This disclosure concerns a system and method for purifying fluids, such as contaminated water, with certain disclosed embodiments specifically concerning purifying fracking wastewater.
The development of hydraulic fracturing technology (fracking) has aided United States' energy security. One side effect of its rapid expansion has been the production of vast quantities of highly toxic water, as much as 30,000 m3 per well from 1.7 million wells, as of 2015. Reinjecting this water in the well risks eventual seepage into freshwater reservoirs and has raised major environmental and health concerns. Reliable data on the costs and energy consumption of the treatment and disposal of this contaminated water are scarce. Notwithstanding the lack of reliable data, at least four major problems have been identified for treating fracking water:
1. The variety of the chemicals: The composition of fracking wastewater is location-dependent and may contain a large and varying number and quantity of chemicals, many of which are absorbed underground. Current water treatment technologies focus on treatment of low-salinity and low-toxicity water and removal of specific chemicals. They fail to handle water with either a wide range or high concentration of contaminants.
2. Portability: About half of all fracking wastewater is produced in the first few weeks of a well's approximately 10-year life. Current contaminated water purification and desalination technologies are designed for massive stationary plants. It is cost-prohibitive to build a suitable treatment facility for only a few weeks of high throughput.
3. Energy consumption and cost: Today's most efficient purification and desalination processes use 3-5 times the minimum required energy. That is greatly amplified when the water in question is of unknown composition, is toxic, and has very high total dissolved chemicals (TDC). In a cost-sensitive industry, handling this water can differentiate an economical system and process from an uneconomical one.
4. Fouling: All membrane-based, as well as some thermal processes, involve contaminated water and/or saline water interacting with porous materials. By design, the solutes accumulate on the porous materials, be they membranes or packed beds. A solution is needed that substantially eliminates interactions between contaminated water and high-surface area porous materials to vastly decrease the rate of unwanted solute accumulation.
Tables 1 and 2 below illustrate the varied and complex composition of typical fracking wastewater.
A variety of water desalination systems are commercially available. However, these systems are all solely intended for processing sea and brackish water and are impractical for reclaiming fracking wastewater for the aforementioned reasons.
Disclosed embodiments of the present system and process address these challenges by taking advantage of water contaminants, operating tightly around the water saturation point, and avoiding any membrane or packed bed. The disclosed invention is largely agnostic of the feed contaminated water source and composition. Accordingly, an important beneficial feature of the present invention is that it can be used to process any contaminated water composition without regard to composition. Some or all contaminants in a particular contaminated water composition may form azeotropes.
Certain disclosed embodiments concern modular, portable, and scalable technology to extract clean water from any contaminated water, with hydraulic fracturing (fracking) wastewater being one particular example. Disclosed embodiments can utilize any heat source to drive the process, although certain particular embodiments use low-grade heat to reduce or eliminate the need for electrical power consumption, providing a purification process that operates less expensively than known processes.
Certain disclosed embodiments use humidification-dehumidification in a swirling nozzle or nozzle-demister, combined with an in-line demister, to reclaim clean water or grey water from contaminated water. The swirling nozzle or nozzle-demister may be thermally actuated to reduce power consumption and enable a more energy-efficient process. Disclosed embodiments take advantage of the properties and behavior of water contaminants, as well as the thermodynamics of humid streams, to efficiently separate and condense water vapor.
One embodiment of a disclosed system comprises: an inlet to receive an aqueous composition comprising water and undesired materials, generally referred to herein as contaminated water, such as wastewater, with one example being fracking wastewater; a heat source configured to heat the contaminated water to produce contaminated water vapor; a nozzle-demister having a gas inlet configured to admit dry gas to the nozzle-demister; a contaminated water vapor inlet; and a condenser/separator, such as a heat exchanger or a demister. The nozzle-demister typically also includes a clean water conduit for receiving clean water from the clean water outlet, and a fluid waste conduit for receiving fluid waste from a fluid waste outlet. The system can be configured, such that the gas inlet, the contaminated water vapor inlet, or both, are injected tangentially into the system to create a swirling fluid flow. Alternatively, or additionally, the nozzle demister may further comprise a vortex generator to produce a rotating or swirling heated gas. The vortex generator may include one or more stationary or annular fins to induce swirl. A swirling motion also may be induced before the flow enters the nozzle. Gas enters the nozzle-demister through a gas inlet port and flows past the vortex generator, which directs the gas into a fast-moving gas jet. Contaminated water can be supplied to the contaminated water tank through the contaminated water inlet or inlets. In certain embodiments, additional heat is added to the contaminated water to produce contaminated water vapor. The contaminated water vapor can be introduced to the nozzle demister through a contaminated water vapor inlet where it mixes with the fast-moving gas jet, yielding a humid stream of gas, water vapor, and waste vapor. In certain embodiments, the humid stream of gas, water vapor, and waste vapor can then be separated by a condenser/separator, such as a heat exchanger or demister, which causes the water to condense out of the humid stream. Condensed water can then be collected at a clean water outlet and directed into the clean water conduit. In certain embodiments, the remaining gas and waste vapor passes through the system and is collected at a fluid waste outlet, from which it flows into a fluid waste conduit.
Yet another disclosed aspect of the invention concerns a system for purifying contaminated water, particularly fracking wastewater, comprising a thermally-actuated swirling nozzle or nozzle-demister. Generally, the system can include a contaminated water tank, at least one contaminated water inlet, a thermally-actuated nozzle-demister, a clean water conduit, and a fluid waste conduit. In certain embodiments, gas enters the thermally-actuated nozzle-demister through a gas inlet port. The gas can be heated, causing it to accelerate within the nozzle-demister. The gas flows past a vortex generator having one or more stationary vanes, which direct the gas into a fast-moving gas jet. In some embodiments, contaminated water can be supplied to the contaminated water tank through the contaminated water inlet or inlets. The contaminated water tank may have a sludge drain to facilitate the removal of dense, solid wastes. Additional heat can be added to the contaminated water to produce contaminated water vapor. The contaminated water vapor can be introduced to the thermally-actuated nozzle-demister through a contaminated water vapor inlet and mixed with the fast-moving gas jet. In certain embodiments, the fast-moving gas jet with entrained contaminated water vapor flows into a converging nozzle that concentrates the flow of the fast-moving jet, increases the jet's speed and reduces its temperature. The temperature of the fast-moving gas jet with entrained contaminated water vapor can be reduced to a temperature below the saturation temperature of the gas to condense water vapor entrained in the gas, yielding a misty mixture of gas, waste vapor, and fine, condensed droplets of clean water. In certain embodiments, an in-line demister separates the fine, condensed droplets of clean water from the mixture of gas and waste vapor. The condensed droplets are collected at a clean water outlet and flow into a clean water conduit. In certain embodiments, the remaining mixture of gas and waste vapor flows through the in-line demister and into a diverging nozzle. In the diverging nozzle, the waste vapor may condense or partially condense, yielding a mixture of gas, gaseous waste, and liquid waste, which can be collected at a fluid waste outlet. The mixture of gas, gaseous waste, and liquid waste flow into a fluid waste conduit.
In certain embodiments, condensation heat from the condensation of water droplets in the converging nozzle can be recovered and transferred to the contaminated water. This may be accomplished, for example, by positioning a heat exchanger between one or more of the contaminated water inlets and the converging nozzle.
In certain embodiments, excess heat from the clean water and the fluid waste can be recovered and transferred to the contaminated water in the contaminated water tank. This may be accomplished, for example, by positioning a heat exchanger between the clean water conduit and the contaminated water tank and/or between the fluid waste conduit and the contaminated water tank.
In certain embodiments, gas supplied to the nozzle-demister may be air, which may, at various sections of the system, also be dry. At various sections of the system, the air may have a first velocity, V1, approaching but greater than 0 m/s. At other sections of the system, the air may have a second velocity, V2, greater than the V1.
Contaminated water that may be processed using various disclosed system embodiments and method for their use may have any of a variety of contaminants, in any and all combinations. Examples of typical contaminants include, without limitation, sand, acids, clay stabilizers, surfactants, ammonia, benzene, toluene, ethylene glycol, 2-butoxy-ethanol, chlorides, sulfates, sodium, boron, strontium, barium, and any and all combinations thereof.
Other disclosed aspects of the invention concern a method for using disclosed embodiments of a contaminated water purification device. One generalized embodiment of the method involves bringing hot, low-humidity gas into contact with contaminated water to form humid gas with entrained water vapor, waste vapor, and vaporized contaminants. The method can further involve accelerating the humid gas with entrained vapors and imparting an angular velocity to enhance the mixing of the gas and vapors. In certain embodiments, the method can further involve reducing the temperature of the humid gas with entrained water vapor, waste vapor, and vaporized contaminants below the saturation temperature of water to condense water from the humid gas, which can be collected while leaving the gas and waste vapor behind.
Yet another disclosed aspect of the invention concerns a method for using a disclosed water purification system comprising a thermally-actuated swirling nozzle or nozzle-demister. The method generally involves supplying contaminated water to a contaminated water tank through one or more contaminated water inlets. Gas having a first velocity is supplied to a nozzle-demister through a gas inlet and accelerated to a second velocity greater than the first velocity. In certain embodiments, the acceleration can be caused by heating the gas within the nozzle-demister. The accelerated gas is directed past a vortex generator to produce a high-speed gas jet. In certain embodiments, the method may further involve supplying contaminated water vapor from the contaminated water tank to the nozzle-demister through a contaminated water vapor inlet. Contaminated water vapor can be entrained in the high-speed gas jet to yield a humid gas-contaminated water stream having entrained water and waste vapors. In certain embodiments, the method can further involve supplying the humid gas-contaminated water stream to a converging nozzle, which increases the velocity and decreases the temperature of the humid gas-contaminated water stream. Reducing the temperature of the gas-contaminated water stream condenses clean water droplets, which may be separated from the gas and waste vapor in the humid stream with an inline-demister. The separated water droplets can then be collected at a clean water outlet in the nozzle-demister and supplied to a clean water conduit. In certain embodiments, the method further involves supplying the remaining gas and waste vapor stream to a diverging nozzle, which decreases the velocity of the gas and waste vapor stream and allows the waste vapor to condense or partially condense. The mixture of gas, gaseous waste, and/or liquid waste exits the nozzle-demister through a fluid waste outlet and passes to a fluid waste conduit.
In certain disclosed embodiments, the method further involves recapturing the heat from the condensation of the clean water droplets within the converging nozzle. This recaptured heat can be supplied to the contaminated water in the contaminated water inlets. The method can also further involve recapturing excess heat from the clean water conduit and the fluid waste conduit. This heat can be supplied to the contaminated water in the contaminated water tank.
In certain embodiments, the gas supplied to the nozzle-demister may be air, which may at various sections of the system also be dry. At various sections of the system, the air may have a first velocity approaching 0 m/s. At other sections of the apparatus, the air may have a second velocity greater than the first.
The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
The following detailed description is provided with reference to the drawings and embodiments described herein. The drawings are illustrative and are not intended to limit the scope of the disclosure.
The following explanations of terms and abbreviations are provided to better describe the present disclosure and to guide those of ordinary skill in the art in the practice of the present disclosure. As used herein, “comprising” means “including” and the singular forms “a” or “an” or “the” include plural references unless the context clearly dictates otherwise. The term “or” refers to a single element of stated alternative elements or a combination of two or more elements, unless the context clearly indicates otherwise.
Unless explained otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and materials are described below. The materials, methods, and examples are illustrative only and not intended to be limiting. Other features of the disclosure are apparent from the following detailed description and the claims.
The disclosure of numerical ranges refers to each discrete point within the range, inclusive of endpoints, unless otherwise noted. Unless otherwise indicated, all numbers expressing quantities of components, molecular weights, percentages, temperatures, times, and so forth, as used in the specification or claims are to be understood as being modified by the term “about.” Accordingly, unless otherwise implicitly or explicitly indicated, or unless the context is properly understood by a person of ordinary skill in the art to have a more definitive construction, the numerical parameters set forth are approximations that may depend on the desired properties sought and/or limits of detection under standard test conditions/methods as known to those of ordinary skill in the art. When directly and explicitly distinguishing embodiments from discussed prior art, the embodiment numbers are not approximates unless the word “about” is recited.
Azeotrope refers to a mixture of two liquids having a substantially constant boiling point and composition during an evaporation process, such as distillation.
Described herein are embodiments of a system for purifying contaminated water, particularly wastewater from a fracking process. Also disclosed herein are embodiments of a method for using the disclosed system.
The following example is provided to illustrate certain aspects of disclosed embodiments for producing clean water. A person of ordinary skill in the art will appreciate that the scope of the present invention is not limited to the particular features of this example.
In one example of a method for producing 1 kg of clean water by the purification of contaminated water, 3 kg of dry air having a first velocity near 0 m/s and a first temperature of 25° C. enters the nozzle demister. Heat is supplied to the dry air, heating it to 85° C. and accelerating it to 25 m/s as it passes a vortex generator that directs the air into a high-speed air jet. 1.1 kg of contaminated water vapor at or near a saturation temperature of 109° C. and having a velocity near 0 m/s is added to the high-speed air jet, yielding 4.1 kg of humid air-contaminated water vapor with a temperature of 95° C., a saturation temperature of 90° C., and a velocity of 18 m/s. The humid air-contaminated water vapor passes into the convergence nozzle and the temperature drops to 86° C. as the vapor accelerates, which is below the saturation temperature of the humid air-contaminated water vapor. 1 kg of water condenses into droplets having a temperature of 86° C., the water is removed from the humid air-contaminated water vapor by an in-line demister, and is collected at the clean water outlet. Clean water collected at the clean water outlet passes into the clean water conduit at 86° C., and excess heat is rejected to the contaminated water reservoir. Condensation heat is transferred from the convergence nozzle to feed contaminated water at 25° C., raising the feed contaminated water temperature before it is added to the contaminated water reservoir. Remaining 3.1 kg of air-contaminated water vapor, having a temperature of 86° C. and a velocity of 148 m/s, passes through the in-line demister and into the divergence nozzle, where it heats to 97° C. and slows to a velocity of 10 m/s. Waste vapor begins to condense into liquid waste, and the mixture of air, gaseous waste, and liquid waste is collected at the air and waste outlet. Excess heat from the mixture of air, gaseous waste, and liquid waste is rejected to the contaminated water reservoir.
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.
This application claims the benefit of the earlier filing date of U.S. provisional patent application No. 62/882,970, filed on Aug. 5, 2019, which is incorporated herein by reference in its entirety.
This invention was made with government support under Award No. DE-AR0001000, awarded by the United States Department of Energy. The government has certain rights in the invention.
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20210039009 A1 | Feb 2021 | US |
Number | Date | Country | |
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62882970 | Aug 2019 | US |