Pressure Exchanger Flush Port for Proppant Wear Reduction
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Solution Overview
Problem
Pressure exchangers used in hydraulic fracturing face premature wear due to interference between proppants and the end cover and rotor, limiting their operational cycle and commercial applicability.
Innovation Solution
A pressure exchanger design that includes a flush port to supply clean fluid and separate fracking fluid from the end cover and rotor, with a clearance gap larger than proppant particles to prevent crushing and reduce wear, utilizing a flush volume to manage flow and prevent contact between proppants and sealing areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a pressure exchanger is used in hydraulic fracturing to transmit pressure energy, then the pump can operate on clean fluid extending its life, but the pressure exchanger suffers wear from proppant interference limiting its operational cycle
Solution Approach 1:
A flush port is introduced as an intermediary component that supplies clean fluid to create a protective barrier between proppants and the sealing area. This mediator prevents direct contact between abrasive particles and critical sealing surfaces, resolving the wear problem while maintaining the pressure exchange function
2Strength
If the end cover and rotor are made of high strength material such as tungsten carbide to resist wear, then material strength increases, but proppants still get crushed between the sealing area and rotor duct edge causing wear
Solution Approach 1:
The harmful interaction between proppants and sealing surfaces is extracted by introducing a separate flush fluid stream through the flush port. This creates a dedicated protective flow path that removes proppants from the sealing area, eliminating the crushing problem despite the presence of high-strength materials
3Reliability
If a tight clearance is maintained between the end cover sealing area and rotor duct edge to prevent leakage, then sealing efficiency improves, but proppant particles get crushed causing wear
Solution Approach 1:
The fluid flow path is segmented into two separate channels: the main fracking fluid flow through the rotor ducts for pressure exchange, and a dedicated flush flow through the flush port for protective purposes. This segmentation allows the tight clearance to maintain sealing while the flush flow prevents proppant intrusion and crushing
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 reduces wear on the end cover and rotor, extending the operational cycle and improving the commercial viability of pressure exchangers by preventing premature wear and maintaining the integrity of proppant particles.
Implementation Method 1
A pressure exchanger is a device that can exchange pressure energy between a high-pressure fluid stream and a low-pressure fluid stream
Implementation Method 2
the first end cover defines a flush port configured to supply a flush volume of the second fluid into a rotor of the pressure exchanger in a state in which the first pair of apertures communicate the first fluid with the first side of the rotor
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A pressure exchanger for hydraulic fracking includes a rotor that includes a plurality of rotor ducts extending parallel to an axis, where each rotor duct extends between a first side and a second side of the rotor that are spaced apart from each other. The pressure exchanger further includes a first end cover that is disposed at the first side of the rotor and defines a first pair of apertures configured to communicate a first fluid including fracking particles, and a second end cover that is disposed at the second side of the rotor and defines a second pair of apertures configured to communicate a second fluid. The first end cover further defines a flush port configured to supply the second fluid into the first side of the rotor in a state in which the first pair of apertures communicate the first fluid with the first side of the rotor.