Method and Apparatus for Pressure Processing a Pumpable Substance

This invention relates to an improved method and apparatus for pressure processing a pumpable substance, for example, abrasive slurries and the like.

Many objectives may be achieved by exposing a pumpable substance to ultrahigh-pressure. For example, ultrahigh-pressure may be used to render any desired physical change in a substance that can be accomplished by pressurizing the substance to a selected pressure for a selected period of time. Fluids and abrasive slurries elevated to ultrahigh-pressures may be used to perform a variety of tasks, such as cutting different types of materials. Ultrahigh-pressure may be used to chemically or physically modify chemical or biological substances. Ultrahigh-pressure processing may be used to improve the quality of existing products, and to generate new products.

Currently, the majority of pressure-based processing is achieved by loading a substance into a large pressure vessel. The pressure vessel is then closed and pressurized to a selected pressure for a selected amount of time, commonly referred to as the "dwell time," to achieve the desired physical change in the substance. The vessel is then depressurized, and the contents unloaded. Alternately, for example in the context of pressurizing a high-pressure slurry, the slurry is discharged from the pressure vessel until the vessel is empty. The pressure vessel is then reloaded with a volume of slurry.

Although current systems produced desirable results, they also have several disadvantages. For example, high-pressure vessels typically require a thick wall construction and massive enclosures to contain the pressure, thereby making the large pressure vessels costly to construct. These current systems are also time-consuming to operate, because a massive enclosure must be removed and replaced for each loading cycle.

It is therefore an object of the present invention to provide an improved ultrahigh-pressure method and apparatus for pressure processing a pumpable substance.

It is another object of this invention to provide in a preferred embodiment an improved ultrahigh-pressure method and apparatus for pressure processing a pumpable substance that is less expensive to use than currently available systems.

It is another object of this invention to provide in a preferred embodiment a faster and more efficient method and apparatus for pressurizing a pumpable substance.

These and other objects of the invention, as will be apparent herein, are accomplished by providing an improved ultrahigh-pressure system that processes a pumpable substance preferably on a continuous basis. In a preferred embodiment, a valve is coupled to a source of a pumpable substance, and to a pressure vessel. The valve is moveable to a first, second and third position. The valve is comprised of three segments, and has an inlet port in a first segment, and an outlet port in a third segment. In a preferred embodiment, the valve is slidably movable along a shaft that passes through a longitudinal axis of the valve, a passageway being provided in the shaft that is open to the pressure vessel. When the valve is in the first position, the inlet port is aligned with the passageway, thereby allowing a volume of pumpable substance to flow through the inlet port and passageway into the pressure vessel. The valve is then slid along the shaft to the second position, thereby sealing the passageway against the valve. The pumpable substance is then pressurized to a selected pressure for a selected period of time, depending on the desired result, after which the pumpable substance is depressurized. The valve is then moved to the third position, thereby aligning the outlet port with the passageway and allowing the pumpable substance to be discharged from the pressure vessel.

In a preferred embodiment, the pressure vessel has a chamber that is divided into a first region and a second region by an isolating member that is sealed along the width of the pressure chamber and that is free to move or expand and contract along the length of the pressure chamber. As the volume of pumpable substance flows into the first region of the chamber, it pushes the isolating member along the length of the chamber to accommodate the volume of pumpable substance.

In a preferred embodiment, a pressurizing medium such as ultrahigh-pressure fluid, is introduced into the second region of the chamber via a second valve, the ultrahigh-pressure fluid acting on the isolating member which in turn compresses and pressurizes the pumpable substance. The second valve is moveable to a first and second position and is comprised of a first and second segment. A port is provided in the first segment, which is aligned with a second passageway that is open to the second region of the chamber, when the second valve is in a first position. When the second valve is moved to a second position, the second passageway is sealed by the second valve. The second passageway is coupled to a source of ultrahigh-pressure fluid. Therefore, a volume of ultrahigh-pressure fluid is introduced through the second passageway into the second region to pressurize the pumpable substance as described above, while the second valve is in the second position. After a selected amount of time, the pressure is released by allowing a quantity of the ultrahigh-pressure fluid to flow out of the second region, and the second valve is moved to a first position. A volume of low-pressure fluid is introduced through the port and flows through the second passageway into the second region, thereby acting on the isolating member and discharging the pumpable substance from the chamber, the pumpable substance exiting through the first passageway and the outlet port of the first valve, the first valve being in its third position.

In a preferred embodiment, low-pressure seals are provided on opposing sides of each of the inlet and outlet ports of the first valve, and on opposing sides of the port of the second valve. Two high-pressure seals are provided in the second segment of each of the first and second valves, such that when the first and second valves are in their respective second positions, the two high-pressure seals of each valve are positioned on opposing sides of the first and second passageways, respectively, thereby sealing the passageways.

By providing a system in accordance with a preferred embodiment of the present invention, it is possible to use ports and passageways having relatively large inner diameters, thereby allowing the processing of viscous substances, substances or fluids containing solid inclusions, and to allow high flow rates of low viscosity fluids, while still adequately sealing against the ultrahigh-pressures. Conventional ultrahigh-pressure systems use tubing having a much smaller inner diameter and conventional ultrahigh-pressure valve seats. If the ultrahigh-pressure valve and tubing are scaled up to accommodate viscous substances, high separation forces are generated at the ultrahigh-pressure shut off valve seats. In the preferred embodiment of the present invention illustrated herein, the ultrahigh-pressure valve seats are eliminated, thereby simplifying the high-pressure containment and allowing the use of large passageways and high flow rates into and out of the pressure vessel.

In a preferred embodiment, multiple systems as described above are coupled together in parallel, thereby processing large volumes of pumpable substance in a fast, cost effective manner.

In an alternative preferred embodiment, a pumpable substance is pressurized and simultaneously discharged from the pressure vessel. The first valve is movable to a first and second position and is comprised of two segments, the valve having a low-pressure, large diameter inlet port in a first segment and an ultrahigh-pressure outlet port in a second segment. Similarly, the second valve is movable to a first and second position, and is comprised of a first and second segment, the second valve having a large diameter outlet port in the first segment and an ultrahigh-pressure inlet port in the second segment. Therefore, a volume of pumpable substance, for example, an abrasive slurry, is introduced into the pressure vessel via the low-pressure inlet port of the first valve, the first valve being in its first position. The second valve is also in its first position, thereby aligning the second passageway with the low-pressure outlet port of the second valve. Therefore, as the abrasive slurry is introduced into the first region of the pressure vessel, the isolating member moves or expands along the length of the chamber to accommodate the pumpable substance and to discharge any fluid in the second region through the second passageway and outlet port of the second valve. The first and second valves are then moved to their second positions, and a volume of ultrahigh-pressure fluid is forced through the ultrahigh-pressure inlet in the second valve, thereby flowing into the second region of the chamber and pressurizing the pumpable substance. The first passageway is aligned with the ultrahigh-pressure outlet port provided in the first valve. Therefore, as the ultrahigh-pressure fluid in the second region of the chamber acts against the isolating member to pressurize the abrasive slurry, it also acts to force the pressurized abrasive slurry out through the first passageway and the ultrahigh-pressure outlet port. In a preferred embodiment, an ultrahigh-pressure nozzle orifice is provided downstream of the ultrahigh-pressure outlet port, such that the pressurized abrasive slurry is forced through the nozzle, thereby generating an ultrahigh-pressure abrasive fluid jet.

FIG. 1 is a cross-sectional elevational view of a valve provided in accordance with a preferred embodiment of the present invention.

FIG. 2 is a partial cross-sectional elevational view of a system for processing a pumpable substance provided in accordance with a preferred embodiment of the present invention.

FIGS. 3-6 are conceptual, cross-sectional elevational views of a system provided in accordance with a preferred embodiment of the present invention, in four different stages of operation.

FIG. 7 is a conceptual, cross-sectional elevational view of a system provided in accordance with an alternative embodiment of the present invention.

FIG. 8 is a conceptual, cross-sectional elevational view of a system provided in accordance with an alternative embodiment of the present invention.

FIG. 9 is a diagram illustrating the steps of a preferred embodiment of the present invention.

FIGS. 10 and 11 are conceptual, cross-sectional elevational views of a system provided in accordance with a preferred embodiment of the present invention, in two stages of operation.

FIG. 12 is a diagram illustrating the steps of an alternative embodiment of the present invention.

FIG. 13 is a conceptual, cross-sectional elevational view of an alternative preferred embodiment to the present invention.

Many objectives may be achieved by processing a pumpable substance with ultrahigh-pressure. Such pressure processing may be used, for example, to render desired physical change in a substance that can be accomplished by pressurizing the substance to a selected pressure for a selected period of time. Fluids and abrasive slurries elevated to ultrahigh-pressures may be used to perform a variety of tasks, such as cutting different types of materials.

A preferred method and apparatus for pressure processing a pumpable substance is provided in accordance with a preferred embodiment of the present invention. As illustrated in FIG. 1 and conceptually illustrated in FIGS. 3-6, a preferred embodiment provides a pressure processing system 10 which includes a first valve 12 having a valve body 16 that is movable to a first position 18, second position 20, and third position 22. Although valve 12 may be moved to these three positions by any appropriate means such as a motor or screwdrive, in a preferred embodiment, valve 12 is moved to a selected position by air cylinder 11.

As illustrated in FIGS. 1 and 3-6, the valve 12 has an inlet port 24 and an outlet port 26. When the valve 12 is in the first position 18, inlet port 24 is aligned with passageway 28 which in turn is open to a chamber 44 of pressure vessel 30. Inlet port 24 is coupled to a source of pumpable substance 14, such that when the valve 12 is in the first position 18, a volume of pumpable substance 14 may be forced into pressure vessel 30. The valve 12 further has an outlet port 26 that is aligned with the passageway 28 when the valve is in the third position 22. When the valve 12 is in the second position 20, the valve body 16 seals passageway 28. In a preferred embodiment, valve 12 is slidably movable along a first shaft 32 that passes through a longitudinal axis of the valve. The passageway 28 is provided in the first shaft 32.

In a preferred embodiment, valve 12 is comprised of a first segment 34, a second segment 36, and a third segment 38, the inlet port 24 being provided in the first segment 34 and the outlet port 26 being provided in the third segment 38. As further illustrated in FIGS. 1 and 3-6, low-pressure seals 40 are provided on opposing sides of both the inlet port 24 and outlet port 26, and two high-pressure seals 42 are provided in the second segment 36. As illustrated in FIGS. 4 and 5, when the valve 12 is in the second position 20, the passageway 28 is aligned with the second segment 36 such that the high-pressure seals 42 are provided on opposing sides of passageway 28. In a preferred embodiment, the high-pressure seals 42 are spaced apart by a distance equal to at least two times the inner diameter of passageway 28, thereby reducing the stress concentration near the entrance 13 of passageway 28. As a result, fatigue damage is reduced and the life of shaft 32 is increased.

To further ensure proper pressure containment, the ratio of the outer diameter 27 to the inner diameter 29 of the high-pressure second segment 36 is at least 2.5 to 1, with preferred results being achieved when the ratio is 3 to 1. The first and third segments 34 and 38 are low-pressure segments and may therefore be made with lower strength materials or with a thinner wall thickness, for example, having an outer diameter to inner diameter ratio that is less than 2.5.

By providing a valve in accordance with the preferred embodiment of the present invention, the high-pressure region and function is separated from the low-pressure regions and functions, thereby allowing the use of an inlet port 24, outlet port 26, and passageway 28 having a relatively large inner diameter, as compared to conventional ultrahigh-pressure tubing. More particularly, a conventional ultrahigh-pressure system uses plumbing lines having a small inner diameter, on the order of 1/8-inch, as well as high-pressure valve seats such as poppet valves. A conventional system is therefore incapable of handling viscous substances or substances having solid inclusions, or high flow rates of non-viscous fluids. If a conventional ultrahigh-pressure system were scaled up in size to accommodate these type of systems and operating conditions, high separation forces are generated at the high-pressure shut-off seats, thereby increasing the size and cost of the valve. In the preferred embodiment of the present invention illustrated herein, however, the ultrahigh-pressure valve seats are eliminated, the pressure forces being transferred to the strong, cylindrical second segment 36. High-pressure containment is therefore simplified, thereby allowing the use of relatively large passageways and high flow rates into and out of the pressure vessel 30. Although in a preferred embodiment an inner diameter of the inlet port 24, outlet port 26, and passageway 28 is 0.25-1.0-inch, it will be understood by one of ordinary skill in the art that the system described may be scaled up to accommodate larger inner diameters.

In a preferred embodiment as illustrated in FIGS. 2-6, the pressure vessel 30 has a chamber 44 that is divided into a first region 50 and a second region 52 by a bladder 15 that is fixed at a first end 19 of chamber 44 and that is free to expand and contract longitudinally along the length of the chamber. Therefore, as a volume of pumpable substance 14 is forced into the first region 50, the pumpable substance 14 acts against bladder 15, causing it to expand along the length of the chamber to accommodate and encapture the volume of pumpable substance. A pressurizing medium, such as ultrahigh-pressure fluid, is introduced into the first region 50 to act against bladder 15 in the opposite direction, thereby compressing and pressurizing pumpable substance 14 to a selected pressure, for a selected period of time. The bladder therefore acts to isolate the pumpable substance from the pressurizing medium and from the inner surface of the chamber 44. This will serve to prevent the pumpable substance from mixing with the pressurizing medium or from chemically reacting with the inner surface of the chamber.

In an alternative embodiment, as illustrated in FIG. 7, a bellows 17 is coupled to the first end 19 of chamber 44 and is free to expand and contract along the length of the chamber to accept, pressurize and discharge the pumpable substance. In a second alternative embodiment, as illustrated in FIG. 8, a piston 46 is provided in the chamber 44. The piston is sealed along the width of the chamber by seal 48, and is free to move longitudinally along the length of the chamber.

In a preferred embodiment, as illustrated in FIGS. 2-6, a second valve 54 is provided, that is movable to a first position 60 and second position 62. The second valve 54 is provided with a port 66 that is aligned with a second passageway 56, when the second valve 54 is in the first position 60. Similar to the first valve 12, the body of the second valve 54 seals the second passageway when the second valve is in the second position 62. In a preferred embodiment, the second valve 54 is slidably movable along second shaft 70 which extends through a longitudinal axis of the second valve 54, the second passageway 56 being provided in the shaft 70. For ease of disassembly for cleaning and servicing, or to allow the use of different materials to minimize cost, the second valve 54 may be provided in a first segment 72 and a second segment 74. As illustrated in FIGS. 2-6, the second passageway 56 is in fluid communication with the second region 52 of chamber 44 and is coupled to a source of ultrahigh-pressure fluid 58 via second port 76.

Therefore, as illustrated in FIGS. 3 and 9, a pumpable substance may be pressure processed in accordance with a preferred embodiment of the present invention by positioning the first valve 12 in the first position 18, such that the inlet port 24 coupled to the source of pumpable substance 14 is aligned with the first passageway 28, step 78. The second valve 54 is positioned in its first position 60 such that the port 66 is aligned with the second passageway 56, step 80. A volume of pumpable substance 14 is then forced through the inlet port and the first passageway into the first region 50 of the chamber 44 of the pressure vessel 30, the pumpable substance 14 forcing the bladder 15 to move longitudinally in the chamber as necessary to accommodate the pumpable substance, step 82. It should be noted that during this step, fluid located on the opposite side of the bladder in the second region 52 of the chamber will be discharged through the port 66 as the pumpable substance is introduced into the first region 50.

After the first valve 12 and the second valve 54 are moved to their respective second positions to seal the first passageway 28 and the second passageway 58, respectively, steps 84 and 86, the pumpable substance is pressurized to a selected pressure for a selected period of time, step 88. In a preferred embodiment, as illustrated in FIG. 4, this is achieved by forcing a volume of ultrahigh-pressure fluid into the second region 52 via the second port 76. After the pumpable substance has been pressurized to the selected pressure for a selected period of time, the pumpable substance is depressurized, for example, by allowing a quantity of the ultrahigh-pressure fluid to flow out of the second region, step 90, as illustrated in FIG. 5.

As illustrated in FIG. 6, the first valve 12 is moved to the third position 22 and the second valve 54 is moved to the first position 60, steps 92 and 94. A volume of low-pressure fluid is forced through the port 66 of the second valve 54, the low-pressure fluid passing through the second passageway 56 into the second region 52 to act on the bladder 15, thereby discharging the pumpable substance 14 from the pressure vessel 30 through the outlet port 26 of the first valve 12, step 96.

In an alternative embodiment, as illustrated in FIGS. 10-12, the pumpable substance is not depressurized, but rather is discharged from the system as pressurized pumpable substance 25. As can be seen in FIGS. 10 and 11, the alternative embodiment illustrated therein has several elements in common with the embodiment illustrated in FIGS. 1-8, and these common elements have been labeled with the same reference characters for simplicity. In the alternative embodiment illustrated in FIGS. 10 and 11, however, the first valve 12 is movable to a first position 18 and a second position 20, the valve being comprised of a first segment 34 and second segment 36. A low-pressure inlet port 24 is provided in the first segment 34 and is aligned with the first passageway 28 when the valve 12 is in the first position 18. An ultrahigh-pressure outlet port 21 is provided in the second segment 36 between high-pressure seals 42, the high-pressure outlet port 21 being aligned with passageway 28 when the valve 12 is in the second position 20.

As further illustrated in FIGS. 10 and 11, the second valve 54 is movable to a first position 60 and a second position 62, the valve having a low-pressure outlet 66 in a first segment 72 and an ultrahigh-pressure inlet port 23 in a second segment 74. The second passageway 56 is aligned with port 66 when the second valve is in the first position 60, and is aligned with the ultrahigh-pressure inlet port 23 when the second valve is in the second position 62.

Therefore, as illustrated in FIG. 12, a volume of pumpable substance 14 is introduced into the first region 50 of pressure vessel 30 via inlet port 24 and the first passageway 28, the first valve being in the first position, step 79. The second valve is in the first position 60, such that as the pumpable substance 14 acts against isolating member 15, any pressurizing fluid found in the second region 52 is discharged from the system via the second passageway 56 and port 66, steps 81 and 83. The first and second valves 12 and 54 are moved to their respective second positions 20 and 62, steps 85 and 87. A volume of ultrahigh-pressure fluid is forced through the ultrahigh-pressure inlet port 23 of the second valve, the ultrahigh-pressure fluid entering the second region 52 to act against isolating member 15, step 89. Given that the first valve 12 is in its second position 20, thereby aligning ultrahigh-pressure outlet port 21 with the first passageway 28, the introduction of ultrahigh-pressure fluid into the second region 52 pressurizes the pumpable substance 50, while discharging it through the first passageway 28 and ultrahigh-pressure outlet port 21 as pressurized pumpable substance 25.

In a preferred embodiment, the system illustrated in FIGS. 10-12 is used to pressurize an abrasive slurry. An ultrahigh-pressure nozzle and orifice are provided downstream of the ultrahigh-pressure outlet port 21, such that pressurized abrasive slurry discharged from the system 10 passes through the orifice to generate an ultrahigh-pressure abrasive fluid jet. The abrasive slurry is comprised of abrasive particles, for example, garnet, mixed with water and a suspension agent. In a preferred embodiment, the abrasive slurry is 5%-50% abrasive by weight. The nozzle orifice downstream of outlet port 21 may have a relatively small orifice diameter, on the order of 20/1000ths of an inch, thereby creating a back pressure that allows the pumpable substance to be pressurized while it is being discharged. It will further be noted that although FIGS. 10 and 11 have been illustrated using a bladder 15, the alternative embodiment illustrated in FIGS. 10 and 11 may also use a bellows 17 or piston 46.

It will be understood that the second valve 54 may alternately be provided with two low-pressure segments and a high-pressure segment, similar to the first valve 12, with a second low-pressure port being provided in the third segment. The second low-pressure port may be used to discharge fluid from the second region 52 of the chamber as pumpable substance is introduced into the first region 50, with port 66 being used to introduce a volume of low-pressure fluid into the second region 52 to discharge the pumpable substance 14, or vice versa.

In an alternative preferred embodiment as illustrated in FIG. 13, the ultrahigh-pressure outlet port 21 is provided in the shaft 32, as an extension of the first passageway 28. In order to contain the ultrahigh-pressure, the ratio of the outer diameter of the shaft to the inner diameter of the shaft is at least 2.5. Similar to the embodiment illustrated in FIG. 11, an ultrahigh-pressure orifice is provided downstream of the ultrahigh-pressure outlet port 21.

An improved method and apparatus for pressure processing a pumpable substance have been shown and described. From the foregoing, it will be appreciated that although embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit of the invention. Thus, the present invention is not limited to the embodiments described herein, but rather is defined by the claims which follow.