Shale-Gas Separator Cyclonic Separation Dust Control
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Solution Overview
Problem
During shale gas drilling, the air drilling process creates a volatile mixture of shale cuttings, dust, gas, and fluid, posing challenges in separation, dust control, and fire safety due to combustible gas clouds, with no effective method to manage these hazards and comply with environmental regulations.
Innovation Solution
A shale-gas separator system comprising a vessel with a tangential intake pipe and a jet assembly, along with an internal aerated cushion system and dust eliminator, which separates gas from the shale-gas-fluid mixture, controls dust, and safely disposes of debris and gas through a flare system, ensuring environmental safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If air drilling process is used in shale formation, then drilling operations can be performed, but volatile mixture of shale cuttings, dust, gas and fluid is created causing fire risk and environmental hazards
Solution Approach 1:
The system divides the drilling operation into separate functional components: a separator unit that divides the volatile mixture into gas, fluid, and solids phases; a dust control unit with water suppression; and a controlled combustion system. This segmentation allows each component to address specific hazards independently while maintaining overall drilling productivity.
Solution Approach 2:
The patent introduces intermediary systems between the drilling operation and the environment: a separator vessel acts as an intermediary to isolate volatile mixtures from the environment; water spray systems serve as intermediaries to suppress dust; and a controlled flare system acts as an intermediary to safely combust gases. These intermediaries mediate between the harmful drilling byproducts and environmental protection requirements.
2Productivity
If gas is encountered during air drilling from previously fractured formation, then drilling can continue, but combustible gas cloud is created posing fire hazard
Solution Approach 1:
The separator unit extracts combustible gases from the volatile mixture generated during drilling. By continuously removing gas from the drilling environment and directing it to a controlled flare system, the patent maintains drilling continuity while eliminating the fire hazard associated with combustible gas clouds accumulating around the wellsite.
Solution Approach 2:
The system converts the harmful combustible gas cloud into a beneficial controlled combustion process. The flare system deliberately burns the extracted gas in a controlled manner, transforming the fire hazard into a safe, controlled energy release that prevents uncontrolled explosions while maintaining drilling operations.
3Productivity
If dust is discharged into environment during air drilling, then drilling operations can proceed, but environmental regulations are violated causing penalties and fines
Solution Approach 1:
The dust control unit utilizes hydraulic principles by introducing water spray into the air stream carrying dust particles. The water droplets collide with and capture dust particles, causing them to settle out of the air stream. This pneumatic-hydraulic interaction effectively removes dust from the discharged air, allowing drilling operations to proceed without violating environmental regulations.
4Device complexity
If shale cuttings, dust, fluid and gas are not separated, then drilling operations are simpler, but effective hazard control and environmental compliance are impossible
Solution Approach 1:
The separator unit segments the volatile mixture into distinct gas, fluid, and solids phases using cyclonic separation and gravitational settling. This segmentation enables targeted handling of each component: gas is directed to flare, fluid to storage or recycling, and solids to disposal. The segmentation transforms an unmanageable mixed hazard into controllable separate streams, making hazard control and environmental compliance achievable.
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
Effectively separates shale gas from the fluid mixture, controls dust, and safely disposes of combustible gases, reducing fire hazards and compliance with environmental regulations by creating a safe distance for gas burning, thus mitigating operational risks and penalties.
Implementation Method 1
The jet assembly has a jetted input and a venturi output
Implementation Method 2
The jet assembly has a jetted input and a venturi output
Implementation Method 3
The IACS pipe has at least one discharge nozzle defined thereon
Implementation Method 4
internal aerated cushion system (IACS) pipe
Implementation Method 5
The intake pipe is positioned to tangentially communicate a shale-gas-fluid mixture into the vessel
Implementation Method 6
provide environmentally safe collection and disposal of the shale debris, fluid and formation gas burned a safe distance from wellbore
Data Source
AI summary
This invention relates to the separation of shale, gas and fluid at a shale-gas well. The shale debris and water from a shale-gas well is tangentially communicated to a vessel where the cyclonic effect within the vessel facilitates the separation of the gas from the shale debris. The separated shale debris and fluid falls to a jet assembly whereby it encounters a jet communicating a fluid therethrough. A venturi provides a motive force to the shale debris and fluid sufficient to propel it into a collection bin. The shale-gas separator incorporates a fluid bypass overflow line to prevent a buildup of fluid within the vessel. The shale-gas separator also incorporates an internal aerated cushion system (IACS) pipe for further motivating the shale debris and into the jet assembly, to ensure the walls of the vessel are clean, and to provide an air cushion restricting gas migration to the jet assembly.