Oil Field Waste Processing via Particle Size Reduction and Recirculation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for disposing of solid wastes from oil field operations face challenges in processing and injecting these wastes underground without clogging equipment or damaging subterranean formations, as existing systems are inefficient in particle size reduction and slurry formation.
Innovation Solution
A system and method involving particle size separation and reduction, using multiple separators and a particle size reduction apparatus to create a slurry that can be injected underground, with recirculation and dilution to ensure effective processing and prevent equipment clogging, including a vacuum conveyance system for waste collection and transportable containers for resistant particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid waste is disposed of at specialized surface landfills, then disposal is achieved, but logistics and environmental problems arise
Solution Approach 1:
The patent extracts the harmful solid waste particles from the slurry stream using particle separation systems. Large particles are removed through screens and separators, while fine particles are managed through controlled injection. This extraction approach eliminates the need for surface landfills by processing and redistributing the waste materials underground, solving both the disposal effectiveness and logistics complexity problems.
Solution Approach 2:
The patent introduces fluid media (water, drilling fluids, or completion fluids) as intermediaries to transform solid waste into pumpable slurry. This intermediary approach enables the waste to be transported and injected underground through existing wellbores, eliminating the need for complex surface landfill logistics while maintaining effective disposal.
2Reliability
If particle size reduction is implemented to prevent equipment clogging, then injection reliability improves, but processing time and energy consumption increase
Solution Approach 1:
The patent segments the particle size reduction process into multiple stages using different separation mechanisms. Coarse particles are removed first through screens and separators, then finer particles are managed through controlled slurry preparation. This segmentation allows efficient processing without requiring excessive time or energy for complete size reduction of all particles.
Solution Approach 2:
The patent changes the physical parameters of the waste material by transforming solids into slurry through fluid addition and mechanical agitation. This parameter change from solid to semi-fluid state enables pumpable consistency without requiring complete particle size reduction, thus maintaining injection reliability while minimizing processing time and energy consumption.
3Manufacturing precision
If recirculation is used to maintain particle size reduction, then slurry quality improves, but energy consumption increases
Solution Approach 1:
The patent implements continuous recirculation of slurry through the particle separation and size reduction system. This continuous action maintains consistent slurry quality by constantly processing material through the separation stages. The system is designed so that the recirculation energy consumption is offset by the elimination of re-processing failures and equipment clogging, making the energy investment worthwhile for maintaining high slurry quality.
Solution Approach 2:
The patent employs feedback control where the recirculated slurry is continuously monitored and adjusted. Particles that are not sufficiently reduced are detected and sent back for further processing, while properly sized particles are directed to injection. This feedback mechanism ensures optimal slurry quality while minimizing unnecessary energy consumption by avoiding over-processing of already suitable particles.
4Reliability
If multiple particle separators are used to reduce particle size, then injection reliability improves, but device complexity increases
Solution Approach 1:
The patent divides the particle separation function into multiple specialized components working in sequence. Different separators target different particle size ranges, with each device optimized for its specific function. This segmentation achieves high injection reliability by comprehensively addressing all particle size issues while keeping each individual component relatively simple and maintainable.
Solution Approach 2:
The patent designs the particle separation system with multi-functional components that can handle various particle types and sizes. The separators are configured to work together as an integrated system that addresses both coarse and fine particle removal, reducing the need for entirely separate systems for different particle categories. This multi-functionality approach improves reliability without proportionally increasing overall system complexity.
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
The system efficiently processes and injects oil field waste underground by reducing particle size and maintaining solids in suspension, preventing equipment clogging and ensuring effective disposal without damaging subterranean formations.
Implementation Method 1
at least a portion of the first slurry is removed and re-circulated back into the first slurry tank, optionally at a velocity sufficient for reducing particle size upon impact of the first solid particles with the first slurry tank
Implementation Method 2
separating the waste through a first particle size separator
Implementation Method 3
a vacuum conveyance system for waste collection
Data Source
AI summary
Systems and methods for processing solid wastes from oil field operations including removal of wastes from oil tanks by a washout and vacuum conveyance system to form a slurry containing solid particles, solid particle size reduction by one or more grinders and, optionally, high velocity transport through recirculation circuits and disposal by injection into a subterranean formation.