Self-Cleaning Gas Buster Tank

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND
1. Field of Inventions

The field of this application and any resulting patent is methods and systems for processing gas, liquids, and solids removed from a wellbore after various downhole operations, such as fracking.

2. Description of Related Art

Various methods and systems have been proposed and utilized for processing gas, liquids, and solids removed from a wellbore after various downhole operations, including some of the methods and systems disclosed in the references appearing on the face of this patent. However, those methods and systems lack all the steps or features of the methods and systems covered by any patent claims below. As will be apparent to a person of ordinary skill in the art, any methods and systems covered by claims of the issued patent solve many of the problems that prior art methods and systems have failed to solve. Also, the methods and systems covered by at least some of the claims of this patent have benefits that could be surprising and unexpected to a person of ordinary skill in the art based on the prior art existing at the time of invention.

SUMMARY

One or more specific embodiments disclosed herein includes a gas buster tank system, comprising a self-cleaning tank, wherein the self-cleaning tank comprises a gas buster attachment port, one or more silos, wherein each of the one or more silos comprises a valve, one or more skimmers, an excess water port, excess water piping, a clean water exit port, a circulation inlet port, a circulation piping loop, one or more baffles, an exit line, wherein the exit line comprises one or more pipe arms and a discharge port, and a control system; a gas buster attachment, wherein the gas buster attachment is attached to the gas buster attachment port; a trailer; and a pump trailer, wherein the pump trailer comprises a first pump attached to the circulation inlet port and a second pump attached to the discharge port.

One or more specific embodiments disclosed herein includes a method of processing gas, liquids, and solids removed from a wellbore, comprising providing a gas buster tank system comprising a self-cleaning tank, wherein the self-cleaning tank comprises a gas buster attachment port, one or more silos, wherein each of the one or more silos comprises a valve, one or more skimmers, an excess water port, excess water piping, a clean water exit port, a circulation inlet port, a circulation piping loop, one or more baffles, an exit line, wherein the exit line comprises one or more pipe arms and a discharge port, and a control system, a gas buster attachment, wherein the gas buster attachment is attached to the gas buster attachment port, a trailer, and a pump trailer, wherein the pump trailer comprises a first pump attached to the circulation inlet port and a second pump attached to the discharge port; pumping materials from a wellbore, wherein the materials comprise sand, debris, water, and liquid chemicals; directing the materials to the gas buster attachment, wherein the gas buster attachment separates gas from the materials; directing the remaining materials to the self-cleaning tank, wherein the materials are deposited in the one or more silos; holding the chemicals in the materials back by employing the one or more skimmers while allowing the water in the materials to proceed through the excess water port, wherein the water exits the self-cleaning tank via the clean water exit port; attaching the first pump to the circulation inlet port, wherein water is pumped into the circulation piping loop, wherein it is sent through the perimeter jets and valve jets to mix with the sand in the one or more silos; actuating the one or more silo valves allowing the sand mixture to move into the one or more pipe arms and into the exit line; and attaching the second pump to the discharge port to pump the sand mixture out of the self-cleaning tank.

A method of transporting a sand mixture, comprising providing a source of water; digging a water pond; digging a sand mine; transporting water from the water well to the water pond, wherein the step of transporting the water from the water well to the water pond employs one or more water well pipes and one or more water well pumps; transporting the water from the water pond to a mixing silo, wherein the step of transporting the water from the water pond to the mixing silo employs one or more water pond pipes and one or more pond pumps, and further wherein the mixing silo comprises one or more silo jets, one or more mixing jets, a sand inlet, a silo shell, a cone bottom, and a discharge outlet; routing the water in the mixing silo using the one or more silo jets and the one or more mixing jets; screening sand from the sand mine using a mobile sand screener and separating the sand into one or more screened sand piles; transporting the screened sand from the one or more screened sand piles to the mixing silo; dumping screened sand into the sand inlet of the mixing silo, wherein the dumped sand collects within the silo shell and the cone bottom, wherein the one or more silo jets assist in moving the dumped sand downward to the cone bottom, and further wherein the one or more mixing jets send pressurized water at the dumped sand near the discharge outlet, wherein the sand mixture is created; transporting the sand mixture from the mixing silo to the one or more hydrocyclones using one or more sand mixture lines, wherein one or more sand mixture pumps maintain pressure within the one or more sand mixture lines; separating the sand mixture inside the one or more hydrocyclones into separated water and separated sand; transporting the separated water from the one or more hydrocyclones to a water storage unit; and dropping the separated sand into one or more storage silos.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a side view of an embodiment of a gas buster tank system.

FIG. 1B shows a perspective view of an embodiment of a pump trailer.

FIG. 2 shows a perspective view of an embodiment of a gas buster attachment.

FIG. 3 shows a side view of an embodiment of a self-cleaning tank.

FIG. 4A shows a perspective view of an embodiment of the inside of a silo.

FIG. 4B shows another view of an embodiment of the inside of a silo.

FIG. 4C shows a side view of an embodiment of the tops of silos.

FIG. 4D shows a perspective view of an embodiment of a silo.

FIG. 5 shows a perspective view of an embodiment of the bottom of a self-cleaning tank.

FIG. 6A shows an embodiment of a flow meter valve and clamps.

FIG. 6B shows an embodiment of a flow meter display.

FIG. 7A shows an embodiment of a self-cleaning tank with components of the control system.

FIG. 7B shows an embodiment of a self-cleaning tank with additional components of the control system.

FIG. 8A shows a back perspective view of an embodiment of a trailer.

FIG. 8B shows a side view of an embodiment of a trailer.

FIG. 8C shows an embodiment of a stabilizer for a trailer.

FIG. 9 shows a perspective view of an embodiment of a dewatering roll off gas buster.

FIG. 10 shows a perspective view of an alternative embodiment of a dewatering roll off gas buster.

FIG. 11 shows an embodiment of a sand mixture transportation system.

FIG. 12 shows an embodiment of a mixing silo.

FIG. 13 shows an alternative embodiment of a sand mixture transportation system.

FIG. 14 shows an alternative embodiment of a sand mixture transportation system with additional silos containing sand mixtures and water.

DETAILED DESCRIPTION
1. Introduction

A detailed description will now be provided. The purpose of this detailed description, which includes the drawings, is to satisfy the statutory requirements of 35 U.S.C. § 112. For example, the detailed description includes a description of the inventions defined by the claims and sufficient information that would enable a person having ordinary skill in the art to make and use the inventions. In the figures, like elements are generally indicated by like reference numerals regardless of the view or figure in which the elements appear. The figures are intended to assist the description and to provide a visual representation of certain aspects of the subject matter described herein. The figures are not all necessarily drawn to scale, nor do they show all the structural details of the systems, nor do they limit the scope of the claims.

Each of the appended claims defines a separate invention which, for infringement purposes, is recognized as including equivalents of the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention” will refer to the subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions, and examples, but the inventions are not limited to these specific embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions when the information in this patent is combined with available information and technology. Various terms as used herein are defined below, and the definitions should be adopted when construing the claims that include those terms, except to the extent a different meaning is given within the specification or in express representations to the Patent and Trademark Office (PTO). To the extent a term used in a claim is not defined below or in representations to the PTO, it should be given the broadest definition persons having skill in the art have given that term as reflected in any printed publication, dictionary, or issued patent.

2. Certain Specific Embodiments

Now, certain specific embodiments are described, which are by no means an exclusive description of the inventions. Other specific embodiments, including those referenced in the drawings, are encompassed by this application and any patent that issues therefrom.

One or more specific embodiments disclosed herein includes one or more silos wherein each of the one or more silos comprises a rectangular section and a V-shaped section.

One or more specific embodiments disclosed herein includes a clean water exit port comprising one or more butterfly valves.

One or more specific embodiments disclosed herein includes a circulation piping loop comprising a plurality of circulation valves, a plurality of perimeter jets, and a plurality of valve jets.

One or more specific embodiments disclosed herein includes a system comprising a flow meter system, wherein the flow meter system comprises an inlet pipe, a flow meter, Victaulic clamps, one or more flow valves, a flow meter display, and a return pipe.

One or more specific embodiments disclosed herein includes a method wherein the water exits the clean water exit port and proceeds to a plant to be treated and reused.

One or more specific embodiments disclosed herein includes a method wherein the circulation valves control the flow of water into the one or more silos.

One or more specific embodiments disclosed herein includes a method wherein the sand mixture is sent to a pit.

One or more specific embodiments disclosed herein includes a method wherein the sand mixture is sent to a dewatering roll off gas buster.

One or more specific embodiments disclosed herein includes a system comprising a plurality of silos.

One or more specific embodiments disclosed herein includes baffles that permit clean water to move between the plurality of silos.

One or more specific embodiments disclosed herein includes a method of transporting a sand mixture, comprising providing a source of water; digging a water pond; digging a sand mine; transporting water from the water well to the water pond, wherein the step of transporting the water from the water well to the water pond employs one or more water well pipes and one or more water well pumps; transporting the water from the water pond to a mixing silo, wherein the step of transporting the water from the water pond to the mixing silo employs one or more water pond pipes and one or more pond pumps, and further wherein the mixing silo comprises one or more silo jets, one or more mixing jets, a sand inlet, a silo shell, a cone bottom, and a discharge outlet; routing the water in the mixing silo using the one or more silo jets and the one or more mixing jets; screening sand from the sand mine using a mobile sand screener and separating the sand into one or more screened sand piles; transporting the screened sand from the one or more screened sand piles to the mixing silo; dumping screened sand into the sand inlet of the mixing silo, wherein the dumped sand collects within the silo shell and the cone bottom, wherein the one or more silo jets assist in moving the dumped sand downward to the cone bottom, and further wherein the one or more mixing jets send pressurized water at the dumped sand near the discharge outlet, wherein the sand mixture is created; transporting the sand mixture from the mixing silo to the one or more hydrocyclones using one or more sand mixture lines, wherein one or more sand mixture pumps maintain pressure within the one or more sand mixture lines; separating the sand mixture inside the one or more hydrocyclones into separated water and separated sand; transporting the separated water from the one or more hydrocyclones to a water storage unit; and dropping the separated sand into one or more storage silos.

One or more specific embodiments disclosed herein includes a plurality of screened sand piles.

One or more specific embodiments disclosed herein includes a plurality of screened sand piles wherein each of the plurality of screened sand piles contains screened sand of one particular size, wherein the size of the screened sand is determined by the mobile sand screener.

One or more specific embodiments disclosed herein includes the step of transporting of the screened sand from the one or more screened sand piles to the mixing silos uses one or more loaders.

One or more specific embodiments disclosed herein includes a step of transporting of the screened sand from the one or more screened sand piles to the mixing silos using one or more pipelines.

One or more specific embodiments disclosed herein includes a step of transporting of the screened sand from the one or more screened sand piles to the mixing silos using one or more loaders and one or more conveyors.

One or more specific embodiments disclosed herein includes one or more hydrocyclones are organized into a cascade.

One or more specific embodiments disclosed herein includes a source of water, wherein the source of water is a water well.

One or more specific embodiments disclosed herein includes a step of transporting the sand mixture comprising transporting the sand mixture to a pipeline prior to transportation of the sand mixture to the one or more hydrocyclones.

3. Specific Embodiments in the Figures

The drawings presented herein are for illustrative purposes only and are not intended to limit the scope of the claims. Rather, the drawings are intended to help enable one having ordinary skill in the art to make and use the claimed inventions.

Referring to FIGS. 1-8C, a specific embodiment, e.g., version or example, of a system for processing gas, liquids, and solids removed from a wellbore after various downhole operations, such as fracking, is illustrated. These figures may show features which may be found in various specific embodiments, including the embodiments shown in this specification and those not shown.

FIG. 1A shows an embodiment of a gas buster tank system 100. In embodiments, the gas buster tank system 100 may comprise a gas buster attachment 105 (see FIG. 2), a self-cleaning tank 110, a trailer 115, and a pump trailer 120. FIG. 1B shows an embodiment of the pump trailer 120.

FIG. 2 shows an embodiment of the gas buster attachment 105. In embodiments, the gas buster attachment 105 may comprise a double gas buster 125, one or more inlets 130, and one or more gas buster jacks 135. In embodiments, the one or more inlets 130 may comprise 15,000-PSI 2-inch inlets. Further, in embodiments the one or more inlets 130 may comprise two inlets. In embodiments, the gas buster attachment 105 may act as a separator to remove gas from fluids circulated in the wellbore. Additionally, the gas buster attachment 105 may be positioned on top of the self-cleaning tank 110 at a gas buster attachment port 140 in FIG. 1A.

FIG. 3 shows an embodiment of the self-cleaning tank 110. FIG. 4A shows an embodiment of the inside of one or more silos 145. FIG. 4B shows another view of an embodiment of the inside of one or more silos 145. FIG. 4C shows a side view of the tops of one or more silos 145. FIG. 4D shows a view of an embodiment of one or more silos 145. In embodiments, the self-cleaning tank 110 may comprise the gas buster attachment port 140 (see FIG. 1A), one or more silos 145, one or more skimmers 150, one or more excess water ports 155, excess water piping 160, a clean water exit port 165, a circulation inlet port 170, a circulation piping loop 175, one or more baffles 180, a flow meter system 185, an exit line 190, and a control system 195.

As also shown in FIG. 1A, in embodiments the gas buster attachment port 140 may be positioned on top of the self-cleaning tank 110. In embodiments, the gas buster attachment 105 may be installed into the gas buster attachment port 140.

In embodiments, each of the one or more silos 145 may comprise a rectangular section 200, a V-shaped section 205, and a silo valve 210. As shown in FIG. 4C, for example, in an embodiment of a single silo 145, the rectangular section 200 may be located higher than the V-shaped section 205. Thus, in embodiments the rectangular section 200 may form a cuboid, and the V-shaped section 205 may form an inverted pyramid. In embodiments, this arrangement may apply to a plurality of silos 145 as well. In embodiments, the one or more silos 145 may be positioned next to each other in series as shown in FIG. 3. Further, in embodiments the silo valve 210 for each of the one or more silos 145 may be located at the bottom of the inverted pyramid of the V-shaped section 205 as shown in FIG. 4A. In embodiments, the silo valve 210 may be opened and closed. In embodiments, the silo valve 210 may be hydraulically operated and controlled. In alternative embodiments, the rectangular section 200 may be in the shape of a square so that the section 200 may form a cube.

In embodiments, each of the one or more skimmers 150 may comprise a rectangular shape as shown in FIG. 4A. Alternatively, in embodiments each of the one or more skimmers 150 may comprise a square shape. In embodiments, each of the one or more skimmers 150 may be located higher than the one or more silos 145. Further, in embodiments the one or more skimmers 150 may be employed to remove chemicals from the sand mixture. In embodiments, the one or more skimmers 150 may descend into the sand mixture. In embodiments, any chemicals in the sand mixture may be lighter than any water in the sand mixture and float to the top of the sand mixture. Thus, in embodiments, the one or more skimmers 150 may descend sufficiently into the sand mixture to separate the chemicals from the sand mixture.

In embodiments, each of the one or more excess water ports 155 may comprise a screen to prevent and/or discourage debris from entering the excess water piping 160 as shown in FIG. 4B. In embodiments, one excess water port 155 may be located in each of the one or more silos 145. In embodiments, each of the one or more excess water ports 155 may be located at an appropriate height so that mainly clean water may enter the one or more excess water ports 155. In embodiments, each of the one or more excess water ports 155 may lead to the excess water piping 160. In embodiments, the excess water piping 160 may lead to the clean water exit port 165. In embodiments, the clean water exit port 165 may allow the clean excess water to be removed from the self-cleaning tank 110. In embodiments, the clean water exit port 165 may comprise one or more valves 215 as shown in FIG. 5. In embodiments, each of the one or more valves 215 may comprise a butterfly valve. In embodiments, each of the one or more valves 215 may be connected to a pump (not shown) by piping or hoses, wherein the clean water exiting the self-cleaning tank 110 may be sent back into the circulation piping loop 175.

In embodiments, the circulation inlet port 170 may lead to the circulation piping loop 175. In embodiments, the circulation piping loop 175 may lead to a plurality of perimeter jets 225 and a plurality of valve jets 230 as shown in FIGS. 4C and 4D. Further, in embodiments the circulation piping loop 175 may comprise a plurality of circulation valves 235, wherein the plurality of circulation valves 235 may control the flow of water into the one or more silos 145. In embodiments, the water that is sent into the one or more silos 145 through the perimeter jets 225 and the valve jets 230 may combine with the sand in the silos 145 to create a mixture that is movable, which may be referred to herein as the sand mixture. In embodiments, the circulation piping loop 175 may comprise pipes with diameters of 4 inches and 6 inches. In embodiments, the circulation valves 235 may comprise jet ball valves.

Returning to FIG. 4A, in embodiments, the one or more baffles 180 may be employed to distribute water between or among the silos 145 when there is a plurality of silos 145. In embodiments, each of the one or more baffles 180 may be positioned lower than the skimmers 150. In embodiments, each of the one or more baffles 180 may comprise a parallelogram shape with a longer base on top. In embodiments, each of the one or more baffles 180 may abut the V-shaped section 205 of one of the silos 145. In other embodiments, each of the one or more baffles 180 may form a part of the V-shaped section 205.

In embodiments, the flow meter system 185 may comprise an inlet pipe 235 (see FIG. 4B), a flow meter 240 (see FIG. 6A), one or more Victaulic clamps 245 (see FIG. 6A), one or more flow valves 250 (not shown), a flow meter display 255 (see FIG. 6B), and return pipe 260. In embodiments, the inlet pipe 235 may comprise a flow meter port 265. In embodiments, the flow meter port 265 may be lower than the excess water port 155. Further, in embodiments the flow meter port 265 may comprise a screen to prevent and/or discourage debris from entering the flow meter port 265. In embodiments, the flow meter display 255 may comprise wiring 270, wherein the wiring 270 may electrically connect the flow meter display 255 to the flow meter 240. In embodiments, the flow meter 240 may comprise a 4-inch flow meter. Further, in embodiments the inlet pipe 235 may allow for the sand mixture to proceed from the silos 145 to the flow meter 240, and the return pipe 260 may allow for the sand mixture to return to the silos 145.

Returning to FIG. 3, in embodiments, the exit line 190 may comprise one or more pipe arms 275 and a discharge port 280. In embodiments, each of the one or more pipe arms 275 may be connected to the exit line 190. In embodiments, each silo valve 210 may be connected to one of the one or more pipe arms 275. In embodiments, when each silo valve 210 is opened, the sand mixture may proceed through the silo valve 210, through the connected pipe arm 275, and into the exit line 190. In embodiments, the sand mixture may proceed down the exit line 190 until is leaves the self-cleaning tank 110 through the discharge port 280. In embodiments, upon leaving through the discharge port 280, the sand mixture may be pumped to a pit 370 or to a dewatering roll off gas buster 400, which is discussed below.

As shown in FIGS. 7A and 7B, in embodiments the control system 195 may comprise a hydraulic solenoid panel 285, one or more hydraulic solenoids 290, and a hydraulic valve control box 295. In embodiments, the hydraulic solenoid panel 285 may control the one or more hydraulic solenoids 290. In embodiments, the one or more hydraulic solenoids 290 may control the silo valves 210. In embodiments, the hydraulic valve control box 295 may be supported by a hydraulic valve controller platform 300.

Referring to FIGS. 8A, 8B, and 8C, in embodiments the trailer 115 may comprise one or more fuel tanks 305, one or more oil tanks 310, one or more landing gear housings 320, a hydraulic motor 325, one or more stabilizer jacks 330, a hydraulic power supply 340, and an engine control panel 345.

FIG. 2 shows an embodiment of the pump trailer 120. In embodiments, the pump trailer 120 may comprise a first pump 350 and a second pump 355. In embodiments, the first pump 350 may be attached to the circulation inlet port 170. In embodiments, the first pump 350 may pump water into the self-cleaning tank 110. In embodiments, the second pump 355 may be attached to the discharge port 280. In embodiments, the second pump 355 may pump the sand mixture to the pit 370 or to the dewatering roll off gas buster 400, which is discussed below.

Wellbores accumulate a great deal of debris and sand from various downhole operations including fracking. Thus, there are times when there is a need to clean out the debris and sand from the wellbore in order to continue operations and/or production. In embodiments, the debris and sand may be pumped out of the wellbore to the gas buster attachment 105, which is located on the top of the self-cleaning tank 110. In embodiments, there are various types of attachments that may be used depending on the needs and regulations in the area where the wellbore is located. In addition to debris and sand, the downhole materials may also include water and liquid chemicals. Further, the downhole materials may also include gas. In some instances, this gas may be vented to the atmosphere, or the gas may be captured depending on the applicable regulations. Different types of attachments may be employed depending, in part, on the applicable regulations. Thus, in embodiments the goal is to deal with the gas, liquids, and solids, such as sand and debris, being removed from the wellbore.

In embodiments, the gas buster attachment 105 may act as a separator to remove the gas from the fluids. As stated above, in embodiments, the gas may be vented to the atmosphere or captured depending on the applicable regulations. In embodiments, the remaining materials, including the sand and debris, may proceed to the self-cleaning tank 110.

In embodiments, the sand, debris, water, and liquid chemicals may be deposited into the one or more silos 145 of the self-cleaning tank 110. In embodiments, even in situations where the one or more silos 145 appear to be full of merely sand, there may in fact be a liquid component as well. In embodiments, the liquid component may comprise water and chemicals.

In embodiments, the one or more skimmers 150 may be employed to hold the chemicals back while the water may exit the one or more silos 145 through the excess water port 155. In embodiments, this water may proceed into the excess water piping 160 and exit the self-cleaning tank 110 through the clean water exit port 165. In embodiments, the water may be sent to a plant located near the self-cleaning tank 110 so that the water may be treated and reused in the gas buster tank system 100.

In embodiments, once the one or more silos 145 are filled with sand to a sufficient level, the first pump 350 of the pump trailer 120 may be attached to the circulation inlet port 170. In embodiments, the first pump 350 may send water into the gas buster tank system 100. More specifically, the water may be sent through the circulation inlet port 170 into the circulation piping loop 175, where it may then be sent into the one or more perimeter jets 225 and the valve jets 230 in order to mix with the sand in the one or more silos 145. In embodiments, the addition of the water into the one or more silos 145 may create a suspension of sand and water (“the sand mixture”), which may be movable. In embodiments, any excess water may be removed from the one or more silos 145 through the excess water port 155. In embodiments, the circulation valves 235 may be employed to control the flow of water into the one or more silos 145.

In embodiments, once the sand mixture is created, the silo valves 210 may be actuated to open in order to allow the sand mixture to move into the one or more pipe arms 275 and then into the exit line 190. In embodiments, the sand mixture may move through the exit line 190 toward the discharge port 280. In embodiments, the second pump 355 of the pump trailer 120 may be attached to the discharge port 280. In embodiments, the sand mixture may be pumped by the second pump 355 to a pit 370 or to the dewatering roll off gas buster 400. In embodiments, the dewatering roll off gas buster 400 may comprise a filter to hold the sand and allow clean water to be pumped back to the circulation inlet port 170 to be reused.

In embodiments, the one or more silos 145 may be positioned in series with the one or more baffles 180, which may allow clean water to be moved between and among the one or more silos 145 to account for nonuniformity in the water distribution between and among the one or more silos 145.

Additionally, in embodiments there may be a need to measure and monitor the amount of pressure of sand, debris, and other downhole materials entering the one or more silos 145. In embodiments, the flow meter system 185 may be employed to perform these measurements and allow for monitoring of the pressure. In embodiments, this measuring and monitoring may be needed in order to ensure that the maximum amount of materials allowed into the gas buster tank system 100 is not being exceeded. Otherwise, too much material may overburden the gas buster tank system 100 or even result in the production of oil and/or gas that may corrupt the gas buster tank system 100 such that the gas buster tank system 100 is inoperable. In embodiments, a certain amount of the sand mixture contained in the one or more silos 145 may be routed into the flow meter port 265 of the inlet pipe 235. In embodiments, the sand mixture may proceed past the flow meter 240 before returning to the one or more silos 145 via the return pipe 260. In embodiments, the flow meter 240 may be wired to the flow meter display 255, which may provide the operator with information on the amount of flow, and therefore the pressure, being introduced into the gas buster tank system 100 from the wellbore.

In embodiments, the gas buster tank system 100 may be controlled hydraulically. For example, in embodiments the silo valves 210, the circulation valves 235, and the flow valves 250 may all be controlled hydraulically. Further, in embodiments the one or more silos 145 may hold between 200,000 to 250,000 pounds of sand. In embodiments, the gas buster tank system 100 may comprise a central command post for the operator where the operator may also control the first pump 350, the second pump 355, and any other pumps associated with the gas buster tank system 100.

Generally, the above describes an improved process and system for processing gas, liquids, and solids removed from a wellbore after various downhole operations, such as fracking.

Additionally, alternative embodiments may further comprise a dewatering roll off gas buster 400. In embodiments, the dewatering roll off gas buster 400 may filter sand from oil and gas production fluid. In embodiments, the dewatering roll off gas buster 400 may be used to capture and separate large volumes of gas within drilling fluid. In embodiments, the dewatering roll off gas buster 400 may also eliminate sand from oil and production fluid. In embodiments, the dewatering roll off gas buster 400 may be connected in series to easily and efficiently filter oil and production fluid. In embodiments, the dewatering roll off gas buster 400 may comprise a main body 405, a filter 410, a plurality of ports 415, a plurality of gas busters 420, and a flange 425. In embodiments, the filter 410 may prevent solids from mixing into the production fluid or oil. In embodiments, the production fluid may circulate through the dewatering roll off gas buster 400 until the production fluid is clean.

In embodiments, the dewatering roll off gas buster 400 may be capable of hooking up high pressure lines (not shown) in series. In embodiments, the dewatering roll off gas buster 400 may filter out sand from oil and gas production fluid. In order to accomplish this, in embodiments the dewatering roll off gas buster 400 may comprise the main body 405, wherein the main body 405 may allow fluids to drip to the bottom of the dewatering roll off gas buster 400. Further, in embodiments the filter 410 may screen out any solids within the production fluid. Additionally, in embodiments the plurality of ports 415 may allow the dewatering roll off gas buster 400 to be connected in series with additional dewatering roll off gas busters 400. Further, in embodiments the plurality of gas busters 420 may create connections for the high-pressure lines (not shown). In embodiments, the flange 425 may create a section wherein the filtered solids can be removed from the dewatering roll off gas buster 400.

As shown in FIGS. 9-10, the dewatering roll off gas buster 400 may filter sand from oil and gas production fluid at a high volume. In embodiments, the dewatering roll off gas buster 400 may allow production fluid to flow through the filter 410 before leaving to external clean water tanks. In embodiments, the filter 410 may be positioned centrally within the main body 405 with the plurality of ports 415 fixed along the front side of the main body 405. In embodiments, the plurality of gas busters 420 may be positioned along the top side of the main body 405 and the flange 425 may be positioned along the bottom side of the main body 405.

In embodiments, the dewatering roll off gas buster 400 may hold the production fluid with the main body 405. In embodiments, the main body 405 may comprise a metal material with a rectangular shape and a V-shape at the bottom. In embodiments, this design may allow for the fluid to easily drip to the bottom of the dewatering roll off gas buster 400. In embodiments, the main body 405 may comprise a screen chamber 430 and a clean water section 435. In embodiments, the screen chamber 430 may be located along the rear side of the main body 405 as shown in FIG. 9. In embodiments, the screen chamber 430 may hold the production fluid before it is filtered through the filter 410. In embodiments, as the production fluid flows from the screen chamber 430, it may move into the clean water section 435 located in the front side of the main body 405. In embodiments, the main body 405 may comprise many various shapes and sizes, and the V-shape may be designed with various angles of steepness.

In embodiments, the filter 410 may connect with the main body 405 in a central section offset where the V-shape begins as seen in FIG. 9. In embodiments, the filter 410 may be designed with a rectangular shape. In embodiments, the filter 410 may comprise a screen with a small mesh size that may allow the filter 410 to filter out solids from the production fluid as it drips down within the main body 405. In embodiments, this design may allow for the production fluid to pass through the filter 410 at least one time to remove any unwanted solids from the production fluid or oil before it moves into the clean water section 435.

In embodiments, the plurality of ports 415 may be flanged and may be positioned on the front side of the main body 405 as seen in FIG. 10. In embodiments, the plurality of ports 415 may comprise a manifold 440 that may allow for external connections into the main body 405. In embodiments, this design may allow for three or four dewatering roll off gas busters 400 to be connected in series, which may increase the volume of fluid held within the main body 405. In embodiments, this may create an adjustable production fluid flow, linking up the clean water at the bottom of the main body 405. In embodiments, by placing multiple main bodies 405 in a row, more space may be created for multiple dewatering roll off gas busters 400 to be placed offset to increase the volume of fluid in the dewatering roll off gas busters 400.

In embodiments, the plurality of gas busters 420 may be positioned above the main body 405 and perpendicular to the sides of the main body 405 as seen in FIG. 9. In embodiments, the plurality of gas busters 420 may be externally connected to high-pressure lines. In embodiments, the plurality of gas busters 420 may allow for the production fluid to initially be introduced into the dewatering roll off gas buster 400. In embodiments, as the production fluid flows through the plurality of gas busters 420 it may be dispersed into the main body 405 before the filter 410 in order to allow solids to be removed from the production fluid.

In embodiments, the flange 425 may be positioned on the rear bottom of the main body 405 as seen in FIG. 9. In embodiments, the flange 425 may be a sealed flange door that creates an airtight seal on the rear bottom of the dewatering roll off gas buster 400. In embodiments, the flange 425 may be designed with a rectangular shape with a hinge that allows for the solids to be easily removed from the dewatering roll off gas buster 400 as they are filtered out from the production fluid.

FIG. 11 illustrates an embodiment of a sand mixture transportation system 600. In embodiments, the sand mixture transportation system 600 may comprise a water pond 605, a sand mine 610, a mixing silo 615, a plurality of pipelines 620, one or more hydrocyclones 625, one or more water storage units 630, one or more dewatering conveyors 635, and one or more worksite sand piles 640. Alternatively, the sand mixture transportation system 600 may comprise one or more worksite sand silos 642.

In embodiments, the water pond 605 may comprise a water well 645, one or more water pond pipes 650, and one or more pond pumps 655. In embodiments, the water well 645 may comprise one or more water well pipes 660 and one or more water well pumps 665. Further, in embodiments, the one or more water pond pipes 650 may connect the water pond 605 to the mixing silo 615 directly or indirectly. Additionally, in embodiments, the one or more pond pumps 655 may be attached to the one or more water pond pipes 650, wherein the one or more pond pumps 655 transport water to the mixing silo 615 directly or indirectly.

In embodiments, the sand mine 610 may comprise a mobile sand screener 670, one or more screened sand piles 675, and one or more loaders 680. Alternatively, the sand mine 610 may comprise one or more conveyors 682. Additionally, in embodiments, the mobile sand screener 670 may comprise multiple screen sizes.

As shown in FIG. 12 in more detail, in embodiments, the mixing silo 615 may comprise a sand inlet 685, a silo shell 690, a cone bottom 695, a discharge outlet 700, one or more silo jets 705, and one or more mixing jets 710. In alternative embodiments, the mixing silo 615 may comprise a filtered water inlet 810, a sand-water mixture inlet 786 from the well 780, a jet line inlet 805, a clean water return 800, and a filtered water inlet 810.

In embodiments, the one or more pipelines 620 may comprise one or more sand mixture lines 715, one or more sand mixture pumps 720, one or more clean water lines 725, one or more clean water pumps 730, one or more return lines 735, and one or more return line pumps 740. In embodiments, the one or more sand mixture lines 715 may receive the sand mixture from the discharge outlet 700 as one sized pipe and then branch into smaller sand mixture lines 715. In embodiments, a single sand mixture line 715 may branch into three smaller sand mixture lines 715. In embodiments, the one or more sand mixture pumps 720 may assist in transporting the sand mixture from the mixing silo 615 to the one or more hydrocyclones 625. In embodiments, the one or more clean water lines 725 may connect the water pond 605 to the one or more hydrocyclones 625. Alternatively, the one or more clean water lines 725 may connect the mixing silo 615 to the one or more hydrocyclones 625. In embodiments, the one or more clean water pumps 730 may assist in transporting water from the water pond 605, or the mixing silo 615, to the one or more hydrocyclones 625. In embodiments, the one or more return lines 735 may connect the one or more hydrocyclones 625 to the water pond 605, wherein the water is returned to the water pond 605. Additionally, in embodiments water may be collected from the one or more dewatering conveyors 635 and routed to the one or more return lines 735, wherein the water is then returned to the water pond 605.

In embodiments, the one or more hydrocyclones 625 may comprise one or more hydrocyclone pipes 745 and one or more hydrocyclone pumps 750. In embodiments, the one or more hydrocyclone pipes 745 may collect water separated from the sand mixture, and the one or more hydrocyclone pipes 745 may return water from the one or more hydrocyclones 625 to the one or more water storage units 630 or the one or more return lines 735. Additionally, in embodiments the one or more hydrocyclone pumps 750 may assist in transporting water from the one or more hydrocyclones 625 to the one or more water storage units 630 or the one or more return lines 735.

In embodiments, the one or more dewatering conveyors 635 may comprise a water collection unit 755, one or more dewatering pipes 760, and one or more dewatering pumps 765. In embodiments, the one or more dewatering pipes 760 may transport collected water, and the one or more dewatering pumps 765 may maintain pressure for collected water transportation.

The following is a discussion of an embodiment of a method of operation for the sand mixture transportation system 600. Initially, the water well 645 is drilled, the water pond 605 dug, and the sand mine 610 dug. Water may be transported from the water well 645 to the water pond 605. This may be accomplished by employing the one or more water well pipes 660 using the one or more water well pumps 665.

Next, water may then be transported from the water pond 605 to the mixing silo 615 via the one or more water pond pipes 660 using the one or more pond pumps 655. Once the water reaches the mixing silo 615, the water may be routed to the one or more silo jets 705 or the one or more mixing jets 710.

Sand may be screened by the mobile sand screener 670 into one or more screened sand piles 675. Each of the one or more screened sand piles 675 may contain sand of different sizes depending on the screen employed by the mobile sand screener 670. Sand from the one or more screened sand piles 675 may be transported to the mixing silo 615 via one or more loaders 680 or one or more conveyors 682 or both. Sand may then be deposited into the sand inlet 685 of the mixing silo 615 where the sand collects in the cone bottom 695 and the silo shell 690. As sand is deposited into the mixing silo 615, the one or more silo jets 705 positioned within the silo shell 690 may send pressurized jets of water around the silo shell 690 to help move the sand downward in the silo shell 690 towards the cone bottom 695.

Once sand gets close to the discharge outlet 700 of the cone bottom 695, one or more mixing jets 710 aimed at the discharge outlet 700 may send pressurized water at the sand near the discharge outlet 700 to create a sand mixture, which allows the sand to be transported via pipeline. The sand mixture then leaves the mixing silo 615 via the discharge outlet 700 and enters the one or more sand mixture lines 715, which transport the sand mixture to the one or more hydrocyclones 625, which may be organized into a cascade. One or more sand mixture pumps 720 may maintain pressure within the one or more sand mixture lines 715 to keep the sand mixture moving to the one or more hydrocyclones 625.

Once the sand mixture reaches the one or more hydrocyclones 625, the sand mixture may be separated within the one or more hydrocyclones 625 into water and sand. The water separated from the sand mixture in the one or more hydrocyclones 625 may enter the one or more hydrocyclone pipes 745. This water may be transported to the one or more water storage units 630 or to the one or more return lines 735. The one or more hydrocyclone pumps 750 may assist in transporting the water to the one or more water storage units 630 or to the one or more return lines 735.

The sand separated from the sand mixture in the one or more hydrocyclones 625 may be dropped onto the one or more dewatering conveyors 635. This separated sand may still contain some water, and the one or more dewatering conveyors 635 may assist in removing more water from the separated sand. The one or more dewatering conveyors 635 may transport the separated sand into one or more worksite sand piles 640 or one or more worksite sand silos 642 for use by the operator. The water removed by the one or more dewatering conveyors 635 may be collected in the water collection unit 755.

Returning to the separated water from the one or more hydrocyclones 625, this separated water may be transported to the one or more return lines 735, and transported back to the water pond 605 or to the mixing silo 615 via the one or more return lines 735. The one or more return line pumps 740 may assist this transportation by maintaining pressure within the one or more return lines 735. Alternatively, this separated water may be transported to the one or more water storage units 630.

Similarly, returning to the collected water in the water collection unit 755, this collected water may be transported from the water collection unit 755 via the one or more dewatering pipes 760 to the one or more return lines 735 or to the one or more water storage units 630. The one or more dewatering pumps 765 may be employed to maintain pressure within the one or more dewatering pipes 760 for transportation of this collected water. In embodiments, the system 600 may be connected to a downhole well 780, wherein the downhole well 780 may comprise one or more frac pumps 785.

FIG. 13 shows an alternative embodiment of the sand mixture transportation system 600 and the operations thereof. In embodiments, the first operation described below is for combining water and sand into a sand mixture to be used downhole with frac'ing operations. The first operation and the second operation described below may be performed in the order of first operation and then second operation—or second operation and then first operation. Alternatively, the first operation may be performed by itself, and the second operation may be performed by itself.

As for the first operation, in embodiments water may be supplied to the mixing silo 615. Initially, the water well 645 may be drilled, the water pond 605 may be dug, and the sand mine 610 may be dug. Water may then be transported from the water well 645 to the water pond 605. This may be done via the one or more water well pipes 660 using the one or more water well pumps 665. Water may then be transported from the water pond 605 to the mixing silo 615 via the one or more water pond pipes 650 using the one or more pond pumps 655. Once this water reaches the mixing silo 615, the water may be routed to the one or more silo jets 705 or the one or more mixing jets 710.

In embodiments, sand may be supplied to the mixing silo 615. The sand may be screened by the mobile sand screener 670 into one or more screened sand piles 675. Each of the screened sand piles 675 may contain sand of different sizes depending on the screen employed by the mobile sand screener 670. The sand from the screened sand piles 675 may be transported to the mixing silo 615 via one or more loaders 680 or one or more conveyers 682 or both. Next, the sand may be dumped into the sand inlet 685 of the mixing silo 615 where the sand may collect in the cone bottom 695 and the silo shell 690.

In embodiments, the water and sand may be mixed in the mixing silo 615 to create the sand mixture. As sand is dumped into the mixing silo 615, the one or more silo jets 705 positioned within the silo shell 690 may send pressurized jets of water around the silo shell 690 to help move the sand downward in the silo shell 690 towards the cone bottom 695. Once the sand gets close to the discharge outlet 700 of the cone bottom 695, one or more mixing jets 710 aimed at the discharge outlet 700 will send pressurized water at the sand near the discharge outlet 700 to create a sand mixture, which allows the sand to be transported via pipeline.

In embodiments, the sand mixture may be supplied to the well 780. The sand mixture leaves the mixing silo 615 via the discharge outlet 700 and enters the one or more sand mixture lines 715, which transport the sand mixture to the well 780, wherein the sand mixture may be used in frac'ing operations. One or more sand mixture pumps 720 may maintain pressure within the sand mixture lines 715 to keep the sand mixture moving to the well 780.

As for the second operation, in embodiments the downhole fluid 782 from the well 780 may be removed and separated into component parts so that the water and sand in the downhole fluid 782 may be recycled.

In embodiments, the downhole fluid 782 may be separated. As part of the cleaning out procedures of the well 780 prior to production, downhole fluid 782, which may comprise sand, water, and other components, is removed from the well 780 employing one or more downhole fluid pipelines 784. The downhole fluid 782 may be transported to one or more hydrocyclones 625, which may be organized into a cascade. Once the downhole fluid 782 reaches the one or more hydrocyclones 625, the downhole fluid 782 may be separated within the one or more hydrocyclones 625 into water and sand.

In embodiments, the water separated from the downhole fluid 782 in the one or more hydrocyclones 625 may enter the one or more hydrocyclone pipes 745. This separated water may be transported to the one or more water storage units 630 or to the one or more return lines 735. The one or more hydrocyclone pumps 750 may assist in transporting the separated water to the water storage units 630. This separated water may be transported back to the water pond 605 or to the mixing silo 615 via the one or more return lines 735. The one or more return line pumps 740 may assist this transportation by maintaining pressure within the one or more return lines 735. Alternatively, this separated water may be transported to the one or more water storage units 630.

In embodiments, the sand separated from the downhole fluid 782 in the one or more hydrocyclones 625 may be dropped onto the one or more dewatering conveyers 635. This separated sand may still contain some water, and the one or more dewatering conveyers 635 may assist in removing more water from the separated sand. The one or more dewatering conveyers 635 may transport the separated sand into one or more worksite sand piles 640 or one or more worksite sand silos 642 for use by the operator. The water removed by the one or more dewatering conveyers 635 may be collected in a water collection unit 755. The collected water in the water collection unit 755 may be transported from the water collection unit 755 via one or more dewatering pipes 760 to the one or more return lines 735 or to the one or more water storage units 630. The one or more dewatering pumps 765 may be employed to maintain pressure within the dewatering pipes 760 for transportation of this collected water.

FIG. 14 shows an alternative embodiment in which one or more worksite sand mixture silos 617 may be located near the well 780. The worksite sand mixture silos 617 may be connected to the mixing silo 615 by a long-distance pipeline 617, wherein the long-distance pipeline 617 may have several separate tributary pipelines, one for each of the worksite sand mixture silos 617. In embodiments, each of the worksite mixture silos 617 may contain a sand mixture with a specific size of sand. In embodiments, the worksite sand mixture silos 617 may be connected to the well 780 via one or more worksite pipelines 618. Additionally, in some embodiments, the sand mixture may be transported from the mixing silo 615 to one single worksite sand mixture silo 617. As the operator is using the sand mixture from this first worksite sand mixture silo 617, more sand mixture may be transported to the second worksite sand mixture silo 617. This process may be repeated for the additional worksite sand mixture silos 617 so that the operator always has a ready supply of the sand mixture near the well 780.

Further, in embodiments, one or more water cleaning silos 850 may also be positioned near the well 780. These water cleaning silos 850 may receive water from the water pond 605 via water silo pipelines 855 or from the hydrocyclones 625 via recycled water pipelines 860. Each of the water cleaning silos 850 may be connected to the worksite sand mixture silos 617 via worksite water mixing lines 865, and each of the water cleaning silos 850 may be connected to the well 780 via water cleaning well lines 870.

	Number	Date	Country
	63481546	Jan 2023	US
	63484687	Feb 2023	US

	Number	Date	Country
Parent	18397550	Dec 2023	US
Child	18944283		US

Self-Cleaning Gas Buster Tank

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (2)

Continuation in Parts (1)