The invention relates to a pressure exchanger for transferring pressure energy from a first liquid of a first liquid system to a second liquid of a second liquid system, comprising a housing having connector openings in the form of inlet and outlet openings for each liquid and a rotor arranged to rotate about its longitudinal axis within the housing, the rotor having a plurality of continuous channels with openings arranged around its longitudinal axis on each rotor end face, in which the rotor channels communicate with the connector openings of the housing via flow openings in the housing; the rotor channels alternately carry liquid at a high pressure and liquid at a low pressure for the respective systems during rotation of the rotor; a flow transition extending primarily axially is formed between the flow openings in the housing and the openings of the rotor channels, whereby the flow openings in the housing are parts of cavities constructed in the form of arcs connected to the connector openings and each cavity simultaneously covers multiple openings of the rotor channels.
A known pressure exchanger design is disclosed in European Patent 1 019 636 B1. With this design, high pressure of a first liquid of a first liquid system is transmitted to a second liquid of a second liquid system to achieve an energy recovery in a plant to which the pressure exchanger is connected. This type of pressure exchanger is not equipped with any external drive. To start operation thereof with such a pressure exchanger, a complex method is necessary to set the rotor in rotation. The liquid stream is responsible for the rotational movement of a rotor, passing through flow openings on the housing from an oblique direction and striking the end faces of the rotor with the openings, thereby inducing a momentum drive of the rotor. During ongoing operation in a continuously operated plant, an equilibrium state is established in the pressure exchanger so that the rotor rotates at an approximately constant rotational speed because of this equilibrium state. It is a disadvantage here that this rotational speed is automatically established at an undefined rotational speed value as a function of altered plant conditions on the high pressure side and the low pressure side. Depending on the different boundary conditions in the two liquid systems, this results in different rotational speeds of the rotor and thus different mixing effects of the two liquids that are alternately contained in the rotor channels.
U.S. Pat. Nos. 3,431,747 and 6,537,035 describe a different pressure exchanger design in which an external drive starts the movement of the rotor and the rotor channels are constructed as bores, a separating element in the form of a ball being arranged in each bore. This ball serves to separate the liquids alternately flowing into the rotor channels with a high or low pressure content and prevents mixing of the liquids in the bores. However, disadvantages here include the arrangement, sealing and design of the separation element and the respective seating faces. In addition, a complex high-pressure gasket is necessary as a shaft seal in the area of a shaft bushing for the external drive.
An object of the present invention is to provide an improved rotary pressure exchanger.
Another object of the invention is to provide a pressure exchanger having a rotor which does not have any separating elements in the rotor channels.
A further object of the invention is to provide a rotary pressure exchanger which operates with minimal mixing losses in the rotor channels during pressure exchange.
It is also an object of the invention to provide a pressure exchanger which maintains an efficient operating state with minimal mixing losses over a large operating range with variable mass flows.
These and other objects are achieved in accordance with the present invention by providing a pressure exchanger for transferring pressure energy from a high pressure liquid of a first liquid system to a low pressure liquid of a second liquid system comprising a housing with inlet and outlet connection openings for each liquid and a rotor arranged in the housing for rotation about a longitudinal axis, the rotor having a plurality of continuous channels arranged around the longitudinal axis with openings on each rotor end face such that the rotor channels are connected with the inlet and outlet connection openings through flow openings in the housing so that during the rotation of the rotor the channels alternately carry high pressure liquid and low pressure liquid from the respective liquid systems; in which a predominantly axially extending flow transition is formed between the flow openings in the housing and the openings of the rotor channels; the flow openings in the housing are parts of arcuately shaped cavities communicating with the connection openings, and each cavity simultaneously covers a plurality of rotor channel openings and has a contour that smoothes out the velocity of flow in the area of the housing flow openings; the rotor has an outside surface contour that converts or transfers energy such that a partial liquid stream impinging with high pressure energy or flow energy against the rotor contour causes the rotor to rotate, and a regulator varies the amount of the partial stream and the rotational speed of the rotor and adjusts the rotor speed to a speed suitable for essentially shock-free admission of the liquid flow into the rotor channels.
In accordance with the present invention, the cavities have a construction which makes the velocity of flow uniform in the area of the flow opening in the housing; the outside surface of the rotor has a shape which converts energy and/or transmits energy; a partial stream of a high pressure energy and/or flow energy striking this shape generates the rotor rotational speed, and a regulator alters the quantity of the partial stream and the rotational speed of the rotor and regulates the rotor speed at a rotational speed for essentially shock-free admission of the mass flow into the rotor channels. With this approach it is easily possible to take a partial stream from the total mass flow flowing to a pressure exchanger in a plant and with the help of this partial stream to generate a certain drive torque for the rotor. This advantageously facilitates a startup procedure of the rotor. Furthermore, this approach offers an opportunity to create a permanent and regulated torque as the driving momentum for continuous operation of the rotor with the help of the partial stream, the amount of which is adjustable. Thus, in the respective operating state, the rotational speed of the rotor is adapted to the prevailing plant conditions through appropriate variation of the partial stream.
Due to the cavities arranged in the housing with their flow-smoothing contour, i.e., the design, shape and course of the wall surfaces surrounding the cavity, a uniform velocity profile of the main stream is established in transition to the rotor and in front of the openings in the rotor channels receiving the oncoming flow in the area of the flow opening in the housing. This is the mass flow of the main stream reduced by the partial stream. The direct drive of the rotor by the partial stream and the development of a uniform velocity profile in the flow opening in the housing yield the advantage that the main stream reaches the rotor channels essentially shock-free. And if a change in the mass flow is also established because of altered plant conditions at the pressure exchanger, i.e., there is a change in mass flow toward a higher or lower flow rate, then there is an adjustment of the rotor speed with a suitably modified partial stream to continue to ensure a substantially shock-free oncoming flow of the main stream is admitted to the rotor channels.
And a uniform velocity profile of the channel flow situated therein is also established in the cross section of the rotor channels due to the uniform flow distribution of the main stream upstream from the openings of the rotor channels. As a result of this, this yields a smaller and more stable mixing zone in the area between the two liquids with their different properties within the rotor channels. This improves the efficiency of such a pressure exchanger and a plant which is influenced thereby. The partial stream used for driving the rotor flows out into a lower pressure zone within the pressure exchanger, i.e., in this case into the second liquid system.
The quantity of the partial stream and the speed of the rotor are adjusted by the regulator. Thus the rotor speed is automatically matched to varying plant conditions. The efficiency of a pressure exchanger in a plant, e.g., a reverse osmosis plant, is thus always kept at the best operating point.
According to preferred embodiments of the invention, a contour arranged in the surface of the rotor is designed as a plurality of distributed blade elements or a plurality of blade elements is arranged in distribution in the area of one or both rotor end faces. These may be arranged only on the end faces as well as in the area of the transitions between the end faces and the circumferential surface. The same functionality is obtained when the shape on the rotor circumference is designed as one or more spiral grooves.
According to additional embodiments, at least one partial stream derived from the first liquid system flows toward the rotor surface contour. This yields a direct flow drive of the rotor. And a mass flow reduced by a partial stream flows as a main stream of the liquids toward the rotor channels essentially without shock.
The liquids circulating within the pressure exchanger are defined here as follows:
The first liquid and the first liquid system have a high pressure. The second liquid and the second liquid system have a low pressure. A total quantity of liquid flowing to the pressure exchanger, e.g., a liquid flowing out of a reverse osmosis module at a high pressure, corresponds to the mass flow to be processed by the pressure exchanger. A partial stream which is directed at the contour and with the help of which the rotor is driven branches off from the mass flow having a high pressure. A partial stream at a lower pressure, whose energy content is thereby reduced by the drive work on the rotor, flows through the gap between the rotor and the housing or through a separate drain into the second liquid system and ultimately out to the atmosphere. For the purpose of pressure exchange, the main stream, the size of which corresponds to the mass flow reduced by the partial stream, flows into the rotor of the pressure exchanger. And the energy converting shape is constructed as a plurality of blade elements or spiral grooves.
With altered plant conditions, the oncoming flow to the rotor channels is essentially shock-free with an adjusted rotor speed for the main stream. This prevents mixing in the rotor channels. And the cavities which are crucial for a uniform velocity profile upstream from the rotor each comprise a diffuser part downstream from the connector openings and a following deflector part and include the flow opening in the housing. With the help of the deflector part, the influence is compensated by the circumferential component of the rotor in a developing velocity profile. And with the diffuser part, the velocity distribution of the flow in the cavity is made more uniform. The transition between the diffuser part and the deflector part may be designed in stages or continuously.
A regulator arranged in the lines of the partial stream acts as a throttle mechanism to alter the flow rate of the partial stream. Thus the rotational speed of the rotor and therefore the efficiency of the pressure exchanger are easily adapted to the respective plant conditions. The partial mass which acts directly on the blade elements of the rotor and thus influences its rotational speed changes as a result of a change in the adjustment by the regulator.
Another embodiment relates to a pressure exchanger of the foregoing type in which an external drive drives the rotor via a shaft. According to the solution to the problem with such an embodiment, the cavities have a shape that makes the velocity of flow more uniform in the area of the flow opening in the housing, and a regulator is provided as a speed regulating device for the external drive, and thus the rotor speed can be regulated at a rotational speed suitable for essentially shock-free admission of the mass flow into the rotor channels as a function of the plant conditions. Thus, the total mass flow of the incoming high pressure flow (HP-in) flows into rotor channels essentially without any shock or impact. Which drive concept is the most advantageous for a given rotor will depend on the conditions prevailing at the site of use.
Sensor elements arranged in the liquid systems monitor the operating states, and a regulating device connected to the sensor elements adjusts the partial stream and/or the rotor speed to the altered operating states when deviations occur.
With one device, the regulating device detects the rotational speeds of the rotor and generates from the rotor speeds appropriate actuating signals for a speed control of one or more pumps in the first and/or second liquid system. This makes it possible to regulate the pumps which generate the pressure in one plant, for example. This may be accomplished by an essentially known electronic actuator which, based on the rotor speed of the pressure exchanger, adjusts the flow rate and/or speed of one or more rotary pumps to altered plant conditions with the help of actuating signals delivered via the device to be processed. This yields improved economic operating conditions.
In addition, a regulator connected downstream from the pressure exchanger in a line for the outgoing low pressure liquid stream (LP-out) adapts the incoming low pressure liquid stream (LP-in) to the enriched high pressure liquid stream (HP-out) via the regulating device.
The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawing figures, in which:
The flow arrow for HP-in corresponds to a vector for the total mass flow MS. A partial stream TS branches off from the mass flow MS, and the mass flow MS reduced by this amount flows as a main stream HS into rotor 1. The partial stream TS is passed through internal or external lines 4 to the surface 5 of the rotor 1 where a contour 6 that transfers energy is arranged. The partial stream TS used for driving the rotor 1 flows out into a zone of lower pressure within the pressure exchanger, i.e., into the second liquid system.
In this example, the contour 6 is arranged centrally on the surface 5 of the rotor 1, resulting in two symmetrical partial surfaces 5 and 5.1. A regulator 7 provided in the line 4 helps to influence the quantity of partial stream TS flowing through the line 4 so that the speed of the rotor 1 is controlled and regulated directly. The contour 6 here may have any suitable shape to convert a partial stream TS of a high pressure energy and/or flow energy acting thereon into a driving momentum for the rotor 1.
In the diagram of
Because of the rotor rotating at circumferential velocity u, the direction of through flow is constantly changing in the channels 13 of the rotor. To achieve the same conditions, the diffuser part 21 and the deflector part 20 are arranged symmetrically, i.e., mirror symmetry. The velocity triangle diagrams depicted in
The flow openings 11-11.3 in the housing have an essentially bean-shaped cross section. The rounded areas on their two ends are tangential to a radius to the longitudinal axis. The wall surfaces of the deflector part 20 developing into the rounded areas extend at the angle a in the axial direction of the cavity 19. A shock-free incoming flow into the rotor channels at the angle α is obtained with the deflector part 20 and the velocity profile of the flow that has been smoothed at the openings 12 of the rotor channels 13. This reliably prevents mixing within the rotor channels 13 in the area of a separation zone between the two different liquids inside the rotor channel.
The two possible types of drives are shown on the pressure exchanger 23 only for the sake of illustration. In practice, the rotor drive takes place via the partial stream or the drive 18. The regulating device 30 and/or a device 31 may also detect the rotational speeds of the rotor and may generate actuating signals for a speed control corresponding to the rotor speeds by one or more of pumps 24, 25 or 27 in the first and/or second liquid systems.
The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof.
Number | Date | Country | Kind |
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10 2004 038 440.1 | Aug 2004 | DE | national |
This application is a continuation of international patent application no. PCT/EP2005/007649, filed Jul. 14, 2005 designating the United States of America and published in German on Feb. 16, 2006 as WO 2006/015682, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 10 2004 038 440.1, filed Aug. 7, 2004.
Number | Date | Country | |
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Parent | PCT/EP05/07649 | Jul 2005 | US |
Child | 11703238 | Feb 2007 | US |