Hydrocarbon Extraction from Drill Cuttings Using Liquid CO2
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Solution Overview
Problem
Current methods for extracting hydrocarbons from drill cuttings are inefficient, costly, and pose environmental hazards due to high energy consumption, complex plant construction, and safety concerns, especially in offshore operations.
Innovation Solution
The use of liquid carbon dioxide at low temperatures and pressures to solubilize hydrocarbons from drill cuttings, with a system comprising a carbon dioxide tank, extraction tank, and recirculation pump for enhanced mass transfer and hydrocarbon recovery, allowing for cleaner cuttings and hydrocarbon reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional hydrocarbon extraction methods are used, then hydrocarbons can be removed from drill cuttings, but energy consumption is high and process complexity increases
Solution Approach 1:
The invention extracts the harmful hydrocarbons from drill cuttings using a simple extraction system consisting of a pressure vessel, pump, and separation equipment. This removes the core problem (hydrocarbon contamination) while avoiding complex processing plants, thereby reducing both energy consumption and device complexity compared to traditional methods.
Solution Approach 2:
The invention changes the physical parameters of the extraction process by using pressurized inert gas (typically nitrogen) at controlled pressures and temperatures to extract hydrocarbons. This parameter-based approach replaces complex chemical treatment processes, reducing both energy requirements and plant complexity while effectively removing hydrocarbons from cuttings.
2Reliability
If conventional hydrocarbon removal methods are employed, then extraction can be achieved, but safety concerns arise especially in offshore operations
Solution Approach 1:
The invention uses an inert gas (typically nitrogen) as the extraction medium, creating an inert atmosphere throughout the process. This eliminates fire and explosion hazards associated with using oxygen or air during hydrocarbon extraction, significantly improving safety especially in offshore operations, while maintaining effective hydrocarbon removal through the inert gas's ability to dissolve and carry away hydrocarbons.
3Productivity
If high energy consumption methods are used, then hydrocarbon extraction is effective, but operational costs increase
Solution Approach 1:
The invention replaces energy-intensive thermal or chemical extraction methods with a mechanical/physical process using pressurized inert gas. The system uses a pump to circulate the inert gas through the cuttings, and separation equipment to recover hydrocarbons, achieving effective extraction at lower energy costs by substituting high-energy thermal processes with lower-energy fluid circulation and phase separation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces energy costs and improves efficiency, achieving hydrocarbon recovery with lower energy requirements compared to traditional methods, while ensuring environmental safety and enabling hydrocarbon reuse.
Implementation Method 1
The use of liquid carbon dioxide at low temperatures and pressures to solubilize hydrocarbons from drill cuttings
Implementation Method 2
The extractant containing the constituents is withdrawn from the pressure vessel and depressurized to render it a nonsolvent for the constituents and to form a two-phase system
Data Source
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AI summary
The present invention relates to a system and a method for the extraction of hydrocarbons from drill cuttings in drilling mud. The system for extracting hydrocarbons from drill cuttings includes at least one extraction tank, a carbon dioxide tank fluidly connected to the at least one extraction tank, and at least one separation tank in fluid communication with the at least one extraction tank. The method for extracting hydrocarbons from drill cuttings consists of exposing the drill cuttings to liquid carbon dioxide, solubilizing hydrocarbons from the drill cuttings with the liquid carbon dioxide, heating the liquid carbon dioxide and the soluble hydrocarbons to convert liquid carbon dioxide to carbon dioxide vapor, separating the hydrocarbons from the carbon dioxide vapor, and collecting the separated hydrocarbons.