Pressure Intensifier System for Abrasive Slurry Pumping
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Solution Overview
Problem
Slurry pumps used in industries like hydraulic fracturing and mineral processing face severe wear due to abrasive nature of slurries, leading to poor reliability and high maintenance costs.
Innovation Solution
A pressure intensifier system with a movable partition and a controller that manages fluid flow and pressure, using a centrifugal pump to transfer hydraulic energy from moderate pressure clear water to abrasive slurry streams at higher pressures, reducing wear and increasing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional slurry pumps are used to pump abrasive slurries, then the pumping function is achieved, but severe wear occurs leading to poor reliability and high maintenance costs
Solution Approach 1:
The patent introduces a two-chamber piston system with separate drive fluid chamber and slurry chamber. The drive fluid (clean water or hydraulic oil) acts as an intermediary that transmits pressure to the slurry without direct contact between the abrasive slurry and the pump's internal moving parts. This mediator approach allows the slurry to be pressurized while minimizing wear on pump components.
Solution Approach 2:
The pump is divided into two distinct chambers: a drive fluid chamber and a slurry chamber, separated by a piston. This segmentation allows independent management of the drive fluid and slurry, enabling the drive fluid to perform the work of pressurizing while the slurry remains isolated from the mechanical components that generate wear.
2Stress or pressure
If direct acting liquid driven pumps are used to pressurize slurry, then high pressure is achieved, but the system complexity increases with multiple pistons or plungers
Solution Approach 1:
The patent merges the functions of multiple pistons or plungers into a single two-chamber piston system. The drive fluid chamber and slurry chamber share a common piston structure, eliminating the need for separate driving mechanisms for each chamber while still achieving the required pressure intensification through the pressure differential across the piston.
3Productivity
If multiple pumps are used to achieve high flow rates for hydraulic fracturing, then the required flow rate is met, but the number of pumps increases maintenance requirements and system complexity
Solution Approach 1:
The patent employs hydraulic pressure intensification using a two-chamber piston system where drive fluid pressure is converted to slurry pressure through the piston mechanism. This hydraulic approach allows a single pump to achieve the high pressures and flow rates previously requiring multiple pumps, thereby reducing system complexity and maintenance requirements.
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 system effectively injects abrasive slurries into high-pressure processes with minimal wear, enhancing the reliability and reducing maintenance costs by efficiently managing fluid pressure and flow.
Implementation Method 1
The piston 14 moves back and forth within the cylinder 12. The piston 14 divides the cylinder 12 into a first volume 20 and a second volume 22. A first port 24 communicates drive fluid into or out of the cylinder 12 at the first volume 20.
Implementation Method 2
The piston 14 may include a plurality of sealing rings 18 disposed on an edge of the piston 14, the piston 14 divides the cylinder 12 into a first volume 20 and a second volume 22. The sealing rings 18 prevent fluid leakage from between the first volume 20 and the second volume 22 within the cylinder 12.
Implementation Method 3
The piston 14 has a first plunger 50 that is received within the first opening 36 and the seal 40 and extends into the first pump barrel 42. The second opening 38 in the second end wall 34 receives a second plunger 52. As the piston 14 moves in the axial direction, the plungers 50, 52 move within the respective barrels 42, 46.
Data Source
AI summary
A pressure intensifier system includes a housing including a piston separating a first volume and a second volume. A high pressure pump, a low pressure manifold are coupled to a drain line and a slurry tank. A plurality of valves comprise a first state coupling the high pressure pump to the first volume and coupling the second volume to the low pressure manifold so a first portion of fluid in the second volume is communicated to the slurry tank and a second portion of the fluid is communicated to the drain. The valves comprise a second state coupling the high pressure pump to the second volume and coupling the first volume to the low pressure manifold so a first portion of fluid in the first volume is in communication with the slurry tank and a second portion of the fluid in first volume is in communication with the drain.