Floating-Piston Pressure Exchanger for Reduced Fluid Mixing
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Solution Overview
Problem
Conventional rotary pressure exchangers experience cross-contamination of fluids during pressure transfer, leading to reduced efficiency and increased maintenance needs in industrial applications, particularly in fracking and desalination processes, due to the mixing of high-pressure and low-pressure fluids.
Innovation Solution
The implementation of a rotary isobaric pressure exchanger with a floating piston and adapter plates that form ducts of varying widths to minimize fluid mixing while maintaining efficient pressure exchange, using pistons to create fluid seals and prevent the piston from exiting the ducts, thereby reducing cross-contamination and extending equipment life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rotary pressure exchangers are used for pressure transfer, then pressure exchange can be achieved, but fluid mixing and cross-contamination occur between high-pressure and low-pressure streams
Solution Approach 1:
The pressure exchanger is divided into multiple separate chambers or flow paths, with physical barriers (such as pistons, diaphragms, or walls) separating the high-pressure and low-pressure fluid streams. This segmentation prevents direct mixing while allowing pressure energy transfer through the barriers, thereby eliminating cross-contamination while maintaining pressure exchange functionality.
Solution Approach 2:
An intermediary substance or structure is introduced between the high-pressure and low-pressure fluid streams to facilitate pressure transfer without direct fluid contact. This could be a piston, diaphragm, or intermediate fluid that transmits pressure energy from one stream to the other while maintaining complete separation, thus preventing cross-contamination.
2Stress or pressure
If pumps are used to increase fluid pressure in industrial applications, then pressure can be increased, but equipment is subject to abrasion and erosion from solid particles
Solution Approach 1:
The harmful solid particles are extracted or removed from the fluid stream before it enters the pressure-exchanging equipment, or the pressure exchange mechanism is designed to eliminate direct contact between solid particles and moving components. This could involve filtration systems upstream or a pressure exchange design where solid-containing fluid remains in a separate path, thereby preventing abrasion and erosion while maintaining pressure increase capability.
Solution Approach 2:
Instead of directly pressurizing the fluid containing solid particles, a copy or representation of the pressure energy is transferred through a separate clean fluid path. The high-pressure clean fluid drives the pressure exchange mechanism, which then transfers pressure to the particle-laden fluid without the mechanism components being exposed to abrasive particles, thus extending equipment lifespan.
3Reliability
If specialized pumps with hardened materials are used to resist abrasion, then equipment durability improves, but manufacturing cost and complexity increase
Solution Approach 1:
The problem of abrasion is solved by removing solid particles from the fluid path before they can contact and damage equipment components, rather than relying on expensive hardened materials. This extraction approach uses simpler, less costly materials while achieving the same durability through particle removal or isolation, thereby reducing manufacturing cost and complexity while maintaining equipment durability.
Solution Approach 2:
Instead of using expensive hardened materials throughout the entire pressure exchange system, simple and inexpensive materials are used for components that are protected from abrasion through design, while only minimal protective measures are applied where necessary. This selective approach reduces overall manufacturing cost while maintaining adequate durability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively reduces fluid mixing, enhances pressure exchange efficiency, and extends the lifespan of equipment by preventing abrasion and erosion, allowing for the use of less expensive materials and reducing maintenance needs in high-pressure applications.
Implementation Method 1
using pistons to create fluid seals and prevent the piston from exiting the ducts
Data Source
AI summary
A pressure exchanger includes a rotor forming a duct from a first duct opening to a second duct opening. The pressure exchanger further includes a floating piston configured to move within the duct between the first duct opening and the second duct opening to prevent mixing of a first fluid and a second fluid while exchanging pressure between the first fluid and the second fluid. The pressure exchanger further includes a first adapter plate configured to prevent the floating piston from exiting the duct at the first duct opening and a second adapter plate configured to prevent the floating piston from exiting the duct at the second duct opening. The first adapter plate forms a first aperture that directs the first fluid to the first duct opening and the second adapter plate forms a second aperture that directs the second fluid to the second duct opening.