System and apparatus for phase separation

Abstract

A system or apparatus comprising a chamber for separating solids, liquids, and / or gases in a slurry mixture. Once separated, the individual components are directed separately for storage, use or disposal. The system described herein is compact and can be transported on a single trailer. It also has minimal components making it easy for assembly and storage when not in use. This system can be used for any industrial application that requires phase separation.

Description

APPLICATION FOR PATENTINVENTORS:ADAM LEE CARILLOFILIBERTO GALLEGOS LOZOYA TITLE:SYSTEM AND APPARATUS FOR PHASE SEPARATIONATTORNEY DOCKET NO.: 70095-1SPECIFICATIONCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and the benefit of co-pending US Provisional Patent Application Serial No. 63 / 527,321 filed on July 17, 2023, titled “SYSTEM AND APPARATUS FOR FLOWBACK WATER TREATMENT.” This reference is incorporated in its entirety.FIELD

[0002] The present disclosure generally relates to a system and apparatus for phase separation of a fluid / slurry stream. Specifically, it deals with systems having solids, liquids, and gases together, wherein it is desirable to separate the elements into their separate phases.BACKGROUND

[0003] Various industrial processes can generate a mixture of solids, liquids, and gases as either waste or intermediary products. Often it is desirable to separate these elements into separate components. This poses a challenge, especially in systems under high pressure, temperature, or both high pressure and high temperature.

[0004] One such exemplary system is a flowback loop from the fracking of an oil well. Often bulky equipment with components that frequently clog or foul with solids (i.e. an auger mechanism) is used to accomplish such a separation.

[0005] These systems often have to be transported utilizing multiple trucks, can take up significant space, can have complex components that need frequent servicing, can require reduced pressures and / or temperatures, and the like.

[0006] It is desirable, therefore, to have a system and apparatus which is compact (i.e. transportable on a single trailer), minimizes the number of components, and completely separates solids, liquids, and gases for further use or disposal.

[0007] The present disclosure meets these needs.

[0008] While an oil well fracking system will be utilized to describe the present disclosure, it should be noted that the system is applicable to any process requiring phase separation.SUMMARY OF THE INVENTION

[0009] The present disclosure generally relates to a system and apparatus which is compact (i.e. transportable on a single trailer), minimizes the number of components, and completely separates solids, liquids, and gases for further use or disposal. It comprises a chamber for separating the phase components and then individually directing them for storage, use, or disposal.

[0010] In one preferred embodiment of the present invention that is a system for separating solids, liquids, and gases, the system comprises a chamber for separating phases. This chamber comprises a vent for discharging a gas; an inlet tube entering the chamber for flowing a slurry, wherein the inlet tube has a cap in the direction of slurry flow and has an opening orthogonal to the direction of slurry flow, and further, wherein the opening is facing substantially upward when the system is in use; and an outlet for solids and liquids.

[0011] In another embodiment of the present invention, the chamber is configured to be rotated for storage or transport. In yet another embodiment, the chamber further comprises a first filter or a first screen positioned between the orthogonal opening and the vent.

[0012] In yet another embodiment, the chamber further comprises a second filter or a second screen positioned between the opening and the outlet. In further yet anotherembodiment, the chamber comprises a safety plate positioned proximate to the inlet tube.

[0013] In still yet another embodiment, the system comprises a shaker positioned to receive mixed liquids and solids from the outlet; a first tank for receiving liquids from the shaker; and a solids egress for dry solids to be ejected from the shaker. In another embodiment, the shaker comprises at least one tray, and each tray is angled such that the lower side is adjacent to the first tank and the higher side is adjacent to the solid egress. In yet another embodiment, the shaker is angled such that the lower side is adjacent to the first tank and the higher side is adjacent to the solid egress.

[0014] In another embodiment, the first tank comprises a first drain. In yet another embodiment, the first tank comprises and overflows into a second tank. In another embodiment, the system comprises a third filter or third screen positioned between the outlet and the shaker. In yet another embodiment, the drain is in fluid communication with a pump for recirculating liquid. In yet another embodiment, the second tank comprises an overflow into a third tank. In another embodiment, the entire system is mounted on a platform or a trailer for transport.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] So that the manner in which the present invention can be better understood, certain illustrations, charts and / or flow charts are appended hereto. It is to be noted, however, that the drawings illustrate only selected embodiments of the inventions and are therefore not to be considered limiting of scope, for the inventions can admit to other equally effective embodiments and applications.

[0016] Moreover, advantages and other aspects of the invention will be readily appreciated by those persons having skill in the art and may be better understood with further reference to the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawings and wherein:

[0017] Figure 1 depicts the components of an exemplary embodiment of the invention in a schematic format.

[0018] Figure 2 depicts the components of an exemplary embodiment of the invention in a schematic format.

[0019] However, it should be understood that the above-described figures are not intended to be limited to only the invention illustrated and to the particular embodiments disclosed, but on the contrary, the invention is intended to disclose all modifications, alternatives, and equivalents falling within the spirit and scope of the invention as defined within the claim’s broadest reasonable interpretation consistent with the specification. To wit, variations in height, length, width may be accomplished so as to accommodate variances in sizes and shapes of the components of the system and apparatus described herein as may be necessary or required.

[0020] The embodiments of the present disclosure are detailed below with reference to the listed Figures.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] Before explaining the present disclosure in detail, it is to be understood that the disclosure is not limited to the specifics of particular embodiments as described and that it can be practiced, constructed, or carried out in various ways.

[0022] While embodiments of the disclosure have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting.

[0023] Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis of the claims and as a representative basis for teachingpersons having ordinary skill in the art to variously employ the present embodiments. Many variations and modifications of embodiments disclosed herein are possible and are within the scope of the present disclosure.

[0024] Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations.

[0025] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and / or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0026] The word “about” means plus or minus 5% of the stated number.

[0027] The use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, and the like.

[0028] When methods are disclosed or discussed, the order of the steps is not intended to be limiting, but merely exemplary unless otherwise stated.

[0029] Accordingly, the scope of protection is not limited by the description herein, but is only limited by the claims which follow, encompassing all equivalents of the subject matter of the claims. Each and every claim is hereby incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure.

[0030] The inclusion or discussion of a reference is not an admission that it is prior art to the present disclosure, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, andpublications cited herein are hereby incorporated by reference, to the extent they provide background knowledge; or exemplary, procedural or other details supplementary to those set forth herein.

[0031] The embodiments of the present disclosure generally relate to a system and apparatus for phase separation of a fluid / slurry stream. Specifically, it deals with systems having solids, liquids, and gases together, wherein it is desirable to separate the elements into their separate phases.

[0032] The present invention comprises a system for separating solids, liquids, and gases. The system can be configured to have a footprint no greater than a standard platform trailer which is approximately 53 feet long for easy transport. In a preferred embodiment, the system is no longer than 43 feet long.

[0033] The system can have a chamber for separating solid, liquid, and / or gas phases. The chamber can be a tank made of different materials, sizes, and shapes, all of which are chosen by persons having ordinary skill in the art to withstand the temperatures and pressures of specific applications. For a system utilized in fracking operations a heavy- duty tank can be used. A typical chamber, or tank, will be taller than it is wide (although this is not a requirement of this disclosure). In such instances, the chamber can be mounted on a frame which pivots to allow the chamber to be laid on its side to allow for ease of transport, and then erected for use when on site.

[0034] The chamber can have a vent for discharging gas. In many industrial operations, the discharged gas will be lighter than air, and hence the vent in such instances can be positioned substantially at the top of the chamber. In embodiments the vent can be in fluid communication with a flare. Additionally, a screen or a filter can be positioned below the vent to prevent any solids from entering the vent.

[0035] The chamber can have an inlet tube for flowing a slurry. Slurry, for the purposes of this disclosure, shall refer to any mixture containing at least two of solids, liquids, or gases. The inlet tube can be of any material and size as desired by persons having ordinaryskill in the art for a specific application. It is desirable to place the inlet tube to enter the chamber horizontally from the side of the chamber, but other angles of entry can be utilized by persons having ordinary skill in the art for specific applications.

[0036] The inlet tube has a cap in a direction of slurry flow and has an opening orthogonal to the direction of slurry flow and the opening is facing substantially upward when the system is in use. As slurry flows into the chamber, the slurry collides with the cap, and the violent collision acts to separate entrained gases from the slurry. As the opening is substantially upward during operation, the slurry will spray upward. Gases, having now been separated from the slurry, can exit via the vent, as solids and liquids fall toward the bottom of the chamber via gravity.

[0037] An outlet for solids and liquids can be positioned near the bottom of the chamber. A screen or a fdter can be positioned above the outlet to prevent any large solids from entering the outlet. . Additionally, a screen or a filter can be positioned between the orthogonal opening of the inlet tube and the vent for gas discharge to prevent solids from entering the vent.

[0038] In embodiments, the chamber can be configured to be rotated for storage or transport. Note that references to “top”, “bottom”, “side”, etc. of the chamber refer to the chamber when positioned for operation to receive a slurry flow, and not when rotated for transport or storage.

[0039] In embodiments, a safety plate can be positioned proximate the inlet tube behind the cap. Often the cap will be welded to the inlet tube. However, the safety plate can be positioned to halt the slurry flow in the event of a cap failure. In addition to protecting the chamber in the event of a cap failure, the safety plate has the novel benefit of performing the same function as the cap, i.e. acting as a surface for the slurry to collide and separate the entrained gasses from the solids and liquids. This has the effect of allowing the system to continue operating even if the cap fails.

[0040] A shaker can be positioned to receive mixed liquids and solids from the outlet of thechamber. Tn embodiments, a screen or filter can be positioned between the outlet and the shaker. The purpose of the shaker is to dry out the solids and drain the liquid into one or more tanks. The term shaker here refers to an industrial shaker which vibrates the contents thereof. As will be shown, the trays of the shaker can be angled causing liquid to move downward and drain into a tank. As the solids dry, vibration causes them to slowly move higher up the tray to a solids egress for collection of the dry solids. In this manner, liquid is drained, and dry solids are collected. This is a large improvement over the current state of the art, which makes use of augers to separate solids and liquids, as the solids are still left wet or damp. In embodiments, the shaker can have multiple trays. In embodiments, the entire shaker can be angled, thereby causing liquid to move downward and drain into a tank.

[0041] A first tank can receive liquids from the shaker. While most solids will have been removed, the first tank can overflow into a second tank to further ensure that minimal solids are present in the liquid. In embodiments, a third and fourth overflow tank can be utilized.

[0042] Turning now to the Figures, Figure 1 depicts the components of an exemplary embodiment of the invention in a schematic format:

[0043] The system can be mounted on a platform 144 or directly to a trailer. The platform can be configured such that it is no longer than fifty-three (53) feet long, which is the size of a typical trailer hauled by a semi-truck.

[0044] The system 100 can have inlet tube 114 entering horizontally into chamber 110. A cap 118 is attached to the inlet tube 114 for the slurry to collide with. An opening 120 is directed upward, orthogonal to the direction of slurry flow 116. The collision of the slurry with cap 118 causes entrained gases to separate from liquids and solids. As, in many instances, the entrained gases are lighter than air, so vent 112 can be placed atop chamber 110 for the gases to exit chamber 110. Vent 112 can be in fluid communication with a flare if desired to combust the gases.

[0045] A safety plate 122 can be positioned in the path of the slurry behind cap 118 in the event that cap 118 becomes detached from inlet tube 114 or malfunctions. Safety plate 122 can be a plate of the same material as cap 118 and of similar or greater thickness.

[0046] A first screen or filter 124 can be positioned between opening 120 and vent 112 to prevent solids from entering vent 112. A second screen or filter 126 can be positioned between opening 120 and outlet 125 to prevent very large solids from entering outlet 125.

[0047] A shaker 130 can be positioned below outlet 125 to receive solids and liquids. A third filter or screen 127 can be positioned between the outlet and the shaker. The shaker 130 can have one or more trays 132 (shown here with three angled trays 132a, 132b, and 132c). Each tray can vibrate any solids as liquids drain into first tank 150. The heavier, wet solids will slide toward the bottom of tray 132 due to gravity. As the solids dry and become lighter, they will progress upward due to the vibratory action of shaker 130 and fall off the top of shaker tray 132, either onto another shaker tray 132 or into solids egressl46 (shown here as a chute). A solids container 148 can be placed near the solids egress 146 to receive the dry solids. Any container suitable for the application can be chosen by persons having ordinary skill in the art.

[0048] First tank 150 can have a drain 136 in fluid communication with a pump for draining liquids from the system. First tank 150 can have an overflow 138 into second tank 152 (if used), which can have an overflow 140 into third tank 154 (if used), which in turn can have an overflow 142 into fourth tank 156 (if used). Tanks 152, 154, and 156 can also have drains (not shown) in fluid communication with a pump.

[0049] Figure 2 depicts the components of an exemplary embodiment of the invention in a schematic format.

[0050] Figure 2 shows frame 128 which supports chamber 110 folded at hinge 134 to allow chamber 110 and associated components to be folded for ease of transport. This reduces the overall height of the components when being transported on a trailer.

[0051] An exemplary use of the present system occurs when hydraulically fracturing, or fracking a well. During the fracturing process, water, sand, and chemicals are injected down a well head under high pressure to create fractures in the rock and release oil and / or gas. This high-pressure injection typically uses a coil injection system that includes coil tubing and a coil pump to inject the fracking mixture from a mixing plant consisting of a holding tank storing water and fracking chemicals to be injected into the well head, such as chemical cleaners and lubricants.

[0052] Following fracking, various fluids rise back to the surface under high pressure as “flowback”, which is a complex mix of water, volatile hydrocarbons, hydraulic fracking fluids, mud, artificial chemicals and metallic ions. Flowback fluid can be disposed of in various ways, including injection into deep subsurface formations through a licensed disposal well, in specialized water treatment plants, or in open-air pits. As applicable in the present disclosure, flowback fluid can also be recycled for further hydraulic fracturing.

[0053] For recycling the backflow fluid, the backflow fluid is flowed as a slurry into the chamber of the disclosed system. The volatile gasses are separated and sent to a flare where they can be burned off. The fluids and solids of the backflow mixture drop onto a shaker, which dries and separates the sand from residual fluid which drains into a series of working tanks that further filter and cleanse the “clean water” so that the water can be reused for further fracking as an input into the mixing plant. As mentioned previously, in some conventional systems, the sand removal process comprises an auger system for extracting the sand from the flowback fluid. This conventional auger mechanism is subject to clogging and other breakdown problems, and also produces wet sand.

[0054] While the present disclosure emphasizes the embodiments, it should be understood that within the scope of the appended claims, the invention might be practiced other than as specifically described herein.

Claims

CLAIMSWhat is claimed is:

1. A system for separating solids, liquids, and gases comprising: a. a chamber for separating phases comprising:(i) a vent for discharging a gas;(ii) an inlet tube entering the chamber for flowing a slurry, wherein the inlet tube has a cap in a direction of slurry flow and has an opening orthogonal to the direction of slurry flow, and further wherein the opening is facing substantially upward when the system is in use; and(iii) an outlet for solids and liquids.

2. The system of claim 1, wherein the chamber is configured to be rotated for storage or transport.

3. The system of claim 1, wherein the chamber further comprises a first filter or a first screen positioned between the opening and the vent.

4. The system of claim 1, wherein the chamber further comprises a second filter or a second screen positioned between the opening and the outlet.

5. The system of claim 1, further comprising a safety plate positioned proximate the inlet tube6. The system of claim 1, further comprising: a. a shaker positioned to receive mixed liquids and solids from the outlet; b. a first tank for receiving liquids from the shaker; and c. a solids egress for dry solids to be ejected from the shaker.

7. The system of claim 6, wherein the shaker comprises at least one tray, and each tray is angled such that the lower side is adjacent the first tank and the higher side is adjacent the solids egress.

8. The system of claim 6, wherein the shaker is angled such that the lower side is adjacent the first tank and the higher side is adjacent the solids egress.

9. The system of claim 6, wherein the first tank comprises a first drain.

10. The system of claim 6, wherein the first tank comprises and overflow into a second tank.

11. The system of claim 6, further comprising a third filter or a third screen positioned between the outlet and the shaker.

12. The system of claim 7, wherein the shaker is angled such that the lower side is adjacent the first tank and the higher side is adjacent the solids egress.

13. The system of claim 9, wherein the drain is in fluid communication with a pump for recirculating liquid.

14. The system of claim 10, wherein the second tank comprises an overflow into a third tank.

15. The system of claim 14, wherein the entire system is mounted on a platform or a trailer for transport.

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