Flow Exchanger System for High Pressure Sand Slurry Delivery
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Solution Overview
Problem
Conventional high pressure pumps used in industrial processes, such as fracturing and acidizing, face issues with abrasive and corrosive materials that reduce their lifespan and require excessive energy for energy recovery and agent metering.
Innovation Solution
A flow exchanger system employing a trans-pressure conduction system to deliver high pressure fluids with near zero horsepower, using a fluid interface separator to compress a sand slurry to high pressure without significant flow loss, and transferring energy from clean fluids to dirty fluids to introduce agents like sand into high pressure streams without direct pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high pressure pumps are used to deliver fluids containing abrasive and corrosive materials, then the desired pressure is achieved, but the pump life is substantially decreased
Solution Approach 1:
The system divides the fluid delivery function into two separate pathways: a high-pressure clean fluid pathway that maintains system pressure, and a low-pressure agent-containing fluid pathway that feeds into the high-pressure stream. This segmentation allows the high-pressure pump to handle only clean fluid, preserving its life while still achieving the required delivery pressure.
Solution Approach 2:
A low-pressure pump serves as an intermediary device that introduces abrasive and corrosive materials into the high-pressure fluid stream indirectly. The low-pressure pump delivers agent-containing fluid to a mixing point where it combines with the high-pressure clean fluid, avoiding direct exposure of the high-pressure pump to damaging materials.
2Reliability
If conventional energy recovery devices are used to transfer pressure energy from clean fluids to unclean fluids, then the use of high pressure pumps for unclean fluids is avoided, but excess energy is required to power additional pumps
Solution Approach 1:
The system merges the functions of pressure delivery and agent introduction into a single integrated flow path. The low-pressure agent-containing fluid stream combines with the high-pressure clean fluid stream, and the combined stream exits at the desired high pressure without requiring separate energy recovery equipment.
Solution Approach 2:
The high-pressure clean fluid stream serves multiple functions: it provides the desired delivery pressure, acts as a carrier for the agent-containing fluid, and eliminates the need for separate energy recovery devices. This multi-functionality reduces overall system energy consumption.
3Reliability
If conventional energy recovery devices are used to transfer pressure energy, then high pressure pumps are avoided for unclean fluids, but elaborated means of metering agent are required
Solution Approach 1:
The low-pressure pump system automatically controls the introduction of agent-containing fluid based on the demand of the high-pressure stream. The system self-regulates the mixing ratio through pressure differential control, eliminating the need for complex external metering devices and control systems.
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 system allows for efficient delivery of high concentration sand slurries into high pressure fluids with minimal energy expenditure, extending pump life and reducing energy requirements, while maintaining flow rates and pressures.
Implementation Method 1
employing a trans-pressure conduction system... transferring energy from clean fluids to dirty fluids... a fluid interface separator to compress a sand slurry to high pressure
Data Source
AI summary
A flow exchanger (FE) system comprising: a supplement pump receiving a supplement first fluid stream and outputting a pressurized supplement first fluid stream; a flow splitter comprising a flow restrictor, wherein the flow splitter receives the pressurized supplement first fluid stream and outputs a power stream and a treatment stream; a main flow manifold, wherein the treatment stream enters the main flow manifold subsequent to passing through the flow restrictor; and an FE cylinder filled downstream with a second fluid and having a fluid interface separator (FIS), wherein the power stream enters the FE cylinder upstream; wherein the power stream engages and pushes FIS downstream, thereby providing for a second fluid stream entering the main flow manifold; wherein a second fluid stream VFR=a power stream VFR; and wherein the main flow manifold provides for a manifold output fluid stream VFR=a pressurized supplement first fluid stream VFR.