Pressure Exchange Valve for Abrasive Fracking Fluid Pressurization
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Solution Overview
Problem
Industrial hydraulic systems face significant wear and maintenance issues due to the use of abrasive, caustic, or acidic fluids, leading to increased downtime and costs, particularly in high-pressure applications like hydraulic fracturing, where proppants in fracking fluids exacerbate pump wear.
Innovation Solution
A pressure exchange device that transfers pressure between clean and dirty fluid streams, isolating high-pressure clean fluid from abrasive fracking fluid, allowing for pressurization of the dirty fluid without direct passage through pumps, thereby reducing wear on equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-pressure pumps are used to pressurize fracking fluid containing proppant, then the required pressure for hydraulic fracturing is achieved, but the pumps experience increased wear and reduced lifespan due to the abrasive nature of proppant
Solution Approach 1:
The patent introduces a pressure exchange device that acts as an intermediary between the pump and the abrasive fracking fluid. The device includes a first chamber receiving clean fluid from the pump, a second chamber receiving the abrasive fracking fluid, and a piston that transfers pressure between the chambers. This intermediary arrangement allows the pump to pressurize clean fluid without directly handling the abrasive proppant-laden fluid, thereby protecting the pump from wear while still achieving the required high pressure in the fracking fluid.
2Stress or pressure
If pumps handle abrasive fracking fluid directly, then pressurization is achieved, but maintenance costs increase and downtime increases due to wear
Solution Approach 1:
The pressure exchange device serves as a mediator that isolates the pump from the abrasive fracking fluid. The pump only handles clean fluid in the first chamber, while the second chamber contains the abrasive fracking fluid. The piston transfers pressure between the chambers, enabling the pump to pressurize the fracking fluid indirectly. This separation eliminates wear on the pump from handling abrasive materials, thereby reducing maintenance frequency and downtime.
3Stress or pressure
If clean fluid is pressurized and then mixed with abrasive fracking fluid, then the required pressure is achieved, but the clean fluid becomes contaminated with proppant
Solution Approach 1:
The pressure exchange device uses a piston as an intermediary barrier between the clean fluid chamber and the abrasive fracking fluid chamber. The piston is configured to be substantially impermeable to both fluids, preventing mixing and contamination. Pressure is transferred through the piston without the fluids coming into direct contact, thus maintaining the purity of the clean fluid while achieving pressurization of the fracking fluid.
Solution Approach 2:
The invention extracts the pressurization function from the direct fluid path. Instead of pressurizing the fracking fluid directly (which would cause contamination), the system pressurizes clean fluid separately and extracts only the pressure component through the piston to apply to the fracking fluid. This separation of the pressurization function from the fluid handling maintains fluid purity.
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
The solution effectively extends the lifespan of high-pressure pumps and reduces maintenance costs by efficiently pressurizing fracking fluids while minimizing contamination and wear, enhancing operational efficiency and productivity.
Implementation Method 1
a device for exchanging pressure between at least two fluid streams
Implementation Method 2
The valve actuator may also be configured to selectively place the fluid at the first higher pressure in communication with the downhole fluid at the first lower pressure
Data Source
AI summary
Devices and systems for exchanging properties between at least two fluid streams and related methods may include a valve device comprising a valve actuator configured to move at variable rates in order to selectively fill and empty at least one tank. Devices for exchanging properties between at least two fluid streams may include a valve device comprising offset openings positioned along a path of a valve actuator. The offset openings may be configured to selectively and gradually place an inlet in communication with at least one tank.