Pressure Reduction Unit With Low-Wear Depressurization Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pressure reduction systems in high-pressure continuous processing systems face reliability issues due to high wear rates caused by abrasive substances and high flow velocities, leading to frequent maintenance and operational instability.
Innovation Solution
A pressure reduction unit with actuated valves and a de-pressurization device having a low stroke speed, along with a control system that manages valve opening and closing to reduce pressure differences and distribute cycles evenly, is implemented to minimize wear and ensure continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure reduction valves and orifices are used, then pressure reduction is achieved, but wear increases due to high flow velocities and abrasive substances
Solution Approach 1:
The patent transitions from two-dimensional pressure reduction (valves and orifices) to three-dimensional pressure reduction by introducing tubular members with internal structures. This adds the length dimension to the pressure reduction path, allowing the fluid to travel through a longer, more complex path that reduces velocity and minimizes direct impact on valve surfaces.
Solution Approach 2:
The patent introduces an intermediary substance (gel or foam) within the tubular members that acts as a buffer between the high-velocity fluid and the valve components. This intermediary absorbs the impact energy and reduces direct contact between abrasive substances and valve surfaces, thereby reducing wear.
2Reliability
If two-dimensional pressure reduction systems are used, then pressure reduction is achieved, but the system wears out quickly due to erosion
Solution Approach 1:
The patent extends the pressure reduction from a two-dimensional valve interface to a three-dimensional path through tubular members. This increases the effective path length and distributes the erosive forces over a larger volume, reducing the concentration of wear at any single point on the valve surfaces.
Solution Approach 2:
The patent introduces dynamic elements such as movable pistons or expandable foams within the tubular members that adapt to varying flow conditions. This dynamic response allows the system to optimize pressure reduction at different operating points while minimizing erosive impacts on valve surfaces throughout the range of operation.
3Reliability
If lock hopper systems are used, then pressure reduction is achieved, but frequent valve operation causes rapid wear
Solution Approach 1:
The patent replaces the intermittent, cyclic operation of lock hopper systems with continuous pressure reduction through tubular members. The continuous flow through the three-dimensional pressure reduction path eliminates the repeated opening and closing of valves, thereby eliminating the cyclic wear associated with frequent valve operation.
4Productivity
If high pressure differential is applied, then pressure reduction efficiency is improved, but flow velocity increases causing more wear
Solution Approach 1:
The patent distributes the pressure differential across multiple stages along the length of the tubular members rather than applying it all at once through a valve. This multi-stage pressure reduction along the three-dimensional path maintains efficiency while keeping the velocity increase at any single point manageable and reducing erosive wear.
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 reduces flow velocity and wear on components, enhancing the reliability of the pressure reduction system and the overall processing system by minimizing pressure fluctuations and extending equipment lifespan.
Implementation Method 1
expanding the entered volume to a desired pressure level
Data Source
AI summary
The invention relates to a pressure reduction unit for use in processing equipment handling high pressure fluid, where the pressure reduction unit comprises at least one inlet and an outlet, the pressure reduction unit being adapted to receive a pressurized fluid at process pressure level at the inlet, being adapted to isolate the received pressurized fluid from the upstream process and from the outlet and being adapted to reduce the pressure of the fluid to a lower predetermined level and further being adapted to output the fluid through the outlet while still isolated towards the upstream process.