The separation of solids from water-containing fluids is performed with a minimum of steps and equipment, saving time and money, by passing a fluid containing high solids through a cavitation device that generates heat together with water-soluble polymeric flocculants, inorganic coagulants, surface active agents, filter aids, or any combination of them, and then to a solids separator without the need for flocculant preparation tanks and other expensive and time-consuming equipment. The process can be used very effectively for any fluid containing solids, including fluids with high solids content such as mine tailings, sewage, industrial waste, used drilling muds and other oil field fluids.
Typically, the separation of solids from liquids, in waste water treatment, sewage treatment, and other contaminated liquids such as used well drilling fluid (oil-based or water based), fluids containing materials known in the bitumen mining industry as fine clay solids, or mine ore waste still containing residual values, involves the use of coagulants and/or flocculants forming particles that are separated by settling in large tanks or that otherwise require extended time and expensive equipment. Flocculation with polymers can be very efficient, but a common preparation for the process requires aging a solution of perhaps 0.25 to 3% polymer by weight to assure that it is fully relaxed and hydrated. The solution must be not only mixed but aged, usually in a large tank; this is especially problematic in a working oil field where there are many other production matters to address. One approach in the prior art to reduce the time involved and the equipment needed is described in Adams et al U.S. Pat. No. 7,338,608 and its related U.S. Pat. No. 7,381,332 to Pena et al, describing the use of undissolved polymers having an average discrete phase particle size of less than about 10 microns, carried in a water-in-oil emulsion, for mixing with an oil-based used drilling mud to facilitate solids-liquid separation. Again, the emulsified treating agent must be prepared in advance of the process. Moreover, even with very small polymer particles, the important mixing step, using more or less conventional mixing apparatus, may not be adequate to fully hydrolyze or dissolve the polymer and, depending on the kind of mixer employed, may risk damaging the polymers. Many other processes using water-soluble polymers require special mixing or dissolving equipment as well as settling tanks, and are quite time-dependent. A more efficient way of separating solids from liquids, particularly liquids containing high concentrations of solids, and, more particularly, difficult to handle fluids such as fluid fine tailings, and such as used well drilling fluids containing solids and other constituents, is needed.
I pass a fluid containing particulate solids through a cavitation device that mixes and efficiently heats the fluid, together with a dry or partially dissolved flocculant, or a coagulant, a surfactant, a filter aid, or any combination thereof, and then to a solids separating device. Cavitation in the devices I use is generated by passing the fluid through a constricted area between a moving cylindrical rotor containing cavities and the substantially concentric interior surface of a housing.
The flocculants may be any of the well-known water-soluble anionic, cationic, or nonionic polymeric flocculants such as polyacrylamide, various cellulose derivatives such as hydroxyethylcellulose (HEC) carboxymethylhydroxyethylcellulose (CMHEC), natural organic polymers such as guar gum, xanthan gum and their derivatives, polymers and copolymers of 2-acrylamido-2-propane sulfonic acid (AMPS) or dimethyl diallyl ammonium chloride (DMDAAC) cationic polymers or copolymers, polyethyleneimine, various other modified polyacrylates and acrylamide copolymers, and the like. They may be either in dry or partially hydrated or partially or completely dissolved form. Coagulants are typically inorganic, such as ferric chloride or alum and may be either in dry or dissolved form. The coagulants and polymers may be fed directly to the cavitation device in solid form, without previous dissolution. If the polymers and/or coagulants are used in partially dissolved or partially hydrated form, they may be at least partially hydrated or dissolved in a separate cavitation device similar to the one to which the fluid to be treated is fed; thus two cavitation devices are connected in series.
The cavitation device is so efficient at mixing the polymers and coagulants, and other solids/liquid separating agents into the fluid that additional solvent (water) is not needed, so long as the treated fluid contains at least 5% water. Dry polymeric flocculants will be hydrated by water present in the fluid. That is, the product provided by the cavitation device is already in an advanced state of coagulation and flocculation or other conditioning when it emerges from the cavitation device together with the treated fluid, so that the usual large settling tanks for the flocculated solids are not necessary, although they may be used if desired. The product may be passed directly from the cavitation device to a solids/liquid separator such as a centrifuge, hydrocyclone, vacuum filter box, filter press, an inclined plate separator, or one or more filters and screens of various types to carry out the complete solids removal. Of course it is possible to utilize a settling tank as a solids/liquid separator but a major advantage of the invention is its ability to obviate the expense and time consumed by settling tanks.
In addition to, or instead of a flocculant or a coagulant, I may introduce a surfactant chosen to render the solid particles more hydrophilic—that is, water wet—which will aid in some forms of solids/liquid separation. Likewise, the cavitation device is excellent for mixing filter aids (for example, certain nano fibers) into difficult solids-containing fluids, to enhance the efficiency of filtration.
Thus, although it is contemplated that the invention will most commonly use polymeric flocculants, it is useful for rapidly and intimately integrating any agent into a solids-containing fluid for enhancing or augmenting solids/liquid separation in a solids/liquid separation device such as a hydrocyclone, a centrifuge, filter, inclined plate separator, or settling tank. I include all such agents in the term “solids/liquid separation enhancing agent.” Flocculants, coagulants, surfactants, and filter aids are all included in this term.
Unlike many other mixers, a cavitation device is able to handle fluids having a very high content of solids (up to 50% by weight) whose particle size may be as large as ¼ inch. Moreover, the extreme turbulence generated within it will hydrate the polymers, activate the coagulants, disperse the surfactants, and thoroughly distribute the filter aids. It is thus frequently not necessary to have more than one pass through the device before going directly to a centrifuge or other separator. The cavitation devices I use will be further described in the Detailed Description of the Invention.
Referring now to
Persons skilled in the art will recognize that the intimate mixing effected by the cavitation device in a very short time will enhance the efficiency of any flocculant, coagulant, surfactant or filter aid in bringing about the ultimate separation desired. But also, the cavitation device's ability to impart heat directly to the fluid (with little or no risk of scale buildup or other undesirable side effects) will accelerate the hydration and dissolution of the polymeric flocculants so that they can act very quickly to flocculate the solids. An increase in temperature of even a few degrees will benefit the hydrolysis process.
In
Fluid in conduit 25 may be recycled, as by conduit 28. Recycling can be regulated by valve 29. It should be understood that the movement of fluid anywhere in my system is effected by appropriate pumps, valves and controls.
Solids/liquid separation device 27 may be any effective solids/liquid separator such as a centrifuge, hydrocyclone, vacuum filter box, filter press, an inclined plate separator, or any of various filters and screens.
Rotating cavitation devices are known in the art of mixing and heating, but have not been used for high speed activation of undissolved polymers or coagulants directly in fluids containing solids, to make a fluid already in an advanced stage of flocculation or coagulation, ready for a separation step and not needing time-consuming settling or the use of other expensive equipment ahead of what normally would be the final separation step in a complicated process. The device of
It should be understood that by a flow-directed cavitation device is meant a cavitation device comprising a rotor including a plurality of cavities on its cylindrical surface, the rotor being within a housing having a conforming cylindrical surface sized to form a cavitation zone, the rotor including a flow director having an apex facing into the incoming fluid. But, as will be seen in
Referring now to
The thoroughly mixed fluid, now containing coagulated solids, proceeds through the outlet 34 of cavitation device A and is directed to the inlet 33 of cavitation device B. A conduit 37 connecting with unit B's inlet 33 may introduce a polymeric flocculant, as a further example of a solids/liquid separation enhancing agent, either in dry form or as a viscous solution; this mixture enters cavitation device B, is circulated through the area between the cylindrical surface of rotor 30 and the housing, and then exits through outlet 34 of unit B to conduit 38. The fluid now contains not only coagulated solids by means of the inorganic coagulants introduced through conduit 35, but also flocculated solids by means of the polymeric flocculant added through conduit 37. This mixture is taken to solids/liquid separator 39 which separates the coagulated and flocculated solids with or without a settling tank. As indicated elsewhere, the separator 39 may be a centrifuge or any other effective separator including a filter.
The particular order of addition of coagulants and polymers recited above is not essential—that is, a polymeric flocculant may be introduced in unit A and a coagulant in unit B; also one or more surfactants or filter aids may be introduced separately or along with either the coagulant or the flocculant.
Cavitation devices useful in the invention need not have the exact configuration shown in
Another useful design for the cavitation device is that of the present inventor's (together with Jeff Fair) U.S. patent application Ser. No. 14/715,160, filed May 18, 2015 titled “Cavitation Pump”; this application is hereby incorporated herein in its entirety. This cavitation device includes a cylindrical rotor as illustrated herein (without a flow director), but also has one or more discs, each having a hole in its center, on the inlet side of the rotor. These rotating discs provide a pumping action to enhance the flow and distribution of the fluid before it contacts the cavitation rotor; they do not impart significant shear or impact such as would a blade or an impeller, and accordingly will not damage the polymers.
Static mixing effects can be contributed by various baffles and in-line obstructions upstream of the cavitation rotor, and these are compatible with the present invention as are even more vigorous, powered mixing parts such as blades, paddles, or impellers, although they are generally not necessary and may damage the polymers. If used downstream of the cavitation rotor, the impact of a blade, paddle, or an impeller also may tend to undo the work of the coagulants and flocculants. My invention utilizes a cavitation rotor with or without such shearing or impacting ancillary mixing on either the inlet side of the outlet side of the rotor.
The viscometer, solids monitor, or other monitor of a physical characteristic of the liquid effluent from the solids/liquid separator generates a signal as a function of a physical characteristic of the effluent; this signal is used to control the feed of the coagulant or polymer. The cavitation device(s) may or may not include a flow director. Note also that
In addition to or instead of monitoring turbidity or viscosity in the liquid effluent (as by solids monitoring device 65), the process may be controlled by measuring the mass flow of the fluid entering the cavitation device and also that leaving the centrifuge or other solids/liquid separation device. The addition of solids/liquid separation enhancing agent can be regulated according to the density and rate of semi-solid cake formation and flow of liquid effluent, as determined by mass flow. Mass flow measurement involves the measurement of density, and density is a physical characteristic of the fluid I treat. Hence a mass flow meter generates a signal as a function of density, a physical characteristic of the fluid both before and after the cavitation device and before and after the solids/liquid separation device. As indicated elsewhere herein, monitoring such physical characteristics is a part of my process and can be used to regulate not only the addition of solids/liquid separation enhancing agent, but also the speed of rotation of the cavitation device, the flow rate of the fluid treated, and/or the operation of the liquid/solids separation device.
An inorganic coagulant can be in the form of solids or a suspension. The flocculant, usually a high-molecular weight water-soluble polymer, can be in dry form, or partially hydrated or otherwise in a concentrated solution; it need not be fully dissolved when introduced to the fluid to be treated. As persons skilled in the art are aware, complete solutions of high molecular weight polymers are quire dilute yet impart significant viscosity to the solution.
Many waste treatment and solids separation processes involve the addition of water at one or more points, either alone or as a solvent or carrier for other additives; the addition of water is not necessary with my method, with many benefits which will be apparent to persons skilled in the art. Major objectives of the flocculation treatment of fine fluid tailings, for example, are (1) to remove water trapped in the particles in order to avoid having to find other sources of water for the bitumen extraction process and (2) to accelerate the settling of the solids as an aid in the reclamation process. My invention clearly helps achieve both objectives. My invention is applicable to the processing of any industrial waste water containing solids, including waste fluids containing as little as 5% water and/or fluids containing large amounts of oil.
This Application claims the benefit of U.S. Provisional Application No. 62/254,273, filed Nov. 12, 2015, and entitled Rapid High Solids Separation, which is hereby incorporated by reference it its entirety.
Number | Date | Country | |
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62254273 | Nov 2015 | US |