or stopping of the movements within an ERD are not always immediately detectable, often requiring significant time and effort to diagnose, and can result in increased energy consumption. Monitoring and mitigating of such malfunctions in ERDs can protect a high cost asset and increase the energy and financial efficiency of the whole system.SUMMARY OF THE INVENTION

[0005] The inventors have found a solution to some of the problems associated with operational inefficiencies in ERD apparatuses by continuously monitoring the rotational speed of the ERD rotor. The system, in some instances, enables real-time detection of a reduction or cessation in rotor rotation, allowing for immediate corrective action in response to potential malfunctions. In one embodiment, the ERD includes a sensor operatively coupled to the rotor, wherein the sensor is electrically connected to a computing device and / or an alarm system. Operatively coupled may mean coupled in a way so that the sensor can detect the rotational speed of the ERD rotor, such as through physical contact or sensing through light detection, one or more wavelength detection, magnetic detection, pressure detection, sound detection, etc. The electrical connection may be a wireless or a wired connection. The sensor can be configured to continuously and accurately measure the rotational speed of the rotor. When the measured speed falls below a predetermined threshold, the computing device and / or alarm system may be configured to autonomously trigger an alert or an action. In certain aspects, the ERD further includes a plurality of conduits for the first liquid and a plurality of conduits for the second liquid. These conduits may be arranged to facilitate the rotation of the rotor and enable the transfer of a portion of the pressure energy from the first liquid to the second liquid. Further, the ERD device may be coupled to a reverse osmosis (RO) unit, booster pump(s), high pressure pump(s), centrifugal pump(s), and / or the power supply system.

[0006] The smart energy recovery devices (ERDs) and associated methods offer several advantages over conventional systems. These include rapid detection of defects to safeguard critical system components, advanced analytics to support informed and optimized decisionmaking, and compatibility with condition-based monitoring strategies. The system is designed to require low capital investment while offering a short payback period. Additional benefits include enhanced operator safety through automation, reduced operational labor costs, decreased pump energy consumption (measured in kWh / m3), a smaller carbon footprint contributing to more sustainable desalination practices, and infrastructure readiness for integration with artificial intelligence (Al) applications.

[0007] These examples of benefits are not an exhaustive list, and other benefits may be achieved using systems and methods described herein or in similar ways such as would be recognized from this disclosure by persons of ordinary skill in the art.

[0008] According to some aspects of the disclosure, an energy recovery device (ERD) apparatus configured to recover pressure energy of a first liquid is described herein. In someaspects, the ERD apparatus may include: a rotor capable of being driven by the first liquid and / or a second liquid; a sensor electrically connected to a computer and / or an alarm, wherein the sensor is capable of measuring a rotational speed of the rotor; a plurality of conduits for the first liquid; and a plurality of conduits for the second liquid.

[0009] In some aspects, the first liquid may be a reverse osmosis (RO) high pressure brine water. In some aspects, the second liquid may be a low pressure feed water having a lower pressure than the RO high pressure brine water. In some aspects, the apparatus may be fluidly connected to a desalination unit. In some aspects, the desalination unit may include at least one RO unit fluidly connected to the ERD. In some aspects, the sensor may be located on and / or in the ERD.

[0010] In some aspects, the plurality of conduits for the first liquid may be capable of receiving a liquid having a pressure of at least 30 bar such as at least any one of, equal to any one of, or between any two of 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150 bar or any range thereof or therebetween. In some aspects, the apparatus may be configured to transfer a portion of the pressure energy to the second liquid. In some aspects, the plurality of conduits for the second liquid may be capable of receiving a liquid having a pressure of at or below 40 bar such as at least any one of, equal to any one of, or between any two of 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 bar or any range thereof or therebetween.

[0011] In some aspects, the sensor may be electrically connected by being wirelessly connected to the computer and / or the alarm. In some aspects, the sensor electrical connection may be a wired connection to the computer and / or the alarm. In some aspects, the computer may be electronically connected to the alarm. In some aspects, the computer may be configured to monitor and / or control the rotor and / or the pressure of the first and / or the second liquid.

[0012] According to some aspects of the disclosure, a method to recover a pressure energy of a first liquid is described herein. In some aspects, the method(s) uses the ERD apparatus described herein. In some aspects, the ERD apparatus described herein is configured to be used in the method(s) herein. In some aspects, the method may include: rotating a rotor by flow of the first liquid and / or a second liquid; measuring rotational speed of the rotor by using a sensor, wherein the sensor is electrically connected to a computer and / or an alarm; andrecovering the pressure energy using the rotor.

[0013] In some aspects, the first liquid has a pressure of at least 30 bar such as at least any one of, equal to any one of, or between any two of 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150 bar or any range thereof or therebetween. In some aspects, the second liquid has a pressure of at or below 40 bar such as at least any one of, equal to any one of, or between any two of 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 bar or any range thereof or therebetween. In some aspects, the pressure energy may be transferred to the second liquid.

[0014] In some aspects, the first liquid may be a reverse osmosis (RO) high pressure brine water. In some aspects, the second liquid may be a low pressure feed water. In some aspects, the first liquid may be supplied to the rotor from a desalination unit.

[0015] In some aspects, the sensor may be located on and / or in an energy recovery device (ERD) housing the rotor. The sensor may be coupled to the ERD in a way so that the sensor can detect the rotational speed of the ERD rotor, such as through physical contact or sensing through light detection, one or more wavelength detection, magnetic detection, pressure detection, sound detection, etc. In some aspects, the sensor may be wirelessly connected to the computer and / or the alarm. In some aspects, the sensor electrical connection may be a wired connection to the computer and / or the alarm. In some aspects, the alarm may be activated when the sensor measures a rotational speed below a threshold. In some aspects, the computer may activate the alarm when the sensor measures a rotational speed below a threshold. In some aspects, the computer may monitor and / or control the rotor and / or the pressure of the first liquid and / or the second liquid. In some instances, the threshold is a rotation per minute (RPM) of 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380,390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570,580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760,770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950,960, 970, 980, 990, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600,3700, 3800, 3900, 4000, 4100, 4200, 4300, 4400, 4500, 4600, 4700, 4800, 4900, 5000, 5100,5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6400, 6500, 6600,6700, 6800, 6900, 7000, 7100, 7200, 7300, 7400, 7500, 7600, 7700, 7800, 7900, 8000, 8100,8200, 8300, 8400, 8500, 8600, 8700, 8800, 8900, 9000, 9100, 9200, 9300, 9400, 9500, 9600,9700, 9800, 9900, 10000, 11000, 12000, 13000, 14000, 15000, 16000, 17000, 18000, 19000, 20000, 21000, 22000, 23000, 24000, 25000, 26000, 27000, 28000, 29000, 30000, 31000,32000, 33000, 34000, 35000, 36000, 37000, 38000, 39000, 40000, 41000, 42000, 43000,44000, 45000, 46000, 47000, 48000, 49000, 50000, 51000, 52000, 53000, 54000, 55000,56000, 57000, 58000, 59000, 60000, 61000, 62000, 63000, 64000, 65000, 66000, 67000,68000, 69000, 70000, 71000, 72000, 73000, 74000, 75000, 76000, 77000, 78000, 79000,80000, 81000, 82000, 83000, 84000, 85000, 86000, 87000, 88000, 89000, 90000, 91000,92000, 93000, 94000, 95000, 96000, 97000, 98000, 99000, 100000, 110000, 120000, 130000, 140000, 150000, 160000, 170000, 180000, 190000, 200000, 210000, 220000, 230000,240000, 250000, 260000, 270000, 280000, 290000, 300000, 310000, 320000, 330000,340000, 350000, 360000, 370000, 380000, 390000, 400000, 410000, 420000, 430000,440000, 450000, 460000, 470000, 480000, 490000, 500000, 510000, 520000, 530000,540000, 550000, 560000, 570000, 580000, 590000, 600000, 610000, 620000, 630000,640000, 650000, 660000, 670000, 680000, 690000, 700000, 710000, 720000, 730000,740000, 750000, 760000, 770000, 780000, 790000, 800000, 810000, 820000, 830000,840000, 850000, 860000, 870000, 880000, 890000, 900000, 910000, 920000, 930000,940000, 950000, 960000, 970000, 980000, 990000, or 1000000 RPM or any number therein, therebetween, greater than, less than, or any range thereof. In some aspects, the computer may monitor and / or control the rotor and / or the pressure of the first liquid and / or the second liquid when the sensor measures a rotational speed below a threshold.

[0016] The terms “about” or “approximately” as used herein are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0017] The terms “wt. %,” “vol.%,” or “mol.%” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, that includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt. % of component.

[0018] The term “substantially” and its variations are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0019] The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and / or the specification includes any measurable decrease or complete inhibition to achieve a desired result.

[0020] The term “effective,” as that term is used in the specification and / or claims, means adequate to accomplish a desired, expected, or intended result.

[0021] The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having” in the claims, or the specification, may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0022] The phrase “and / or” can include “and” or “or.” To illustrate, A, B, and / or C can include: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0023] The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0024] Other objects, features and advantages of the present invention will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be to scale.

[0026] FIG. 1 is a non-limiting schematic illustration of a proposed ERD apparatus integrated with a RO plant.

[0027] FIG. 2 is a non-limiting schematic illustration of a rotor inside of a proposed ERD.

[0028] FIG. 3 is a schematic drawing of an ERD with a speed sensor positioned adjacent to the rotating component of the rotor, configured to detect and monitor the rotor’s rotational speed.

[0029] FIG. 4 is a graph illustrating the effects of flow rate, rotor speed, and mixing percentage on the performance of the energy recovery device (ERD), comparing normal (left graph) and abnormal (right graph) operating conditions.

[0030] FIG. 5 is a graph illustrating the differences in cost and time required for repair between a conventional energy recovery device (ERD) (left graph) and the proposed smart ERD (right graph).

[0031] FIG. 6(A) illustrates a flowchart outlining the process for measuring the rotor speed in the proposed smart Energy Recovery Device (ERD) system.

[0032] FIG. 6(B) depicts the installation of the electromagnetic speed sensor on the outer casing of the ERD.DETAILED DESCRIPTION OF THE INVENTION

[0033] The inventors have found a solution to some of the problems associated with operational inefficiencies in ERD apparatuses by continuously monitoring the rotational speed of the ERD rotor. The rotor is configured to be driven by a first liquid and / or a second liquid. The system enables real-time detection of a reduction, inhibition, or cessation in rotor rotation, allowing for immediate corrective action in response to potential malfunctions. In one embodiment, the ERD includes a sensor operatively coupled to the rotor, wherein the sensor iselectrically connected to a computing device and / or an alarm system. The electrical connection may be a wireless or a wired connection. The sensor is configured to continuously and accurately measure the rotational speed of the rotor. When the measured speed falls below a predetermined threshold, the computing device and / or alarm system is configured to autonomously trigger an alert or an action. In certain aspects, the ERD further includes a plurality of conduits for the first liquid and a plurality of conduits for the second liquid. These conduits are arranged to facilitate the rotation of the rotor and enable the transfer of a portion of the pressure energy from the first liquid to the second liquid.

[0034] The smart energy recovery device (ERD) and associated method offer several advantages over conventional systems. These include rapid detection of defects to safeguard critical system components, advanced analytics to support informed and optimized decisionmaking, and compatibility with condition-based monitoring strategies. The system is designed to require low capital investment while offering a short payback period. Additional benefits include enhanced operator safety through automation, reduced operational labor costs, decreased pump energy consumption (such as those measured in kWh / m3), a smaller carbon footprint contributing to more sustainable desalination practices, and infrastructure readiness for integration with artificial intelligence (Al) applications. Further, the ERD device may be coupled to reverse osmosis (RO) unit, booster pump(s), high pressure pump(s), centrifugal pump (s), and / or a power supply system.

[0035] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.A. Energy Recovery Device (ERD) Apparatus

[0036] With reference to FIG. 1, a non-limiting system of an energy recovery device apparatus integrated with RO unit system 100 in a desalination plant to recover pressure energy of a first liquid is disclosed.

[0037] In some aspects, the system 100 may include an ERD component such as 101 configured to receive the first liquid such as high pressure brine water such as 102 and second liquid low pressure feed water such as 103. In some aspects, a reverse osmosis unit such as 108 may be fluidly connected to the ERD unit 101 and configured to provide reverse osmosis high pressure brine as the first liquid 102. In some aspects, at least one centrifugal pump such as I l l is fluidly connected to the ERD unit 101 and configured to provide low pressure feed wateras the second liquid 103. In some aspects, the ERD unit 101 may be configured to exchange the pressure between the high pressure brine 102 and low pressure feed 103 and to form a low pressure brine reject stream 104 and a high pressure feed reject stream such as 105, respectively, from the ERD unit. In some aspects, the high pressure feed reject stream 105 and low pressure feed stream 103 are fluidly connected to the RO unit 108 as a feed water 106. In some aspects, the system may further be equipped with high pressure pump such as 110 and booster pump such as 109 to force the feed water through semi-permeable membranes in the RO unit 108. In some aspects, the system may further be equipped with one or more cartridge filter (CF). In some aspects, a permeate stream such as 107 and low pressure brine such as 104 are fluidly connected to further downstream units for other applications.

[0038] With reference to FIG. 2 and FIG. 3, a non-limiting ERD apparatus 200 / 300 and its function to recover pressure energy of a liquid are disclosed therein.

[0039] In some aspects, the ERD apparatus 200 / 300 may include a rotor such as 201 / 303 capable of being driven by the first liquid such as 202 and / or a second liquid such as 203. In some aspects, a sensor such as 301 is electrically connected to a computer and / or an alarm (not shown). In some aspects, the sensor is capable of measuring a rotational speed of the rotor 201 / 303. In some aspects, a plurality of conduits for the first liquid; and a plurality of conduits for the second liquid.

[0040] In some aspects, the first liquid 202 may be a reverse osmosis (RO) high pressure brine water and produces a low pressure brine reject stream 204. In some aspects, the second liquid 203 may be a low pressure feed water and produce a high pressure feed reject stream 205.

[0041] In some aspects, the apparatus may be further include a desalination unit fluidly connected to the ERD. In some aspects, the desalination unit may include at least one RO unit fluidly connected to the ERD, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more RO unit. In some aspects, the sensor 301 may be located on and / or in the ERD. In some aspects, the plurality of conduits for the first liquid may be capable of receiving a liquid having a pressure of at least 30 bar such as at least any one of, equal to any one of, or between any two of 30, 40, 50, 60, 70, 80 ,90, 100, 110, 120, 130, 140, 150 or any range thereof or therebetween.

[0042] In some aspects, the apparatus may be configured to transfer a portion of the pressure energy to the second liquid. In some aspects, the rotor 201 / 303 inside the ERD, the first liquid and the second liquid moves through the ducts of the rotor in the ERD in a plug flow regimewith a very little amount of mixing (e.g., 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7 % or less by volume) at certain RPM. In some instances, the reduction in the speed of the rotor may causes increase in the mixing time between the first liquid and the second liquid. In some aspects, the salinity of water that passes to RO the unit membrane may increase if the rotation of the rotor decreases. In these situations a high pressure pump such as 110 may be used to increase the pressure of the RO feed, such as the feed water 106, to overcome the increased difficulty in producing permeate in the RO unit due to the salinity increase. In some aspects, rotor speed of the ERD may contribute to the overall power consumption of the system, where increased speed requires the system to consume less power.

[0043] In some aspects, the sensor 301 may be wirelessly connected to the computer and / or the alarm. In some aspects, the sensor 301 electrical connection may be a wired connection to the computer and / or the alarm. In some aspects, the computer may be electronically connected to the alarm. In some aspects, the computer may be configured to monitor and / or control the rotor and / or the pressure of the first and / or the second liquid. In some aspects, the computer may have a display or be electrically connected to a display, such as 302. In some aspects, the computer may display or be controlled at least in part by a graphic user interface, or an input apparatus such as a keyboard and / or mouse. In some aspects, the computer may be electronically connected to a other components to control the ERD, the streams entering and / or exiting the ERD, and / or the streams entering and / or exiting the RO. In some instances, those other components may include, but are not limited to alarms, pumps, user interfaces, valves, etc.

[0044] In some aspects, the apparatus may include a mixing zone such as 206 for first and second liquids. In some aspects, the apparatus may include a display, such as a speed display screen, such as 302 and an outer casing 304.

[0045] In some aspects, ERD failure or less than optimal speed may be detected by the apparatus and systems detection of the spinning speed of the ERD’s rotor. In some instances, the apparatus and / or systems herein are capable of being used in the methods herein. In some instances, the methods herein use the apparatus and / or systems herein.1: Inductive Proximity Sensor: In some aspects, the system includes an Electromagnetic Field (EMF) sensor, a magnetic implant, and / or a speed display screen:EMF sensor: In some instances, it passes through a hole in the outer wall of the ERD and is fixed close to the rotor. In some aspects, the sensor picks up a magnetic signal from the rotor.Magnet implant: In some instances, this generates a magnetic pulse for each rotation of the rotor, the pulses may be picked up by the EMF sensor and the pulses can be used to determine the speed of the rotor.Speed display screen: In some instances, the speed display screen is connected to the sensor, and equipped with a microcomputer that translates magnetic pulses into speed units.2: Tachometer: In some aspects, the system includes a light sensor, a light reflector, and / or a speed display screen:Light sensor: In some instances, a laser beam passes through a hole in the outer wall of the ERD, the light sensor may generate the laser and / or detects reflected laser light from the rotor.Light reflector: In some instances, a reflective material, such as a piece of tape and / or paint can reflect the laser light to the sensor. The light reflector can in some instances be located on the rotor and / or on a surface on a wall of the chamber holding the rotor.Speed display screen: In some instances, the speed display screen is connected to the light sensor, and equipped with a microcomputer that translates light pulses into speed units.3: Stroboscope: In some aspects, the system includes a stroboscope. In some aspects, this device emits light pulses at certain frequencies that match or correlate with the rotation of the rotor. In some instances, the light pulses are not transmitted when the rotor is stationary. In some instances, the frequency of the emitted light is equal to the speed of the rotor.System for Measuring the Speed of Energy Recovery Devices

[0046] With reference to FIG. 6A and FIG. 6B, a non-limiting ERD apparatus to recover pressure energy of a first liquid is disclosed. This system enables continuous (online) monitoring and display of the rotor speed in energy recovery devices, both locally andremotely. It comprises an electromagnetic speed sensor (405) mounted through a threaded port (413) in the device casing (403). A magnet (412) embedded in a dedicated cavity (411) on the rotor (402) to generate pulses as it rotates. A microcontroller (409) that powers the sensor, processes the pulses, and converts them into speed units. An on-site display (404) connected to the microcontroller for local speed readout. A control room display (406) connected via a main controller (410), which is programmed to receive and display speed data and issue alerts if speed drops below a set threshold. In some aspects, drilling the outer casing (403) to install the sensor via a threaded opening. Embedding the magnet (412) in a rotor cavity (411) precisely sized for secure placement.

[0047] In some aspects, the energy recovery device (401) typically lacks a built-in port for an electromagnetic speed sensor. Therefore, this invention includes the creation of a threaded port (413) in the device casing (403), sized to accommodate the electromagnetic speed sensor (405). Additionally, a cavity (411) is machined into the rotor (402) to house a magnet (412). The cavity is dimensioned to securely hold the magnet using industrial adhesive, ensuring it is fully recessed to avoid contact with the inner surface of the casing (403). Once installed, the sensor (405) detects the passing magnet and sends pulses to a microcontroller (409), which powers the sensor and converts the pulses into speed data. This data is displayed on a local screen (404) and transmitted to a main controller (410) in the control room. The main controller (410) is programmed to display the speed on a control room screen (406) monitored by the operator (408). If the rotor speed drops below a predefined threshold, an alert message "energy recovery device speed stopped or low" (407) is triggered on the control room display.B. Method to Recover a Pressure Energy of a Liquid

[0048] With reference to FIG. 1, FIG. 2, and FIG. 3, a non-limiting method to recover pressure energy of a first liquid is disclosed.

[0049] In some aspects, the method may include rotating a rotor such as 201 / 303 by flow of the first liquid 102 / 202 and / or a second liquid 103 / 203. In some aspects, rotational speed of the rotor 201 / 303 is measured by using a sensor such as 301. In some aspects, the sensor is electrically connected to a computer and / or an alarm (not shown). In some aspects, the pressure energy from the high pressure first liquid 102 / 202 is recovered by using the rotor. In some aspects, the first liquid may be a reverse osmosis (RO) high pressure brine water. In some aspects, the second liquid may be a low pressure feed water.

[0050] In some aspects, the pressure energy may be transferred to the second liquid 103 / 203. In some aspects, the first liquid 102 / 202 may be supplied to the rotor 201 / 303 from a desalination unit comprising a reverse osmosis (RO) unit such as 108. In some aspects, the sensor 301 may be located on and / or in an energy recovery device (ERD) housing the rotor such as 304. In some aspects, the sensor 301 may be wirelessly connected to the computer and / or the alarm. In some aspects, the sensor 301 electrical connection may be a wired connection to the computer and / or the alarm. In some aspects, the alarm may be activated when the sensor 301 measures a rotational speed below a threshold. In some aspects, the computer may activate the alarm when the sensor 301 measures a rotational speed below a threshold. In some aspects, the computer may monitor and / or control the rotor 201 / 303 and / or the pressure of the first liquid 102 / 202 and / or the second liquid 103 / 203. In some instances, the threshold is a rotation per minute (RPM) of 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280,290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470,480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660,670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850,860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800,2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, 4000, 4100, 4200, 4300,4400, 4500, 4600, 4700, 4800, 4900, 5000, 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800,5900, 6000, 6100, 6200, 6300, 6400, 6500, 6600, 6700, 6800, 6900, 7000, 7100, 7200, 7300,7400, 7500, 7600, 7700, 7800, 7900, 8000, 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800,8900, 9000, 9100, 9200, 9300, 9400, 9500, 9600, 9700, 9800, 9900, 10000, 11000, 12000, 13000, 14000, 15000, 16000, 17000, 18000, 19000, 20000, 21000, 22000, 23000, 24000,25000, 26000, 27000, 28000, 29000, 30000, 31000, 32000, 33000, 34000, 35000, 36000,37000, 38000, 39000, 40000, 41000, 42000, 43000, 44000, 45000, 46000, 47000, 48000,49000, 50000, 51000, 52000, 53000, 54000, 55000, 56000, 57000, 58000, 59000, 60000,61000, 62000, 63000, 64000, 65000, 66000, 67000, 68000, 69000, 70000, 71000, 72000,73000, 74000, 75000, 76000, 77000, 78000, 79000, 80000, 81000, 82000, 83000, 84000,85000, 86000, 87000, 88000, 89000, 90000, 91000, 92000, 93000, 94000, 95000, 96000,97000, 98000, 99000, 100000, 110000, 120000, 130000, 140000, 150000, 160000, 170000, 180000, 190000, 200000, 210000, 220000, 230000, 240000, 250000, 260000, 270000,280000, 290000, 300000, 310000, 320000, 330000, 340000, 350000, 360000, 370000,380000, 390000, 400000, 410000, 420000, 430000, 440000, 450000, 460000, 470000,480000, 490000, 500000, 510000, 520000, 530000, 540000, 550000, 560000, 570000,580000, 590000, 600000, 610000, 620000, 630000, 640000, 650000, 660000, 670000,680000, 690000, 700000, 710000, 720000, 730000, 740000, 750000, 760000, 770000,780000, 790000, 800000, 810000, 820000, 830000, 840000, 850000, 860000, 870000,880000, 890000, 900000, 910000, 920000, 930000, 940000, 950000, 960000, 970000,980000, 990000, or 1000000 RPM or any number therein, therebetween, greater than, less than, or any range thereof.

[0051] In some aspects, the computer may monitor and / or control the rotor and / or the pressure of the first liquid and / or the second liquid when the sensor measures a rotational speed below a threshold. In some aspects, the first liquid 102 / 202 may have a pressure of at least 30 bar such as at least any one of, equal to any one of, or between any two of 30, 40, 50, 60, 70, 80 ,90, 100, 110, 120, 130, 140, 150 or any range thereof or therebetween.

[0052] In some aspects, the method may include recovering the energy by using an energy recovery device (ERD) such as 101 / 200 / 300 of any one of the methods described herein.

[0053] In some aspects, a method for recovering energy is described herein. In some aspects, the method may include that the computer monitor the rotor and activates the alarm and / or controls the rotor and / or the pressure of the first liquid 102 / 202 and / or the second liquid 103 / 203 when the sensor 301 measures a rotational speed below a threshold.C. Uses of ERD Apparatus and Method

[0054] These systems and methods may recover energy from a first liquid as disclosed herein. The systems and methods have many applications, such as in the field of desalination plants (seawater and brackish water RO), to recover pressure energy from the high-pressure brine stream and transfer it to the low pressure feedwater. Further, the ERD may reduce energy consumption by up to or greater than 60%, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 % or greater, or any range or number therein or therebetween. The use of the system and / or methods may make desalination more cost-effective and sustainable.

[0055] In some instances, the applications include drinking water treatment, wastewater treatment, and / or reclaimed water treatment. For example, mitigating power failures when using renewable energy sources. These ERD systems and methods disclosed herein also helpmanage the high energy demands of concentrating and crystallizing waste streams such as in zero liquid discharge (ZLD) systems. In some instances, the applications include improved energy management. For example, renewable energy integration, such as in hybrid systems combining solar or wind power with RO. ERDs may help optimize energy use and stabilize performance.

[0056] In some instances, fresh water is produced in the desalination industry through various processes that convert seawater, brackish water, and other salty waters into fresh water. Most references to "seawater," "saline water," or "feedwater" as the feed water are made for ease of reference. These references are not meant to be limiting, as the feed water can be any saline water recognized as possible feed water to, within, or from a desalination facility by those of ordinary skill in the art.

[0057] Further, key benefits of using ERDs include, energy efficiency such as major reduction in power consumption, cost savings such as lower electricity bills and operational costs, environmental impact such as reduced carbon footprint, system longevity such as less strain on high-pressure pumps and membranes, and compact design such as modem ERDs are small and easy to integrate with other systems.EXAMPLES

[0058] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters that can be changed or modified to yield essentially the same results.Example 1

[0059] FIG. 4 and FIG. 5 are illustration of a non-limiting examples of ERD performance. Referring to FIG. 4, selected parameters such as flow rate, rotor speed, and mixing percentage differences as shown can occur for normal and abnormal ERDs. The Abnormal Case shows what is expected to occur when the speed of the rotor slows due to buildup or interference with the rotor. Lower rotor speed can cause a higher mixing between the first and second liquids, which in turn reduces the performance of the ERD.

[0060] Referring to FIG. 5, the diagrams illustrate the cost and time differences that can occur between use of a conventional ERD and the ERDs as described herein (smart ERD). The smart ERD is expected to achieve greater savings by detecting failures early and mitigating them more quickly so that the loses to energy recovery are avoided.

Claims

CLAIMSWhat is claimed is:

1. An energy recovery device (ERD) apparatus configured to recover pressure energy of a first liquid, the apparatus comprising: a rotor capable of being driven by the first liquid and / or a second liquid; a sensor electrically connected to a computer and / or an alarm, wherein the sensor is capable of measuring a rotational speed of the rotor; a plurality of conduits for the first liquid; and a plurality of conduits for the second liquid.

2. The apparatus of claim 1, further comprising a desalination unit fluidly connected to the ERD.

3. The apparatus of any one of claims 1 to 2, wherein the sensor is located on and / or in the ERD.

4. The apparatus of any one of claims 1 to 3, wherein the plurality of conduits for the first liquid are capable of receiving a liquid having a pressure of at least 30 bar.

5. The apparatus of any one of claims 1 to 4, configured to transfer a portion of the pressure energy to the second liquid.

6. The apparatus of any one of claims 1 to 5, wherein the sensor is wirelessly connected to the computer and / or the alarm.

7. The apparatus of any one of claims 1 to 6, wherein the computer is electronically connected to the alarm.

8. The apparatus of any one of claims 1 to 7, wherein the computer is configured to monitor and / or control the rotor and / or the pressure of the first and / or the second liquid.

9. A method to recover a pressure energy of a first liquid comprising:rotating a rotor by flow of the first liquid and / or a second liquid; measuring rotational speed of the rotor by using a sensor, wherein the sensor is electrically connected to a computer and / or an alarm; and recovering the pressure energy using the rotor.

10. The method of claim 9, where the pressure energy is transferred to the second liquid.

11. The method of any one of claims 9 to 10, wherein the first liquid is supplied to the rotor from a desalination unit.

12. The method of any one of claims 9 to 11, wherein the sensor is located on and / or in an energy recovery device (ERD) housing the rotor.

13. The method of any one of claims 9 to 12, wherein the sensor is wirelessly connected to the computer and / or the alarm.

14. The method of any one of claims 9 to 13, wherein the alarm is activated when the sensor measures a rotational speed below a threshold.

15. The method of any one of claims 9 to 14, wherein the computer activates the alarm when the sensor measures a rotational speed below a threshold.

16. The method of any one of claims 9 to 15, wherein the computer monitor and / or controls the rotor and / or the pressure of the first liquid and / or the second liquid.

17. The method of claim 9 to 16, wherein the computer controls the rotor and / or the pressure of the first liquid and / or the second liquid when the sensor measures a rotational speed below a threshold.

18. The method of any one of claims 9 to 17, wherein the first liquid has a pressure of at least 30 bar.

19. A method for recovering energy of a liquid, the method comprising recovering the energy by using an energy recovery device (ERD) of any one of claims 1 to 8.

20. The method for recovering energy, wherein the computer activates the alarm and / or controls the rotor and / or the pressure of the first liquid and / or the second liquid when the sensor measures a rotational speed below a threshold.

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