Pressure Reduction Unit Using Piston Pumps to Minimize Abrasive Wear
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Solution Overview
Problem
High-pressure processing systems face reliability issues due to significant wear from abrasive materials, leading to frequent maintenance and operational instability in pressure reduction systems, particularly when using two-dimensional valves and lock hopper systems.
Innovation Solution
A pressure reduction unit comprising multiple piston pumps with controlled valves and position indicators, utilizing hydraulic pressure amplification and energy recovery to manage pressure and flow, minimizing wear and ensuring 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 from abrasive materials causes frequent maintenance and reduced reliability
Solution Approach 1:
The patent transitions from two-dimensional pressure reduction (valves/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 wear on sealing surfaces.
Solution Approach 2:
The patent introduces an intermediary substance (fluid) to transfer energy and momentum in the pressure reduction process. The fluid acts as a mediator between the high-pressure source and the low-pressure outlet, allowing gradual pressure reduction through expansion and mixing rather than direct mechanical impact on valve surfaces.
2Reliability
If two-dimensional pressure reduction systems are used, then pressure reduction is achieved, but flow velocity becomes excessively high causing rapid wear
Solution Approach 1:
The patent extends the pressure reduction path from two-dimensional (across a valve orifice) to three-dimensional (through tubular members with internal structures). This increases the path length and allows velocity to be reduced gradually along the flow path, preventing excessive flow velocity at any single point.
Solution Approach 2:
The patent divides the pressure reduction process into multiple stages by using series-connected tubular members with different internal structures. Each tubular member performs a portion of the pressure reduction, segmenting the overall process to maintain lower velocities throughout the system.
3Reliability
If lock hopper systems are used, then pressure reduction is achieved, but frequent valve operation leads to rapid wear and operational interruptions
Solution Approach 1:
The patent enables continuous pressure reduction operation by using a system of multiple pressure reduction units with staggered operation cycles. While one unit is reducing pressure, another is being prepared or is in a different phase of operation, ensuring uninterrupted continuous service without frequent shutdowns for maintenance.
Solution Approach 2:
The patent employs periodic operation of multiple pressure reduction units in a coordinated sequence. Each unit operates in cycles with slight time offsets from others, creating a continuous overlapping operation pattern that maintains system functionality while allowing individual units to be maintained during their off-cycles.
4Reliability
If multiple pressure reduction valves in series are used, then pressure reduction is achieved, but system complexity and cost increase significantly
Solution Approach 1:
The patent makes each pressure reduction unit multi-functional by combining pressure reduction, flow regulation, and energy recovery capabilities in a single integrated system. The tubular members with internal structures perform multiple functions simultaneously, reducing the total number of separate components needed while maintaining precise pressure control.
Solution Approach 2:
The patent merges multiple functions into fewer components by combining pressure reduction, flow control, and energy recovery into integrated pressure reduction units. This consolidation reduces system complexity by eliminating the need for separate valves, regulators, and energy recovery devices that would otherwise be required.
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 enhances the reliability and longevity of high-pressure processing systems by reducing wear on valves and seals, allowing for continuous operation with minimal pressure fluctuations and efficient energy utilization.
Implementation Method 1
utilizing hydraulic pressure amplification and energy recovery to manage pressure and flow
Implementation Method 2
utilizing hydraulic pressure amplification and energy recovery to manage pressure and flow
Data Source
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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.