U.S. patent application number 12/228670 was filed with the patent office on 2010-02-18 for drill cuttings treatment systems.
Invention is credited to George Alexander Burnett, Brian Bender Madsen, Dale Alton Pierce.
Application Number | 20100038143 12/228670 |
Document ID | / |
Family ID | 41152171 |
Filed Date | 2010-02-18 |
United States Patent
Application |
20100038143 |
Kind Code |
A1 |
Burnett; George Alexander ;
et al. |
February 18, 2010 |
Drill cuttings treatment systems
Abstract
A thermal treatment system for receiving liquid from drill
cuttings material in which a metering screw system feeds material
to a vessel of a thermal reactor. This abstract is provided to
comply with the rules requiring an abstract which will allow a
searcher or other reader to quickly ascertain the subject matter of
the technical disclosure and is submitted with the understanding
that it will not be used to interpret or limit the scope or meaning
of the claims, 37 C.F.R. 1.72(b).
Inventors: |
Burnett; George Alexander;
(Aberdeen, GB) ; Madsen; Brian Bender; (Nyborg,
DK) ; Pierce; Dale Alton; (The Woodlands,
TX) |
Correspondence
Address: |
National Oilwell Varco
c/o Williams, Morgan & Amerson, 10333 Richmond, Suite 1100
Houston
TX
77042
US
|
Family ID: |
41152171 |
Appl. No.: |
12/228670 |
Filed: |
August 14, 2008 |
Current U.S.
Class: |
175/209 |
Current CPC
Class: |
B09B 3/00 20130101; B09C
1/06 20130101; E21B 21/066 20130101 |
Class at
Publication: |
175/209 |
International
Class: |
E21B 21/06 20060101
E21B021/06 |
Claims
1. Each invention disclosed herein.
2. A thermal treatment system for removing liquid from drill
cuttings material, the thermal treatment system having a metering
screw apparatus for receiving and feeding drill cuttings material
to a reactor system, including apparatus and a control system for
controlling the metering screw apparatus and for insuring that the
metering screw apparatus is maintained full or nearly full of
material and/or for controlling the mass flow rate into a reactor
of the thermal treatment system by adjusting the speed of the
metering screw apparatus.
3. A thermal treatment system for treating drill cuttings material
in which apparatus and a control system are provided to maintain an
airlock at a material inlet to a thermal reactor of the thermal
treatment system by maintaining a desired amount of material in a
container above a feeder system that feeds material into the
thermal reactor.
4. The system of claim 3 wherein apparatus and a control system
provide for control of temperature in the thermal reactor by
controlling the mass flow rate of material into the thermal reactor
by controlling a metering screw system that feeds material into the
thermal reactor.
5. The system of claim 3 wherein the thermal treatment system has
an engine that rotates friction elements within a reactor vessel of
the thermal reactor and performance of said engine is optimized by
controlling a metering screw system that feeds material into the
reactor vessel (e.g., based on sensed speed in rpm's of said
engine).
6. The system of claim 3 including at least one load cell apparatus
or two load cell apparatuses beneath the container to provide
information to indicate an amount of material in the container.
7. The system of claim 3 including at least one load cell apparatus
or two load cell apparatuses beneath the thermal reactor to provide
information to assist in control of the discharge rate of solids
from the thermal reactor.
8. The system of claim 6 wherein a control system controls the
amount of material in the thermal reactor.
9. The system of claim 8 wherein the control system controls said
amount to maintain an airlock at the discharge from the thermal
reactor.
10. The system of claim 3 including apparatus and a control system
to maintain a desired temperature in the thermal reactor.
11. The system of claim 3 including a first feed of drilling
cuttings material into the container.
12. The system of claim 11 wherein the first feed is from drilling
operations solids control equipment which is at least one of shale
shaker, centrifuge, vortex dryer, and hydrocyclone.
13. The system of claim 11 wherein the first feed is from a
cuttings conveyance system.
14. The system of claim 11 including a secondary feed into the
container from a cuttings storage or transfer system.
15. The system of claim 1 wherein apparatus and a control system
provide for control of temperature in the thermal reactor by
controlling the mass flow rate of material into the thermal reactor
by controlling a metering screw system that feeds material into the
thermal reactor.
16. The system of claim 1 wherein the thermal treatment system has
an engine that rotates friction elements within a reactor vessel of
the thermal reactor and performance of said engine is optimized by
controlling a metering screw system that feeds material into the
reactor vessel (e.g., based on sensed speed in rpm's of said
engine).
17. The system of claim 1 including at least one load cell
apparatus or two load cell apparatuses beneath the container to
provide information to indicate an amount of material in the
container.
18. The system of claim 1 wherein a control system controls the
amount of material in the thermal reactor.
19. The system of claim 1 including apparatus and a control system
to maintain a desired temperature in the thermal reactor.
20. The system of claim 1 including a first feed of drilling
cuttings material into the container, wherein the first feed is
from drilling operations solids control equipment which is at least
one of shale shaker, centrifuge, vortex dryer, and hydrocyclone,
and including a secondary feed into the container from a cuttings
storage or transfer system.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field Of The Invention
[0002] This invention is directed to systems and methods for
separating hydrocarbons from drill cuttings from a wellbore being
drilled in the earth; and, in certain particular aspects, to such
systems and methods which employ a screw feed apparatus for feeding
drilled cuttings material to a thermal reactor.
[0003] 2. Description of Related Art
[0004] The prior art discloses a variety of systems and methods for
the thermal treatment of material and thermal treatment of drilled
cuttings material. For example, and not by way of limitation, the
following U.S. patents present exemplary material treatment
systems: U.S. Pat. Nos. 5,914,027; 5,724,751; and 6,165,349--all
these patents incorporated fully herein for all purposes.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention, in certain aspects, discloses a
thermal treatment system for removing liquid from drill cuttings
material, the thermal treatment system having a metering screw
apparatus for receiving and feeding drill cuttings material to a
reactor system, including apparatus and a control system for
controlling the metering screw apparatus and for insuring that the
metering screw apparatus is maintained full or nearly full of
material and/or for controlling the mass flow rate into a reactor
of the thermal treatment system by adjusting the speed of the
metering screw apparatus.
[0006] The present invention, in certain aspects, discloses a
thermal treatment system for treating drill cuttings material in
which apparatus and a control system are provided to maintain an
airlock at a material inlet to a thermal reactor of the thermal
treatment system by maintaining a desired amount of material in a
container above a feeder system that feeds material into the
thermal reactor. In one aspect in such a system apparatus and a
control system provide for control of temperature in the thermal
reactor by controlling the mass flow rate of material into the
thermal reactor by controlling a metering screw system that feeds
material into the thermal reactor.
[0007] Accordingly, the present invention includes features and
advantages which are believed to enable it to advance thermal drill
cuttings treatment technology. Characteristics and advantages of
the present invention described above and additional features and
benefits will be readily apparent to those skilled in the art upon
consideration of the following detailed description of preferred
embodiments and referring to the accompanying drawings.
[0008] Certain embodiments of this invention are not limited to any
particular individual feature disclosed here, but include
combinations of them distinguished from the prior art in their
structures, functions, and/or results achieved. Features of the
invention have been broadly described so that the detailed
descriptions that follow may be better understood, and in order
that the contributions of this invention to the arts may be better
appreciated. There are, of course, additional aspects of the
invention described below and which may be included in the subject
matter of the claims to this invention. Those skilled in the art
who have the benefit of this invention, its teachings, and
suggestions will appreciate that the conceptions of this disclosure
may be used as a creative basis for designing other structures,
methods and systems for carrying out and practicing the present
invention. The claims of this invention are to be read to include
any legally equivalent devices or methods which do not depart from
the spirit and scope of the present invention.
[0009] What follows are some of, but not all, the objects of this
invention. In addition to the specific objects stated below for at
least certain preferred embodiments of the invention, there are
other objects and purposes which will be readily apparent to one of
skill in this art who has the benefit of this invention's teachings
and disclosures. It is, therefore, an object of at least certain
preferred embodiments of the present invention to provide:
[0010] New, useful, unique, efficient, non-obvious thermal drilled
cuttings treatment systems; and
[0011] Such systems with a screw feed for feeding drilled cuttings
material to a thermal reactor.
[0012] The present invention recognizes and addresses the problems
and needs in this area and provides a solution to those problems
and a satisfactory meeting of those needs in its various possible
embodiments and equivalents thereof. To one of skill in this art
who has the benefits of this invention's realizations, teachings,
disclosures, and suggestions, other purposes and advantages will be
appreciated from the following description of certain preferred
embodiments, given for the purpose of disclosure, when taken in
conjunction with the accompanying drawings. The detail in these
descriptions is not intended to thwart this patent's object to
claim this invention no matter how others may later attempt to
disguise it by variations in form, changes, or additions of further
improvements.
[0013] The Abstract that is part hereof is to enable the U.S.
Patent and Trademark Office and the public generally, and
scientists, engineers, researchers, and practitioners in the art
who are not familiar with patent terms or legal terms of
phraseology to determine quickly from a cursory inspection or
review the nature and general area of the disclosure of this
invention. The Abstract is neither intended to define the
invention, which is done by the claims, nor is it intended to be
limiting of the scope of the invention in any way.
[0014] It will be understood that the various embodiments of the
present invention may include one, some, or all of the disclosed,
described, and/or enumerated improvements and/or technical
advantages and/or elements in claims to this invention.
[0015] Certain aspects, certain embodiments, and certain preferable
features of the invention are set out herein. Any combination of
aspects or features shown in any aspect or embodiment can be used
except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] A more particular description of embodiments of the
invention briefly summarized above may be had by references to the
embodiments which are shown in the drawings which form a part of
this specification. These drawings illustrate certain preferred
embodiments and are not to be used to improperly limit the scope of
the invention which may have other equally effective or equivalent
embodiments.
[0017] FIG. 1A is a schematic view of a system according to the
present invention.
[0018] FIG. 1B is a top view of the system of FIG. 1A.
[0019] FIG. 1C is a partial side view of part of the system of FIG.
1A.
[0020] FIG. 1D is a cross-section view of a feeder system of the
system of FIG. 1A.
[0021] FIG. 1E is a cross-section view of a feeder system useful in
a system like the system of FIG. 1A.
[0022] FIG. 1F is a cross-section view of a container of a feeder
system according to the present invention.
[0023] FIG. 2A is a side cross-section view of a feeder system
according to the present invention.
[0024] FIG. 2B is an end view of the system of FIG. 2A.
[0025] FIG. 2C is a top view of the system of FIG. 2A.
[0026] FIG. 2D is a top view of part of the system of FIG. 2A.
[0027] FIG. 2E is an end view of a slide of the system of FIG.
2A.
[0028] FIG. 3 is a top view of a system according to the present
invention.
[0029] FIG. 4 is a schematic view of a system according to the
present invention.
[0030] FIG. 5 is a schematic view of a system according to the
present invention.
[0031] Presently preferred embodiments of the invention are shown
in the above-identified figures and described in detail below.
Various aspects and features of embodiments of the invention are
described below and some are set out in the dependent claims. Any
combination of aspects and/or features described below or shown in
the dependent claims can be used except where such aspects and/or
features are mutually exclusive. It should be understood that the
appended drawings and description herein are of preferred
embodiments and are not intended to limit the invention or the
appended claims. On the contrary, the intention is to cover all
modifications, equivalents and alternatives falling within the
spirit and scope of the invention as defined by the appended
claims. In showing and describing the preferred embodiments, like
or identical reference numerals are used to identify common or
similar elements. The figures are not necessarily to scale and
certain features and certain views of the figures may be shown
exaggerated in scale or in schematic in the interest of clarity and
conciseness.
[0032] As used herein and throughout all the various portions (and
headings) of this patent, the terms "invention", "present
invention" and variations thereof mean one or more embodiment, and
are not intended to mean the claimed invention of any particular
appended claim(s) or all of the appended claims. Accordingly, the
subject or topic of each such reference is not automatically or
necessarily part of, or required by, any particular claim(s) merely
because of such reference. So long as they are not mutually
exclusive or contradictory any aspect or feature or combination of
aspects or features of any embodiment disclosed herein may be used
in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIGS. 1A-1D illustrate a system 10 according to the present
invention which has a thermal reactor section 12 and a feeder
system 40 according to the present invention. Drill cuttings
material M is fed from the feeder system 40 into a reactor vessel
14 (mounted on supports 18) of the thermal reactor section 12
through an inlet 13. Treated material exits the vessel 14 through a
discharge outlet 15. An engine section 16 has an engine 17 that
rotates internal rotors (or friction elements) 8 in the vessel 14.
The vessel 14 has, optionally, a plurality of inlets 7 into which
drill cuttings material for treatment can be fed. Load cell
apparatuses 3 in communication with a control system CS indicate
the amount of material in the vessel 14.
[0034] FIGS. 1C and 1D illustrate the feeder system 40 which has a
base 42 with sides 44, 44a, and 44b, and a bottom 45 within which
is mounted a container 46 for holding drill cuttings material to be
fed to the vessel 14. It is within the scope of the present
invention to have a container 46 with a substantially horizontal
level bottom with a metering screw system beneath it which is also
substantially horizontal; or, as shown in FIG. 1D, the container 46
has an inclined bottom 48 with a trough 47 and a metering screw
system 60, which receives material from the container 46. The
system 60 inclined to correspond to the incline of the bottom 48.
Material falls into a trough 3 at the bottom of the container 46
(in which a screw 62 of the system 60 is located). The bottom of
the container 46 may be any suitable shape to facilitate the flow
and movement of material to the system 60; e.g. as shown in FIG.
1F, walls 46w of a container 46a are inclined above a trough
47a.
[0035] Drill cuttings material from a wellbore drilling operation
indicated by an arrow 49 is fed by an auger apparatus 50 through an
inlet 51 into the container 46. The drill cuttings material may
come from any suitable apparatus or equipment, including, but not
limited to, from shale shaker(s), centrifuge(s), tank(s), cuttings
storage apparatus, vortex dryer(s), hydrocyclone(s), or any solids
control equipment that produces a stream or discharge of drill
cuttings material.
[0036] Optionally drill cuttings material is introduced into the
container 46 through a line 53 from a system 54 (not directly from
drilling operation equipment, like shale shakers or centrifuges)
that transfers and/or transports drill cuttings material (e.g., but
not limited to, the known BRANDT FREE FLOW (TRADEMARK) cuttings
transfer and transportation system). Optionally, the material is
fed to a vortex dryer VD for processing and the solids output of
the vortex dryer is fed to the container 46.
[0037] A valve assembly 56 is used to selectively control the flow
of free flowing material (e.g. liquids) from the system 60 into the
vessel 14 as described below. Such liquids are not moved so much by
the screw 62 as they flow freely past the screw 62 to the valve 56
through the system 60.
[0038] Optionally, (especially for material that may be easily
compacted) if additional lubricant is needed for the material to be
introduced into the vessel 14, the lubricant is injected into
material in the system 60 through injection ports or nozzles 57
from a lubricant system 58 (e.g., but not limited to, a lubricant
that is base oil, an oil component of a drilling fluid). In one
aspect, if a load on a motor 52 which rotates the screw 62 (e.g. an
hydraulic motor) is increased beyond a pre-selected set point,
lubricant is injected through the nozzles 57 to facilitate material
flow within the system 60 and lessen the load on the motor 52.
[0039] Optionally, a pump 70 in fluid communication with the
interior of the container 46 pumps free liquid from within the
container 46 to reduce the liquid content of the material. This can
optimize the performance of the system by insuring that the feed to
the vessel 14 has a reduced amount of free liquid. Optionally, as
shown in dotted line in FIG. 1D, a pump 70a may be located within
the container 46 (in one aspect, in the material M).
[0040] As shown in FIG. 1E, a conveyor apparatus for conveying
material to a vessel like the vessel 14 can have a constant pitch
screw 62s; or, as shown in FIG. 1D, the screw 62 of the system 60
has areas of different pitch, e.g. areas 62a, 62b, (with the
tightest pitch at the end near the motor 52) and 62c which reduce
the likelihood of material compaction in the system 60 and
facilitates material flow in the system 60. In one particular
aspect, the system 60 is about ten inches in diameter; the
container 46 has a volume of about eighteen cubic meters; and the
bottom 45 is about four meters long. In certain aspects, the
container 46 has therein, at any given time, between three to
sixteen cubic meters of material and, in one particular aspect,
about sixteen cubic meters. The screw may have two, four or more
areas of different pitch.
[0041] In one aspect, during operation of the system 10, an amount
of material is maintained in the container 46 (e.g. in one aspect,
a minimum of about three cubic meters) so that an airlock is
maintained at the inlet 13. By insuring, using the control system
CS as described below, that a sufficient amount of material is
within the vessel 14, an airlock is maintained at the discharge
outlet 15 of the system 12.
[0042] Load cell apparatuses 72 (one, two, or more) indicate how
much material (by weight) is in the container 46. This correlates
with the level of the material so that, as shown in FIG. 1C, a
level "a" can be maintained indicative of the volume of material
sufficient to maintain the airlock at the inlet 13 described above.
The load cell(s) is also used with the control system CS to
calculate the rate of metering of material into the vessel 14 and
to set and control maximum and minimum levels of material in the
container 46. In one aspect the level "a" is between 50 mm and 1000
mm and, in one particular aspect, is 500 mm. Optionally, or in
addition to the load sensor(s) 72, a level indicating apparatus 79
is used to obtain data to determine the amount of material in the
container 46 and its level. In one aspect, the apparatus 79 is an
ultrasonic distance measuring apparatus.
[0043] Personnel P can, optionally, remove free liquid from the top
of material in the container 46 (e.g. from the top thereof) by
manually placing an end 75a of a pipe 75 within a conduit 77
connected to the container 46 to pump free liquid (e.g. drilling
fluid and some water, inter alia); from the container 46 thereby
reducing the liquid content of material introduced into the vessel
14. In one aspect the pipe 75 is connected to the pump 70; or some
other pump is used. In one aspect a pump system is placed within
the container 46.
[0044] A control system CS controls the various operational parts
and apparatuses of the system 10 as shown schematically in FIGS.
1A, 1B, and 1D. In particular aspects, the control system CS
receives information from the load cell(s) 72, and from sensors 2
on the engine 17 (e.g. torque and/or speed in rpm's) and from
sensor(s) 52a on the motor 52 (e.g. motor speed in rpm's). The
control system CS controls the operation of the engine 17, the
motor 52, the valve 56, the auger apparatus 50, the system 60, the
system 58, the system 54, the pump 70, and an hydraulic power
supply HPP which supplies power to the motor 52 and any other
hydraulically powered item. In one aspect, sensing of the load on
the motor 52 is done using a pressure sensor 52a (shown
schematically). In one aspect, thus monitoring the pressure of
hydraulic fluid applied to the motor 52 provides the information
needed to activate the injection of additional lubricant via the
nozzles 57. Via sensing of the temperature within the vessel 14
(using a sensor or sensors; e.g., in one aspect three sensors along
the top of the vessel 14), the control system CS maintains the flow
of material into the vessel 14 by controlling the system 00 at a
sufficient rate that the temperature within the vessel 14 is
maintained at a sufficiently high level (without exceeding a
pre-set maximum) to effectively heat liquid phase(s) in the drill
cuttings material to vaporize the liquid phase(s). The motor 52,
engine 17, pump 70 and/or other powered items in these systems can
be powered electrically, pneumatically, or hydraulically.
[0045] In certain particular aspects, the oil content of feed into
the container 46 is maintained between 15% to 30% by weight and the
water content is maintained between 8% to 20% by weight.
[0046] In other aspects, the solids content of the material
introduced into the container 46 is, preferably, at least 70%
solids by weight; and the liquid content of the material fed into
the vessel 14 is 30% or less (liquid includes oil and water). A
pump or pumps (e.g., but not limited to, the pump 70) reduces (and,
in certain aspects, minimizes) the amount of free liquid fed to the
vessel 14. If too much liquid is fed into the vessel 14,
undesirable "wash out" may occur, a sufficient amount of solids
will not be present, and, therefore, sufficient friction will not
be developed to achieve a desired temperature within the vessel 14
for effective operation. In certain aspects, the temperature within
the vessel 14 is maintained by the control system between 250 and
400 degrees Centigrade.
[0047] It is also desirable for efficient operation that the engine
17 operate at an optimal loading, e.g. at 95% of its rated
capacity. If the control system CS learns, via a speed sensor 2 on
the engine 17 that the RPM's of the engine 17 are dropping off from
a known maximum, this may indicate too much material is being fed
into the vessel 14. The control system CS then reduces the mass
transfer rate into the vessel 14 (by controlling the system 60).
Power generated typically drops off as the RPM's drop off, as can
be seen on a typical performance curve. Insuring that the power
generated is maximized provides the maximum energy available to
generate the heat required within the vessel 14.
[0048] Initially at start up, in one aspect, the valve 56 is opened
slowly. As free flowing liquid and material flow into the vessel
14, the temperature is maintained. If there is no dramatic drop in
temperature, this indicates that the flow of material has an
appropriate liquid content so that a desired operational
temperature and effective operation can be achieved. Then the valve
56 is fully opened as the system 60 is controlled by the control
system CS and full flow commences.
[0049] The container 46 may be filled continuously or in
batches.
[0050] FIG. 1E shows a system 10a, like the system 10 described
above, and like numerals indicate like parts. The initial feed of
drill cuttings material to the container 46 is from one or more
shale shakers SS (or other processing equipment) whose drill
cuttings material output (e.g. off the tops of the shaker screens
or from a centrifuge) is fed to a buffer apparatus BA to maintain a
desired liquid content of the material in the container 46, and, in
one aspect, to minimize this liquid content. The buffer apparatus
BA can be any suitable system or apparatus; e.g., but not limited
to: a system according to the present invention (e.g., but not
limited to a system as in FIGS. 1A, 2A, or 3); a storage system for
drill cuttings material; a skip system; a cuttings containment and
transfer system (e.g., but not limited to, a known system as
disclosed in U.S. Pat. No. 7,195,084, co-owned with the present
invention); or a transfer/transport system, e.g., but not limited
to, the BRANDT FREE FLOW (TRADEMARK) systems.
[0051] FIG. 2A shows a system lob like the system 10 described
above and like numerals indicate like parts.
[0052] The system lob has a slider system 80 with a slider frame 82
selectively movable by a piston mechanism 84 with one part
connected to the slider frame 82 and controlled by the control
system CS. Power for the piston mechanism 84 is provided by an
hydraulic power pack HPP (which also provides power to the motor
52). The slider frame 82 moves material on the bottom 48 of the
container 46 to facilitate the flow of material down to the screw
62 of the system 60. A slider frame may be used as shown in U.S.
Pat. No. 7,195,084.
[0053] The slider frame 82 has a central beam 86, and, optionally,
bevelled end edges 88. The slide 82 moves material facilitating its
entry into a trough 47 in which is located the screw 62.
Optionally, the slider frame 82 is smaller than shown with no
central beam 86 and is movable to and from the trough 47 on both
sides thereof.
[0054] FIG. 3 illustrates a system 10c, like the system 10, and
like numerals indicate like parts The reactor section 12c has
multiple material inlets 13c into which material is introducible
into a vessel 14c. One feeder system may be used at one inlet 13c
or multiple feeder systems 40c may be used (three shown in FIG.
3).
[0055] FIG. 4 illustrates improvements to systems of U.S. Pat. No.
5,914,027 (fully incorporated herein for all purposes) and shows a
system 200 with a feeder system 210 (like any feeder system
disclosed herein according to the present invention) which feeds
material into a reactor chamber or vessel 201 with a rotor 202
including friction elements 203. The rotor 202 further includes a
shaft 204 sealed in the reactor with mechanical seals 205. The
friction elements 203 are pivotably mounted in rotor plates 207 (as
in U.S. Pat. No. 5,914,027). Each pair of adjacent rotor plates 207
carries a number of friction elements 203. The friction elements
203 are staggered relative to each other. The staggered arrangement
may achieve turbulent action in a bed of grained solids in the
vessel. The friction elements 203 are pivotably mounted in between
adjacent rotor plates 207 by rods extending over the length of the
rotor 202 (as in U.S. Pat. No. 5,914,027).
[0056] The rotor 202 is driven by a rotating source 209 which can
be an electrical motor, a diesel engine, a gas or steam turbine or
the like. The material is brought to the reactor from the feeder
system 210 via a line 211. Water and/or oil (e.g., base oil) can be
added to the flow from the pipe 212. Cracked hydrocarbon gases
(and, in one aspect, over-saturated steam) leaves the reactor via a
line 213 and, in one aspect, flows to a cyclone 214 and proceed to
a condenser unit 215 which can be a baffle tray condenser, a
tubular condenser or a distillation tower. The different fractions
of the oil can be separated directly from the recovered hydrocarbon
gases. The heat from condensation is removed by an oil cooler 216
cooled either by water or air. The recovered oil is discharged from
the condenser by a pipe 217 to a tank 218.
[0057] Solids leave the reactor via a rotating valve 219 and a
transport device 220 which can be a screw or belt conveyor or an
air transportation pipe system to a container 221. The solids
separated from the cyclone 214 are transported via a rotating valve
222 to the container 221 either by being connected to the transport
device 220 or directly to the container 221 by a cyclone transport
device 223.
[0058] Non-condensable gases exit in a pipe 224 and can flow from
the pipe 224 to a filter unit or to a flare tower or are
accumulated in a pressure tank--not shown. The system 200 may be
operated in any way described in U.S. Pat. No. 5,914,027. The items
downstream of the vessel 201 may be used with any system according
to the present invention.
[0059] FIG. 5 illustrates that the present invention provides
improvements to the systems and methods of U.S. Pat. No. 5,724,751
(fully incorporated herein for all purposes) and shows a system 300
according to the present invention with a process chamber with a
rotor 302 and blades 303 driven by an engine 304. A mass of
material is fed into the process chamber by a feeder system 320
(any feeder system disclosed herein according to the present
invention). The mass in the process chamber is whipped by the
blades and subjected to energy or vibrations from the said blades
and ribs 308, which are sufficiently closely spaced to each other
to cause turbulence during the rotation of the blades. Additional
energy may be supplied in some form of heated gas from a combustion
engine 309. Gases, mist and vapors leave the process chamber 301
via an output opening via a vent fan 311 and on to either open air
or to a condenser. Dried material is led through an output opening
312 via a rotating gate 313. The system 300 may be operated in any
way described in U.S. Pat. No. 5,724,751. The items downstream of
the process chamber of the system 300 may be used with any system
according to the present invention.
[0060] The present invention, therefore, provides in some, but not
in necessarily all, embodiments a thermal treatment system for
removing liquid from drill cuttings material, the thermal treatment
system having a metering screw apparatus for receiving and feeding
drill cuttings material to a reactor system, including apparatus
and a control system for controlling the metering screw apparatus
and for insuring that the metering screw apparatus is maintained
full or nearly full of material and/or for controlling the mass
flow rate into a reactor of the thermal treatment system by
adjusting the speed of the metering screw apparatus.
[0061] The present invention, therefore, provides in some, but not
in necessarily all, embodiments a thermal treatment system for
treating drill cuttings material in which apparatus and a control
system are provided to maintain an airlock at a material inlet to a
thermal reactor of the thermal treatment system by maintaining a
desired amount of material in a container above a feeder system
that feeds material into the thermal reactor.
[0062] Any system according to the present invention may include
one or some, in any possible combination, of the following: wherein
apparatus and a control system provide for control of temperature
in the thermal reactor by controlling the mass flow rate of
material into the thermal reactor by controlling a metering screw
system that feeds material into the thermal reactor; wherein the
thermal treatment system has an engine that rotates friction
elements within a reactor vessel of the thermal reactor and
performance of said engine is optimized by controlling a metering
screw system that feeds material into the reactor vessel (e.g.,
based on sensed speed in rpm's of said engine); a sensor or sensors
or at least one load cell apparatus or two load cell apparatuses
beneath the container to provide information to indicate an amount
of material in the container; a sensor or sensors or at least one
load cell apparatus or two load cell apparatuses beneath the
thermal reactor to provide information to assist in control of the
discharge rate of solids from the thermal reactor; wherein a
control system controls the amount of material in the thermal
reactor; wherein the control system controls said amount to
maintain an airlock at the discharge from the thermal reactor;
apparatus and a control system to maintain a desired temperature in
the thermal reactor; a first feed of drilling cuttings material
into the container; wherein the first feed is from drilling
operations solids control equipment which is at least one of shale
shaker, centrifuge, vortex dryer, and hydrocyclone; wherein the
first feed is from a cuttings conveyance system; a secondary feed
into the container from a cuttings storage or transfer system;
and/or apparatus and a control system for control of temperature in
the thermal reactor by controlling the mass flow rate of material
into the thermal reactor by controlling a metering screw system
that feeds material into the thermal reactor; the thermal treatment
system having an engine that rotates friction elements within a
reactor vessel of the thermal reactor and performance of said
engine is optimized by controlling a metering screw system that
feeds material into the reactor vessel (e.g., based on sensed speed
in rpm's of said engine); at least one load cell apparatus or two
load cell apparatuses beneath the container to provide information
to indicate an amount of material in the container.
[0063] In conclusion, therefore, it is seen that the present
invention and the embodiments disclosed herein and those covered by
the appended claims are well adapted to carry out the objectives
and obtain the ends set forth. Certain changes can be made in the
subject matter without departing from the spirit and the scope of
this invention. It is realized that changes are possible within the
scope of this invention and it is further intended that each
element or step recited in any of the following claims is to be
understood as referring to the step literally and/or to all
equivalent elements or steps. The following claims are intended to
cover the invention as broadly as legally possible in whatever form
it may be utilized. The invention claimed herein is new and novel
in accordance with 35 U.S.C. .sctn.102 and satisfies the conditions
for patentability in .sctn.102. The invention claimed herein is not
obvious in accordance with 35 U.S.C. .sctn.103 and satisfies the
conditions for patentability in .sctn.103. The inventor may rely on
the Doctrine of Equivalents to determine and assess the scope of
the invention and of the claims that follow as they may pertain to
apparatus not materially departing from, but outside of, the
literal scope of the invention as set forth in the following
claims. All patents and applications identified herein are
incorporated fully herein for all purposes. It is the express
intention of the applicant not to invoke 35 U.S.C. .sctn.112,
paragraph for any limitations of any of the claims herein, except
for those in which the claim expressly uses the words `means for`
together with an associated function. In this patent document, the
word "comprising" is used in its non-limiting sense to mean that
items following the word are included, but items not specifically
mentioned are not excluded. A reference to an element by the
indefinite article "a" does not exclude the possibility that more
than one of the element is present, unless the context clearly
requires that there be one and only one of the elements.
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