Plasma Arc Torch Mining Byproduct Treatment
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Solution Overview
Problem
Current oil and gas production methods face challenges in recovering valuable mining fluids and treating produced water efficiently, leading to environmental concerns and increased production costs due to ineffective heat transfer in steam-assisted gravity drainage (SAGD) processes, where contaminants reduce boiler efficiency and require frequent maintenance.
Innovation Solution
A plasma treatment system that recovers mining fluids by melting mining byproducts into inert materials, uses hydrogen as a plasma gas to reduce diesel emissions, and upgrades heavy oil, while also recycling water and reducing environmental impacts through a closed-loop system incorporating a plasma arc torch and electrolysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal desorption units are used to treat mining byproducts, then hydrocarbons can be removed, but the units are bulky, have many moving parts, and require indirect heating which is inefficient
Solution Approach 1:
The patent replaces the mechanical thermal desorption system with a plasma-based treatment system. The plasma torch directly heats mining byproducts without requiring bulky mechanical components or indirect heating systems, achieving efficient hydrocarbon removal through direct plasma contact and pyrolysis.
Solution Approach 2:
The patent changes the heating parameter from indirect thermal heating to direct plasma heating. The plasma torch generates extremely high temperatures that directly contact and pyrolyze the mining byproducts, fundamentally changing the heating mechanism from inefficient indirect heating to efficient direct heating.
2Reliability
If vertical centrifuges are used to reduce ROC, then discharge limits can be met, but LCM and cement cannot be effectively treated and the centrifuge must be shut down and cleaned
Solution Approach 1:
The plasma torch system provides universal treatment capability for all mining byproducts including LCM and cement that clog vertical centrifuges. The high-temperature plasma can pyrolyze and vaporize all types of materials simultaneously, eliminating the need to bypass certain operations and enabling continuous treatment of diverse waste streams.
Solution Approach 2:
The patent converts the problematic LCM and cement materials that cause centrifuge clogging into beneficial products. Through plasma pyrolysis, these materials are transformed into usable byproducts such as activated carbon and other valuable substances, turning a operational headache into a resource recovery opportunity.
3Loss of substance
If air dryers or friction dryers are used to dry cuttings, then moisture can be removed, but base fluids cannot be recovered and fine powders are produced that are difficult to separate
Solution Approach 1:
The patent changes the drying parameter from mechanical drying to plasma pyrolysis. The plasma torch rapidly heats and pyrolyzes the mining byproducts, instantly vaporizing moisture and base fluids while simultaneously carbonizing the cuttings into coarser, easier-to-handle particles rather than fine powders.
Solution Approach 2:
The patent utilizes phase transitions through plasma heating. Water and base fluids transition from liquid to vapor phase through rapid plasma heating, enabling their separation and recovery. The cuttings undergo pyrolysis and carbonization, transitioning from organic material to carbon-rich solids with different physical properties.
4Productivity
If SAGD process is used for enhanced oil recovery, then heavy oil can be upgraded, but heat transfer efficiency is reduced due to contaminants requiring frequent maintenance
Solution Approach 1:
The plasma torch system extracts contaminants from mining byproducts and produced water through pyrolysis and vaporization. By removing these contaminants before they can deposit in boilers and heat exchangers, the system maintains high heat transfer efficiency in the SAGD process, eliminating the need for frequent maintenance while preserving oil recovery productivity.
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 effectively recovers valuable resources, reduces environmental impacts, and enhances oil recovery by utilizing a plasma treatment process that melts mining byproducts, recycles water, and improves heat transfer efficiency, thereby lowering production costs and environmental footprint.
Implementation Method 1
a plasma arc torch that melts mining byproducts into inert materials
Implementation Method 2
utilizing a plasma treatment process that melts mining byproducts
Implementation Method 3
recycling water and reducing environmental impacts through a closed-loop system incorporating a plasma arc torch and electrolysis
Data Source
Figure 1
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AI summary
The present invention provides various systems, methods and apparatuses for recovering mining fluids, providing enhanced oil recovery and treating produced water. Plasma arc torches and electrolysis cells are used in various combinations. The plasma arc torch includes a cylindrical vessel, a first tangential inlet/outlet connected to or proximate to a first end, a second tangential inlet/outlet connected to or proximate to a second end, an electrode housing connected to the first end such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle is connected to the second end such that the hollow electrode nozzle is aligned with the longitudinal axis, the hollow electrode nozzle is partially disposed within the cylindrical vessel and outside the cylindrical vessel.