Pressure Exchanger Rotor Port Layout to Minimize Fluid Mixing
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Solution Overview
Problem
Conventional pressure exchangers face inefficiencies due to fluid mixing, which increases energy consumption, contaminates fluids, and causes wear and tear on components, while also generating noise and vibration, especially in applications like hydraulic fracturing and desalination systems.
Innovation Solution
The design of a pressure exchanger with a rotor that forms ducts from one end to another, featuring specific port configurations and end covers with radial sidewalls, spacers, and spot faces to minimize fluid mixing, reduce noise, and control cavitation and vibration, optimizing pressure exchange efficiency and component longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional pressure exchanger design is used, then pressure exchange function is provided, but fluid mixing occurs which increases energy consumption and contaminates fluids
Solution Approach 1:
The pressure exchanger is divided into multiple separate chambers (first chamber for first fluid, second chamber for second fluid) with distinct flow paths. The rotor contains multiple ducts that sequentially communicate with different ports, creating segmented zones that prevent fluid mixing while enabling pressure exchange between separated fluid streams.
Solution Approach 2:
The patent introduces an intermediary fluid (such as oil or gas) that acts as a mediator between the two process fluids. This intermediary fluid transmits pressure from one fluid to the other without allowing direct contact or mixing between the process fluids, thereby preventing contamination while maintaining pressure exchange efficiency.
2Power
If pressure exchange is performed, then pressure transfer occurs, but fluid mixing causes component wear and tear
Solution Approach 1:
The pressure exchanger employs segmented chambers and ducts that separate the two fluid streams throughout the pressure exchange process. This segmentation ensures that high-velocity fluid jets and turbulent flows occur within isolated chambers, preventing direct fluid contact that would cause mixing-induced wear on shared components.
Solution Approach 2:
An intermediary fluid is used as a buffer between the two process fluids during pressure exchange. This mediator absorbs the mechanical stress and turbulence of pressure transfer, protecting the structural components from direct exposure to high-velocity fluid jets and reducing wear from fluid mixing.
3Power
If pressure exchange operation continues, then pressure transfer is maintained, but noise and vibration increase
Solution Approach 1:
The pressure exchanger divides the pressure transfer process into multiple discrete stages across separate chambers and ducts. This segmentation distributes the pressure transfer events over time and space, preventing concentrated high-velocity fluid jets that generate intense noise and vibration. Each chamber handles a portion of the pressure exchange, reducing peak disturbance levels.
Solution Approach 2:
The intermediary fluid serves as a damping medium that absorbs mechanical disturbances, noise, and vibration generated during pressure exchange. By using this mediator fluid instead of direct fluid-to-fluid contact, the system reduces the transmission of harmful vibrations and noise to the surrounding environment while maintaining effective pressure transfer.
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 design enhances pressure exchange efficiency, reduces energy consumption, minimizes fluid contamination and component wear, decreases noise and vibration, and extends equipment lifespan by minimizing mixing and optimizing fluid dynamics within the pressure exchanger.
Implementation Method 1
a rotor configured to exchange pressure between a first fluid at a first pressure and a second fluid at a second pressure
Implementation Method 2
Mixing of the fluids may occur
Data Source
AI summary
A pressure exchanger includes a rotor configured to exchange pressure between a first fluid at a first pressure and a second fluid at a second pressure. The rotor forms ducts that are routed from a first distal end to a second distal end. The pressure exchanger further includes a first end cover that forms a high pressure in (HPIN) port configured to provide the first fluid at the first pressure in a substantially axial direction into the ducts. The first end cover forms a low pressure out (LPOUT) port configured to receive the first fluid from the ducts at a third pressure. The pressure exchanger further includes a second end cover that forms a low pressure in (LPIN) port configured to provide the second fluid at the second pressure into the ducts and forms a high pressure out (HPOUT) port configured to receive the second fluid from the ducts at a fourth pressure.