Drill cuttings treatment systems

• US 9,073,104 B2
• Filed: 09/20/2011
• Issued: 07/07/2015
• Est. Priority Date: 08/14/2008
• Status: Active Grant

• Current Assignee: National Oilwell Varco LP (NOV, Inc.)
• Original Assignee: National Oilwell Varco LP (NOV, Inc.)
• Inventors: Burnett, George Alexander, Madsen, Brian Bender, Pierce, Dale Alton
• Primary Examiner(s): Prince, Fred
• Application Number:
  US13/237,604
• Publication Number:
  US 20120073932A1
• Time in Patent Office: 1,386 Days
• Field of Search: 210/86, 210/97, 210/149, 210/767, 210/770, 210/774, 175/207
• US Class Current: 1/1
• CPC Class Codes: B09B 3/00 Destroying solid waste or transforming solid waste into something useful or harmless
• CPC Class Codes: B09C 1/06 thermally
• CPC Class Codes: E21B 21/066 with further treatment of the solids, e.g. for disposal
• CPC Class Codes: F26B 1/00 Preliminary treatment of solid materials or objects to facilitate drying , e.g. mixing or backmixing the materials to be dried with predominantly dry solids F26B5/005 takes precedence
• CPC Class Codes: F26B 3/00 Drying solid materials or objects by processes involving the application of heat in specific machines or apparatus F26B9/00 - F26B19/00
• CPC Class Codes: F26B 3/36 by using mechanical effects, e.g. by friction by using ultrasonic vibrations F26B5/02
• CPC Class Codes: F26B 5/08 by centrifugal treatment

Abstract

Generally, the present disclosure is related to systems and methods for separating hydrocarbons and/or other liquids from drill cuttings material. One illustrative embodiment disclosed herein is directed to a system that includes, among other things, a thermal reactor that is adapted to remove liquid from drill cuttings material by heating the drill cuttings material to at least a first temperature that is sufficiently high enough to vaporize the liquid. The illustrative system also includes a feeder system that is adapted to controllably feed a flow of the drill cuttings material to the thermal reactor, and a control system that is adapted to control the flow of the drill cuttings material from the feeder system so as to maintain a temperature in the thermal reactor at or above the first temperature.

Claims

1. A system, comprising:

a thermal reactor that is adapted to remove liquid from drill cuttings material by heating said drill cuttings material to at least a first temperature, wherein said first temperature is sufficiently high enough to vaporize said liquid;

a feeder system that is adapted to controllably feed a flow of said drill cuttings material to said thermal reactor; and

a control system that is adapted to control said flow of said drill cuttings material from said feeder system to said thermal reactor so as to maintain a temperature in said thermal reactor at or above said first temperature, wherein said control system is further adapted to increase said flow of said drill cuttings material from said feeder system to said thermal reactor when said temperature in said thermal reactor decreases.

2. A thermal treatment system, comprising:

a thermal reactor that is adapted to remove liquid from drill cuttings material;

a feeder system that is adapted to controllably feed a flow of said drill cuttings material to said thermal reactor; and

a control system that is adapted to control said feeder system so as to increase said flow of said drill cuttings material to said thermal reactor when a temperature in said thermal reactor decreases.

3. The system of claim 2, wherein said control system is adapted to decrease said flow of said drill cuttings material from said feeder system to said thermal reactor when said temperature in said thermal reactor increases.

4. The thermal treatment system of claim 2, wherein said control system is adapted to control a level of said drill cuttings material in said feeder system so as to substantially maintain an airlock condition at a material inlet to said thermal reactor.

5. The thermal treatment system of claim 2, wherein said feeder system comprises a metering screw apparatus and a container that is adapted to receive said drill cuttings material.

6. The thermal treatment system of claim 5, wherein said metering screw apparatus comprises a metering screw having areas of different screw pitch.

7. The thermal treatment system of claim 5, wherein said control system is adapted to maintain at least one of a minimum amount of said drill cuttings material in said container and a minimum level of said drill cuttings material above said metering screw apparatus.

8. The thermal treatment system of claim 7, wherein said feeder system comprises at least one load cell apparatus that is adapted to provide information to said control system that is indicative of an amount of said drill cuttings material in said container.

9. The thermal treatment system of claim 7, wherein said feeder system comprises a slider system that is adapted to facilitate movement of said drilling cuttings material in a lower portion of said container proximate said metering screw apparatus.

10. The thermal treatment system of claim 5, wherein said container is adapted to receive a first feed of drill cuttings material from at least one of a shale shaker, a centrifuge, a vortex dryer, and a hydrocyclone.

11. The thermal treatment system of claim 10, further comprising a conveyance system that is adapted to feed said first feed of drill cuttings material to said container.

12. The thermal treatment system of claim 10, wherein said container is adapted to receive a secondary feed of drill cuttings material from at least one of a cuttings storage system and a cuttings transfer system.

13. The thermal treatment system of claim 2, further comprising a temperature sensing apparatus that is adapted to provide information to said control system that indicates said temperature in said thermal reactor.

14. The thermal treatment system of claim 2, wherein said control system is adapted to control said temperature in said thermal reactor.

15. The thermal treatment system of claim 14, wherein said control system is adapted to maintain said temperature in said thermal reactor above a pre-defined minimum temperature and below a pre-defined maximum temperature.

16. The thermal treatment system of claim 2, further comprising an engine that is adapted to controllably rotate a plurality of rotatable friction elements inside of said thermal reactor, wherein said plurality of rotatable friction elements are adapted to generate heat during said controllable rotation.

17. The thermal treatment system of claim 16, wherein said control system is adapted to decrease said flow of said drill cuttings to said thermal reactor when a rotational speed of said engine decreases.

18. The thermal treatment system of claim 17, wherein said engine comprises a speed sensor that is adapted to provide information to said control system that indicates said rotational speed of said engine.

19. The thermal treatment system of claim 2, wherein said control system is adapted to control an amount of said drill cuttings material in said thermal treatment system so as to substantially maintain an airlock condition at a material outlet from said thermal reactor.

20. The thermal treatment system of claim 2, wherein said thermal reactor comprises at least one load cell apparatus that is adapted to provide information to said control system that is indicative of an amount of drill cuttings material in said thermal reactor.

21. A thermal treatment system, comprising:

a thermal reactor comprising a plurality of rotatable friction elements, wherein said thermal reactor is adapted to remove liquid from drill cuttings material;

an engine that is adapted to controllably rotate said plurality of rotatable friction elements, wherein said plurality of rotatable friction elements are adapted to generate heat during said controllable rotation;

a feeder system comprising a metering screw apparatus and a container positioned above said metering screw apparatus, wherein said container is adapted to receive said drill cuttings material and said feeder system is adapted to controllably feed a flow of said drill cuttings material to said thermal reactor; and

a control system that is adapted to control said feeder system so as to increase said flow of said drill cuttings material to said thermal reactor when a temperature in said thermal reactor decreases, and to decrease said flow of said drill cuttings material to said thermal reactor when said temperature in said thermal reactor increases.

22. The thermal treatment system of claim 21, wherein said control system is adapted to control a level of said drill cuttings material in said feeder system so as to substantially maintain an airlock condition at a material inlet to said thermal reactor, and wherein said control system is further adapted to control an amount of said drill cuttings material in said thermal treatment system so as to substantially maintain an airlock condition at a material outlet from said thermal reactor.

23. A system, comprising:

a thermal reactor that is adapted to remove liquid from drill cuttings material by heating said drill cuttings material to at least a first temperature, wherein said first temperature is sufficiently high enough to vaporize said liquid;

a feeder system that is adapted to controllably feed a flow of said drill cuttings material to said thermal reactor; and

a control system that is adapted to control said flow of said drill cuttings material from said feeder system to said thermal reactor so as to maintain a temperature in said thermal reactor at or above said first temperature, wherein said control system is adapted to decrease said flow of said drill cuttings material from said feeder system to said thermal reactor when said temperature in said thermal reactor increases.