Pressure Exchanger Rotor Chamfers for Cavitation and Vibration Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional pressure exchangers face inefficiencies due to fluid mixing, cavitation, noise, and vibration, leading to increased energy consumption, component wear, and contamination, particularly in applications like hydraulic fracturing and desalination systems.

Innovation Solution

The pressure exchanger design includes optimized rotor ducts and end covers with specific port configurations and materials to minimize fluid mixing, reduce cavitation, and control noise and vibration, enhancing efficiency and reducing wear on components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional pressure exchanger design is used, then pressure exchange function is provided, but fluid mixing occurs leading to contamination and reduced efficiency

Engineering Contradiction:

Improvefluid separationVSAvoiddesign complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The pressure exchanger is divided into multiple independent ducts within the rotor, each duct serving as a separate fluid pathway. This segmentation prevents mixing between different fluid streams while maintaining pressure exchange functionality, directly addressing the fluid separation requirement without excessive complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the rotor ducts are designed with specific properties: sealed leading ends prevent fluid entry from one side, while trailing ends allow controlled fluid exit. This local differentiation of duct characteristics enables effective fluid separation while maintaining overall system simplicity

Inventive Principle:

Principle #3Local quality

2Reliability

If conventional pressure exchanger operation is used, then pressure exchange occurs, but cavitation damage happens to components

Engineering Contradiction:

Improvecomponent durabilityVSAvoidcavitation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The rotor ducts are designed with sealed leading ends that prevent fluid from entering the ducts during rotation. This preliminary prevention of fluid entry eliminates the conditions that would lead to cavitation formation and subsequent component damage, directly protecting against cavitation harm

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The harmful cavitation process is eliminated by extracting the fluid entry mechanism from the conventional pressure exchanger design. By sealing the duct leading ends and preventing fluid ingress, the cavitation-generating process is completely removed from the system

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If conventional pressure exchanger is used, then pressure exchange is achieved, but noise and vibration increase

Engineering Contradiction:

Improveoperational efficiencyVSAvoidnoise and vibration

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The noise and vibration generation mechanisms are eliminated by removing the fluid mixing and cavitation processes from the system. The sealed duct design prevents fluid ingress and eliminates the turbulent flow and pressure fluctuations that generate harmful noise and vibration

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The design converts the potential harm of fluid entry into a benefit by using the pressure differential to keep fluids out of the ducts. The sealed leading ends utilize the rotating motion and pressure conditions to prevent fluid entry, transforming what would be a harmful fluid interaction into a protective mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 optimized design achieves higher efficiency, lower energy consumption, reduced component wear, and decreased noise and vibration, leading to less maintenance and extended equipment life in fluid handling systems.

Implementation Method 1

a first end cover forms a high pressure in (HPIN) port configured to provide the first fluid at the first pressure into the ducts

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

Reducing cavitation, noise, and vibration in a pressure exchanger

Methodology Applied

Scientific EffectCavitation: Cavitation

Data Source

PatentUS12410821B2Reducing cavitation, noise, and vibration in a pressure exchanger

Publication Date: 2025.09.09 ENERGY RECOVERY INC

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 rotor forms chamfers on trailing edge rotor duct walls. 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 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.