Patent Application
20130168291
Not Applicable.
Not Applicable.
The drawings constitute a part of this specification and include exemplary embodiments of the Method, Apparatus, and System for Hydrocarbon recovery, which may be embodied in various forms. It is to be understood that in some instances, various aspects may be shown exaggerated or enlarged to facilitate an understanding of certain features. Therefore the drawings may not be to scale.
a) is an enlarged fragmentary view depicting one half of a process for hydrocarbon recovery, including the heating and solid removal portions.
b) is an enlarged fragmentary view depicting the other half of a process for hydrocarbon recovery, including the condensing portions of the process.
The instant invention concerns the removal of hydrocarbons from solid materials, such as from drill cuttings in drilling mud, which contain hydrocarbons. During rotary drilling operations, a volume of subterraneous material encountered is removed to provide the well bore. This material is generally referred to as drill cuttings. The cuttings are usually mixed with the drilling fluid used and any water or hydrocarbons encountered subterraneously during drilling operations.
In a typical drilling operation, the cuttings are separated from the drilling fluid by way of a shale shaker. The recovered drilling fluid is usually recirculated for further use in the drilling operation. The cuttings removed by the shale shaker are not only coated with but contain a mixture of water, hydrocarbons, and constituents of the drilling fluid. In some cases, the drilling fluid itself may contain hydrocarbons which contribute to the contamination of the drill cuttings.
The disposal of the drill cuttings and drilling mud is a complex environmental problem. Drill cuttings contain not only the residual drilling mud product that would contaminate the surrounding environment, but may also contain oil and other waste that is particularly hazardous to the environment, especially when drilling in a marine environment.
In addition to shakers, various methods for removing hydrocarbons and contaminants from drill cuttings and drilling fluids have been employed. However, the high costs and plant construction complexity, significant energy waste, limited safety, especially when operating offshore, and low efficiency have rendered such previous methods disadvantageous for extraction of hydrocarbons.
Accordingly, there exists a continuing need for methods and systems for extracting hydrocarbons from drill cuttings.
The methods of treating solids described herein may, in one embodiment, comprise delivering a contaminated energetic material to a heat source or heat chamber; subjecting the contaminated energetic material to a temperature sufficient to vaporize substantially all of the diesel fuel present in the contaminated energetic material; and condensing a portion of the diesel fuel from the contaminated energetic material. As used herein, the phrase “contaminated energetic material” refers to a material comprising hydrocarbon fuel and contaminants. As used herein, the term “heat source” refers to any known source capable of producing the required heat. Examples of heat sources which can be used include, but are not limited to, evaporators, rotary heaters, or any machines capable of deriving heat from the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. In a related example, the contaminated energetic material contains drill cuttings; and the step of subjecting the contaminated energetic material to a temperature sufficient enough to vaporize substantially all of the diesel fuel present is carried out by a calciner. In a related example, the heat source is a rotary heater. In a further related example, the heat source is a calciner. In a further example, the heat source is provided by fuel burners. In a further related example, the heat source is provided by electric heating. In a further related example, the heat source is provided by steam heating.
The methods of treating solids described herein may, for example, comprise delivering a first material to a first zone; heating the first material in the first zone thereby producing a second material in vapor form and a third material having a lower water and hydrocarbon content than the first material; delivering the second material to a second zone; and condensing at least a portion of the second material in the second zone thereby separating a fuel from the second material such that a fuel containing liquid and a fourth material are produced. In a related example, the heating of the first material in the first zone is accomplished by a heat source; a condenser in fluid communication with the heat source condenses at least a portion of the fuel in the second material. As used herein, the term “condenser” may refer to any device capable of condensing a vapor into liquid form. For example, the condensing may occur through direct condensing by a direct condenser including, but not limited to, scrubbers with spray nozzles, packed or frayed columns, or dispersion of the vapor within a column of cooler liquid. The condensing may also occur through indirect condensing by an indirect condenser including, but not limited to, a heat exchanger or heat trap.
In a further related example, fuel is condensed wherein the fuel is selected from gasoline, diesel, kerosene, jet fuel, and fuel oil.
In a still further related example, the heating of the first material in the first zone is accomplished by a rotary heater; a condenser in fluid communication with the rotary heater condenses at least a portion of the fuel; the largest component of the second material is water vapor; the solids content of the third material is higher than the solids content of the first material; and the fuel released from the second material contains hydrocarbons. In a further related example, the condenser is a scrubber condenser, in a related example, the condensing occurs by subjecting the vapors to cooler temperatures in a tank. In a related example, the heat source is a rotary heater. In a further related example, the heat source is a calciner. In a further example, the heat source is provided by fuel burners. In a further related example, the heat source is provided by electric heating. In a further related example, the heat source is provided by steam heating.
A solids treatment apparatus described herein may for example, comprise a first zone comprising one or more vessels, a first zone feed stream, a first zone first outlet stream, a first zone second outlet stream, and a heat source; a second zone comprising one or more vessels, a second zone first outlet stream, a second zone second outlet stream, and a condenser; wherein the first zone feed stream comprises a hydrocarbon fraction, a water fraction, and a solids fraction; and wherein the hydrocarbon fraction comprises a first hydrocarbon component having an atmospheric boiling point of between 250° F. and 1000° F. As used herein, the term “stream” encompasses the movement of both fluid and non-fluid material. In a related example, the first zone feed stream comprises drill cuttings; the first zone heat source is an indirect heat source arranged and configured to heat the accepted contents of the first zone feed stream; the first zone first output stream is in fluid communication with a first condenser; the first condenser circulates a liquid hydrocarbon scrubber stream; and the second one second outlet stream is in fluid communication with a second condenser. In a related example, the first zone feed stream comprises drill cuttings. The heat source may be any known source capable of producing the required heat. Examples of heat sources which can be used include, but are not limited to, evaporators, rotary heaters, calciners, or any machines capable of deriving heat from the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. In one embodiment, the heat source is an evaporator. In another embodiment, the heat source is a rotary heater. In another embodiment the heat source is a calciner. In a related example, the heat source comprises a rotary calciner. In another embodiment, the heat source is an indirect heat source arranged and configured to heat the accepted contents of the first zone feed stream. In another related example, the first condenser is a scrubber condenser. In another related example, the second condenser is a scrubber condenser. In another related example, the second zone first outlet is connected to a storage vessel. In another related example, the second zone second outlet stream is in fluid communication with a second condenser.
In another related example, the first zone feed stream comprises drill cuttings; the first zone first outlet stream is in fluid communication with a first condenser; the second one second outlet stream is in fluid communication with a second condenser; the first condenser circulates a liquid hydrocarbon scrubber condenser stream; the first zone further comprises a calciner; the first zone second outlet stream has a solids content that is higher in the solids content of the first zone feed stream; the second zone is arranged and configured to accept contents of the first zone first outlet stream; the second zone first outlet stream comprises condensed hydrocarbons; and the second one second outlet stream has a water vapor content that is higher than the water vapor content of the first zone first outlet stream. In a related example, the first zone second outlet stream is connected to a solids residue vessel. In a further related example, the solids residue vessel is connected to a vent. In a further related example, the solids residue vessel is connected to a solids residue scrubber, and material three discussed above is exposed to the solids residue scrubber. In a related example, the first condenser has a third outlet which is used to expel excess sludge particulates from the second material.
In another related example, the first condenser operates as an indirect condenser. In a further related example, the first condenser is a heat trap; wherein ambient temperatures cooler than the temperature of the vapors cool and condense the vapors. In another example, the condenser is any device capable of condensing the vapors.
The subject matter described herein is described with specificity to meet statutory requirements. However, the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Although the terms “step” and/or “block” or “module” etc. might be used herein to connote different components of methods or systems employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of heating the first zone feed stream, condensing the hydrocarbons, and condensing the water vapor. One skilled in the relevant art will recognize, however, that said heating and condensing may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
Referring to
The heat source 50 may take many forms including a rotary drum and rotary or other indirect-heated dryers. The supply of heat to the heat source 50 may include but is not limited to the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. The operating temperatures of heat source 50 may be selected based on a reference compound either theoretically or actually selected for removal, in one embodiment the operating temperatures may be greater than or equal to the boiling point of the first reference compound. In one embodiment, the heat source 50 is a calciner that uses the indirect heat of the calcining process to drive of all of the volatile components supplied by heat source feed line 45. In one embodiment, the calciner is set up to evaporate diesel hydrocarbons and has three temperature zone ranges: calciner zone one at 700° F. to 800° F., calciner zone two at 800° F. to 1000° F. and calciner zone three at 1000° F. Catchier zone one raises the temperature of the feed material to vaporize most of the water content, calciner zone two begins the vaporization of the hydrocarbon material, and calciner zone three removes any hydrocarbon compounds with a higher boiling point. These volatile components leave heat source 50 by vapor line 53. Solid residue from heat source 50 is removed by a conveyance system to solids residue vessel 80. This conveyance system is of a type capable of moving dry hot solids, including but not limited to screw, belt, or spiral conveyors. In one embodiment, this conveyance system includes a hood 55 to direct the solid residues, a horizontal auger 60 and inclined auger 70 which ultimately transport the solid residues from heat source 50 to solids residue vessel 80. In an alternate embodiment horizontal auger 60 is a trough auger and incline auger 70 is a tube auger.
Incline auger 70 conveys solid residue to solids residue vessel 80. Solids residue vessel 80 can be any vessel capable of housing solid residues conveyed from heat source 50. In one embodiment, a solids residue vessel vent 83 is attached to solids residue vessel 80. In one embodiment, solids residue vessel vent 83 is a fan driven vent that maintains a negative pressure to aid in air flow within solids residue vessel 80. In another embodiment, solids residue vessel vent 83 is a vent with a water scrubber. Solid residues are transported from solids residue vessel 80 to disposal 90 by solids residue conveyor 85. Solids residue conveyor 85 can include, but is not limited to, any of the following, alone, or in combination: roil off box, fork lift, truck or other form of transportation or conveyance for dry materials. From disposal 90, the solid residue can be transported to a landfill or combined with additional drill cuttings to solidify the drill cuttings for disposal. In one embodiment, the hydrocarbon content in the solid residue is in the range of 1500 to 5000 parts per million (ppm).
Referring now to
Referring now to an alternate embodiment in
A stream of un-condensed gas and vapors containing water vapor leaves diesel trap tank 220 through water vapor exhaust line 223 and travels to Water condenser system 280. Condensed liquids from diesel trap tank 220 are intermittently sprayed into water vapor exhaust line 223 to aid in the condensing process. Remaining water and condensable matter delivered through water vapor exhaust line 223 are condensed in water condenser system 280. Sludge and debris from the condensing process are removed from water condenser system 280 by way of sludge removal line from water condenser system 284 and condensed water line to water storage 286 carries the remaining condensed water from water condenser system 280 to water storage tank 300. Water storage tank 300 vents to the atmosphere through vent to atmosphere 304 and drains through water washout for disposal 306. Vent to atmosphere 304 contains a fan which creates a negative flow or suction which aids in pulling the volatile vapors released from heat source 50 through the system. Water from water storage tank 300 is recirculated by water supply line 310 and water condenser bypass line 312. A portion of the water traveling through water supply line 310 is routed to water condenser system 280 by way of water condenser liquid water feed line 314.
In one embodiment, contaminated solids are fed into the feed pit 30 at a rate of one ton per hour. The contaminated solids have a hydrocarbon concentration of 15% by weight, water concentration of 20% by weight, and solids content of 65%. In this example, the hydrocarbon is primarily diesel. The materials are pumped through feed line 35 to heat source 50 by concrete pump 40 so that the hydrocarbons can be vaporized and removed through evaporation. In one embodiment, heat source 50 is a rotary catchier which is separated into three heat zones that heat the material through the ambient temperatures it provides. Upon entering the rotary catchier of heat source 50, the solid materials reach calciner zone one and are subjected to an externally measured temperature range of 850° F. to 950° F. The temperatures of catchier zone one are sufficient to vaporize substantially all of the water in the contaminated solids. Continuing through the catchier, the materials arrive to catchier zone two and are subjected to an externally measured temperature range of 1000° F. to 1100° F., vaporizing most of the hydrocarbons in the contaminated solids. The remaining material continues down the calciner to calciner zone three where an externally measured temperature of 950° F. to 1000° F. is maintained to vaporize the final small amount of the hydrocarbon that, remains. The solid residues exit the calciner and are transported to solids residue vessel 80 via a conveyance system. Through this calcining process, all of the water is vaporized. Furthermore, substantially all of the hydrocarbon is vaporized. The hydrocarbon content is reduced from 15% by weight in the contaminated material to a range of 1500 to 4500 parts per million (PPM) in the solid residue. This marks a total removal of hydrocarbons in the range of 99.9965% to 99.9985%. From solids residue vessel 80, the cleansed solid residues are conveyed to disposal 90.
In order to adequately pull the volatile vapors from the calciner through the condensing zones, the entire operation is maintained at a negative pressure measured in a range of −02 to −0.6 inches of water column. The volatile vapors are transported from the heat source 50 calciner to diesel condenser 120 through vapor line 53. In one embodiment, diesel condenser 120 is a scrubber condenser which condenses the diesel vapors by spraying them with a stream of cooled vapors that are recirculated from a diesel storage tank 160. In an alternate embodiment, diesel is condensed indirectly via a heat exchanger instead of directly through contact with cool liquid diesel. From the diesel condenser, the condensed diesel is transported to the diesel storage tank. The condensed diesel is collected, stored, and eventually sold for reuse. The uncondensed water vapors exit diesel condenser and are transported to water condenser system via water vapor exhaust line 123. The water vapor system is a scrubber condenser which directly condenses the water vapors by spraying cooled liquid water into the vapors. The condensed water is transported to water storage tank 200. At least a portion of the cool condensed water in water storage tank 200 is recirculated into water condenser system to be sprayed by the scrubber condenser. Through this process a portion of the water is condensed and recovered while the balance of the water is vented to the atmosphere as saturated gas. In one embodiment, cooled liquids are sprayed into water exhaust line in order to aid in the condensing of the water vapor.
For the purpose of understanding the Method, System and Apparatus for Hydrocarbon Recovery, references are made in the text to exemplary embodiments of the Method, System and Apparatus for Hydrocarbon Recovery, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, designs, and equipment may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized should be or are in any single embodiment. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the method may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles disclosure. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.
Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change to the basic function to which it is related.
This application claims priority to the provisional U.S. patent application No. 61/580,757 entitled “Hydrocarbon Recovery,” filed Dec. 28, 2011.
| Number | Date | Country | |
|---|---|---|---|
| 61580757 | Dec 2011 | US |
