U.S. patent application number 13/704891 was filed with the patent office on 2013-08-22 for screening methods and apparatus.
The applicant listed for this patent is Marshall Graham Bailey. Invention is credited to Marshall Graham Bailey.
Application Number | 20130213903 13/704891 |
Document ID | / |
Family ID | 42583005 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130213903 |
Kind Code |
A1 |
Bailey; Marshall Graham |
August 22, 2013 |
SCREENING METHODS AND APPARATUS
Abstract
An apparatus (25) for use in screening a liquid and solids
mixture feed (2) comprises a conduit (18), including a screening
portion (22) that is formed and arranged to divide a liquid and
solids mixture feed flowing through the conduit. The feed (2) is
divided into a first, cleaned stream (C1) comprising liquid and
solid particles of below a selected size limit, and a second,
concentrated, stream (24) comprising liquid, and particles above
the selected size limit. The apparatus (25) may be a stand alone
module, part of a system with other solids and liquids separating
equipment or an integral part of a solids and liquid separator such
as a shale shaker. Methods of using the apparatus (25) are also
described.
Inventors: |
Bailey; Marshall Graham;
(Dubai, AE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bailey; Marshall Graham |
Dubai |
|
AE |
|
|
Family ID: |
42583005 |
Appl. No.: |
13/704891 |
Filed: |
June 24, 2011 |
PCT Filed: |
June 24, 2011 |
PCT NO: |
PCT/GB2011/000960 |
371 Date: |
March 4, 2013 |
Current U.S.
Class: |
210/780 ;
210/252; 210/253; 210/259; 210/324; 210/335; 210/359; 210/416.1;
210/435; 210/767; 210/787; 210/806 |
Current CPC
Class: |
B07B 1/46 20130101; B07B
2230/01 20130101; E21B 21/065 20130101; B07B 1/28 20130101; B07B
2201/04 20130101; B07B 13/16 20130101; Y10T 137/794 20150401 |
Class at
Publication: |
210/780 ;
210/435; 210/359; 210/335; 210/416.1; 210/324; 210/767; 210/787;
210/806; 210/252; 210/259; 210/253 |
International
Class: |
E21B 21/06 20060101
E21B021/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 25, 2010 |
GB |
GB1010731.6 |
Claims
1. An apparatus for use in screening a liquid and solids mixture
feed, the apparatus comprising: a conduit, including a screening
portion and formed and arranged to divide a liquid and solids
mixture feed flowing through the conduit into a first, cleaned
stream comprising liquid and solid particles of below a selected
size limit, and a second, concentrated, stream comprising liquid,
and particles above the selected size limit.
2. An apparatus according to claim 1 wherein at least the screening
portion of the conduit is subject to vibration provided by
vibration means.
3. An apparatus according to claim 2 wherein at least the screening
portion of the conduit is: mounted on resilient mountings; or is
located in a basket mounted on resilient mountings; and the
screening portion of the conduit or the basket containing it is
subject to vibration by the vibration means.
4. An apparatus according to claim 1 wherein the conduit is a pipe
or channel having a screen mesh or other filter material that
replaces part of its wall.
5. An apparatus according to claim 1 wherein the conduit
incorporates a secondary, internal conduit, for example a pipe,
that has a portion of wall replaced by a screen mesh or other
screen or filter material.
6. An apparatus according to claim 1 wherein the conduit comprises
at least two screens, provided in one or more screening portions of
the conduit, wherein the at least two screens are formed and
arranged to operate in a series fashion whereby the first, cleaned
stream is passed successively through both screens.
7. An apparatus according to claim 1 wherein the conduit is formed
and arranged so that the screening of the feed effected by the
screening portion of the conduit is carried out in an upwardly
flowing direction through the screening portion.
8. An apparatus according to claim 1 wherein the conduit is formed
and arranged so that the screening of the feed effected by the
screening portion of the conduit is carried out in a downwardly or
a horizontally flowing direction through the screen.
9. An apparatus according to claim 1 formed and arranged so that
the screening is carried out at a slight positive pressure provided
by one or more of the following: an inlet for the conduit is at a
height greater than the height of the screening portion of the
conduit; an outlet for the conduit, in the form of a weir or an
orifice, is at a greater height than the screening portion of the
conduit; a pump supplies the liquid and solids mixture feed to the
conduit; and an outlet orifice from the screening portion of the
conduit is restricted with respect to the size of the inlet
flow.
10. An apparatus according to claim 9 wherein at least one of:
inlet height; outlet height; pumping rate; and outlet orifice size;
is manually or automatically variable to adjust the flow rate and
the pressure applied for screening.
11. An apparatus according to claim 9 wherein the screening portion
of conduit has a portion of screen mesh or other filter material on
an upwards facing portion of wall and the feed is supplied at a
slight positive pressure so as to effect upwards filtration through
the screen mesh.
12. An apparatus according to claim 9 wherein the screening portion
of conduit has a portion of screen mesh or other filter material on
a vertical or downwards facing portion of wall and the feed is
supplied at a slight positive pressure so as to effect horizontal
or downwards filtration through the screen mesh.
13. An apparatus according to claim 8 wherein the conduit: a) is
mounted in a vibrating basket or is itself mounted on resilient
members and is directly vibrated; b) has a downwards directed, for
example vertical, inlet end followed by a generally horizontally
disposed screening portion that has a screen mesh replacing a
portion of conduit wall; and c) the conduit continues by having an
upwardly directed, for example vertical, outlet end at a lower
height than the inlet end.
14. An apparatus according to claim 1 further comprising a scalping
screen, formed and arranged to remove large particles from the
liquid and solids mixture feed before it flows through the
conduit.
15. An apparatus according to claim 14 wherein the scalping is
subject to vibration by vibration means.
16. A method of screening a liquid and solids mixture feed, the
method comprising: providing a conduit, including a screening
portion and formed and arranged to divide the feed flowing through
the conduit into a first, cleaned stream comprising liquid and
solid particles, of below a selected size, and a second,
concentrated, stream comprising liquid and particles above the
selected size; and passing a liquid and solids mixture feed through
the conduit.
17. A method according to claim 14 wherein the method further
comprises: directing the second stream to an apparatus for further
processing.
18. The method according to claim 17 wherein the second stream is
processed by a method comprising passing the second stream through
at least one of a vibratory screening machine, a centrifuge and a
hydrocyclone.
19. A method according to claim 16 wherein the method further
comprises: processing a liquid and solids mixture feed through at
least one of: a scalping screen, a vibratory screening machine, a
centrifuge and a hydrocyclone: before passing a resulting liquid
and solids mixture feed through the conduit.
20. (canceled)
21. A method according to claim 17 wherein the at least one
apparatus employed to process the second stream is a shale
shaker.
22. A system for screening a liquid and solids mixture feed, the
system comprising: an apparatus including a conduit, the conduit
including a screening portion formed and arranged to divide a
liquid and solids mixture feed flowing through the conduit into a
first, cleaned stream comprising liquid and solid particles of
below a selected size limit, and a second, concentrated, stream
comprising liquid, and particles above the selected size limit; and
screening or liquid and solids separating apparatus for processing
the second stream.
23. A system according to claim 22 wherein the apparatus including
a conduit is as wherein at least the screening portion of the
conduit is subject to vibration provided by vibration means.
24. A system according to claim 22 wherein the screening apparatus
for processing the second stream is selected from the group
consisting of hydrocyclones, centrifuges, decanting centrifuges,
vibratory screening machines such as shale shakers, and
combinations thereof.
25. A vibratory screening machine for separating solids from
liquid, in a liquid and solids mixture feed, the machine including
as an integral part: an apparatus comprising: a conduit, including
a screening portion and formed and arranged to divide a liquid and
solids mixture feed flowing through the conduit into a first,
cleaned stream comprising liquid and solid particles of below a
selected size limit, and a second, concentrated, stream comprising
liquid, and particles above the selected size limit.
26. A vibratory screening machine according to claim 25 wherein the
apparatus is mounted in the vibrating basket of a shale shaker.
27. A vibratory screening machine according to claim 26 formed and
arranged so that the second concentrated stream comprising liquid
and particles above the selected size limit is fed to one or more
screens of the shale shaker for further processing.
28. A vibratory screening machine according to claim 26 formed and
arranged so that the liquid and solids mixture feed is processed
through at least one scalping screen of the shale shaker, before
being fed to the apparatus comprising: the conduit.
29. A vibratory screening machine according to claim 26 further
comprising a switchable flow distributor formed and arranged to:
receive the second concentrated stream from the apparatus
comprising the conduit; and to divide said second concentrated
stream to feed, in parallel, a stack of at least two vibrating
screens in the basket; or to feed said second concentrated stream
successively through a stack of at least two vibrating screens in
the basket.
30. A system for screening a liquid and solids mixture feed, the
system comprising: screening or liquid and solids separating
apparatus for processing the feed to produce at least one processed
liquid and solids mixture stream; followed by an apparatus
including a conduit, the conduit being formed and arranged to
receive the at least one processed liquid and solids mixture and
including a screening portion formed and arranged to divide the
processed liquid and solids mixture flowing through the conduit
into a first, cleaned stream comprising liquid and solid particles
of below a selected size limit, and a second, concentrated, stream
comprising liquid, and particles above the selected size limit.
31. A system according to claim 30 further comprising screening or
liquid and solids separating apparatus for processing the second
stream.
32. A system according to claim 30 wherein at least the screening
portion of the conduit is subject to vibration provided by
vibration means.
Description
FIELD OF THE INVENTION
[0001] The invention relates to methods used for the separation of
drilled solids generated during the process of drilling an oil
well, from drilling mud. It is also applicable in wider
applications such as mineral processing, dewatering, processing of
waste fluid streams, quarrying, pharmaceuticals and food
processing. Apparatus for use in the methods is also provided.
BACKGROUND TO THE INVENTION
[0002] Screening is used to separate solids according to particle
size and or to separate solids from fluids. The solids to be
screened may be dry or wet and may often be screened from a
flowable solids and liquids mixture (slurry). The process is used
in many industries including: mineral and metallurgical processing,
quarrying, pharmaceuticals, food and the drilling of oil, water and
gas wells. The design of screening equipment varies widely but will
generally be of one of two types, either static or moving.
[0003] Static screens generally include coarse screens and sieve
bends. These are normally mounted at an angle such that solids on
the screen roll over it by gravity and in so doing either pass
through the screen or roll off it. Static screens are typically
used to screen down to 5 mm. Sieve bends may be used to screen
finer sizes.
[0004] Moving screens are generally described according to the
motion of the screen. Types will typically include: revolving
rotary screens, shaking screens, gyratory screens, linear screens
and high frequency vibratory screens. Moving screen arrangements
normally have two elements, the screen panel and the screening
machine.
[0005] Screen panels will generally be mounted in the screening
machine in such a manner that they may be removed and replaced
either when worn or damaged or when a change in separation size is
required. Screen panels may be constructed of widely differing
materials, including but not limited to, woven wire mesh, wedge
wire, moulded plastics, synthetic woven fabrics and drilled plates
of either plastic or metal. Screen panels are made with different
hole sizes to provide separation at different sizes.
[0006] The function of the screen panel is: [0007] To retain solids
above screen aperture size on the panel. [0008] To transmit the
motion generated within the screening machine to the solids and
liquid, such that the fluid passes through the screen and the
solids retained on the screen are transported on the screen to a
point of discharge from the screen. [0009] To allow fluid and
solids under screen aperture size to pass through the screen.
[0010] To ideally offer resistance to blinding and plugging of the
screen apertures from solids that are of similar size to the screen
aperture size.
[0011] The screening machine design will vary widely according to
the movement that it is required to impart to the screen panel, the
number of screen panels, the method of feeding the panels, the
process application, working environment and process capacity
required. The screening machine motion will normally be arranged to
impart energy to the screen panel such that: [0012] Solids under
screen aperture size are moved in such a manner that encourages
them to pass through the screen. These solids are termed
`undersize` [0013] Solids that are larger than the screen aperture
and as such cannot pass through the screen are retained by the
screen and transported off the screen. These solids are generally
termed `oversize`. Any fluid discharged from the screen with the
oversize solids is generally termed `screen overflow`. [0014]
Fluids carrying solids are encouraged to pass through the screen.
Fluid passing through the screen is generally termed `screen
underflow`.
[0015] Moving screens are used for the screening of either dry or
wet solids and or the screening of solids from fluids. Dry
screening will typically be used for separation of dry solids down
to 1 mm diameter. For sizes lower than 1 mm, wet screening will
normally be used. This method eliminates dust. Wet screening will
normally be the screening of solids from a flowable slurry, being a
mixture of solids and a fluid (liquid).
[0016] Where a slurry is screened to remove the majority of the
fluid from the solids, without any specific need to size the
solids, the function of the screen is generally termed
`dewatering`. This term is applied to the function of the machine
and will apply to slurries that are made with water or any other
liquid as the fluid.
[0017] Where slurry is screened to achieve a specific size split
the function of the screen is termed `classification`.
[0018] In addition to screening equipment making use of screen
panels as described above, other types of solids/liquids separators
can be used, for example centrifuges such as decanting centrifuges,
to separate a solids/liquids mixture.
[0019] Whilst screening machines, especially vibratory screening
machines such as the so called `shale shakers` of the oil well
drilling industry are used with success in methods of
solids/liquids separation, especially classification, there is a
need to improve throughput and effectiveness. This is especially
the case where available space is severely limited, for example on
offshore oil rigs, and the option of increasing equipment size or
the numbers of machines employed may not be available.
[0020] During the drilling of an oil well, fluid known as mud is
circulated, under pressure, inside the drilling assembly to the
drill bit. One of the functions of the drilling mud is to carry the
rock cuttings generated during the drilling process at the drill
bit, out of the borehole.
[0021] The constitution of drilling mud varies according to the mud
type. Generally the mud will contain a fluid phase and a solids
phase. The solids phase may include a weighting agent such as
Barite that is added to the fluid to control the density of the
mud. Other weighting agents can be employed. Generally weighting
agents are made of materials that are of high specific gravity,
typically within the range of 3.2 to 4.4 SG. The weighting agent
will normally be an inert material that will have minimum impact on
the viscosity and fluid properties of the drilling fluid when added
in various concentrations. The size of the weighting agent
particles will normally be below 74 microns with the majority of
the particles being under 40 microns diameter. As the weighting
agent is added to the drilling mud to control the density of the
drilling mud during use, it is generally desirable that the
weighting agent is not removed from the mud system but retained
within it. Other desirable solids can be incorporated into the mud
system such as `Bridging` and `Lost Circulation Material`. These
solids will generally be of within a desirable size range such that
they perform the function for which they are designed.
[0022] When the drilling mud arrives at the drilling rig the solids
fraction of the mud will contain desirable solids and drilled
solids. The drilled solids are generally undesirable solids
comprised predominantly of rock but can contain metal fragments.
The drilled solids are undesirable as these are generally rock
cuttings that if allowed to accumulate at increased concentrations
result in undesirable effects on the fluid properties of the mud.
As the concentrations of drilled solids in a mud increases the
fluid properties are affected until the mud becomes unusable and
requires replacement or the addition of new mud to dilute the
concentration of drilled solids such that the desired fluid
properties are restored. The removal and control of the
concentrations of drilled solids is generally regarded as a most
important activity in contributing to the successful, safe and
economic drilling of an oil well, within the planned time and
cost.
[0023] The process of removal of drilled solids must remove drilled
solids while leaving desirable solids such as weighting material
within the fluid. Drilled solids are conventionally removed from
the mud using first shale shakers to screen the fluid. Rock
cuttings above screen size are removed during screening and the
fluid passes into storage tanks for subsequent mechanical and
chemical processing, where this is desirable, and ultimate
recirculation to the oil well. After screening at the shale shaker
additional solids separation techniques can be applied to remove
any drilled solids that have passed through the shale shaker, being
smaller than the screen size fitted to the shale shaker.
[0024] These techniques conventionally include the use of
hydrocyclones of various sizes and centrifuges. A large diameter
hydrocyclone is conventionally termed a Desander and smaller
diameter hydrocyclones is conventionally termed a Desilter. The
terms Sand and Silt used in the context above are geological terms
referring to the size of the particle concerned. Sand in generally
above 74 microns diameter and silt can range down to a few microns
in diameter. Centrifuges can be of varying types and configuration,
decanting centrifuges are typically employed to separate fine
drilled solids. A combination of decanting centrifuges can be used
to recover weighting agents and remove drilled solids.
[0025] Solids control equipment typically removes solids within the
following size ranges:
TABLE-US-00001 Conventional Shale shakers Solids above 74 microns.
High efficiency Shale Shakers Solids above 40 microns. Desanders
Solids between 1000 and 74 microns. Desilters Solids between 74 and
10 microns. Decanting centrifuges Solids between 200 and 5
microns.
[0026] When choosing the type of equipment to be employed to remove
and control the concentration of drilled solid in the mud the
following are generally accepted desirable criteria:
[0027] The process should be as simple as possible.
[0028] Drilled solids should be removed at the earliest possible
opportunity when they are at their largest size.
[0029] Pumping, recirculation to the oil well and aggressive
handling that results in the fracture of the drilled solid into
smaller particles must be avoided, as small solids are
significantly more difficult to remove from the mud than large
solids.
[0030] Drilled solids should not be allowed to be recirculated to
the oil well as during recirculation they will be broken down and
become increasingly difficult to remove.
[0031] The minimum equipment necessary to achieve the function
should be employed.
[0032] Equipment should be easy to operate for the operators
thereof.
[0033] The installed system should ideally be of low weight, size
and power consumption.
[0034] The system should offer high efficiency of separation.
[0035] The system should be reliable.
[0036] The efficiency of drilled solids removal should be easily
measured.
[0037] Desanders, desilters and centrifuges suffer from the
following undesirable features: [0038] A feed tank containing feed
mud is required this is generally large and heavy, [0039] A feed
pump is required resulting in high power requirements, maintenance,
weight and space. [0040] During pumping of the drilled solid it is
normally fractured and reduced in size making it significantly more
difficult to remove from the mud. [0041] Basis of separation is by
the mass of the cutting not size. Desirable solids such as
weighting material are of high specific gravity. Drilled solids are
generally of lower specific gravity material within the range of
2.8-2.2 sg. The mass of a weighting agent particle can be similar
to the mass of a much larger drilled solid, resulting in the
hydrocyclone separating both desirable weighting material and
undesirable drilled solids of similar mass. It will be noted that
this problem does not occur with screening as the screen separates
by size. [0042] Separation efficiency is variable as fluid
properties vary. [0043] Separation efficiency is difficult to
measure. [0044] Decanting centrifuges capital cost and maintenance
cost are high.
[0045] Shale shakers are conventionally employed in preference to
other equipment due to the following characteristics [0046] No feed
tank required. [0047] Equipment is simple for the operator to
understand and easy to operate and maintain. [0048] Installed space
and weight and typically low. [0049] Power consumption is low.
[0050] Basis of separation is size. [0051] Separation efficiency is
easily determined being directly relative to the mesh size fitted.
[0052] Separation efficiency is not variable with fluid properties
provided the fluid passes through the mesh size fitted.
[0053] The drilling mud returning to the drilling rig from a well
normally contains a low concentration of drilled solids within a
large volume of fluid. The drilled solids removal system is thus
required to process a large volume of fluid to remove a small
volume of drilled solids. Consequently the size of a drilled solids
removal system has historically been directly relative to the
volume of fluid to be processed and NOT the volume of solids to be
removed.
[0054] The oil industry has previous employed hydrocyclone and
screen (e.g. in shale shakers) combinations to concentrate the
volume of solids into a smaller volume of fluid. One such typical
apparatus is called a mud cleaner. Mud cleaners typically employ
hydrocyclone assemblies mounted above a shale shaker or shakers.
Mud is pumped to the hydrocyclone, where the mud is split into two
streams, the hydrocyclone overflow, comprising cleaned fluid and
the hydrocyclone underflow containing fluid and drilled solids that
is passed to the shaker for removal of oversize solids. Analysis of
the performance of the mud cleaner has demonstrated that low solids
removal efficiencies resulted due to the following: [0055] Drilled
solids were fractured into smaller particles during pumping to the
hydrocyclone resulting in them becoming increasingly difficult to
separate. [0056] Separation efficiency was highly variable,
dependant on mud fluid properties. [0057] The hydrocyclone was
easily overloaded with solids. When overloaded drilled solids were
returned to the mud system in the cone overflow thus bypassing the
separation system. [0058] Monitoring the separation efficiency of
the hydrocyclone was difficult and complex.
[0059] The analysis also demonstrated that the efficiency of
separation achieved by the fine screen element of the mud cleaner
was consistently high, determinable and easy to monitor in the
field. Historically this analysis led the industry away from
hydrocyclone/screen combinations and towards the development of
higher capacity shale shakers such as the AX1 Shale Shaker
manufactured by Axiom Process Limited.
[0060] One or more shale shakers are used depending upon the volume
of fluid being pumped and the separation efficiency required.
Generally as finer screens are fitted to the shale shaker the
process capacity of the shaker decreases while the efficiency of
separation of solids increases. Typically screening will take place
using screens, generally made of woven wire mesh, of between 10 and
400 mesh. These screens will contain between 10 and 400 wires per
inch respectively and aperture hole size will vary according to the
weave pattern and diameter of the wire used in the weave.
[0061] To achieve the required process capacity and separation
efficiency a drilling rig shale shaker installation will typically
contain between one and eight shale shakers although some
installations can employ more machines. Machines will be employed
to work in parallel where the fluid from the oil well is split into
multiple streams and processed by an equal number of machines.
Installations of shale shakers can thus be appreciable in size.
[0062] Alternatively an installation can contain multiple machines
working sequentially (in series), each separating at a
progressively finer size. Alternatively an installation can contain
a combination of machines working in parallel and series.
[0063] The need to design a vibratory screening machine to provide
the required fluid throughput while transporting solids to the
point of discharge from the screen has resulted in conventional
machines being of a larger size or in greater numbers than is ideal
where space and weight are restricted by either physical or
economic factors.
[0064] An object of the current invention is to provide methods and
apparatus that can significantly increase the processing capacity
of a screening system allowing the size of the system to be
significantly reduced, relative to a conventional approach, for a
given process capacity.
[0065] The invention herein relates to a method and equipment for
improving the volumetric capacity of wet screening equipment.
Typically the equipment will be used for performing a
classification function and typically the solids particle size
range will be of the order of between 10 mm and 10 microns. However
the methods and apparatus may be used for other solids/liquids
separations, with particle sizes out with that range.
DESCRIPTION OF THE INVENTION
[0066] According to a first aspect the present invention provides a
method of screening a liquid and solids mixture feed, suitable for
use in recycling drilling mud, the method comprising: [0067]
dividing the feed, by screening, into a first, cleaned stream
comprising liquid and solids of below a selected particle size and
a second, concentrated, stream comprising liquid and solids above a
selected particle size; and [0068] directing the second stream to
an apparatus for further processing.
[0069] The further processing may include separating at least some
of the solids from the liquid in the second stream.
[0070] The apparatus for further processing may be a screening
apparatus such as a vibratory screening machine (e.g. a shale
shaker) for example. The shale shaker may separate solids of a
selected size from the second stream. Alternatively the second
stream may be further divided, for example by a hydrocyclone into
further streams with different loads of solids in each. Other
options are discussed hereafter.
[0071] The division of the feed into the two streams may be
accomplished by use of a suitable screen for example a screen of a
woven wire mesh, wedge wire, moulded plastics, synthetic woven
fabrics or drilled plates of either plastic or metal. The apertures
in screening plates may be produced by laser or chemical etching
processes or some other suitable method. The screen may be mounted
in a suitable screening machine. Both of the two streams are
flowable; the first stream can flow or be pumped to a holding tank,
or to a further processing step or be recycled directly and reused.
The second stream can flow or be pumped to the screening or other
solids liquid separation apparatus. The second stream is
concentrated in the sense that the amount of solid particles above
the selected size has been increased relative to the liquid volume.
The first stream removes liquid (and undersize solids) from the
stream that is then further processed in the screening or other
solids liquid separation apparatus.
[0072] The feed may be subject to a pre-treatment before being
divided, for example it may be passed through a screen, typically a
coarse mesh screen (a "scalping screen") to remove large
particles.
[0073] Screening apparatus employed to process the second stream
may be of any suitable type for the solids/liquid separation
intended, for example a centrifuge, such as a decanting centrifuge
or a vibratory screening machine (a shale shaker). A combination of
different screening apparatus may be employed, for example high
efficiency shale shakers followed by centrifuges. In this context
the processing of the second stream may include any chosen method
or combination of methods of processing that may alter the solids
content (in terms of concentration of solids or classification by
particle size or particle density). Thus the processing methods may
include use of apparatus such as hydrocyclones to further divide
the second stream. For example the second stream may be divided
into e.g. a third stream containing higher mass particles and a
fourth stream containing lower mass particles.
[0074] The design of the High Capacity Shale Shaker mentioned above
in the Background to the Invention is limited by the need to
separate fluid and solids while providing a mechanism for the
solids to be discharged from the shale shaker screen. In the
application of the current invention separation is achieved in
stages. The first stage does not require separation of solids from
liquid as it uses screening to separate the fluid into two streams,
the first stream being the majority of the fluid volume and solids
under screen size, and the second stream being the minority of the
fluid volume within which is concentrated the majority of solids
above screen size. After processing by the invention the first
fluid stream is typically directed to a storage system, (for
example the mud storage system when dealing with used drilling mud)
for recirculation and the second fluid stream is directed to high
efficiency shale shakers, or other liquid and solids separation
equipment, where fluid and drilled solids are separated.
[0075] The advantages of the method of the invention may be
summarised as follows:
[0076] The use of screening allows all of the advantages of
screening separation to be used eliminating the disadvantages or
hydrocyclone and centrifuges.
[0077] Separation efficiency is easily determined on site, without
complex analysis as it is based on size not mass.
[0078] The equipment is simple to build, operate, monitor and
understand.
[0079] The elimination of the need to separate solids and liquids
in the first stage allows screening techniques to be employed in
the invention that result in previously unobtainable fluid
throughputs from any given screen (typically a mesh) area resulting
in a significant reduction in machine size.
[0080] The size, weight, power requirement and cost of the
downstream shale shaker installation (or other screening system,
processing equipment or combination of processing equipment) can be
reduced.
[0081] The process is simple and easy to understand, monitor and
operate.
[0082] As the process capacity of the invention is significantly
higher than conventional screens and the load on downstream shale
shakers is reduced the efficiency of solids removal can be
increased by the use of finer screens.
[0083] Conveniently the division of the feed into the two streams
is carried out as the feed flows along a conduit fitted with a
screening portion.
[0084] Thus according to a second aspect the present invention
provides a method of screening a liquid and solids mixture feed,
the method comprising: [0085] providing a conduit, including a
screening portion and formed and arranged to divide the feed
flowing through the conduit into a first, cleaned stream comprising
liquid and solid particles, of below a selected size, and a second,
concentrated, stream comprising liquid and particles above the
selected size; and [0086] passing a liquid and solids mixture feed
through the conduit.
[0087] The method may include directing the second, concentrated
stream to a screening apparatus (or more than one of the same or
different types) for subsequent treatment where solids are
separated from the liquid of the second stream (or are otherwise
further processed using suitable equipment) as described in respect
of the first aspect of the invention. However if a solids/liquid
separation is not required the conduit may be used simply to
concentrate a liquid and solids feed. As a yet further alternative
the solids and liquids mixture feed may already have been processed
before it is passed through the conduit. For example larger
particles may have been removed by a scalping screen or the feed
may have been processed through one or more of a vibratory
screening machine (e.g. a shale shaker), centrifuges, hydrocyclones
such as desanders, desilters or the like.
[0088] A significant advantage provided by the method is that a
screening operation is carried out without a requirement for solids
handling. The screening operation using the conduit produces two
fluid (i.e. flowable) streams of a liquid and solids mixture, by
appropriate choice of equipment for a given task.
[0089] Avoiding concentrating the oversize solids to the point
where they are a solid or semi-solid mass has notable
advantages.
[0090] The flowable streams can be readily conveyed (e.g. along a
pipe by pumping and/or gravity) to their destination for further
processing, storage or use. Handling isolated solids, (especially
isolated wet solids that are often cohesive i.e. sticky) as occurs
with other screening methods requires more complex equipment. By
making use of the method of the invention a substantive screening
process can be carried out producing two flowable streams. Even if
one or even both of the streams produced is to be subject to a
further processing including a solids isolating step, the work
required on a given stream is reduced in terms of volume of fluid
and/or amount of solids to be handled.
[0091] It will be appreciated that either of the two streams
produced may be of higher value or greater use than the other,
depending on the application and the reason for the screening
process being carried out. Thus the term `cleaned` when referring
to the first stream as used herein simply denotes the removal of
larger sized particles, by the use of the screening portion of the
conduit, from the original feed.
[0092] Thus the present invention provides an apparatus for use in
screening a liquid and solids mixture feed, the apparatus
comprising: [0093] a conduit, including a screening portion and
formed and arranged to divide a liquid and solids mixture feed
flowing through the conduit into a first, cleaned stream comprising
liquid and solid particles of below a selected size limit, and a
second, concentrated, stream comprising liquid, and particles above
the selected size limit.
[0094] The apparatus may be used in the methods according to the
first or second aspects of the invention. The liquid and solids
mixture feed may be a drilling mud composition, in particular a
used drilling mud composition comprising drill cuttings.
[0095] The conduit may be formed and arranged to direct the second,
concentrated stream to a screening apparatus, or other processing
equipment, for subsequent treatment.
[0096] Advantages of the apparatus include:
[0097] The apparatus may be used as a stand alone module or as an
integral part of a screening machine; and
[0098] The apparatus can be used in combination with existing
shaker installations allowing upgrade of existing installations at
low cost.
[0099] The apparatus may be used ahead of equipment other than
shale shakers, such as centrifuges, for example decanting
centrifuges. In this application the apparatus will reduce the
fluid load on such equipment allowing performance to be improved
and or less equipment used.
[0100] As an alternative the apparatus may be used after
conventional equipment. For example to provide fine screening of a
used drilling mud after drill cuttings and larger particles have
been removed by shale shakers and/or other processing
equipment.
[0101] Typically when used ahead of other separating equipment the
subsequent processing will involve separating solids from the
second stream solids and liquid mixture, for example by use of a
vibratory screening machine, a centrifuge or other solids/liquid
separations device. The methods described herein have the advantage
of reducing the volume of mixture feed that has to be processed by
relatively complex, expensive and often bulky screening equipment.
The proportion of solids relative to liquid present in the second
stream is increased. Thus the equipment that separates the solids
from the liquid may be reduced in size for a given volume of feed
to be processed.
[0102] Screening by the conduit can therefore reduce the overall
footprint of screening apparatus employed, for example in oil
drilling operations and/or improve throughput. At the same time as
the mixture feed is divided into streams that flow (solids
dispersed in a liquid) by the method, there is no requirement for
extra solids handling operations. The screening portion operates to
"pre-screen" the feed in advance of a solids removal step by the
screening or other liquid solids separation apparatus.
[0103] Advantageously for some applications the conduit may include
two or more screens that may be located in the same screening
portion or in different screening portions of the conduit. The
screens are formed and arranged to operate in a series fashion with
successive screens having finer mesh.
[0104] For example where two screens are used the liquid and solids
feed is divided by the first screen into a first cleaned stream
(passing through the first screen) and a second concentrated stream
not passing through the first screen as described above.
[0105] The first, cleaned, stream is then processed further by the
second screen which will have a finer mesh than the first. This
results in a first cleaned stream that has passed successively
through both screens and another concentrated stream, of liquid and
solids that has passed the coarser first screen but not the finer
second screen. The two concentrated streams produced may be
recombined for further processing or use or they may be kept
separate and directed (e.g. along separate branches of conduit or
pipe) for separate further processing storage or use.
[0106] Therefore the methods and apparatus described herein may be
used for progressive screening operations without necessarily
requiring the use of other processing equipment.
[0107] Thus the present invention provides a system for screening a
liquid and solids mixture feed, the system comprising: [0108] an
apparatus including a conduit, the conduit including a screening
portion formed and arranged to divide a liquid and solids mixture
feed flowing through the conduit into a first, cleaned stream
comprising liquid and solid particles of below a selected size
limit, and a second, concentrated, stream comprising liquid, and
particles above the selected size limit; and [0109] screening or
liquid and solids separating apparatus for processing the second
stream.
[0110] The screening apparatus for processing the second stream may
be a screening machine such as a shale shaker or any other type of
vibratory screening device. Alternatively hydrocyclones,
centrifuges or any other solids and liquids separator may be
employed. A combination of screening apparatus of the same or
different types may be used in the system. They may operate in
series or parallel or some combination of series and parallel.
[0111] In an alternative approach the present invention provides a
system wherein the liquids and solids mixture feed is processed in
the conduit as discussed above but the second stream is not
necessarily further processed. This can occur when the system has
screening or liquid and solids separating apparatus provided before
the apparatus including the conduit and the conduit carries out a
final screening operation.
[0112] In the field of drilling operations the methods, apparatus
and system of the invention can be operated particularly
advantageously. Typical drill cuttings and drilling mud streams
generally contain a high proportion of liquid to solid. For example
during the drilling of an oil well the mud returning to the surface
for processing by a shale shaker (vibratory screening machine) will
typically contain between 0.1 and 10% by volume of drilled solids
that are of a size capable of separation by a shale shaker. The
volume of drilled solids to be separated by the shale shaker will
thus normally be a relatively small volume compared to the volume
of fluid to be processed.
[0113] The throughput of screening apparatus employed, such as
vibratory screening machines, tends to be limited by the volume of
liquid being processed rather than by the solids content. By
dividing the feed into the two streams the screening or other
liquid solids separation apparatus can be used more effectively, on
a concentrated (second) stream of solids and liquids.
[0114] The first, cleaned stream may be directed to a tank or other
receptacle for subsequent treatment, recycle, reuse or disposal.
Alternatively the first stream may be reused, (e.g. where the feed
is a used drilling mud, by returning the cleaned stream into a
drilling mud stream) immediately after screening in the conduit
screening portion. As a yet further alternative the first stream
may be directed to further processing equipment, for example a
vibratory screening machine where at least some of the solids
content may be removed before reuse, recycle or disposal.
[0115] The screening portion of the conduit employed in the
apparatus, methods and systems described herein may take several
different forms. For example the conduit may be a pipe or channel
having a screen mesh or other filter material that replaces part of
its wall. Screens may be mounted vertically, horizontally or at any
angle or combination of angles between vertical and horizontal. The
first, cleaned stream or filtrate (liquid together with solids
below the mesh size) will pass through the mesh and can be directed
to subsequent treatment as desired. For example, by means of a
further section (e.g. a branch) of conduit.
[0116] Alternatively the conduit may incorporate a secondary,
internal conduit (e.g. a pipe) that has a portion of wall replaced
by a screen mesh or other screen or filter material. Liquid and
undersized solids from the feed passing along the (outer) conduit,
passes through the screen mesh and into the internal conduit and is
then directed as required.
[0117] Multiple internal conduits may be employed and may be formed
in any convenient shape or shapes to provide the desired division
into the two streams and overall flow rate. For example cylinders,
hexagonal prisms or cuboids as illustrated hereafter with reference
to specific embodiments.
[0118] Where multiple screens operating in series are used in a
conduit screens may be for example, spaced apart from each other
and stacked in a section of conduit. Alternatively series screening
in the conduit may be obtained e.g. by having two internal
conduits, one inside the other and each having a screening
portion.
[0119] Multiple conduits such as those described herein may be
employed in the method. The conduit or conduits may be of any
convenient shape.
[0120] For efficient operation of the apparatus the screening
portion should operate with minimum downtime, in particular it
should be arranged to, as far as possible, avoid blinding or
clogging of the screen mesh or other filter material during use.
This possibility may be avoided to some extent by the flow of the
feed along the conduit constantly washing the screen mesh.
[0121] Additional clearing action can be achieved by having at
least the screening portion of the conduit subject to vibration.
For example by locating the conduit in a "basket" that is mounted
on resilient mountings such as springs and vibrated in a similar
fashion to that of a typical vibratory screening machine. Typically
vibration is by means of a pair of electric motors having eccentric
(or eccentrically weighted) shafts turning in opposite directions.
The vibration tends to keep particles in the feed mobile or
fluidised and can provide a clearing effect, removing particles of
solid blocking a screen mesh or other screening material while
assisting fluid to flow through the screen. The conduit may also be
designed such that the fluid passes through it when in turbulent
flow e.g. by the provision of baffles, thus further assisting the
passage of oversize solids through the conduit.
[0122] It will be readily apparent to the skilled person that the
design of the apparatus can be adjusted to provide the desired
degree of screening to the first stream and concentration to the
second stream, for a given expected feed, in a number of ways.
[0123] Adjustment of the following factors can be made: [0124] a)
The method of entry of the feed to the screen; [0125] b) Employing
different methods to avoid settling of solids such as: [0126]
pre-screening using e.g. a scalping screen to remove large
particles or a [0127] hydrocyclone to remove dense particles;
[0128] providing baffles to obtain turbulent flow; [0129] adjusting
the flow rate across the screen face; [0130] adjusting the depth of
fluid on each side of screen; [0131] changing vibration
characteristics applied to the conduit; and [0132] changing any one
or more of the shape or size of: the screen, the conduit, and the
fluid outlet for concentrated fluid.
[0133] For typical operations fluid flow velocities within the
conduit may be in an operational range of about from 5 to 500 feet
per minute (about 1.5 to 150 metres per minute).
[0134] Thus when provided as a stand alone module the apparatus may
comprise the conduit with means to vibrate it. The feed may be
supplied to the vibrating conduit by means of a conduit or pipe,
that may provide the feed from a source such as a head tank or by a
pump from a storage tank The vibrating conduit may be connected to
the feed conduit by a portion of flexible pipe or bellows.
Similarly the two product streams from the module may be directed
onwards for further processing or storage via suitable conduits or
piping that may be connected to the vibrating conduit by flexible
connections. A stand alone module may also include a scalping
screen (that may be vibrated) upstream of the conduit, for removal
of large particles that might reduce the effectiveness of the
conduit and contribute to reduced conduit screen life.
[0135] As an alternative the apparatus may be integrated within
further processing equipment, for example may be provided in the
basket of a vibratory screening machine, such as a shale shaker.
For example the apparatus in a shale shaker basket may provide a
first screening to a used drilling mud feed. The cleaned stream may
be suitable for reuse directly in drilling mud or may be further
processed. The second, concentrated stream is then passed through
the screen(s) of the shale shaker to remove the larger sized solid
particles and provide further fluid for reuse or further
processing. Conveniently the feed may be fed through a scalping
screen, to remove large particles before being passed through the
conduit. The scalping screen can be provided integral with the
basket.
[0136] As a yet further alternative the apparatus may be integrated
in a basket of a shale shaker or other vibratory screening machine,
but may be located after the screens to divide already screened
fluid into a cleaned stream and a second, concentrated stream.
[0137] Advantageously the screening of the feed effected by the
screening portion of the conduit is carried out in an upwardly
flowing direction. The fluid that is screened passes upwardly from
the conduit through the screen mesh. This approach has the
advantage that the screen mesh tends to be kept clear by the action
of gravity. Oversize particles held against the screen mesh will
tend to fall off, back into the flow of feed towards subsequent
screening apparatus. Alternatively filtration through the mesh may
be in a downward or lateral direction or in any other suitable
direction or combination of directions.
[0138] Furthermore where a vibratory action is employed the
presence of a layer of screened fluid above the mesh, as described
hereafter with reference to a specific embodiment, may be
advantageous. The vibrating action can result in a to and fro
pumping action in the fluid through from one side of the mesh to
the other that assists in keeping both sides of the screen clear of
accumulated solids.
[0139] Advantageously the screening portion of conduit has a
portion of screen mesh or other filter material on an upwards
facing portion of wall and the feed is supplied at a slight
positive pressure so as to effect upwards filtration through the
screen mesh. Even where the screening portion is at any angle
supplying the feed at a slight positive pressure so as to encourage
its passage through the screen mesh is advantageous.
[0140] Conveniently this can be arranged by having a feed conduit
with a screening portion that is at a lower height than the inlet
end of the conduit, thus producing a pressure (a head pressure) at
the screening portion.
[0141] Conveniently either the outlet from the conduit may be
limited in size, such that a head of fluid creating a positive
pressure on the screen is created. Alternatively or additionally
the outlet from the conduit may be positioned at a level above the
height of the screen such that a head of fluid is created resulting
in a positive pressure on the screen. A weir arrangement may be
provided as discussed below. In either case the positive pressure
on the screen assists flow through the screen.
[0142] Fluid throughput is proportional to pressure for a given
size of conduit. Typically a head or pressure equivalent to between
50 mm and 2000 mm will be used. The head will be limited by the
ability of screening material employed to withstand the load i.e.
the operating pressure will be determined by the ability of the
screening material to withstand the operating pressure without
failing. Where a screening material has the ability to be operated
with higher pressure heads above 2000 mm may be used. For example a
wedge wire screen will typically be capable of operation at a
pressure significantly higher than that of a woven wire screen with
a similar aperture size.
[0143] In a particularly advantageous arrangement the conduit is
mounted in a vibrating basket or is itself mounted on resilient
members and is directly vibrated. It has a downwards directed (e.g.
vertical) inlet end followed by a generally horizontally disposed
screening portion that has a screen mesh replacing a portion, for
example an upper portion of conduit wall. The conduit continues by
having an upwardly directed (e.g. vertical) outlet end. The end of
the outlet end is at a lower height than the inlet and acts as a
weir over which the second stream flows and may then be directed to
a subsequent screening apparatus. This form of conduit, with an
overall `U` (or `J`) shape provides a robust, relatively simple in
construction apparatus. The mixture feed flows around the U by
virtue of the head pressure from the inlet end. The head pressure
produced by the raised outlet end acts to force liquid and
undersize solids upwards through the screen mesh (where it is on an
upper portion of conduit wall) to produce the first cleaned stream,
that can then be directed as desired, for example to a tank for
recycling. Such an arrangement is shown in an embodiment described
in more detail hereafter.
[0144] Advantageously the height of the outlet end or a weir
associated with the outlet end can be variable. This allows the
flow rate along the conduit to be controlled so as to obtain the
desired amount of screening in the screening portion whilst at the
same time maintaining sufficient flow rate to avoid settling out of
solids within the conduit. The height of the outlet may be fixed or
varied either manually or automatically. If controlled
automatically or manually the head of fluid may be varied to
increase or decrease the head in order to achieve the required
process flow rate of the screen to process the flow arriving at the
inlet.
[0145] Alternative arrangements are possible. For example the
conduit may have a generally U shape as described above but the
screening portion, in the form of a portion of conduit with a mesh
panel replacing part of the wall, may be formed on the downwardly
directed (inlet) end or on the upwardly directed (outlet) end. In
either case the pressure produced by the head will force liquid and
undersized solids outwardly through the mesh panels or other filter
material employed.
[0146] Alternatively the conduit may be L shaped with the inlet end
above the screen and the discharge end below the screen. The rate
of discharge is controlled by a size of the discharge orifice. The
orifice may be fixed size or variable. If variable it may be
manually controlled or controlled by an automated control system
such that a head of fluid is maintained within the conduit and the
resulting pressure assists flow of the fluid through the screen. If
controlled automatically or manually the head of fluid may be
varied to increase or decrease to achieve the required process flow
rate of the screen to process the flow arriving at the inlet.
[0147] Alternatively the solids and liquid mixture may be pumped
into the conduit at a pressure that is suitable to assist flow
through the conduit and the screening action.
[0148] The outlet from a conduit supplied by a pump may be over a
weir the height of which may be adjustable or fixed. In this
arrangement the head of fluid created by the height of the weir
assists flow across the screen and thus the rate of processing of
the fluid while the rate of pumping controls the velocity of fluid
in the conduit. According to this arrangement the fluid velocity
can be controlled to ensure that no settling of solids occurs
within the conduit and all solids are carried forward to the
conduit outlet. Control of the height of the weir may be manually
or automatically adjustable. If automatically control is employed a
suitable control system may be employed to adjust either the height
of the weir, thus controlling the pressure of fluid on the
screening portion of the conduit and consequently the process rate
through the screen. Alternatively the pumping rate may be adjusted
to ensure adequate fluid velocity is maintained within the conduit.
Alternatively both the height of the weir and the input rate are
controlled to allow optimisation of process rate and velocity for a
given feed mixture.
[0149] Alternatively the solids and liquid feed may be pumped into
the conduit at a pressure suitable to assist flow across the screen
and the outlet from the conduit arranged with an orifice of
variable or fixed size. The position of the orifice may be either
above or below the screen. In this arrangement the pressure within
the conduit is maintained at a level suitable to effect flow
through the screen by a combination of input rate and the size of
outlet orifice. The pump rate and pressure may be fixed or variable
either manually or by an automated method. The orifice size may be
fixed or variable either manually or by an automated method.
Advantageously adjustment of the pump rate, pressure and orifice
size may be automated to effect optimum operation of the system.
The pressure employed may typically be equivalent to the head
pressures discussed above with respect to apparatus including a
weir and/or an inlet above the height of the screening portion.
[0150] When used for oil well drilling operations the first stream
comprising screened cleaned fluid will typically be, but is not
limited to, between 20 and 80 percent by volume of the total flow
arriving at the shale shaker or other solids/liquids separator,
from the oil well. This stream having been processed is directed to
the mud storage system where it may be subjected to further
processing by equipment such as centrifuges or chemical processing
prior to recirculation to the oil well.
[0151] The second, concentrated, stream will typically be, but is
not limited to, between 20 and 80 percent by volume of the total
flow arriving at the shale shaker from the oil well. This stream is
passed to, for example, a shale shaker for screening where fluid
and drilled solids above screen size are separated. Drilled solids
are rejected and processed fluid is directed to the mud storage
system where it may be subjected to further processing by equipment
such as centrifuges or chemical processing prior to recirculation
to the oil well. The volume of fluid to be processed by the shale
shaker is significantly reduced and the size of the shale shaker
can be reduced proportionately.
[0152] The two stage process described herein--first screening the
mixture in the conduit and then carrying out a solids liquid
separation--allows techniques to obtain high fluid throughput to be
adopted in the design of the first stage equipment without the need
to separate solids into a separate stream from the fluid. This
allows significant flexibility in the design to be adopted. A
design can be adopted that allows a large proportion of the fluid
arriving from e.g. a well to be processed through a screen of small
physical size (the screen on the screening portion of the conduit).
The remaining fluid, the second stream, in which the solids above
screen size are concentrated, can be processed by a second stage
screen or other screening/liquids and solids separation machine
such as a centrifuge, that is physically smaller than that
previously used for single stage processing.
[0153] This two stage approach allows the overall volumetric
process capacity of a screening machine to be significantly
increased resulting in a smaller machine, the requirement for fewer
machines, a smaller installation, a lighter installation and/or
significantly increased efficiency of separation.
[0154] Screen life is an economic factor in the operation of solids
separation equipment. It has found that screen life of fine meshes
can be relative to the volume of solids to be separated by the
screen. A method of reducing the volume of solids to be separated
by a fine screen is to pre screen the fluid reaching the fine
screen with meshes that remove coarser solids leaving the fine mesh
to remove only a limited quantity of the solids contained in e.g.
mud returning from an oil well in process of being drilled. The
process of removing solids with progressively finer screens may be
referred to as `Progressive Screening`. To achieve `Progressive
Screening` a number of conduits may be arranged in series such that
each conduit is fitted with a progressively finer mesh and the two
fluid streams exiting each conduit are each screened with
progressively finer meshes.
[0155] As an alternative the invention may be employed after fluid
containing solids, (for example returning for processing from an
oil well being drilled), has initially been processed with
progressively finer meshes using conventional equipment and
methods. Employment of the invention in this manner allows coarser
solids to be removed prior to the invention acting to concentrate
the finer solids into a smaller volume of fluid for subsequent
processing. This approach has the advantage that the process
capacity of conventional equipment is highest when removing coarse
solids and lowest when removing fine solids. Employing the
invention to process pre screened fluid extends fine screen life
while significantly reducing the volume of fluid to be processed by
the equipment further downstream of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0156] Further preferred features and advantages of the present
invention will appear from the following detailed description given
by way of example of some preferred embodiments illustrated with
reference to the accompanying drawings in which:
[0157] FIGS. 1(a to c) illustrate schematically the operation of
prior art vibratory screening machines;
[0158] FIGS. 2a and 2b illustrate schematically use of apparatus of
the invention in combination with a vibratory screening
machine;
[0159] FIGS. 3a, 3b and 3c illustrate schematically apparatus of
the invention;
[0160] FIGS. 3d to 3g illustrate schematically further apparatus of
the invention;
[0161] FIGS. 4a to 4k illustrate schematically apparatus of the
invention in use with vibratory screening machines;
[0162] FIG. 5 illustrates schematically apparatus of the invention
in use with a centrifuge;
[0163] FIGS. 6 and 7 illustrate schematically alternative
conduits;
[0164] FIGS. 8a to 8e illustrate schematically alternative
conduits;
[0165] FIGS. 9a and 9b illustrate schematically prior art screening
systems;
[0166] FIG. 10 illustrates schematically a screening system of the
invention; and
[0167] FIG. 11 illustrate schematically an apparatus of the
invention integrated with a shale shaker.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO SOME
PREFERRED EMBODIMENTS
[0168] Prior Art
[0169] A typical (prior art) vibratory screening machine is shown
schematically in FIG. 1a and indicated by the reference numeral 1.
The general method for dealing with solids/liquid separation is as
follows.
[0170] The solids and liquid mixture feed (slurry) 2 is fed onto a
screen 4 as a relatively thin layer or pool 6. The screen may be a
wire mesh or made of other suitable screen material. The action of
gravity and the vibratory motion 8 (that may be applied in a number
of ways such as are well known in the art) assists undersize solid
to pass through the screen together with liquid, as a screened
slurry 9. The vibratory motion 8 causes oversize solids 10 to `walk
up` the screen and be conveyed to the oversize discharge 12.
[0171] Classification difficulties can arise where the solids
contained in the fluid that are under screen size do not reach the
screen face and hence pass through the screen. These undersized
solids will be discharged together with the oversize solids. If the
fluid fails to pass through the screen and reports to the oversize
discharge 12 it will generally carry undersize solids with it,
consequently reducing classification efficiency.
[0172] A key requirement is that the screen apertures remain open
to allow solids to pass through the screen. A common problem
experienced is screen `blinding`. This occurs when solids become
trapped in the apertures of the screen. When `blinding` occurs the
number of apertures in the screen is reduced, the effective size of
the apertures is reduced and the process capacity of the screen is
reduced. The performance and often the operating life of a screen
suffering `blinding` will be different from a screen that is not
`blinded`.
[0173] In conventional equipment multiple methods of eliminating or
reducing blinding are employed. Typically these may include but are
not limited to: the use of shaped apertures, wedgewire screen
construction, layered wire meshes, the screen motion and frequency
of screen vibration.
[0174] Other problems that can limit the efficiency of this type of
screening apparatus include agglomeration of the oversize solids
10. Oversize solids can form agglomerations or a thick bed of
solids on the screen 4 face that contain, trap or act as a filter
to trap undersize material. Generally it is recognised that once an
agglomeration or bed of dewatered or partially dewatered solids is
formed, any undersize solids in the agglomeration or bed can be
trapped inside the agglomeration and will thereafter report to the
oversize fraction. To counteract this tendency low feed rate may be
employed or liquid sprays may be used to break up
agglomerations.
[0175] Historically machines of this type have been constructed as
a compromise between the need to enhance fluid throughput, provide
sufficient screen area to achieve the required throughput and
transport solids from the screen face. Typically prior art machines
have incorporated features such as illustrated schematically in
FIGS. 1b and 1c.
[0176] The machine 1 of FIG. 1b has a screen 4 inclined at a screen
angle of typically between 0 and 15 degrees. As the screen angle is
increased the depth of the pool 6 increases and the screen
throughput increases as a consequence (an increased head [indicated
by h] of feed). However as the angle of the screen increases the
speed of transport of solids 10 up the screen face to the point of
discharge generally reduces.
[0177] The section 14 of the screen 4 that is processing the feed 2
is generally referred to as the fluid pool. The length of the fluid
pool will typically be between 20 and 70 percent of the screen
length. The section of the screen that is drying the oversize
solids 10 retained on the screen and transporting those solids to
the screen discharge 12 is termed the beach 16. The length of the
beach will typically be between 20 and 60 percent of the screen
length. Typically the fluid content of the solids discharged (the
dryness of the oversize solids) will be affected by the length of
the beach 16.
[0178] FIG. 1c shows an arrangement similar to that of FIG. 1b
except that the screen 4 has a generally horizontal section 14
where the fluid pool 6 collects, before the inclined beach 16.
[0179] In addition to the above some machines have incorporated
multiple screen decks with feed mechanisms that allow the feed
stream to be split between the decks, and can allow series or
parallel processing of the slurry on those decks.
[0180] The New Method
[0181] The new method is illustrated schematically in FIGS. 2a and
2b. FIG. 2a shows a vibratory screening machine 1 of the same
general form to that shown in FIG. 1. A feed 2 of oil well drilling
mud and drill cuttings is being processed. The % figures indicate a
typical breakdown of the range of volume of the feed that may be
processed in each stream (indicated by arrows).
[0182] Before the feed 2 is fed onto the machine 1 it is passed
through conduit 18, where as indicated by arrows a first, cleaned
or screened, stream C1 is separated off by passing through the
screen 20 of a screening portion 22 of the conduit 18. The screen
20 has a mesh sized so that the first stream C1, in this example,
is suitable for recycling directly to the drill mud supply tank
(not illustrated) used for more drilling operations. i.e. the
particles passing through screen 20 with the accompanying liquid
are of a suitable size for reuse as drilling mud components.
[0183] The remaining feed 2 constitutes a second stream 24 that is
relatively concentrated in terms of larger particles (oversize with
respect to screen 20) vs. liquid content. the remaining feed is
directed to the vibratory screening machine 1 where the second
stream is screened on the screen 4 as described above with respect
to the prior art. The oversize (with respect to screen 4) particles
of solids 10 are discharged for disposal at the end of the screen 4
and the screened liquid and undersize (with respect to screen 4)
solids form a cleaned stream C2 that can be added to first stream
C1 for reuse.
[0184] The volume of feed 2 passed through shale shaker 1 is
therefore greatly reduced allowing the shale shaker to be smaller
in size and/or allowing the use of fewer shale shakers to process a
given feed 2.
[0185] The % by volume of the various streams produced and
processed in a typical oil well drilling operation is indicated in
FIG. 2b. As can be seen the oversize solids 10 represents only
about 5% of this volume. The concentration in the second stream 24
to a mixture of about 25% liquid (plus undersize solids) and 5%
oversize solids allows much more efficient throughput in the shale
shaker 1.
[0186] FIGS. 3a to 3c illustrate an example apparatus 25 including
a conduit. In this case the apparatus is in the form of a stand
alone module. The module may be used as part of a system of the
invention. However similar arrangements may be used as part of an
integrated machine that carries out additional processing. The
conduit 18 is shown in perspective view, partially cut away to
allow viewing of the internal structure in FIG. 3a and in cross
section elevation in FIG. 3b. A perspective view is shown in FIG.
3c.
[0187] The conduit 18 forms a box like structure or basket, with a
U shaped flow path 26, indicated by the arrow marked FLOW, for the
feed 2 and consequent second stream 24, when viewed in elevation
(FIG. 3b).
[0188] The apparatus 25 is mounted for vibration on mounts such as
springs 28 and is vibratable by any means such as well known in the
art. As an alternative to a separate vibrating arrangement the
apparatus may be mounted together with a screen or screens in a
vibrating basket such as found in a typical shale shaker. In such
an arrangement the apparatus 25 may be an integral part of flow
dividing apparatus that directs slurry to selected screens in a
stack for parallel or series processing such as described in
WO2004/110589 (Axiom Process Limited).
[0189] A solids and liquids mixture feed 2 passes down the vertical
inlet end 30 to the generally horizontally disposed screening
portion 22 fitted with mesh 20 (only partially shown) for upwards
filtration of the feed 2, resulting in first stream C1 containing
liquid and solids of below the mesh 20 size, and second stream 24.
Second stream 24, typically between 20 and 80 percent by volume of
the feed 2, then passes up through two outlet ends 32 at either
side of the screening portion 22 and over their associated weirs 34
(bottom edges of slots 35 in the outlet ends) from where it is
directed for further processing (liquids and solids separation)
typically in a shale shaker or assembly of shale shakers. Only one
each of the outlet ends 32, weirs 34, slots 35 and side walls 36
are shown in FIG. 3a due to the cut away.
[0190] Side walls 36 and the inlet end 30 contain flow C1 so that
after passing through the screen 20 it is directed out of the
basket between the two outlet ends 32. As it has already been
processed through screen 4, C1 may be passed to the mud system for
reuse or if required subjected to chemical or further mechanical
processing.
[0191] High volumetric throughput is achieved by screen 20 due to
the head of fluid and vibratory action acting on the screen. The
head of fluid results from the differential in height H between the
screen 20 and the weirs 34.
[0192] The design of outlets 32 is an important feature of the
invention. The dimension of these ducts must be such that the
velocity of the liquid/solids mixture of the second stream 24
during operation is sufficiently high for the solid to be carried
forward over weirs 34. These can be readily determined from a
consideration of the expected relative densities of the particles,
the liquid employed, the flow rate into the inlet end 30 and simple
tests. Advantageously the height H is made adjustable, for example
by the provision of moveable plates (not shown) that can partially
cover the slots 35 in the outlet ends 32.
[0193] Alternative conduit designs are possible. FIG. 3d shows
schematically in elevation an alternative apparatus 25. The conduit
is arranged with the inlet end 30 above the screen 20 and having a
discharge orifice 37 located below the screen 20. The rate of
discharge is controlled by a size of the discharge orifice 37. The
orifice may be fixed size or variable. If variable it may be
manually controlled or controlled by an automated control system
such that a head of fluid h is maintained within the conduit and
the resulting pressure assists flow of the fluid through the screen
20. If controlled automatically or manually the head of fluid h may
be varied to increase or decrease to achieve the required process
flow rate of the screen to process the flow 2 arriving at the
inlet.
[0194] In an alternative embodiment of the invention shown in FIG.
3e the apparatus 25 may be configured with two layers of screen 20,
20a. In this example the apparatus is arranged similarly to that in
FIG. 3d, making use of orifice discharges 37,37a, but two (or more)
screen stages may be obtained when making use of weir arrangements
as in FIGS. 3a,3b, 3c.
[0195] In FIG. 3e the feed 2 passes through initial screen 20
creating a partially cleaned fluid stream C1 a proportion of which
then passes finer screen 20a to produce cleaned stream C2. The
fluid and solids passing the first screen 20 but not the second
stream 20a form a further second stream 24a. The cleaned stream C2
passing the two screens 20,20a may be e.g. passed for recirculation
to an oil well or be subject to further processing. Second stream
24a passing the first screen 20 but not the second screen 20a may
be either passed for recirculation to an oil well, subject to
further processing or recombined with the stream 24 not passing
either screen. The aim of this arrangement may be to protect the
fine screen 20a and increase its operating life. Additionally
second stream 24a will contain particles classified in size between
the two screen mesh sizes. These screens 20,20a may be selected so
that the particles in second stream 24a are of a desirable size
range for reuse. For example the two screens 20,20a may be used to
select desired particulates such as lost circulation material for
recycling into an oil well drilling mud.
[0196] The apparatus 25 may be fitted with more than two layers of
screens 20 producing multiple fluid streams that may be either
recombined or processed in any combination as suitable to the
application.
[0197] FIG. 3f shows schematically an alternative arrangement where
the apparatus 25 is fed by a pump P. A weir 34 (that may be fixed
or variable height) is also employed. The combination of weir 34
and pump P allows control of the velocity of the feed through the
conduit and the rate of the flow through screen 20.
[0198] FIG. 3g shows a similar arrangement to that of FIG. 3f
except that the second stream 24 exits apparatus 25 by an orifice
37 (fixed or variable) rather than over a weir.
[0199] Further examples of conduit arrangements are shown in FIGS.
6, 7 and 8 as described hereafter.
[0200] Apparatus such as that shown in FIG. 3 can be operated as a
stand alone unit or integrated in to a screening machine such as a
vibratory screening machine.
[0201] Many alternative configurations are possible and schematic
illustrations of these are shown in FIG. 4 with apparatus 25 shown
accepting feeds 2 and dividing them into cleaned first streams C
and concentrated second streams 24. The screens in apparatus 25 are
not shown in these schematics, for clarity. Also not shown are
details of shale shaker machines, for example flow back pans that
may be provided between screens mounted in a stack to control
direction of screened fluid.
[0202] Depending on the nature of the feed, it may be desirable to
screen large solids out of the feed, prior to processing. A screen
to remove coarse particles is normally referred to as a scalping
screen. An apparatus such as the arrangement of FIG. 3 can be
operated with or without a scalping screen to remove relatively
coarse particles from the feed 2.
[0203] FIG. 4a shows the arrangement as in FIG. 2a where no
scalping screen is used, the feed 2 is processed in the apparatus
25 containing the conduit. The second stream 24 is then processed
through a shale shaker 1 in this example.
[0204] In FIG. 4b a scalping screen 38 is fitted before the
apparatus 25 that includes the conduit. In this example the solids
40 from the scalping screen are combined with the solids (oversize
10) from the screening apparatus 1, but they may be kept separate
if required.
[0205] In FIG. 4c the apparatus 25 containing the conduit is
integral with a single deck shale shaker machine 1. For example a
single basket or container that is vibrated may contain both
apparatus 25 and the screen (or screens) of the vibratory screening
machine 1.
[0206] In FIG. 4d an integral arrangement as in FIG. 4c is shown
but also including a scalping screen 38 to screen large particles
in advance of processing through apparatus 25.
[0207] In FIG. 4e the arrangement is as in FIG. 4d, including a
scalping screen 38 but with a second screen 42 fitted below the
first screen 4 of the screening machine 1. The scalping screen 38
is optional. The second screen 42 may be provided as an integral
part of the machine 1, in this example below and in the same
vibrating basket as first screen 4. Alternatively the second screen
42 may be provided in a separate vibrating basket or even in a
separate machine. The second screen 42 is operating in series with
the first, receiving the screened slurry 9 and screening it again
to produce the second cleaned stream C2. Generally the second
screen 42 has a finer mesh than the first 20. Further screens 42
may be fitted in a stack of screens if required (typically a total
of three in a stack).
[0208] In FIG. 4f the arrangement is as shown in 4e except the two
screens 4 and 42 of the screening machine 1 are operating in
parallel with the second stream 24 (concentrated with oversize
solids) being divided onto both screens 4 and 42, each of which
produces a C2 cleaned stream. Parallel processing has the advantage
of increasing throughput in the machine 1 as the screen area
employed is doubled. As with FIG. 4e the scalping screen 38 is
optional. Also as with FIG. 4e the two screens 4, 42 are provided
as a stack in a single screening machine, fitted with suitable flow
divider to allow parallel processing. Alternatively the screens
4,42 may be in separate vibrating baskets or even in separate
machines 1.
[0209] Conveniently the arrangements of FIGS. 4e and 4f can be
obtained with one set of equipment by providing a screening machine
1 that includes a flow directing arrangement that is
switchable--either dividing second stream 24 to the two screens 20
and 42 acting in parallel (FIG. 4f) or directing all to the first
screen 20 and then directing the resulting screened slurry 9 to the
second screen 42 for a series operation (FIG. 4e). A screening
machine with such a switchable flow distributor is described in
WO2004/110589 (Axiom Process limited).
[0210] FIG. 4g shows schematically a composite arrangement where
two arrangements (two modules 44, 46) such as shown in FIG. 4d are
provided. The feed 2 is divided into two streams 2a and 2b for
processing in parallel through each apparatus 25a and 25b. Optional
scalping screens 38a and 38b are shown in this example but the
solids flow from them is omitted for clarity. The second streams
(24a, 24b) from each apparatus 25 are processed through the
corresponding screening machines 1a and 1b. Thus cleaned streams
C1a,C1b,C2a and C2b are produced This arrangement can conveniently
be provided as a single integral apparatus with side by side or
vertically stacked apparatus 25a, 25b and screens 4a and 4b mounted
together in a single vibrated basket or container or in an adjacent
pair of baskets. Multiple screens in stacks may be provided as in
FIG. 4e and parallel or series processing through them may be
used.
[0211] The two modules may be operated with the screens 4a and 4b
in parallel as illustrated in FIG. 4g or in series as in FIG. 4h
(optional scalping screens not shown). In 4h the cleaned stream C2a
from the screen 4a of the first module 44 being processed further
in the second module 46 (with a finer screen mesh 4b used). In this
arrangement the two apparatus 25a and 25b are fitted with a mesh 20
(not shown for clarity) that is as fine as that of screen 4b. This
ensures that all the cleaned streams (C1a, C2a, and C2b) are
processed through a mesh of the same size. Advantageously screen 4a
may be coarser than screen 4b. Coarser screens generally have a
longer life. At the same time as the feed to fine screen 4b (stream
C2a) has been first passed through 4a the life of screen 4b will
also be extended.
[0212] It will be appreciated that other arrangements are possible,
for example a two module arrangement may be used with the modules
44, 46 operating in parallel with each other as in FIG. 4g or they
may be operated in series with all the feed 2 directed to the first
module 44 and the resulting cleaned streams C1a and C2a combined
and used as the feed for the second module, flowing into apparatus
25b.
[0213] An alternative two module arrangement is illustrated in FIG.
4i. Module 44 contains only an apparatus 25a from which the cleaned
stream C1a is passed to a storage tank for reuse and second stream
24a is fed to the apparatus 25b of the second module 46 for
dividing again into a cleaned stream C1b and a second stream 24b
that is processed through screening machine 1b that in this example
is an integral part of module 46.
[0214] Alternative two module arrangements are shown in 4j and
4k.
[0215] In 4j modules 44 and 46 are used to process feed 2 in
series, producing one cleaned stream C1b and both second streams
24a and 24b are directed to vibrating shale shaker type screen 4
provided in the second module 46.
[0216] In FIG. 4k modules 44 and 46 are used in series and 24a and
24b second stream flows are then processed in series through
successive screens 4, 42 of a separate shale shaker 1.
[0217] FIG. 4l shows schematically a use of the apparatus 25 after
a solids and liquid feed such as a used drilling mud from an oil
well has been processed through a shale shaker stage. The feed 2
has been progressively screened through two screens (coarse and
finer) 4 and 42 of a shale shaker 1a. The feed, free of large
particulates is then processed through apparatus 25. The second
stream 24 produced from apparatus 25 is then screened through a
(finest) mesh in shale shaker 1b. The two cleaned streams C1 and C2
can be combined if desired. This approach reduces the load on the
finest screens employed in the process, (the screen in apparatus 25
and the screen in shale shaker 1b) by first removing the larger
particles in shale shaker 1a.
[0218] FIG. 4m shows schematically the use of an apparatus 25 with
2 screens (e.g. as described in FIG. 3e) producing two concentrated
second streams 24 and 24a. The details of the outlet system of 25
are not shown for clarity. The apparatus 25 produces cleaned stream
C1, fluid and solids passing through both screens 20 and 20a. The
second stream 24 not passing through screen 20 is processed in
shale shaker 1a to produce cleaned stream C2. The second stream 24a
passing through screen 20 but not screen 20a may be processed
(following path A) together with stream 24 in shale shaker 1a,
contributing to cleaned stream C2.
[0219] Alternatively stream 24a follows path B and is processed in
shale shaker 1b, producing cleaned stream C3. This allows the
classified solids (sized between screens 20 and 20a) of stream 24a
to be collected separately for reuse if desired.
[0220] The cleaned streams C1, C2, C3 may be combined for
reuse.
[0221] In general any combination of apparatus 25 of the invention
may be operated in series or parallel with any combination of
screens operated in series or parallel either as an integrated
machine or with the apparatus 25 and screens as separate
machines.
[0222] Different combinations of screens (different aperture/mesh
sizes) may be used with any combination of machines 25.
[0223] The apparatus 25, for example as shown in FIG. 3 may be used
to concentrate the solid in a fluid stream to be passed downstream
of the invention to process equipment other than screening
apparatus. Decanting centrifuges and screen bowl centrifuges are
commonly used to process oil well drilling mud. These machines can
be expensive and be limited in their volumetric capacity. As
demonstrated in FIG. 5 the invention may be employed ahead of such
equipment (e.g. centrifuge 48) to reduce the fluid volume that is
required to be processed by that equipment. The equipment (e.g.
centrifuge 48) is required to process a fluid stream of
significantly reduced volume into which solids above screen size
are concentrated. Combinations of centrifuges or other
solids/liquids separators may be used, in series or parallel as
with vibratory screening machines. Thus apparatus 25 may be
employed with trains of centrifuges operating in series or
parallel.
[0224] FIG. 6 illustrates schematically an alternative conduit
design to that of the apparatus 25 of FIG. 3. In FIG. 6 the conduit
18 has a screen 20 that is in a vertically disposed screen portion
22. The feed 2 flows down the conduit past the screen 20 where a
first stream C1 passes out onto a plate 50 from where it can be
directed, for example by side walls (not shown) as desired, for
example to a holding tank (also not shown). The second concentrated
stream 24 passes round the U shaped path defined by the conduit 18
and may be processed further by a screening machine.
[0225] FIG. 7 illustrates schematically a yet further alternative
conduit design to that of the apparatus 25 of FIG. 3. In FIG. 7 the
conduit 18 has a screen 20 that is in a downwardly angled screen
portion 22. The feed 2 flows down the conduit past the screen 20
where a first stream C1 passes out from where it can be directed,
for example by falling into a second conduit (not shown) as
desired, for example to a holding tank (also not shown). The second
concentrated stream 24 passes round the U shaped path defined by
the conduit 18 and may be processed further by a screening
machine.
[0226] FIG. 8a shows in schematic elevation a conduit 18 provided
with an internally located screen 20, in this example a series of
circular cross section pipes 52 (see cross section along X-X, FIG.
8b). The pipes include screens 20 as at least part of their walls.
As the feed 2 passes through the conduit a first cleaned stream C1
is formed by screening through the screens of the pipes 52 and
exits the conduit 18 via the branch 54. The second concentrated
stream exits the conduit via the outlet end 32 of the conduit 18
for further processing as desired.
[0227] FIGS. 8c and 8d are cross section schematics as in FIG. 8b
but illustrating alternative pipes 52. In FIG. 8c they are
hexagonal in cross section. In FIG. 8d rectangular. Designs such as
these may be used to adjust the flow rate through the screens 20,
depending on the amount of screen 20 surface area desired for a
given application. Similarly FIG. 8e shows a simpler arrangement
where a screen 20 divides the available volume of the conduit
screening portion in two.
[0228] FIGS. 9a and 9b illustrate prior art screening systems such
as are used in oil well drilling operations to clean drilling mud
for reuse.
[0229] The following description for FIGS. 9 and 10 follows the
cleaned stream C through each stage of the system; at each stage
solids removed are discarded. Pumps are indicated by P in these
figures.
[0230] In FIG. 9a the system includes low efficiency shale shakers
(typically using up to 100 mesh screens) 56 (three required in this
example) that process the feed 2 from a drilling operation. The
screened feed is passed into a shaker holding tank 58 and then
passed to a desander holding tank 60. It is then pumped to desander
hydrocyclones 62 from where the cleaned stream passes to a desilter
tank 64. The cleaned stream is then passed through a mud cleaner
comprising a set of hydrocyclones 68 and a shale shaker 70. Next
the cleaned stream is passed to centrifuge tanks 72 from where it
passes through centrifuges 74 and finally to the cleaned mud
storage tank (not shown).
[0231] In FIG. 9b the low efficiency shale shakers 56 of FIG. 9a
are replaced with high efficiency shale shakers (five) 76 working
with screen meshes typically at up to 200 mesh. This finer
screening requires a greater number of shaker machines 9 or
alternatively more screen decks within the shale shakers used) but
allows the desander and mud cleaner of FIG. 9a to be discarded. The
cleaned stream is sent directly to centrifuge tanks 72 for
subsequent processing by centrifuges 74. Thus the footprint and
complexity of the system has been reduced by the use of high
efficiency shale shakers.
[0232] FIG. 10 shows an example system of the invention. An
apparatus 25 such as described before, operating at up to 400 mesh
screen, works together with three high efficiency shale shakers 76
also operating with up to 400 mesh screens to produce cleaned
stream C that is further processed by the centrifuges 74. The
combination of the apparatus 25 and high efficiency shale shakers
76 can produce a highly screened stream C efficiently with a lower
footprint, complexity and capital cost in comparison with those of
FIGS. 9a and 9b. It will be understood from the forgoing
description that many other apparatus and shale shaker arrangements
may be employed in a system, for example shale shakers with
integrated apparatus 25 such as shown in FIG. 4c may be
employed.
[0233] FIG. 11a shows in schematic perspective an alternative
arrangement to that of FIGS. 3a to 3c. It may be mounted for
vibration in a similar fashion to that described for the FIGS. 3a
to 3c apparatus. In FIG. 11a apparatus 25 includes a conduit 18
with a vertical inlet end 30 passing the feed 2 down to a generally
horizontally disposed, box like, screening portion 22, fitted with
mesh 20 for an upwards filtration that produces cleaned first
stream C1. The first stream C1 is directed out of the apparatus 25
with the assistance of walls 36. Typically the stream C1 will be
fed by gravity and/or by pump to a storage tank for reuse,
optionally after further processing.
[0234] The second stream 24, concentrated in solids content (solids
greater than the size of mesh 20), passes out of outlet end 32,
over weir 34. In this example the second stream 24 is then
processed further by a vibratory screen or screens indicated by
schematic inclined screen 4 in the drawing. Oversize (for screen 4)
solids 10 are "walked up" screen 4 by the vibratory action and
leave by discharge 12. Cleaned stream C2, passing through screen 4
may be further processed or combined with stream C1 as
appropriate.
[0235] The arrangement of FIG. 11a, having inlet end 30 at right
angles to outlet 32, with the screening portion 22 in between,
provides a turbulent flow. The feed 2 flowing into the box like
screening portion 22 will swirl as filtration through screen 20
occurs and as the outlet 32 takes the second stream 24 out in a
different direction to that of the feed flow.
[0236] The arrangement of FIG. 11a may be used in a stand alone
module, or as a modular part of a system as discussed above with
respect to the arrangement of FIGS. 3a to 3c.
[0237] Alternatively and as shown in the schematic elevation of
FIG. 11b the apparatus 25 may conveniently be provided as an
integral part of a vibratory screening machine, in this example a
shale shaker 1.
[0238] In FIG. 11b apparatus 25, for example of the form shown in
FIG. 11a, is fitted into a basket (indicated schematically by
broken line 78) of a shale shaker 1. The basket is subject to
vibratory motion in the usual way. The basket includes two scalping
screens 38 and 38a and two screens 4 and 4a for processing solids
and liquid mixtures. Flow back pans 80, 80a are provided between
screens in the stack of screens in the basket, to direct filtrate
passing through the screens for onwards processing in the usual
way.
[0239] A solids and liquid feed 2 such as a used drilling mud
including drill cuttings is passed through scalping screen 38
before entering the inlet end (not shown in this drawing, see 30 in
FIG. 11a) of apparatus 25. The scalping screen 38 removes large
particulates such as chunks of drill cuttings that are walked along
screen 38 and then 38a to discharge 12a by the vibratory
motion.
[0240] The feed 2 is then processed by the apparatus 25, producing
first stream C1 for reuse as drilling mud (with or without further
processing as appropriate). The concentrated stream 24, passing
over the weir 34 is then fed into a flow distributor 82 that may be
a switchable flow distributor as described in WO2004/110589 (Axiom
Process limited). The flow distributor 82 acts to divide the stream
24 into two parts 24a and 24b for parallel processing on screens 4
and 4a (of the same mesh size) respectively.
[0241] Solids 10 filtered off by the screens 4 and 4a are walked up
the screens and discharged at 12b and 12c in the usual fashion. The
cleaned stream C2 produced from screen 4 is directed by flowback
pan 80a and flow distributor 82 out of the bottom of basket 78. The
cleaned stream C3 passes out of the bottom (sump) of the basket 78.
As desired or required the streams C2 and C3 may be combined, in
the sump of the basket 78 or elsewhere. They may also be combined
with stream C1 to produce a single stream of reuse/recycle.
[0242] If a switchable flow distributor 82 is employed then the
equipment of FIG. 11b may be readily reconfigured to provide series
processing; processing all of stream 24 through screen 4 and the
resulting filtrate through screen 4a. This allows progressive
screening through screens of decreasing mesh size (using a screen
4a of finer mesh than that of screen 4). If series processing is
used the solids from discharge 12b may be collected separately from
those of the other discharges. These solids have been classified
between the mesh sizes of screens 4 and 4a. With appropriate choice
of mesh sizes the classified solids can comprise e.g. the weighting
agent that is a desired component of drilling mud or a "lost
circulation material" that is often added to drilling mud to block
cracks or other defects in a well bore.
* * * * *