U.S. patent application number 13/729900 was filed with the patent office on 2013-07-04 for method, apparatus and system for hydrocarbon recovery.
This patent application is currently assigned to OMNI ENERGY SERVICES CORP.. The applicant listed for this patent is Andy Dufrene, Brian Recatto. Invention is credited to Andy Dufrene, Brian Recatto.
Application Number | 20130168291 13/729900 |
Document ID | / |
Family ID | 48693998 |
Filed Date | 2013-07-04 |
United States Patent
Application |
20130168291 |
Kind Code |
A1 |
Recatto; Brian ; et
al. |
July 4, 2013 |
Method, Apparatus and System for Hydrocarbon Recovery
Abstract
The present invention relates to a system, method and apparatus
for the extraction of hydrocarbons from contaminated solids. The
method for separating hydrocarbons from solids comprising exposing
the solid to a heat source of sufficient temperature to release
substantially all of the hydrocarbon and water from the solids as
volatile vapors, condensing at least a portion of the hydrocarbon
vapor, and condensing the water vapor. The apparatus for extracting
hydrocarbons from solids comprises a heat source capable of
reaching temperatures sufficient to vaporize substantially all of
the hydrocarbons in the contaminated solids and at least one
separation tank in fluid communication with an outlet of said heat
source for condensing at least part of the hydrocarbons. The
present invention also relates the system for applying said method
to said apparatus to extract and recover hydrocarbons from
contaminated solids.
Inventors: |
Recatto; Brian; (Lafayette,
LA) ; Dufrene; Andy; (Houma, LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Recatto; Brian
Dufrene; Andy |
Lafayette
Houma |
LA
LA |
US
US |
|
|
Assignee: |
OMNI ENERGY SERVICES CORP.
Carencro
LA
|
Family ID: |
48693998 |
Appl. No.: |
13/729900 |
Filed: |
December 28, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61580757 |
Dec 28, 2011 |
|
|
|
Current U.S.
Class: |
208/187 ;
196/46 |
Current CPC
Class: |
C10G 1/02 20130101; C10G
1/04 20130101 |
Class at
Publication: |
208/187 ;
196/46 |
International
Class: |
C10G 1/04 20060101
C10G001/04 |
Claims
1. A method for treating solids, comprising: a. delivering a
contaminated energetic material to a heat source, said contaminated
energetic material comprising a hydrocarbon filet and water; b.
utilizing said heat source to heat said contaminated energetic
material to a temperature sufficient to vaporize substantially all
of said hydrocarbon fuel and water present comprising said
contaminated energetic material, producing a vaporized hydrocarbon
fuel and vaporized water; c. condensing at least a portion of said
vaporized hydrocarbon fuel from said contaminated energetic
material, producing a condensed hydrocarbon fuel; d. collecting
said condensed hydrocarbon fuel; and e. introducing said vaporized
water to a condenser.
2. The method for treating solids of claim 1, wherein the solid
residue of said contaminated energetic material is collected after
said contaminated energetic material is vaporized.
3. The method for treating solids of claim 1, wherein said heat
source is a rotary heater.
4. The method for treating solids of claim 1, wherein said heat
source is a rotary calciner.
5. The method for treating solids of claim 1, wherein the method
further comprises condensing at least a portion of said vaporized
water.
6. The method for treating solids of claim 1, wherein at least one
condensing step is carried out by at least one direct
condenser.
7. The method for treating solids of claim 1, wherein at least one
condensing step is carried out by at least one scrubber
condenser.
8. The method for treating solids of claim 1, wherein at least one
condensing step is carried out by at least cue indirect
condenser.
9. The method for treating solids of claim 1: a. wherein the
contaminated energetic material comprises drill cuttings and said
hydrocarbon fuel is selected from the group consisting of gasoline,
diesel, kerosene, jet fuel, and fuel oil; b. wherein said heat
source is a rotary calciner; and, c. wherein at least one scrubber
condenser is used to carry out at least one condensing step.
10. The method of treating solids of claim 1, further comprising
condensing said hydrocarbon fuel and wherein the fuel is selected
from the group consisting of gasoline, diesel, kerosene, jet fuel,
and fuel oil.
11. The method of treating solids of claim 1 further comprising: a.
delivering said contaminated energetic material to a heat source;
b. heating said contaminated energetic material to a temperature
sufficient to vaporize substantially all of the hydrocarbon fuel
and water present in the contaminated, energetic material; c.
wherein said heat source is a rotary heater; d. introducing the
vaporized hydrocarbon fuel and water to a first condenser; e.
condensing at least a portion of said vaporized hydrocarbon fuel in
said first condenser; f. introducing said vaporized water from said
first condenser to a second condenser in fluid communication with
said first condenser; g. condensing at least a portion of said
vaporized water in said second condenser; h. collecting the solid
residues remaining after the heating of said contaminated energetic
material; and i. wherein said hydrocarbon fuel is selected from the
group consisting of gasoline, diesel, kerosene, jet fuel, and fuel
oil.
12. A method for treating solids comprising: a. delivering a first
material comprising a hydrocarbon fuel and water to a first zone;
b. heating said first material in said first zone thereby producing
a second material in vapor form and a third material having a lower
hydrocarbon and water content than said first material; c.
delivering said second material to a second zone; and d. condensing
at least a portion of said second material in said second zone
thereby producing a hydrocarbon fuel in liquid form and a fourth
material having a lower hydrocarbon content than said second
material.
13. The method for treating solids of claim 12: a. wherein the
heating of said first material in said first zone is accomplished
by a rotary heater; b. wherein said second material comprises a
hydrocarbon fuel; c. wherein a first condenser in said second zone
is in fluid communication with said rotary heater and said first
condenser condenses at least a portion, of said hydrocarbon fuel;
d. wherein said fourth material comprises water vapor; and e.
wherein a second condenser in said second zone is in fluid
communication with said first condenser and said second condenser
condenses at least a portion of said water vapor present in the
fourth material.
14. The method of treating solids of claim 12: a. wherein the
hydrocarbon content of said first material is between approximately
7 wt. % and approximately 26 wt. %; b. wherein the solids content
of said third material is higher than the solids content of said
first material; c. wherein the largest component of said fourth
material is water vapor; and d. wherein said hydrocarbon fuel
released from said second material comprises hydrocarbons.
15. The method of treating solids of claim 12 further comprising
delivering the third material to a storage vessel.
16. The method for treating solids of claim 12, wherein at least
one of said first and second condenser is a scrubber condenser.
17. The method of treating solids of claim 12, wherein at least one
condenser is an indirect condenser.
18. The method of treating solids of claim 12, wherein said
indirect condenser is a heat exchanger.
19. The method for treating solids of claim 12, wherein said
hydrocarbon fuel is selected from the group consisting of gasoline,
diesel, kerosene, jet fuel, and fuel oil.
20. The method for treating solids of claim 12 further comprising:
a. delivering said first material to a first heat zone, wherein the
heating of said first material in said first zone is accomplished
by a rotary heater; wherein said first material is a contaminated
energetic material; wherein said first material comprises between
approximately 7 wt. % and approximately 26 wt. % hydrocarbon by
weight; b. heating said first material in said first zone,
producing a second material in vapor form and a third material
having a lower hydrocarbon and water content than said first
material, wherein the solids content of said third material is
higher than the solids content of said first material; c.
delivering said second material to a second zone, wherein said
second material comprises a hydrocarbon component and a water vapor
component; d. introducing said second material to a first
condenser, said first condenser in fluid communication with said
rotary beater; condensing at least a portion of said hydrocarbon
component in the second material in said second zone, thereby
producing a hydrocarbon in liquid form and a fourth material having
a lower hydrocarbon content than said second material, wherein the
largest component of said fourth material is water vapor; e.
introducing said fourth material to a second condenser, said second
condenser in fluid communication with said first condenser; and f.
condensing at least a portion of said water vapor in said fourth
material.
21. An apparatus for extracting hydrocarbons from a material
comprising said hydrocarbons which comprises: a. a heat zone for
subjecting said material to a temperature sufficient to vaporize
substantially all of the hydrocarbons in said material; b. a first
condenser zone for condensing at least a portion of said
hydrocarbons; and c. a second condenser zone for condensing water
vapors that have been vaporized from said material.
22. The apparatus as in claim 21, wherein said first and second
condensers are scrubber condensers.
23. The apparatus of claim 21, wherein at least a portion of said
hydrocarbons are condensed via a heat exchanger.
24. A system of extracting hydrocarbons from a material comprising
hydrocarbons which comprises: a. delivery of a first material to a
first zone, wherein said first zone comprises a heat chamber and
said heat chamber comprises at least two outlets; b. subjecting
said first material to a heat chamber in said first zone, thereby
forming a second material, which is a vapor comprising a higher
concentration of a fuel and water than said first material, and a
third material, comprising a lower concentration of a hydrocarbon
than does said first material; c. transporting said second material
from said heat chamber, through one of said at least two outlets,
to a first condenser in a second zone, wherein said outlet is in
fluid connection with said first condenser in said second zone and
the vapor of said second material is exposed to a sprayer of cooled
condensed vapors, causing the vapor in said second material to
condense and separate into a fuel and a fourth material, said
fourth material comprising water vapor; d. transporting said fourth
material from said first condenser to a second condenser, said
second condenser in fluid communication with said first condenser,
wherein said fourth material is exposed to a sprayer of cooled
condensed vapors causing said water vapor in said fourth material
to condense into liquid water; and e. transporting said third
material from said heat chamber in said first zone to a dust
trap.
25. A solids treatment apparatus comprising: a. a first zone
comprising one or more vessels, a first zone feed stream, a first
zone first outlet stream, a first zone second outlet stream, and a
heat chamber; and b. a second zone comprising one or more vessels,
a first condenser, a second zone first outlet stream, a second zone
second outlet stream, and a second condenser; wherein said first
zone feed stream comprises a hydrocarbon fraction, a water
fraction, and a solids fraction and said hydrocarbon fraction
comprises a first hydrocarbon component with an atmospheric boiling
point of between approximately 250.degree. F. and approximately
1000.degree. F.
26. A solids treatment apparatus comprising: a. a first zone
comprising one or more vessels, a receiving pit for the intake of
materials, a feed pit, and a heat source, wherein said feed pit is
in fluid connection with said heat source, wherein a flow pump is
used to convey said materials from said feed pit to said heat
source, wherein said heat source has a first zone first outlet
stream and a first zone second outlet stream; wherein said first
zone first outlet stream is in fluid connection with a vessel in a
second zone; and wherein said first zone second outlet stream is in
connection with a vessel in a fourth zone; b. a second zone
comprising one or more vessels, a first condenser, a second zone
storage vessel, and a sludge removal vessel; wherein said first
condenser is in fluid communication with said heat source via said
first zone first outlet stream; wherein said condenser has a second
zone first outlet stream which is in fluid connection with said
sludge removal vessel; wherein said condenser has a second zone
second outlet stream in fluid connection with a vessel in a third
zone; c. a third zone comprising one or more vessels, a second
condenser, a second storage vessel, and a sludge removal line;
wherein said second condenser has a third zone first outlet stream
in fluid communication with said second storage vessel; wherein
said second condenser has a third one second outlet stream; wherein
said second storage vessel has a second condenser feed line in
fluid connection with said second condenser; wherein said second
condenser feed line has a bypass line in fluid connection with
second storage vessel; and d. a fourth zone comprising one or more
vessels, a solids residue vessel, and a disposal; wherein said
solids residue vessel receives solids residue from said heat source
through first zone second output stream.
27. The solids treatment apparatus of claim 26: a. wherein said
first condenser has a second zone third outlet stream which is in
fluid connection with said storage vessel; b. wherein said second
zone storage vessel has a first condenser feed line in fluid
connection with said first condenser; and c. wherein said sludge
removal vessel is in fluid communication with said second zone
storage vessel.
28. The solids treatment apparatus of claim 26: a. wherein said
first condenser has a second zone third outlet stream which is in
fluid connection with said storage, vessel; b. wherein said second
zone storage vessel has a first condenser feed line in fluid
connection with said first condenser; c. wherein cooled liquids are
recirculated from said second zone storage vessel to said first
condenser through said first condenser feed line; and d. wherein
said sludge removal vessel is in fluid communication with said
second zone storage vessel.
29. The solids treatment apparatus as in claim 26: a. wherein said
first condenser has a second zone third outlet stream which is in
fluid communication with said second zone second outlet stream; and
b. wherein said sludge removal vessel is in fluid communication
with said second zone storage vessel.
30. The solids treatment apparatus of claim 26, wherein said heat
source is a rotary heater.
31. The solids treatment apparatus of claim 26, wherein said heat
source is a calciner.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the provisional U.S.
patent application No. 61/580,757 entitled "Hydrocarbon Recovery,"
filed Dec. 28, 2011.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO A "SEQUENCE LISTING," A TABLE, OR A COMPUTER
PROGRAM
[0003] Not Applicable.
DESCRIPTION OF THE DRAWINGS
[0004] The drawings constitute a part of this specification and
include exemplary embodiments of the Method, Apparatus, and System
for Hydrocarbon recovery, which may be embodied in various forms.
It is to be understood that in some instances, various aspects may
be shown exaggerated or enlarged to facilitate an understanding of
certain features. Therefore the drawings may not be to scale.
[0005] FIG. 1 depicts a flow diagram illustrating one embodiment of
a process for Hydrocarbon Recovery.
[0006] FIG. 2(a) is an enlarged fragmentary view depicting one half
of a process for hydrocarbon recovery, including the heating and
solid removal portions.
[0007] FIG. 2(b) is an enlarged fragmentary view depicting the
other half of a process for hydrocarbon recovery, including the
condensing portions of the process.
[0008] FIG. 3 is a fragmentary view depicting an alternate
embodiment for a process for condensing the hydrocarbon and water
vapors resulting from the process depicted in FIG. 2(a).
DESCRIPTION
[0009] The instant invention concerns the removal of hydrocarbons
from solid materials, such as from drill cuttings in drilling mud,
which contain hydrocarbons. During rotary drilling operations, a
volume of subterraneous material encountered is removed to provide
the well bore. This material is generally referred to as drill
cuttings. The cuttings are usually mixed with the drilling fluid
used and any water or hydrocarbons encountered subterraneously
during drilling operations.
[0010] In a typical drilling operation, the cuttings are separated
from the drilling fluid by way of a shale shaker. The recovered
drilling fluid is usually recirculated for further use in the
drilling operation. The cuttings removed by the shale shaker are
not only coated with but contain a mixture of water, hydrocarbons,
and constituents of the drilling fluid. In some cases, the drilling
fluid itself may contain hydrocarbons which contribute to the
contamination of the drill cuttings.
[0011] The disposal of the drill cuttings and drilling mud is a
complex environmental problem. Drill cuttings contain not only the
residual drilling mud product that would contaminate the
surrounding environment, but may also contain oil and other waste
that is particularly hazardous to the environment, especially when
drilling in a marine environment.
[0012] In addition to shakers, various methods for removing
hydrocarbons and contaminants from drill cuttings and drilling
fluids have been employed. However, the high costs and plant
construction complexity, significant energy waste, limited safety,
especially when operating offshore, and low efficiency have
rendered such previous methods disadvantageous for extraction of
hydrocarbons.
[0013] Accordingly, there exists a continuing need for methods and
systems for extracting hydrocarbons from drill cuttings.
[0014] The methods of treating solids described herein may, in one
embodiment, comprise delivering a contaminated energetic material
to a heat source or heat chamber; subjecting the contaminated
energetic material to a temperature sufficient to vaporize
substantially all of the diesel fuel present in the contaminated
energetic material; and condensing a portion of the diesel fuel
from the contaminated energetic material. As used herein, the
phrase "contaminated energetic material" refers to a material
comprising hydrocarbon fuel and contaminants. As used herein, the
term "heat source" refers to any known source capable of producing
the required heat. Examples of heat sources which can be used
include, but are not limited to, evaporators, rotary heaters, or
any machines capable of deriving heat from the combustion of
hydrocarbons such as natural gas, liquid petroleum gas, petroleum
liquids, hot combustion gases from other sources (flares, engines,
or heaters), steam, or electricity. In a related example, the
contaminated energetic material contains drill cuttings; and the
step of subjecting the contaminated energetic material to a
temperature sufficient enough to vaporize substantially all of the
diesel fuel present is carried out by a calciner. In a related
example, the heat source is a rotary heater. In a further related
example, the heat source is a calciner. In a further example, the
heat source is provided by fuel burners. In a further related
example, the heat source is provided by electric heating. In a
further related example, the heat source is provided by steam
heating.
[0015] The methods of treating solids described herein may, for
example, comprise delivering a first material to a first zone;
heating the first material in the first zone thereby producing a
second material in vapor form and a third material having a lower
water and hydrocarbon content than the first material; delivering
the second material to a second zone; and condensing at least a
portion of the second material in the second zone thereby
separating a fuel from the second material such that a fuel
containing liquid and a fourth material are produced. In a related
example, the heating of the first material in the first zone is
accomplished by a heat source; a condenser in fluid communication
with the heat source condenses at least a portion of the fuel in
the second material. As used herein, the term "condenser" may refer
to any device capable of condensing a vapor into liquid form. For
example, the condensing may occur through direct condensing by a
direct condenser including, but not limited to, scrubbers with
spray nozzles, packed or frayed columns, or dispersion of the vapor
within a column of cooler liquid. The condensing may also occur
through indirect condensing by an indirect condenser including, but
not limited to, a heat exchanger or heat trap.
[0016] In a further related example, fuel is condensed wherein the
fuel is selected from gasoline, diesel, kerosene, jet fuel, and
fuel oil.
[0017] In a still further related example, the heating of the first
material in the first zone is accomplished by a rotary heater; a
condenser in fluid communication with the rotary heater condenses
at least a portion of the fuel; the largest component of the second
material is water vapor; the solids content of the third material
is higher than the solids content of the first material; and the
fuel released from the second material contains hydrocarbons. In a
further related example, the condenser is a scrubber condenser, in
a related example, the condensing occurs by subjecting the vapors
to cooler temperatures in a tank. In a related example, the heat
source is a rotary heater. In a further related example, the heat
source is a calciner. In a further example, the heat source is
provided by fuel burners. In a further related example, the heat
source is provided by electric heating. In a further related
example, the heat source is provided by steam heating.
[0018] A solids treatment apparatus described herein may for
example, comprise a first zone comprising one or more vessels, a
first zone feed stream, a first zone first outlet stream, a first
zone second outlet stream, and a heat source; a second zone
comprising one or more vessels, a second zone first outlet stream,
a second zone second outlet stream, and a condenser; wherein the
first zone feed stream comprises a hydrocarbon fraction, a water
fraction, and a solids fraction; and wherein the hydrocarbon
fraction comprises a first hydrocarbon component having an
atmospheric boiling point of between 250.degree. F. and
1000.degree. F. As used herein, the term "stream" encompasses the
movement of both fluid and non-fluid material. In a related
example, the first zone feed stream comprises drill cuttings; the
first zone heat source is an indirect heat source arranged and
configured to heat the accepted contents of the first zone feed
stream; the first zone first output stream is in fluid
communication with a first condenser; the first condenser
circulates a liquid hydrocarbon scrubber stream; and the second one
second outlet stream is in fluid communication with a second
condenser. In a related example, the first zone feed stream
comprises drill cuttings. The heat source may be any known source
capable of producing the required heat. Examples of heat sources
which can be used include, but are not limited to, evaporators,
rotary heaters, calciners, or any machines capable of deriving heat
from the combustion of hydrocarbons such as natural gas, liquid
petroleum gas, petroleum liquids, hot combustion gases from other
sources (flares, engines, or heaters), steam, or electricity. In
one embodiment, the heat source is an evaporator. In another
embodiment, the heat source is a rotary heater. In another
embodiment the heat source is a calciner. In a related example, the
heat source comprises a rotary calciner. In another embodiment, the
heat source is an indirect heat source arranged and configured to
heat the accepted contents of the first zone feed stream. In
another related example, the first condenser is a scrubber
condenser. In another related example, the second condenser is a
scrubber condenser. In another related example, the second zone
first outlet is connected to a storage vessel. In another related
example, the second zone second outlet stream is in fluid
communication with a second condenser.
[0019] In another related example, the first zone feed stream
comprises drill cuttings; the first zone first outlet stream is in
fluid communication with a first condenser; the second one second
outlet stream is in fluid communication with a second condenser;
the first condenser circulates a liquid hydrocarbon scrubber
condenser stream; the first zone further comprises a calciner; the
first zone second outlet stream has a solids content that is higher
in the solids content of the first zone feed stream; the second
zone is arranged and configured to accept contents of the first
zone first outlet stream; the second zone first outlet stream
comprises condensed hydrocarbons; and the second one second outlet
stream has a water vapor content that is higher than the water
vapor content of the first zone first outlet stream. In a related
example, the first zone second outlet stream is connected to a
solids residue vessel. In a further related example, the solids
residue vessel is connected to a vent. In a further related
example, the solids residue vessel is connected to a solids residue
scrubber, and material three discussed above is exposed to the
solids residue scrubber. In a related example, the first condenser
has a third outlet which is used to expel excess sludge
particulates from the second material.
[0020] In another related example, the first condenser operates as
an indirect condenser. In a further related example, the first
condenser is a heat trap; wherein ambient temperatures cooler than
the temperature of the vapors cool and condense the vapors. In
another example, the condenser is any device capable of condensing
the vapors.
DETAILED DESCRIPTION
[0021] The subject matter described herein is described with
specificity to meet statutory requirements. However, the
description itself is not intended to necessarily limit the scope
of claims. Rather, the claimed subject matter might be embodied in
other ways to include different steps or combinations of steps
similar to the ones described in this document, in conjunction with
other present or future technologies. Although the terms "step"
and/or "block" or "module" etc. might be used herein to connote
different components of methods or systems employed, the terms
should not be interpreted as implying any particular order among or
between various steps herein disclosed unless and except when the
order of individual steps is explicitly described.
[0022] Furthermore, the described features, structures, or
characteristics may be combined in any suitable manner in one or
more embodiments. In the following description, numerous specific
details are provided, such as examples of heating the first zone
feed stream, condensing the hydrocarbons, and condensing the water
vapor. One skilled in the relevant art will recognize, however,
that said heating and condensing may be practiced without one or
more of the specific details, or with other methods, components,
materials, and so forth. In other instances, well-known structures,
materials, or operations are not shown or described in detail to
avoid obscuring aspects of the invention.
[0023] The schematic flow chart diagrams included herein are
generally set forth as logical flow chart diagrams. As such, the
depicted order and labeled steps are indicative of one embodiment
of the presented method. Other steps and methods may be conceived
that are equivalent in function, logic, or effect to one or more
steps, or portions thereof, of the illustrated method.
Additionally, the format and symbols employed are provided to
explain the logical steps of the method and are understood not to
limit the scope of the method. Although various arrow types and
line types may be employed in the flow chart diagrams, they are
understood not to limit the scope of the corresponding method.
Indeed, some arrows or other connectors may be used to indicate
only the logical flow of the method. For instance, an arrow may
indicate a waiting or monitoring period of unspecified duration
between enumerated steps of the depicted method. Additionally, the
order in which a particular method occurs may or may not strictly
adhere to the order of the corresponding steps shown.
[0024] Referring to FIG. 2(a), incoming materials 8 are supplied by
roll off box, rail, truck or other form of transportation to
incoming materials handling area 10. In one embodiment, incoming
materials are wet solids contaminated with hydrocarbons such as
oilfield waste, drilling mud, drill cuttings, contaminated soil or
sludge. Incoming materials 8 are then moved from incoming materials
handling area 10 to receiving pit 20 by receiving pit supply line
15. In an alternate embodiment, incoming materials 8 are loaded
directly into receiving pit 20. Material from receiving pit 20 is
then supplied by feed pit supply line 25 to feed pit 30. Feed pit
30 provides material to heat source 50 by way of a conveyance
system. Various embodiments of the feed conveyance system will
include any of the following, alone, or in combination: conveyers
including but not limited to screw, belt or spiral conveyors or
pumps including but not limited to centrifugal, diaphragm, positive
displacement and screw pumps. In an embodiment of the invention,
the conveyor system includes a feed line 35, concrete pump 40, and
heat source feed line 45. In one embodiment, feed line 35 is a
horizontal auger.
[0025] The heat source 50 may take many forms including a rotary
drum and rotary or other indirect-heated dryers. The supply of heat
to the heat source 50 may include but is not limited to the
combustion of hydrocarbons such as natural gas, liquid petroleum
gas, petroleum liquids, hot combustion gases from other sources
(flares, engines, or heaters), steam, or electricity. The operating
temperatures of heat source 50 may be selected based on a reference
compound either theoretically or actually selected for removal, in
one embodiment the operating temperatures may be greater than or
equal to the boiling point of the first reference compound. In one
embodiment, the heat source 50 is a calciner that uses the indirect
heat of the calcining process to drive of all of the volatile
components supplied by heat source feed line 45. In one embodiment,
the calciner is set up to evaporate diesel hydrocarbons and has
three temperature zone ranges: calciner zone one at 700.degree. F.
to 800.degree. F., calciner zone two at 800.degree. F. to
1000.degree. F. and calciner zone three at 1000.degree. F. Catchier
zone one raises the temperature of the feed material to vaporize
most of the water content, calciner zone two begins the
vaporization of the hydrocarbon material, and calciner zone three
removes any hydrocarbon compounds with a higher boiling point.
These volatile components leave heat source 50 by vapor line 53.
Solid residue from heat source 50 is removed by a conveyance system
to solids residue vessel 80. This conveyance system is of a type
capable of moving dry hot solids, including but not limited to
screw, belt, or spiral conveyors. In one embodiment, this
conveyance system includes a hood 55 to direct the solid residues,
a horizontal auger 60 and inclined auger 70 which ultimately
transport the solid residues from heat source 50 to solids residue
vessel 80. In an alternate embodiment horizontal auger 60 is a
trough auger and incline auger 70 is a tube auger.
[0026] Incline auger 70 conveys solid residue to solids residue
vessel 80. Solids residue vessel 80 can be any vessel capable of
housing solid residues conveyed from heat source 50. In one
embodiment, a solids residue vessel vent 83 is attached to solids
residue vessel 80. In one embodiment, solids residue vessel vent 83
is a fan driven vent that maintains a negative pressure to aid in
air flow within solids residue vessel 80. In another embodiment,
solids residue vessel vent 83 is a vent with a water scrubber.
Solid residues are transported from solids residue vessel 80 to
disposal 90 by solids residue conveyor 85. Solids residue conveyor
85 can include, but is not limited to, any of the following, alone,
or in combination: roil off box, fork lift, truck or other form of
transportation or conveyance for dry materials. From disposal 90,
the solid residue can be transported to a landfill or combined with
additional drill cuttings to solidify the drill cuttings for
disposal. In one embodiment, the hydrocarbon content in the solid
residue is in the range of 1500 to 5000 parts per million
(ppm).
[0027] Referring now to FIG. 2(b) of the drawings, vapor from the
heat source 50 is in fluid communication with the diesel condenser
120 via vapor line 53. Vapors exiting the heat source 50 via vapor
line 53 may be condensed indirectly via a heat exchanger or
directly by contact with a cool liquid. Condensation through direct
contact may be accomplished by one of several methods including
scrubbers with spray nozzles, packed or trayed columns, or
dispersion of the vapor within a column of cooler liquid. In one
embodiment, condensation occurs through direct contact of the heat
source vapors with a circulating hydrocarbon stream. In one
embodiment, diesel condenser 120 condenses the hydrocarbon vapor
directly by contact with a cooled liquid diesel stream. Diesel
condenser 120 also collects diesel and drains to sludge settling
and separation box 140 by line to sludge settling 125. Sludge
settling and separation tank 140 separates diesel from sludge
removing the sludge through sludge removal line to landfill 146 and
supplies diesel to diesel storage tank 160 through sludge separator
line to diesel storage 142. Diesel condenser 120 is supplied with
cooled liquid diesel for the condensing of diesel vapors from
diesel storage tank 160 by diesel condenser spray feed line 165.
Diesel condenser 120 also directly supplies diesel to diesel
storage tank 160 through condensed diesel line to diesel storage
128. A stream of un-condensed gas and vapors containing water vapor
leaves diesel condenser 120 through water vapor exhaust line 123
and travels to water condenser system 180. Remaining water and
condensable matter delivered through water vapor exhaust line 123
are condensed in water condenser system 180. Sludge and debris from
the condensing process are removed from water condenser system 180
by way of sludge removal line from water condenser system 184 and
condensed water line to water storage 186 carries the remaining
condensed water from water condenser system 180 to water storage
tank 200. Water storage tank 200 vents to the atmosphere through
vent to atmosphere 204 and drains through water washout for
disposal 206. Vent to atmosphere 204 contains a fan which creates a
negative flow or suction which aids in pulling the volatile vapors
released from heat source 50 through the system. Water from water
storage tank 200 is recirculated by water supply line 210 and water
condenser bypass line 212. A portion of the water traveling through
water supply line 210 is routed to water condenser system 180 by
way of water condenser liquid water feed line 214.
[0028] Referring now to an alternate embodiment in FIG. 3, vapor
from the heat source 50 is in fluid communication with the diesel
trap tank 220 via vapor line 53. Vapors exiting the heat source 50
via vapor line 53 may be condensed indirectly via a heat exchanger
or directly by contact with a cool liquid. The vapors are
indirectly condensed by exposure to ambient temperatures sufficient
to condense substantially all of the diesel vapor in diesel trap
tank 220. The condensed diesel vapors are then transported to
sludge settling and separation tank 240 through line to sludge
settling 225. In one embodiment, a pump is used to transport the
condensed vapors from diesel trap tank 220 to sludge settling and
separation tank 240. Sludge settling and separation tank 240
separates diesel from sludge removing the sludge through sludge
removal line to landfill 246 and supplies diesel to diesel storage
tank 260 through sludge separator line to diesel storage 242.
Condensed diesel exits diesel storage tank 260 through diesel
removal to sales 265. Excess sludge in diesel storage tank 260 is
removed through sludge removal line from diesel storage to landfill
263.
[0029] A stream of un-condensed gas and vapors containing water
vapor leaves diesel trap tank 220 through water vapor exhaust line
223 and travels to Water condenser system 280. Condensed liquids
from diesel trap tank 220 are intermittently sprayed into water
vapor exhaust line 223 to aid in the condensing process. Remaining
water and condensable matter delivered through water vapor exhaust
line 223 are condensed in water condenser system 280. Sludge and
debris from the condensing process are removed from water condenser
system 280 by way of sludge removal line from water condenser
system 284 and condensed water line to water storage 286 carries
the remaining condensed water from water condenser system 280 to
water storage tank 300. Water storage tank 300 vents to the
atmosphere through vent to atmosphere 304 and drains through water
washout for disposal 306. Vent to atmosphere 304 contains a fan
which creates a negative flow or suction which aids in pulling the
volatile vapors released from heat source 50 through the system.
Water from water storage tank 300 is recirculated by water supply
line 310 and water condenser bypass line 312. A portion of the
water traveling through water supply line 310 is routed to water
condenser system 280 by way of water condenser liquid water feed
line 314.
[0030] In one embodiment, contaminated solids are fed into the feed
pit 30 at a rate of one ton per hour. The contaminated solids have
a hydrocarbon concentration of 15% by weight, water concentration
of 20% by weight, and solids content of 65%. In this example, the
hydrocarbon is primarily diesel. The materials are pumped through
feed line 35 to heat source 50 by concrete pump 40 so that the
hydrocarbons can be vaporized and removed through evaporation. In
one embodiment, heat source 50 is a rotary catchier which is
separated into three heat zones that heat the material through the
ambient temperatures it provides. Upon entering the rotary catchier
of heat source 50, the solid materials reach calciner zone one and
are subjected to an externally measured temperature range of
850.degree. F. to 950.degree. F. The temperatures of catchier zone
one are sufficient to vaporize substantially all of the water in
the contaminated solids. Continuing through the catchier, the
materials arrive to catchier zone two and are subjected to an
externally measured temperature range of 1000.degree. F. to
1100.degree. F., vaporizing most of the hydrocarbons in the
contaminated solids. The remaining material continues down the
calciner to calciner zone three where an externally measured
temperature of 950.degree. F. to 1000.degree. F. is maintained to
vaporize the final small amount of the hydrocarbon that, remains.
The solid residues exit the calciner and are transported to solids
residue vessel 80 via a conveyance system. Through this calcining
process, all of the water is vaporized. Furthermore, substantially
all of the hydrocarbon is vaporized. The hydrocarbon content is
reduced from 15% by weight in the contaminated material to a range
of 1500 to 4500 parts per million (PPM) in the solid residue. This
marks a total removal of hydrocarbons in the range of 99.9965% to
99.9985%. From solids residue vessel 80, the cleansed solid
residues are conveyed to disposal 90.
[0031] In order to adequately pull the volatile vapors from the
calciner through the condensing zones, the entire operation is
maintained at a negative pressure measured in a range of -02 to
-0.6 inches of water column. The volatile vapors are transported
from the heat source 50 calciner to diesel condenser 120 through
vapor line 53. In one embodiment, diesel condenser 120 is a
scrubber condenser which condenses the diesel vapors by spraying
them with a stream of cooled vapors that are recirculated from a
diesel storage tank 160. In an alternate embodiment, diesel is
condensed indirectly via a heat exchanger instead of directly
through contact with cool liquid diesel. From the diesel condenser,
the condensed diesel is transported to the diesel storage tank. The
condensed diesel is collected, stored, and eventually sold for
reuse. The uncondensed water vapors exit diesel condenser and are
transported to water condenser system via water vapor exhaust line
123. The water vapor system is a scrubber condenser which directly
condenses the water vapors by spraying cooled liquid water into the
vapors. The condensed water is transported to water storage tank
200. At least a portion of the cool condensed water in water
storage tank 200 is recirculated into water condenser system to be
sprayed by the scrubber condenser. Through this process a portion
of the water is condensed and recovered while the balance of the
water is vented to the atmosphere as saturated gas. In one
embodiment, cooled liquids are sprayed into water exhaust line in
order to aid in the condensing of the water vapor.
[0032] For the purpose of understanding the Method, System and
Apparatus for Hydrocarbon Recovery, references are made in the text
to exemplary embodiments of the Method, System and Apparatus for
Hydrocarbon Recovery, only some of which are described herein. It
should be understood that no limitations on the scope of the
invention are intended by describing these exemplary embodiments.
One of ordinary skill in the art will readily appreciate that
alternate but functionally equivalent components, materials,
designs, and equipment may be used. The inclusion of additional
elements may be deemed readily apparent and obvious to one of
ordinary skill in the art. Specific elements disclosed herein are
not to be interpreted as limiting, but rather as a basis for the
claims and as a representative basis for teaching one of ordinary
skill in the art to employ the present invention.
[0033] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized should be or are in
any single embodiment. Rather, language referring to the features
and advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment. Thus, discussion
of the features and advantages, and similar language, throughout
this specification may, but do not necessarily, refer to the same
embodiment.
[0034] Furthermore, the described features, advantages, and
characteristics may be combined in any suitable manner in one or
more embodiments. One skilled in the relevant art will recognize
that the method may be practiced without one or more of the
specific features or advantages of a particular embodiment. In
other instances, additional features and advantages may be
recognized in certain embodiments that may not be present in all
embodiments.
[0035] Reference throughout this specification to "one embodiment,"
"an embodiment," or similar language means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment. Thus,
appearances of the phrases "in one embodiment," "in an embodiment,"
and similar language throughout this specification may, but do not
necessarily, all refer to the same embodiment.
[0036] It should be understood that the drawings are not
necessarily to scale; instead, emphasis has been placed upon
illustrating the principles disclosure. In addition, in the
embodiments depicted herein, like reference numerals in the various
drawings refer to identical or near identical structural
elements.
[0037] Moreover, the terms "substantially" or "approximately" as
used herein may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change to the basic function to which it is related. [0038]
8--Incoming materials [0039] 10--Incoming materials handling area
[0040] 15--Receiving pit supply line [0041] 20--Receiving pit
[0042] 25--Feed pit supply line [0043] 30--Feed pit [0044] 35--Feed
line [0045] 40--Concrete pump [0046] 45--Heat source teed line
[0047] 50--Heat source [0048] 53--Vapor line [0049] 55--Hood [0050]
60--Horizontal auger [0051] 70--Incline auger [0052] 80--Solids
residue vessel [0053] 83--Solids residue vessel vent [0054]
85--Solids residue conveyor [0055] 90--Disposal [0056] 120--Diesel
condenser [0057] 123--Water vapor exhaust line [0058] 125--Line to
sludge settling [0059] 128--Condensed diesel line to diesel storage
[0060] 140--Sludge settling and separation tank [0061] 142--Sludge
separator line to diesel storage [0062] 146--Sludge removal line to
landfill [0063] 160--Diesel storage tank [0064] 165--Diesel
condenser spray feed line [0065] 180--Water condenser system [0066]
184--Sludge removal line from water condenser system [0067]
186--Condensed water line to Water storage [0068] 200--Water
storage tank [0069] 204--Vent to atmosphere [0070] 206--Water
washout for disposal [0071] 210--Water supply line [0072]
212--Water condenser bypass line [0073] 214--Water condenser liquid
water feed line [0074] 220--Diesel trap tank---Need new term for
this [0075] 223--Water vapor exhaust line [0076] 225--Line to
sludge settling (needs to be pumped now, not gravity) [0077]
227--Spray line [0078] 240--Sludge settling and separation tank
[0079] 242--Sludge separator line to diesel storage [0080]
246--Sludge removal line to landfill [0081] 260--Diesel storage
tank [0082] 263--Sludge removal line from diesel storage to
landfill [0083] 265--Diesel removal to sales; [0084] 280--Water
condenser system [0085] 284--Sludge removal line from water
condenser system [0086] 286--Condensed water line to water storage
[0087] 300--Water storage tank [0088] 304--Vent to atmosphere
[0089] 306--Water washout for disposal [0090] 310--Water supply
line [0091] 312--Water condenser bypass line [0092] 314--Water
condenser liquid water feed line
* * * * *