Slurrification system and method for formation waste
Patent Information
- Application Number
- PCT/US2026/023864
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-04-15
- Filing Date
- 2026-04-15
- Publication Date
- 2026-10-22
Smart Images
Figure US2026023864_22102026_PF_FP_ABST
Abstract
Description
PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683SLURRIFICATION SYSTEM AND METHOD FOR FORMATION WASTECROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No 63 / 789,148, filed April 15, 2025, entitled "Slurrification System and Method for Formation waste," the entire contents of which are incorporated herein by reference.FIELD OF THE INVENTION
[0002] The present invention relates generally to formation waste processing systems and methods and, more particularly, to a closed-loop slurrification system and method for processing formation waste, including particulate solids produced from wellbore drilling and production activities, into a slurry suitable for reinjection into a subterranean formation.BACKGROUND OF THE INVENTION
[0003] Exploration and production (E&P) operations generate significant quantities of waste material from a variety of sources, including drilling operations, reclamation facilities, production facilities, and tank cleanouts, much of which is classified as E&P Class II waste. For example, waste material from drilling operations may include particulate solids such as rock cuttings and other debris generated during drilling operations. In some regions, such waste may include naturally occurring radioactive material (NORM) or technologically enhanced naturally occurring radioactive material (TENORM), which presents additional handling and disposal challenges. Managing this waste presents significant logistical and environmental challenges. Conventionally, formation waste is handled by external disposal methods, such as hauling the waste material offsite, which is costly, time-consuming, and environmentally undesirable. In the case of radioactive waste such as NORM or TENORM, external disposal may require transportation by truck across state lines to distant disposal facilities, further increasing cost, risk, and environmental burden.
[0004] Slurrification, i.e., the process of mixing particulate waste material with a conveyance fluid to produce a slurry, has been used as a technique to process formation waste for reinjection into a formation. However, prior art slurrification systems are typically openloop systems that result in some solid waste that must be removed and handled separately from any slurry that is produced. That is, prior art systems are unable to process all of the formation waste to a particle size suitable for reinjection. As a result, a portion of the waste material —4924-3311-1456 v.l 1PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683particularly harder or larger solids — must be segregated and disposed of through external means, adding cost and complexity to the waste handling process. Furthermore, existing slumfication systems are limited in throughput capacity, with typical prior art systems capable of processing on the order of only about 100 barrels of waste per day, which is insufficient to address the large volumes of E&P waste generated in active production regions.
[0005] Traditionally, slumfication systems such as described above use various types of pumps to process the slurry. Typically, the goal of the pumps is to maximize flow rate and pump throughput. Thus, where centrifugal pumps are used in such systems, the pumps employ closed vaned impellers that minimize the residence time of fluid passing through the pump. Such pumps are not designed to degrade solids suspended in the fluid and, in fact, centrifugal degradation pumps are not commonly used in the oilfield because they would cause inefficiency of the drilling fluids and create additional low gravity solids that add mechanical issues to the drilling fluid.
[0006] Accordingly, there is a need for an improved slumfication system and method that is capable of processing all formation waste into a slurry suitable for reinjection, thereby eliminating the need for external waste disposal and enabling higher-volume processing of drilling waste in a closed-loop fashion. There is a further need for a system capable of processing radioactive waste materials, such as NORM and TENORM, on-site to eliminate the need for transporting hazardous materials across long distances for disposal.SUMMARY OF THE INVENTION
[0007] The present invention provides a closed-loop slumfication system and method for processing formation waste, allowing the formation waste to be entrained in a fluid and reinjected back into a formation as a slurry, such as in the form of drilling mud. Because the system is closed-loop, it mitigates the need to dispose of formation waste through external formation waste removal, and it allows for a higher volume of drilling waste to be processed than traditional slumfication systems. The system is operable as a stand-alone processing facility capable of receiving waste material from various sources, including drilling operations, reclamation facilities, production facilities, and tank cleanouts. The system is further capable of processing radioactive waste materials, including NORM and TENORM, on-site, thereby eliminating the need to transport such materials to distant disposal facilities. The cascading4924-3311-1456 v.l 2PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683classification and degradation architecture of the system enables substantially higher throughput than prior art systems.
[0008] In one aspect, the present invention provides a slurrification system for formation waste comprising a solids storage vessel; a mixing vessel with a fluid inlet and a slurry outlet; a first conveyance mechanism between the solids storage vessel and the mixing vessel; a conveyance fluid source in fluid communication with the fluid inlet of the mixing vessel; at least three degradation and classification stages arranged in series, each stage comprising a centrifugal degradation pump and a processing system having a screen assembly with a mesh size; a second conveyance mechanism in communication with solids outlets of the processing systems; and a crushing system having a solids inlet in communication with the second conveyance mechanism and a solids outlet in communication with the solids storage vessel.
[0009] In another aspect, the present invention provides a method for slurrification and disposal of formation waste comprising mixing waste material from a formation with a conveyance fluid to produce a first slurry; passing the first slurry through a centrifugal degradation pump to produce a second slurry; sieving the second slurry to produce a third slurry and a first solid of an average first particle size; repeating the degradation and sieving steps through at least three stages; processing the removed solids through a crushing system to produce crushed material of a reduced average particle size; and returning the crashed material to the mixing vessel for further processing.
[0010] Importantly, because the slurrification system is closed-loop, particulate matter will remain in the slurrification system and subject to the slurrification process until the particle size of the particulate matter is sufficiently small that the particulate matter can be removed from the slurrification system as part of the output slurry for reinjection into a formation, such as via a wellbore.BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 is a schematic diagram of a first embodiment of a slurrification system for formation waste.4924-3311-1456 v.l 3PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0013] FIG. 2 is a schematic diagram of a second embodiment of a slurrification system for formation waste having additional centrifugal degradation pumps.
[0014] FIG. 3 is an illustrative example of a centrifugal degradation pump usable in the slurrification system.
[0015] FIG. 4 is an illustrative example of a screen assembly usable in the slurrification system.
[0016] FIG. 5 is a flow diagram illustrating one embodiment of a method for slurrification of formation waste.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The following detailed description is made with reference to the accompanying drawings, which form a part hereof. In the drawings, like reference numerals may be used to designate like or similar parts in the several views. It will be appreciated that the embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention.
[0018] Described herein is a closed-loop slurrification system 10 and method 200 for slurrification of formation waste, allowing waste from a formation 12, such as wellbore waste, to be entrained in a fluid and reinjected back into a formation 12 as a slurry. In one embodiment, the slurry may be reinjected back into the formation 12 by injection equipment 14 as drilling mud in a wellbore. Because the system is closed-loop, it mitigates the need to dispose of formation waste through external waste removal, and it allows for a higher volume of formation waste to be processed than traditional slurrification systems. The slurrification system 10 is particularly desirable because it provides for classifying, slurrifying, and storage of a high-volume of formation waste for disposal by injection in a closed-loop system. The formation waste includes, but is not limited to, particulate solids such as rock produced from wellbore drilling and production activities, as well as waste from reclamation facilities, production facilities, and tank cleanouts — generally, any waste originating from exploration and production operations classified as E&P Class II waste. The slurrification system 10 does not differentiate between radioactive and non-radioactive formation waste material, and is4924-3311-1456 v.l 4PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683therefore suitable for processing NORM and TENORM waste on-site without the need for separate handling or off-site transportation.
[0019] In one or more embodiments, the slurrification system 10 is operable as a standalone processing facility that does not receive waste material directly from a wellbore during drilling operations but rather receives waste material that has been delivered to the facility from various sources. In such embodiments, the solids storage vessel 16 may serve as an accumulation area for incoming waste material from multiple sources prior to processing.
[0020] Referring now to FIGS. 1 and 2, the slurrification system 10 generally utilizes at least three centrifugal degradation pumps 18, 20, 22 and a mechanical crusher 24, such as a hammermill, jaw crusher, cone crusher, impact crusher, or gyratory crusher, operating in conjunction with a series of processing systems 26, 28 30 functioning as classification units of decreasing mesh size, where a centrifugal degradation pump and a classification unit together form a degradation and solids screening, i.e., classification, stage. While system 10 can have more or fewer stages, in one or more embodiments, system 10 has three stages corresponding to processing systems 26, 28, 30 and their respective centrifugal degradation pumps 18, 20, 22. The system 10 is designed to eliminate non-degradable material by cascade effect through at least three stages utilizing the centrifugal degradation pumps 18, 20, 22 and separate classification units where each stage utilizes a screening assembly, 32, 34, 36 with a select mesh size M that gradually decreases between stages. A mechanical hammermill or other crushing system 24 is utilized in conjunction with the classification stages for hard rock formation material that cannot be broken down utilizing the centrifugal degradation pumps 18, 20, 22.
[0021] More specifically, slurrification system 10 for formation waste includes a solids storage vessel 16 for receiving and holding formation waste material. A first conveyance mechanism 38 is disposed to move the waste material from the solids storage vessel 16 to a mixing vessel 40. In some embodiments, a feed hopper is positioned adjacent the first conveyance mechanism 38 and includes a set of grizzly bars, i.e., a series of spaced metal bars, positioned at the feed hopper inlet to serve as an initial screening mechanism. Material larger than the spacing of the grizzly bars is caught on the bars and removed before entering the system 10. The mixing vessel 40 has a fluid inlet 42 in fluid communication with a conveyance fluid source 44, and a slurry outlet 46. In operation, the first conveyance mechanism 38 transfers particulate solids from the solids storage vessel 16 into the mixing vessel 40, where4924-3311-1456 v.l 5PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683the particulate solids are combined with a conveyance fluid from the conveyance fluid source 44 to produce an input slurry that exits the mixing vessel 40 through the slurry outlet 46. In one or more embodiments, the target composition of the input slurry is approximately 10-20% solids and 80-90% fluid by volume.
[0022] The input slurry from the mixing vessel 40 is directed through at least three degradation and classification stages arranged in series. In a first stage, the first centrifugal degradation pump 18 has an inlet 48 in fluid communication with the slurry outlet 46 of the mixing vessel 40. First centrifugal degradation pump 18 also has an outlet 50 that delivers the slurry to a first processing system 26. The first processing system 26 has a slurry inlet 52 in fluid communication with the outlet 50 of the first centrifugal degradation pump 18, as well as a slurry outlet 54 and a solids outlet 56. In addition, the first processing system 26 includes a first processing vessel 58 and a first screen assembly 32, where the first screen assembly 32 has a screen 60 with a first mesh size Ml. In one or more embodiments as is well known in the art, the first screen assembly 32 is positioned above the first processing vessel 58 with the slurry inlet disposed to deliver slurry to the first screen assembly 32, typically to an upper surface of the screen 60. The solids outlet 56 is adjacent the first screen assembly 32 positioned to remove solids from the first screen assembly 32. Finally, the slurry outlet 54 is positioned in the first processing vessel 58 to remove slurry passing through the first screen assembly 32 collecting within the first processing vessel 58.
[0023] In the second stage, the second centrifugal degradation pump 20 has an inlet 62 in fluid communication with the slurry outlet 54 of the first processing system 26. Second centrifugal degradation pump 20 also has an outlet 64 that delivers the slurry to a second processing system 28. The second processing system 28 has a slurry inlet 66 in fluid communication with the outlet 64 of the second centrifugal degradation pump 20, as well as a slurry outlet 68 and a solids outlet 70. In addition, the second processing system 28 includes a second processing vessel 72 and a second screen assembly 34, where the second screen assembly 34 has a screen 74 with a second mesh size M2. In one or more embodiments as is well known in the art, the second screen assembly 34 is positioned above the second processing vessel 72 with the slurry inlet 66 disposed to deliver slurry to the second screen assembly 34, typically to an upper surface of the screen 74. The solids outlet 70 is adjacent the second screen assembly 34 positioned to remove solids from the second screen assembly 34. Finally, the4924-3311-1456 v.l 6PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683slurry outlet 68 is positioned in the second processing vessel 72 to remove slurry passing through the second screen assembly 34 collecting within the second processing vessel 72.
[0024] In the third stage, the third centrifugal degradation pump 22 has an inlet 76 in fluid communication with the slurry outlet 68 of the second processing system 28. Third centrifugal degradation pump 22 also has an outlet 78 that delivers the slurry to a third processing system 30. The third processing system 30 has a slurry inlet 80 in fluid communication with the outlet 78 of the third centrifugal degradation pump 22, as well as a slurry outlet 82 and a solids outlet 84. In addition, the third processing system 30 includes a third processing vessel 86 and a third screen assembly 36, where the third screen assembly 36 has a screen 88 with a third mesh size M3. In one or more embodiments as is well known in the art, the third screen assembly 36 is positioned above the third processing vessel 86 with the slurry inlet 80 disposed to deliver slurry to the third screen assembly 36, typically to an upper surface of the screen 88. The solids outlet 84 is adjacent the third screen assembly 36 positioned to remove solids from the third screen assembly 36. Finally, the slurry outlet 82 is positioned in the third processing vessel 86 to remove slurry passing through the third screen assembly 36 collecting within the third processing vessel 86.
[0025] Downstream of the third stage, a pump 90 has an inlet 92 in fluid communication with the slurry outlet 82 of the third processing system 30 and a slurry outlet 94 for delivering the processed slurry for storage or reinjection into formation 12. In one or more embodiments, slurry outlet is in fluid communication with the fluid inlet 127 of a slurry storage tank 128 where the processed slurry suitable for reinjection can be stored until injection into formation 12 by injection equipment 14.
[0026] A second conveyance mechanism 96 is in communication with the solids outlet 56 of the first processing system 26, the solids outlet 70 of the second processing system 28, and the solids outlet 84 of the third processing system 30 for collecting particulate matter removed at each stage. The second conveyance mechanism 96 includes a solids outlet 98 that feeds into a crushing system 24. The crushing system 24 has a solids inlet 100 in communication with the solids outlet 98 of the second conveyance mechanism 96 and a solids outlet 102 in communication with the solids storage vessel 16, thereby returning the crushed material for further processing through the system 10 in a closed-loop fashion.4924-3311-1456 v.l 7PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0027] In one or more embodiments, one or more centrifugal degradation pumps 18, 20, 22 and / or transfer pump in the slurrification system 10 may be controlled by a variable frequency drive (VFD) 104.
[0028] In one or more embodiments, the slurrification system 10 may further include one or more sensors 106 disposed on or adjacent to each screen assembly 32, 34, 36 for monitoring screen loading conditions. The sensors 106 may be operably connected to a VFD 104 of a corresponding pump 18, 20, 22 to enable automated adjustment of pump speed based on realtime screen loading.Centrifugal Degradation Pumps
[0029] The centrifugal degradation pumps 18, 20, 22 are arranged serially and are an important aspect of the slurrification system 10 because each of the centrifugal degradation pumps 18, 20, 22 helps break down solids suspended in the slurry passing through the pump. Importantly, the centrifugal degradation pumps 18, 20, 22 are not standard centrifugal pumps that may be found in the oil and gas industry generally. Traditional centrifugal pumps typically employ closed vaned impellers and are used to maximize flow rate and pump throughput, minimizing the residence time of fluid passing through such centrifugal pumps. Centrifugal degradation pumps, namely, centrifugal pumps having open or semi-open impellers designed to increase residence time and promote particle attrition, are not commonly used in the oilfield because, in conventional drilling operations, the use of such pumps would degrade the drilling fluid solids themselves, causing inefficiency of the drilling fluids by breaking down the engineered solids that are intentionally added to the drilling fluid to control its properties. Furthermore, centrifugal degradation pumps would create additional low gravity solids that add mechanical issues to the drilling fluid, such as increased wear on downhole equipment and reduced fluid performance. However, despite their disfavor in conventional drilling practices, centrifugal degradation pumps are uniquely well-suited for a dedicated waste slurrification system where the goal is the opposite, that is, to break down particulate solids rather than preserve them. In contrast to conventional applications, the centrifugal degradation pumps 18, 20, 22 of the present invention are focused on increasing residence time of slurry within the pump to promote degradation of suspended particulate solids through particle-on-particle impingement within the pump housing. Specifically, the enlarged gap between the impeller and the pump housing creates a highly turbulent environment within the pump casing such that, as material passes through, the hard-faced inserts on the impeller cause particles to collide with4924-3311-1456 v.l 8PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683one another, breaking them down through particle-on-particle degradation rather than through grinding against the pump housing itself.
[0030] Referring to FIG. 3, a centrifugal degradation pump of the disclosure, such as centrifugal degradation pumps 18, 20 and 22, generally include an open or semi -open impeller 108 having a plurality of vanes 110, which impeller 108 is mounted within a pump housing 112 that forms a volute 114 therein, the housing also having a pump inlet 118 and a pump outlet 120. In one or more embodiments, the open or semi-open impeller 108 has hard-faced inserts 116, meaning a hard, more wear-resistant material, applied to the impeller vanes 110. The inserts 116, which are often welded to the vanes, create a rough surface along the vanes 110. The inserts 116 may be attached to one or both sides of one or more impeller vanes 116 to promote solids degradation. In contrast, centrifugal pumps focused on increasing pump volume throughput have smooth vanes and are often fully closed. In the case of the centrifugal degradation pumps as described herein, hard-faced impellers that are open or at least semiopen tend to have lower throughput rates and longer residence time, which is desirable for the described application of particle attrition because the longer residence time increases the opportunity for solids to degrade within the pump housing 112 and the volute 114 in particular.
[0031] In this regard, it will be appreciated in some embodiments that while semi-open impellers may be utilized as impeller 108, fully open impellers, namely impellers without any shrouds, will be the most effective in achieving the degradation described herein. In one or more embodiments, the hard-faced inserts 116 applied to the impeller vanes 110 may be formed of tungsten carbide or a silicon carbide.
[0032] Moreover, commonly, an impeller 108 is mounted in a pump housing 112 forming a gap B between the impeller's outer diameter ODi and the pump casing inner diameter IDp. This gap or clearance is referred to as the impeller “radial gap”, also known as “gap B,” and is typically the narrowest space between the impeller vane tips and the casing wall. The gap B is one throughput design parameter that impacts pump efficiency and performance. For pumps intended to maximize throughput, gap B is typically designed to be a small percentage of the impeller diameter, often between 0.5% and 1.5%, to minimize residency time and maximize throughput time. In other words, for such pumps, the gap B is selected to maximize pump throughput while minimizing leakage and recirculation of the fluid, which would otherwise reduce the pump's efficiency.4924-3311-1456 v.l 9PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0033] However, in the centrifugal degradation pumps of the present invention, there is a desire to increase residency and agitation time of the fluid in the pump, sacrificing throughput for enhanced solids degradation within the pump housing. Thus, in addition to utilizing open impellers that are hard-faced, as opposed to smooth impellers, the impeller and pump housing of the centrifugal degradation pumps may be selected in some embodiments to have a gap B that is often between 10-15% of the impeller diameter, decreasing efficiency of flow throughput but increasing residence time to permit more degradation of the solid particles passing through the pump.Additional Centrifugal Degradation Pumps
[0034] While each of the first three stages has at least one centrifugal degradation pump 18, 20, 22, each of the first three stages may have an additional centrifugal degradation pump (e.g., 122, 124, 126), extending residence time at a stage prior to solids screening. An additional degradation pump may be positioned to process the flow from another degradation pump before passing a slurry onto a screen. For example, as illustrated in FIG. 2, in the first stage, an additional centrifugal degradation pump 122 is arranged in series with centrifugal degradation pump 18 between the first stage centrifugal degradation pump 18 and the first screen assembly 32. Similarly, an additional centrifugal degradation pump 126 is illustrated in the third stage between the third stage centrifugal degradation pump 22 and the third screen assembly 36.
[0035] It will be appreciated that, in one or more embodiments, not all pumps in the slurrification system 10 need be centrifugal degradation pumps. In some embodiments, one or more additional intermediate pumps positioned between stages may be standard fluid-moving centrifugal pumps that serve primarily to transfer slurry between stages, while degradation is accomplished by the centrifugal degradation pumps at designated stages. For example, in one embodiment, the first and third stage pumps are centrifugal degradation pumps while one or more additional intermediate stage pumps are standard centrifugal pumps.Conveyance Mechanisms
[0036] The conveyance mechanism between the solids storage vessel 16 and the mixing vessel 40 is not limited to a particular mechanism. In some embodiments, the conveyance mechanism may be a conduit extending between the solids storage vessel 16 and the mixing vessel 40. In some embodiments, the conveyance mechanism may be an auger conveyor or belt conveyor extending between the solids storage vessel 16 and the mixing vessel 40. In some4924-3311-1456 v.l 10PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683embodiments, the conveyance mechanism may be a materials handling bucket movable between the solids storage vessel 16 and the mixing vessel 40. In some embodiments, the conveyance mechanism may be a pump. In the case of a pump, it will be appreciated that the waste material may be kept sufficiently "wet" in the solids storage vessel 16 so as to be pumpable. In some embodiments, a hopper may be positioned adjacent the conveyance mechanism to facilitate handling of the waste material.Screen Assemblies and Mesh Sizes
[0037] Referring to FIG. 4, a standard screen assembly is depicted. The screen assembly as disclosed herein is not limited to a particular system, other than the arrangement of screen sizing as described. In one or more embodiments, screen assembly 32, 34, 36 is a shaker as is known in the art. The it will be appreciated that mesh size M described above refers to the number of openings per linear inch in the screen, which sizes are generally classified under American Petroleum Institute (API) guidelines. Under the API designation system, fine mesh screens generally range from API 100 to API 325 and are suited for finer solids control needs for separation of smaller particles; medium mesh screens generally range from API 60 to API 100, allowing a larger capacity of solids to pass therethrough; and coarse mesh screens generally range from API 20 to API 60, and are best suited to handle larger solid volumes, separating the most coarse solids.
[0038] In one or more embodiments, the first screen assembly 32, second screen assembly 34, and third screen assembly 36 are arranged in the overall slurrification system 10 to have a consecutively decreasing mesh size (which translates into a consecutively increasing API number). In some embodiments, the first screen assembly 32 is a coarse mesh screen assembly, removing the largest solids from the slurry; the second screen assembly 34 is of a medium mesh; and the third screen assembly 36 is a fine mesh such that any solids passing through the third screen assembly 36 are of a small enough size that they are readily entrained in the slurry flowing from the third processing vessel 86.
[0039] Thus, in some embodiments, the first mesh size Ml is API 60 or less, the second mesh size M2 is API 60 to API 100, and the third mesh size M3 is API 100 or more. In other embodiments, the first mesh size Ml is simply larger than the second mesh size M2, which is larger than the third mesh size M3, i.e., the first mesh size as an API number that is smaller than the API number of the second mesh size, which second mesh size has an API number that4924-3311-1456 v.l 11PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683is smaller than the third mesh size. Tn other embodiments, the first, second, and third mesh sizes need not be consecutively decreasing; however, ultimately, at least one of the mesh sizes needs to be of a size through which solid particles to be reinjected can pass.Crushing System
[0040] Crushing system 24 is not limited to a particular, system. In one or more embodiments, crushing system 24 may be a hammermill and include a chamber with a perforated screen wall and steel hammers that rotate at high speed, wherein solid material introduced into the hammermill cannot leave the chamber until the solids are small enough to pass through the screen's holes.System Operation
[0041] Referring to FIGS. 1, 2, and 5, in operation, method 200 for slurrification and disposal of formation waste will now be described. A solids storage vessel 16 receives waste from a formation 12, such as from the drilling of a wellbore or mining operations. The storage vessel 16 may include a container, an open-air pit, a tank, or other containment devices. The formation waste includes particulate solids of varying size. Instead of externally disposing of some or all of the formation waste, the formation waste is introduced into a closed-loop system where it is continually processed until it is suitable for reinjection into the formation 12 by injection equipment 14, meaning that the particulate matter will remain in the system 10 and subject to processing until it is no larger than a predetermined mesh size allowing it to be readily suspended in a slurry for reinjection.
[0042] In step 200 of method 200, a first conveyance mechanism 38 transfers the particulate solids from the solids storage vessel 16 to a mixing vessel 40 where a conveyance fluid from a conveyance fluid source 44 is mixed with the particulate solids to produce an input or first slurry. The conveyance mechanism 38 is not limited to a particular mechanism. Nonlimiting examples of conveyance mechanisms include a feed hopper, a conveyor system, a movable bucket, or a pump. The conveyance fluid from a conveyance fluid source 44 may include water, drilling mud, or some other pumpable liquid component. Mixing vessel 40 may further include a mechanical mixer, such as paddles, or other mixing device so long as the first slurry exiting the mixing vessel 40 through a slurry outlet 46 can be pumped.4924-3311-1456 v.l 12PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0043] In one or more embodiments, the conveyance fluid from the conveyance fluid source 44 may also include waste water received from E&P operations, such that the waste water itself is incorporated into the slurry rather than requiring separate disposal.First Stage
[0044] In step 210, the first slurry is then directed into a first stage having a first centrifugal degradation pump 18. Within the first centrifugal degradation pump 18, at least a portion of the particulate solids in the first slurry are degraded to produce a second slurry. Specifically, the first centrifugal degradation pump 18 preferably includes open or semi-open vanes. The centrifugal degradation pump may include hard-faced vanes wherein the vanes may include tungsten carbide or silicon carbide inserts attached thereto. The centrifugal degradation pump may have a gap B size of at least 8-10%. In one or more embodiments, the first slurry may optionally be passed through an additional centrifugal degradation pump 122 in series with the first centrifugal degradation pump 18 in step 212 before proceeding to the sieving step, thereby extending the residence time and further degrading the particulate solids to produce the second slurry.
[0045] In step 214, as part of the first stage, the second slurry is then directed to a first processing system 26 where particulate matter of a first size is removed from the second slurry to produce a third slurry. Specifically, the second slurry is directed onto or across a first screen assembly 32 of the first processing system 26 where the first screen assembly 32 has a first mesh size Ml . The first screen assembly 32 is utilized to sieve the second slurry, allowing fluid and particulate matter smaller than the first mesh size Ml to fall or otherwise pass into and collect with a first processing vessel 58 as the third slurry . Particulate matter of a first size that is larger than the first mesh size Ml, namely a first solid of an average first particle size, is removed from the screen assembly and introduced into a crushing system 24 as described below.Second Stage
[0046] In step 216, the third slurry is then directed into a second stage having a second centrifugal degradation pump 20. Within the second centrifugal degradation pump 20, at least a portion of the particulate solids in the third slurry are degraded to produce a fourth slurry. Specifically, the second centrifugal degradation pump 20 preferably includes open or semiopen vanes. The centrifugal degradation pump may include hard-faced vanes wherein the vanes4924-3311-1456 v.l 13PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683may include tungsten carbide or silicon carbide inserts attached thereto. The centrifugal degradation pump may have a gap B size of at least 8-10%. In one or more embodiments, the third slurry may optionally be passed through an additional centrifugal degradation pump 124 in series with the second centrifugal degradation pump 20 in step 228 before proceeding to the sieving step, thereby extending the residence time and further degrading the particulate solids to produce the fourth slurry.
[0047] In step 218, as part of the second stage, the fourth slurry is then directed to a second processing system 28 where particulate matter of a second size is removed from the fourth slurry to produce a fifth slurry. Specifically, the fourth slurry is directed onto or across a second screen assembly 34 of the second processing system 28 where the second screen assembly 34 has a second mesh size M2 that is smaller than the first mesh size Ml. The second screen assembly 34 is utilized to sieve the fourth slurry, allowing fluid and particulate matter smaller than the second mesh size M2 to fall or otherwise pass into a second processing vessel 72 as the fifth slurry. Particulate matter of a second size that is larger than the second mesh size M2, namely a second solid of an average second particle size, is removed from the second screen assembly 34 and introduced into a crashing system 24 as described below.Third Stage
[0048] In step 220, the fifth slurry is then directed into a third stage having a third centrifugal degradation pump 22. Within the third centrifugal degradation pump 22, at least a portion of the particulate solids in the fifth slurry are degraded to produce a sixth slurry. Specifically, the third centrifugal degradation pump 22 preferably includes open or semi-open vanes. The centrifugal degradation pump may include hard-faced vanes wherein the vanes may include tungsten carbide or silicon carbide inserts attached thereto. The centrifugal degradation pump may have a gap B size of at least 8-10%. In one or more embodiments, the fifth slurry may optionally be passed through an additional centrifugal degradation pump 126 in series with the third centrifugal degradation pump 22 in step 228 before proceeding to the sieving step, thereby extending the residence time and further degrading the particulate solids to produce the sixth slurry.
[0049] In step 222, as part of the third stage, the sixth slurry is then directed to a third processing system 30 where particulate matter of a third size is removed from the sixth slurry to produce a seventh slurry. Specifically, the sixth slurry is directed onto or across a third screen4924-3311-1456 v.l 14PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683assembly 36 of the third processing system 30 where the third screen assembly 36 has a third mesh size M3 that is smaller than the second mesh size M2. The third screen assembly 36 is utilized to sieve the sixth slurry, allowing fluid and particulate matter smaller than the third mesh size M3 to fall or otherwise pass into a third processing vessel 86 as the seventh slurry. Particulate matter of a third size that is larger than the third mesh size M3, namely a third solid of an average third particle size, is removed from the third screen assembly 36 and introduced into a crushing system 24 as described below.Fourth Stage and Solids Recirculation
[0050] In a fourth stage, a fourth stage pump 90 pumps the seventh slurry to a slurry storage tank 128 for storage until the seventh slurry is pumped into formation 12, such as a wellbore, by injection equipment 14, either directly or after having mixed with additional fluid. In step 230, the seventh slurry may be injected into a formation, such as subterranean formation 7, for disposal. In one or more embodiments, the seventh slurry may be utilized as a drilling mud component for injection into a wellbore. In one or more embodiments, the seventh slurry may be disposed of via slurry fracture injection into a subterranean formation.
[0051] One or more second conveyance mechanisms 96 may be utilized to introduce particulate matter removed from the first, second, and third stages into one or more crushing systems 24. In some embodiments, each of the first, second and third stages may include a separate crushing system 96. A single second conveyance mechanism 96 may receive the particulate matter removed from all three stages, or a separate conveyance mechanism 96 may be utilized for the particulate matter from each stage. Likewise, a single crushing system 24 may receive the combined particulate matter removed from all three stages, or a separate crushing system 24 may be utilized for the particulate matter from each separate stage. Finally, in some embodiments, where each stage has a separate crushing system 96, conveyance mechanism 96 may be eliminated and each crushing system 24 may communicate directly with the solids outlet of the respective stage.
[0052] In one or more embodiments, the crushing system 24 is a hammermill. In one or more other embodiments, the crushing system 24 may be a jaw crusher, cone crusher, impact crusher, or gyratory crusher. In step 224, the crushing system 24 is utilized to process the first, second, and third solids removed at the first, second, and third stages, respectively, to produce a fourth solid of an average particle size that is smaller than the average first particle size. In4924-3311-1456 v.l 15PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683one or more embodiments, step 224 includes combining the first, second, and third solids and crashing at least a portion of the combined first, second, and third solids in the crashing system 24. In one or more other embodiments, the particulate matter removed at each stage may be crashed separately or simultaneously. After crushing, in step 226, the fourth solid, i.e., the crashed material, is introduced back into either the solids storage vessel 16 or the mixing vessel 40 for further processing in the first, second, and third stages as described, and thereafter the step of mixing (step 200) is repeated with the fourth solid mixed with waste material from the formation.
[0053] In any event, it will be appreciated that the foregoing slurrification process can be repeated until the particle size of the particulate matter is sufficiently small that the particulate matter can be removed from the slurrification system 10 as part of the seventh slurry. Moreover, because the slurrification system 10 is closed-loop, the particulate matter will remain in the slurrification system 10 and subject to the slurrification process until the particle size of the particulate matter is sufficiently small that the particulate matter can be removed from the slurrification system as part of the seventh slurry.
[0054] In one or more alternative embodiments of method 200, the particulate matter removed at each stage may be crashed individually at each respective stage rather than being combined before crashing. In such embodiments, the particulate matter of the first size removed at step 214 is crashed before or concurrently with the particulate matter of the second size removed at step 218 and the particulate matter of the third size removed at step 222. The crashed particulate matter of the first, second, and third sizes may then be combined with particulate solids from the formation, and the step of mixing (step 200) is repeated with the combined particulate matter. This per-stage crashing embodiment is particularly suited for implementations where each stage has a separate crashing system 24 communicating directly with the solids outlet of the respective stage.
[0055] It will further be appreciated that method 200 may be described in a generalized fashion as follows: mixing particulate solids from a formation, such as a wellbore, with a fluid to produce an input slurry; and then repeating the following steps at least three times to produce an output slurry: degrading the size of at least a portion of the particulate solids in the input slurry within a centrifugal pump to produce an intermediate slurry; and producing a subsequent input slurry by removing particulate matter from the intermediate slurry. The removed particulate matter is then crushed and combined with particulate solids from the formation to4924-3311-1456 v.l 16PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683produce a solids mixture, and the step of mixing is thereafter repeated with the solids mixture. In this generalized form, each repetition of the degrading and removing steps corresponds to one of the at least three processing stages described above, and the output slurry corresponds to the seventh slurry produced after the final stage.
[0056] It should be emphasized that the slurrification system 10 and process of the present invention is an improvement over prior art formation waste handling systems because there need be no solid waste discharge as in prior art systems. In other words, the slurrification system 10 is a closed-loop system, whereas prior art slurrification systems are open-loop systems that result in some waste that must be removed and handled separate and apart from any slurry that may also be produced by the prior art slurrification systems. Rather, particulate material from a formation can remain in the slurrification system 10 until the particulate material has been sufficiently processed that the particulate material can be reinjected into a wellbore.
[0057] The slurrification system 10 is particularly well-suited for processing naturally occurring radioactive material (NORM) and technologically enhanced naturally occurring radioactive material (TENORM) waste generated by formation drilling or recovery operations. Because the system 10 does not differentiate between NORM and non-NORM material, radioactive waste can be processed on-site through the same closed-loop process as nonradioactive waste. The processed slurry may then be disposed of via slurry fracture injection into a subterranean formation. This approach provides significant environmental benefits by eliminating the need to transport radioactive waste by truck to distant disposal facilities, thereby reducing transportation risk, cost, and environmental impact.
[0058] In one or more embodiments, each centrifugal degradation pump and / or transfer pump in the slurrification system 10 is controlled by a variable frequency drive (VFD) 104, which allows the pump speed to be adjusted to match the capacity of the corresponding screen assembly. Coarser screen assemblies permit higher flow rates, while finer screen assemblies require reduced pump speed to prevent material from overwhelming and bypassing the screen. Screen sizes are selected based on the pump’s capacity, and pump volume is adjusted via the VFD 104 to prevent overflow of the screen assembly. In this manner, the VFD enables coordination between each pump and its corresponding screen assembly to ensure proper classification at each stage.4924-3311-1456 v.l 17PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0059] In one or more embodiments, the slurrification system 10 may further include one or more sensors 106 disposed on or adjacent to each screen assembly 32, 34, 36 for monitoring screen loading conditions. The sensors 106 may be operably connected to the VFD 104 corresponding to a pump to enable automated adjustment of pump speed based on real-time screen loading. In such embodiments, the system 10 may operate as a fully automated process without the need for manual adjustment of pump speed, the sensors 106 providing feedback to the VFD 104 to increase or decrease pump speed in response to changing material loading on the screen assemblies.
[0060] In one or more embodiments, each pump in the slurrification system 10 has a redundant pump associated therewith, providing built-in redundancy to permit continued operation in the event of a pump failure or during maintenance.
[0061] As a result of the cascading classification architecture and the closed-loop design, the slurrification system 10 is capable of processing substantially higher volumes of waste than prior art systems. In one or more embodiments, the system 10 is capable of processing on the order of approximately 1 ,000 barrels of solid waste per day, which represents approximately ten times the throughput capacity of existing slurrification systems that typically process on the order of only about 100 barrels per day.
[0062] Thus, a slurrification system has been described. In one or more embodiments, the slurrification system may include a solids storage vessel; a mixing vessel with a fluid inlet and a slurry outlet; a first conveyance mechanism between the solids storage vessel and the mixing vessel; a conveyance fluid source in fluid communication with the fluid inlet of the mixing vessel; a first stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the mixing vessel, the first centrifugal degradation pump further having an outlet; a first processing system having a slurry inlet in fluid communication with the outlet of the first centrifugal degradation pump, a slurry outlet, a solids outlet, a first processing vessel and a first screen assembly having a first mesh size Ml ; a second stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the first processing system, the second centrifugal degradation pump further having an outlet; a second processing system having a slurry inlet in fluid communication with the outlet of the second centrifugal degradation pump, a slurry outlet, a solids outlet, a second processing vessel and a second screen assembly having a second mesh size M2; a third stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the second processing system,4924-3311-1456 v.l 18PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683the third centrifugal degradation pump further having an outlet; a third processing system having a slurry inlet in fluid communication with the outlet of the third centrifugal degradation pump, a slurry outlet, a solids outlet, a third processing vessel and a third screen assembly having a third mesh size M3; a pump having an inlet in fluid communication with the slurry outlet of the third processing system, the fourth pump further having a slurry outlet; a second conveyance mechanism in communication with each of the solids outlet of the first processing system, the solids outlet of the second processing system and the solids outlet of the third processing system, the second conveyance mechanism further including a solids outlet; and a crushing system having a solids inlet in communication with the solids outlet of the second conveyance mechanism, the crushing system further including a solids outlet in communication with the solids storage vessel. In one or more other embodiments, the slurrification system may include a solids storage vessel; a conveyance fluid source; a mixing vessel in communication with the solids storage vessel and the conveyance fluids source; a first stage centrifugal degradation pump in fluid communication with the mixing vessel; a first screen assembly having a first screen of a first mesh size Ml , the first screen assembly disposed to receive slurry from the first stage centrifugal degradation pump; a first processing vessel disposed to receive a slurry from the first screen assembly; a second stage centrifugal degradation pump in fluid communication with the first processing vessel; a second screen assembly having a second screen of a second mesh size M2, the second screen assembly disposed to receive slurry from the second stage centrifugal degradation pump; a second processing vessel disposed to receive a slurry from the second screen assembly; a third stage centrifugal degradation pump in fluid communication with the second processing vessel; a third screen assembly having a third screen of a third mesh size M3, the third screen assembly disposed to receive slurry from the third stage centrifugal degradation pump; a third processing vessel disposed to receive a slurry from the third screen assembly; and a crushing system disposed to receive solids from each of the first screen assembly, the second screen assembly and the third screen assembly. In one or more other embodiments, the slurrification system may include a formation waste material source; a conveyance fluid source; a mixing vessel in communication with the formation waste material source and the conveyance fluid source; at least three processing stages arranged in series, where each processing stage comprises a centrifugal degradation pump, a screen assembly having a mesh size M, and a processing vessel, wherein the centrifugal degradation pump of a stage is in fluid communication with the screen assembly of the stage to deliver a4924-3311-1456 v.l 19PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683slurry to the screen assembly; and a crushing system disposed to receive solids from each of the first screen assembly, the second screen assembly and the third screen assembly.
[0063] For any of the foregoing slurrification systems, one or more of the following limitations may be included, alone or in combination with any other limitations:
[0064] at least one additional centrifugal degradation pump in a stage arranged in series with another centrifugal degradation pump in the same stage;
[0065] the screen assembly comprises a screen having a mesh size M;
[0066] a mixing mechanism disposed in the mixing vessel;
[0067] an agitator disposed in the mixing vessel;
[0068] the solids storage vessel is a container;
[0069] the solids storage vessel is an open-air pit;
[0070] the solids storage vessel is a tank;
[0071] the conveyance mechanism is a feed hopper;
[0072] the conveyance mechanism is a conveyor system;
[0073] the conveyance mechanism is a tubular;
[0074] the conveyance mechanism is a movable bucket;
[0075] the conveyance mechanism is a pump;
[0076] the slurrification system is a closed loop for solids;
[0077] the conveyance fluids source is a water source:
[0078] the conveyance fluid is water;
[0079] the conveyance fluids source is a drilling mud source;
[0080] the conveyance fluid is drilling mud;
[0081] the crushing system comprises a hammer mill;
[0082] the third mesh size is smaller than the second mesh size which is smaller than the first mesh size;4924-3311-1456 v.l 20PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0083] a slurry storage tank having a slurry inlet in fluid communication with the slurry outlet of the additional pump;
[0084] the conveyor system comprises an auger conveyor;
[0085] the auger is a ribbon auger;
[0086] the conveyor system comprises a belt conveyor;
[0087] the first screen assembly has an upper screen side, a lower screen side and is disposed above the first processing vessel and the slurry inlet of the first processing system is disposed adjacent the upper screen side of the first screen assembly;
[0088] the first processing system further comprises a shaker system for agitating the first screen assembly;
[0089] the second screen assembly has an upper screen side, a lower screen side and is disposed above the second processing vessel and the slurry inlet of the second processing system is disposed adjacent the upper screen side of the second screen assembly;
[0090] the second processing system further comprises a shaker system for agitating the second screen assembly;
[0091] the third screen assembly has an upper screen side, a lower screen side and is disposed above the third processing vessel and the slurry inlet of the third processing system is disposed adjacent the upper screen side of the third screen assembly;
[0092] the third processing system further comprises a shaker system for agitating the third screen assembly;
[0093] the first mesh size is a coarse API screen size;
[0094] the second mesh size is a medium API screen size;
[0095] the second mesh size is a fine API screen size;
[0096] the first slurry is a coarse slurry having particles of no larger than 780-925 micron entrained therein;4924-3311-1456 v.l 21PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0097] the second slurry is a medium slurry having particles of no larger than 390- 425 micron entrained therein;
[0098] the third slurry is a fine slurry having particles of no larger than 275-327.5 micron entrained therein;
[0099] a solid is any waste material that is made of particles;
[0100] a solid is any waste material that is not a liquid or gas;
[0101] the centrifugal degradation pump comprises a pump housing with an open impeller mounted therein;
[0102] the centrifugal degradation pump comprises a pump housing with a semiopen impeller mounted therein;
[0103] the impeller of the centrifugal degradation pump is hard-faced;
[0104] the impeller of the centrifugal degradation pump comprises a plurality of vanes with inserts attached to the vanes;
[0105] the inserts attached to the vanes are formed of tungsten carbide or a silicon carbide;
[0106] the centrifugal degradation pump comprises a housing with an impeller rotatably mounted in the housing, the housing having an inner casing diameter and the impeller having an outer impeller diameter with the impeller mounted in the housing so that a gap is formed between the impeller outer diameter and the pump casing inner diameter, the gap being between 5-15% of the impeller diameter;
[0107] the centrifugal degradation pump comprises a housing with an impeller rotatably mounted in the housing, the housing having an inner casing diameter and the impeller having an outer impeller diameter with the impeller mounted in the housing so that a gap is formed between the impeller outer diameter and the pump casing inner diameter, the gap being at least 8% of the impeller diameter;
[0108] the centrifugal degradation pump comprises a housing with an impeller rotatably mounted in the housing, the housing having an inner casing4924-3311-1456 v.l 22PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683diameter and the impeller having an outer impeller diameter with the impeller mounted in the housing so that a gap is formed between the impeller outer diameter and the pump casing inner diameter, the gap being between 10-15% of the impeller diameter;
[0109] each centrifugal degradation pump is controlled by a variable frequency drive (VFD);
[0110] one or more sensors disposed on or adjacent to a screen assembly for monitoring screen loading, the sensors being operably connected to the VFD of a corresponding pump to enable automated pump speed adjustment;
[0111] each pump in the slurrification system has a redundant pump associated therewith;
[0112] the first conveyance mechanism includes a feed hopper having grizzly bars at an inlet thereof for initial screening of waste material;
[0113] the input slurry has a composition of approximately 10-20% solids and 80- 90% fluid by volume;
[0114] one or more intermediate pumps between stages are standard centrifugal pumps rather than centrifugal degradation pumps.
[0115] Thus, a method for slurrification of formation waste has been described. In one or more embodiments, the slurrification method may include mixing waste material from a formation with a conveyance fluid to produce a first slurry; passing the first slurry through a centrifugal degradation pump to produce a second slurry; sieving the second slurry to produce a third slurry and a first solid of an average first particle size; passing the third slurry through a centrifugal degradation pump to produce a fourth slurry; sieving the fourth slurry to produce a fifth slurry and second solid of an average second particle size; passing the fifth slurry through a centrifugal degradation pump to produce a sixth slurry; sieving the sixth slurry to produce a seventh slurry and third solid of an average third particle size; processing the first, second and third solids to produce a fourth solid of an average particle size smaller than the average first particle size; and mixing the fourth solid with waste material from the formation. In one or more other embodiments, the slurrification method may include mixing particulate solids from a formation with a fluid to produce a first slurry; passing the first slurry through a centrifugal4924-3311-1456 v.l 23PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683degradation pump to produce a second slurry; separating the second slurry into particulate matter of a first size and a third slurry; crushing the particulate matter of the first size; passing the third slurry through a centrifugal degradation pump to produce a fourth slurry; separating the fourth slurry into particulate matter of a second size and a fifth slurry; crushing the particulate matter of the second size; passing the fifth slurry through a centrifugal degradation pump to produce a sixth slurry; separating the sixth slurry into particulate matter of a third size and a seventh slurry; crushing the particulate matter of the third size; combining the ground particulate matter of the first, second and third sizes with particulate solids from a formation; and repeating the step of mixing with the combined particulate matter. In one or more other embodiments, the slurrification method may include mixing particulate solids from a formation with a fluid to produce a first slurry; degrading the size of at least a portion of the particulate solids in the first slurry within a centrifugal pump to produce a second slurry; producing a third slurry by removing particulate matter of a first size from the second slurry; degrading the size of at least a portion of the particulate solids in the third slurry within a centrifugal pump to produce a fourth slurry; producing a fifth slurry by removing particulate matter of a second size from the fourth slurry; degrading the size of at least a portion of the particulate solids in the fifth slurry within a centrifugal pump to produce a sixth slurry; producing a seventh slurry by removing particulate matter of a third size from the sixth slurry; crushing the removed particulate matter from the second, fourth and sixth slurries and combining the ground particulate matter with particulate solids from a formation to produce a solids mixture; and thereafter, repeating the step of mixing with the solids mixture. In one or more other embodiments, the slurrification method may include mixing particulate solids from a formation with a fluid to produce an input slurry; repeating the following steps at least three times to produce an output slurry: degrading the size of at least a portion of the particulate solids in an input slurry within a centrifugal pump to produce an intermediate slurry; producing an input slurry by removing particulate matter from the intermediate slurry; crushing the removed particulate matter and combining the ground particulate matter with particulate solids from a formation to produce a solids mixture; and thereafter, repeating the step of mixing with the solids mixture.
[0116] For any of the foregoing slurrification methods, one or more of the following limitations may be included, alone or in combination with any other limitations:4924-3311-1456 v.l 24PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0117] passing in series slurry from a centrifugal degradation pump in a stage to an additional centrifugal degradation pump in the same stage before a subsequent sieving step;
[0118] processing comprises combining the first, second and third solids and crushing at least a portion of the combined first, second and third solids;
[0119] the slurrification method is a closed loop method for solids having a particle size greater than the average third particle size;
[0120] injecting the seventh slurry into a formation;
[0121] introducing the seventh slurry into a formation;
[0122] sieving comprises passing the slurry through a screen having an API mesh size;
[0123] processing the first, second and third solids comprises combining the first, second and third solids and introducing the combined first, second and third solids into a hammer mill;
[0124] processing the first, second and third solids comprises combining the first, second and third solids and crushing at least a portion of the combined first, second and third solids;
[0125] utilizing the seventh slurry as drilling mud component for a wellbore;
[0126] combining the particulate matter of first, second and third sizes together before crushing;
[0127] simultaneously crushing the particulate matter of first, second and third sizes;
[0128] the first size is larger than the second size and the second size is larger than the third size;
[0129] the method for slurrification is a closed loop process.
[0130] adjusting pump speed via a variable frequency drive (VFD) to match the capacity of a corresponding screen assembly;4924-3311-1456 v.l 25PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683
[0131] automatically adjusting pump speed based on real-time screen loading monitored by one or more sensors;
[0132] disposing of the seventh slurry via slurry fracture injection into a subterranean formation;
[0133] the waste material comprises naturally occurring radioactive material (NORM) or technologically enhanced naturally occurring radioactive material (TENORM).
[0134] Although various embodiments have been shown and described, the disclosure is not limited to such embodiments and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed; rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.4924-3311-1456 v.l 26
Claims
PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683CLAIMS WHAT IS CLAIMED IS:
1. A slurrification system for formation waste, the slurrification system comprising: a formation waste material source;a conveyance fluid source;a mixing vessel in communication with the formation waste material source and the conveyance fluid source;at least three processing stages arranged in series, where each processing stage comprises a centrifugal degradation pump, a screen assembly having a mesh size, and a processing vessel, wherein the centrifugal degradation pump of a stage is in fluid communication with the screen assembly of the stage to deliver a slurry to the screen assembly; anda crushing system disposed to receive solids from each of the screen assemblies of the at least three processing stages.
2. The slurrification system of claim 1, wherein the mesh sizes of the screen assemblies of the at least three processing stages are consecutively decreasing.
3. The slurrification system of claim 1, wherein the crushing system has a solids outlet in communication with at least one of the formation waste material source and the mixing vessel.
4. The slurrification system of claim 1, wherein each centrifugal degradation pump comprises a pump housing with an open or semi-open impeller mounted therein, the impeller being hard-faced with inserts formed of tungsten carbide or silicon carbide.
5. The slurrification system of claim 1, wherein each centrifugal degradation pump has a radial gap between the impeller outer diameter and the pump casing inner diameter that is between 5-15% of the impeller diameter.
6. A slurrification system for formation waste, the slurrification system comprising: a solids storage vessel;a mixing vessel with a fluid inlet and a slurry outlet;a first conveyance mechanism between the solids storage vessel and the mixing vessel;4924-3311-1456 v.l 27PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683a conveyance fluid source in fluid communication with the fluid inlet of the mixing vessel;a first stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the mixing vessel, the first centrifugal degradation pump further having an outlet;a first processing system having a slurry inlet in fluid communication with the outlet of the first centrifugal degradation pump, a slurry outlet, a solids outlet, a first processing vessel, and a first screen assembly having a first mesh size;a second stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the first processing system, the second centrifugal degradation pump further having an outlet;a second processing system having a slurry inlet in fluid communication with the outlet of the second centrifugal degradation pump, a slurry outlet, a solids outlet, a second processing vessel, and a second screen assembly having a second mesh size;a third stage centrifugal degradation pump having an inlet in fluid communication with the slurry outlet of the second processing system, the third centrifugal degradation pump further having an outlet;a third processing system having a slurry inlet in fluid communication with the outlet of the third centrifugal degradation pump, a slurry outlet, a solids outlet, a third processing vessel, and a third screen assembly having a third mesh size;a pump having an inlet in fluid communication with the slurry outlet of the third processing system, the pump further having a slurry outlet;a second conveyance mechanism in communication with each of the solids outlet of the first processing system, the solids outlet of the second processing system, and the solids outlet of the third processing system, the second conveyance mechanism further including a solids outlet; anda crushing system having a solids inlet in communication with the solids outlet of the second conveyance mechanism, the crashing system further including a solids outlet in communication with the solids storage vessel.
7. The slurrification system of claim 6, further comprising at least one additional centrifugal degradation pump in a stage arranged in series with another centrifugal degradation pump in the same stage.4924-3311-1456 v.l 28PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 0000276838. The slurrification system of claim 6, further comprising a slurry storage tank having a slurry inlet in fluid communication with the slurry outlet of the pump.
9. The slurrification system of claim 6, wherein the third mesh size is smaller than the second mesh size, which is smaller than the first mesh size.
10. The slurrification system of claim 6, wherein the slurrification system is a closed loop for solids.
11. The slurrification system of claim 6, wherein each centrifugal degradation pump comprises a pump housing with an open or semi-open impeller mounted therein.
12. The slurrification system of claim 11, wherein the impeller of each centrifugal degradation pump is hard-faced.
13. The slurrification system of claim 12, wherein the impeller of each centrifugal degradation pump comprises a plurality of vanes with inserts attached to the vanes, the inserts being formed of tungsten carbide or silicon carbide.
14. The slurrification system of claim 11, wherein each centrifugal degradation pump comprises a housing with an impeller rotatably mounted in the housing, the housing having an inner casing diameter and the impeller having an outer impeller diameter with the impeller mounted in the housing so that a gap is formed between the impeller outer diameter and the pump casing inner diameter, the gap being between 10-15% of the impeller diameter.
15. The slurrification system of claim 6, wherein the crushing system comprises a hammermill.
16. The slurrification system of claim 6, wherein the first conveyance mechanism comprises at least one of a feed hopper, a conveyor system, a movable bucket, and a pump.
17. The slurrification system of claim 6, wherein the conveyance fluid source is a water source or a drilling mud source.
18. The slurrification system of claim 6, wherein at least one of the first processing system, the second processing system, and the third processing system further comprises a shaker system for agitating the respective screen assembly.4924-3311-1456 v.l 29PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 00002768319. A method for slurrification and disposal of formation waste, the method comprising:mixing waste material from a formation with a conveyance fluid to produce a first slurry;passing the first slurry through a first centrifugal degradation pump to produce a second slurry;sieving the second slurry through a first screen assembly having a first mesh size to produce a third slurry and a first solid of an average first particle size;passing the third slurry through a second centrifugal degradation pump to produce a fourth slurry;sieving the fourth slurry through a second screen assembly having a second mesh size to produce a fifth slurry and a second solid of an average second particle size;passing the fifth slurry through a third centrifugal degradation pump to produce a sixth slurry;sieving the sixth slurry through a third screen assembly having a third mesh size to produce a seventh slurry and a third solid of an average third particle size;processing the first, second, and third solids to produce a fourth solid of an average particle size smaller than the average first particle size; andmixing the fourth solid with waste material from the formation.
20. The method of claim 19, further comprising passing slurry in series from a centrifugal degradation pump in a stage to an additional centrifugal degradation pump in the same stage before a subsequent sieving step.
21. The method of claim 19, wherein processing the first, second, and third solids comprises combining the first, second, and third solids and crushing at least a portion of the combined first, second, and third solids.
22. The method of claim 19, further comprising injecting the seventh slurry into a formation.
23. The method of claim 19, further comprising utilizing the seventh slurry as a drilling mud component for a wellbore.
24. The method of claim 19, wherein the method for slurrification is a closed-loop process.4924-3311-1456 v.l 30PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 00002768325. A method for slurrification of formation waste, the method comprising:mixing particulate solids from a formation with a fluid to produce a first slurry; passing the first slurry through a centrifugal degradation pump to produce a second slurry;separating the second slurry into particulate matter of a first size and a third slurry; crushing the particulate matter of the first size;passing the third slurry through a centrifugal degradation pump to produce a fourth slurry;separating the fourth slurry into particulate matter of a second size and a fifth slurry; crushing the particulate matter of the second size;passing the fifth slurry through a centrifugal degradation pump to produce a sixth slurry; separating the sixth slurry into particulate matter of a third size and a seventh slurry; crushing the particulate matter of the third size;combining the crushed particulate matter of the first, second, and third sizes with particulate solids from a formation; andrepeating the step of mixing with the combined particulate matter.
26. The method of claim 25, further comprising injecting the seventh slurry into a wellbore.
27. A method for slurrification of formation waste, the method comprising:mixing particulate solids from a wellbore with a fluid to produce a first slurry; degrading the size of at least a portion of the particulate solids in the first slurry within a centrifugal pump to produce a second slurry;producing a third slurry by removing particulate matter of a first size from the second slurry;degrading the size of at least a portion of the particulate solids in the third slurry within a centrifugal pump to produce a fourth slurry;producing a fifth slurry by removing particulate matter of a second size from the fourth slurry;degrading the size of at least a portion of the particulate solids in the fifth slurry within a centrifugal pump to produce a sixth slurry;producing a seventh slurry by removing particulate matter of a third size from the sixth slurry;4924-3311-1456 v.l 31PCT Patent Application Atty Docket No. 48068.28WO01Customer No. 000027683crushing the removed particulate matter from the second, fourth, and sixth slurries and combining the crushed particulate matter with particulate solids from a wellbore to produce a solids mixture; andthereafter, repeating the step of mixing with the solids mixture.
28. A method for slurrification of formation waste, the method comprising:mixing particulate solids from a wellbore with a fluid to produce an input slurry; repeating the following steps at least three times to produce an output slurry: degrading the size of at least a portion of the particulate solids in an input slurry within a centrifugal pump to produce an intermediate slurry;producing an input slurry by removing particulate matter from the intermediate slurry; crushing the removed particulate matter and combining the crushed particulate matter with particulate solids from a wellbore to produce a solids mixture: andthereafter, repeating the step of mixing with the solids mixture.
29. The method of claim 28, further comprising introducing the output slurry into a wellbore.
30. The method of claim 28, further comprising utilizing the output slurry as a drilling mud component for a wellbore.4924-3311-1456 v.l 32