CROSS REFERENCE TO RELATED APPLICATIONThis application is a regular application of U.S. Provisional Patent Application Ser. No. 61/422,630 filed Dec. 13, 2010 and entitled, “CONTAMINATED FLUID TREATMENT SYSTEM AND APPARATUS”, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTIONThe present invention relates generally to treatment of contaminated fluids and, more particularly, to a system and apparatus for reducing the amount of contaminated fluids that typically exist at well drilling sites, such as waste water or drilling fluid, by evaporating and boiling off at least a portion thereof for disposal and returning clean water to the atmosphere.
BACKGROUND OF THE INVENTIONOil and gas well exploration, drilling or service operations often produce significant quantities of contaminated fluids, such as waste water, drilling mud or other drilling fluid. Containment and disposal of these contaminated fluids is expensive, especially where such fluids have to be transported off-site for subsequent treatment and disposal. As such the prior art teaches various systems and apparatus for treatment of these contaminated fluids, so as to reduce the amount of fluid that must be collected and transported to off-site locations.
Canadian patent no. 2,535,672 (Patmore) discloses an apparatus, method and system for treating contaminated water. The apparatus of Patmore comprises a base member with a peripheral containment wall and having a dividing member dividing the apparatus into a settling region and an evaporation region. The settling region comprises an inlet, weir means, and an outlet, and the evaporation region comprises an inlet and heat application means, the settling region outlet in fluid communication with the evaporation region inlet. The heat application means of Patmore are either: (i) steam pipes or (ii) electric coils. Hatch grating and walkway grating are optionally provided to create a cover for allowing a person to walk across the apparatus, while not interfering with the evaporation process.
As another example, Canadian patent no. 2,531,870 (Gelleny et al.) teaches an evaporator for evaporating a waste material, comprising: a) a tank, comprising side walls and a bottom forming a tank interior, the tank having at least one passage distal the bottom, extending between the tank interior and atmosphere, the tank adapted to receive waste material; and b) heating means adapted to convert at least a portion of the waste material to a vapour when in the tank, the heating means proximate to, but spaced from the bottom of the tank. The heating means of Gelleny et al. is either: (i) a steam tube adapted to heat the contents of the tank, (ii) an electric heater or (iii) both. A meshed or grated cover, or partially meshed or grated cover, is optionally provided to keep workers, tools and debris out of the tank while still allowing vapours to escape.
A third example is Canadian patent application no. 2,576,240 by Page et al. which teaches a waste water treatment system, comprising: a platform; and a phase separation tank, evaporation tank and clean water recovery tank mounted together on the platform with a fluid transfer system between the separation tank and the evaporation tank and a condenser for collecting evaporated water from the evaporation tank and providing the evaporated water to the clean water recovery tank. To heat the contaminated fluid, Page teaches either: (i) directing hot exhaust gases through exhaust piping which is disposed in the evaporation tank and contaminated fluid held therein, or (ii) directing steam through a series of steam lines that are similarly disposed in the evaporation tank and the contaminated fluid held therein. The evaporation tank of Page may include a peaked steam hood placed above said tank, to condense evaporated water when steam recovery is desired.
However, these prior art systems and apparatus still leave room for improvement, in particular with regards to evaporation efficiency. Typical prior art evaporator systems will only evaporate 2 m3to 4 m3of water per day.
Moreover, contaminated fluid in the well drilling sector often contains many heavy solids, such as sand, sawdust, clay and gravel, as well as fluid contaminants, such as oil and diesel, and soap scum from washing machines and spray wands used to clean worker clothing and drilling and servicing rig equipment. Over time, these contaminants build up in and along the steam tubes, electric heaters, coils, exhaust piping, steam lines and other similar heat application means that are used to transfer heat to the contaminated fluid. Such contaminant build up often requires around the clock supervision, clean out and maintenance of the heat application means by operators to ensure proper functioning of the heating component of such evaporators. Alternatively, complex separation systems need be provided, such as the phase separation tank of Page or the settling region of Patmore.
As such, there is also still room for improvement on the current apparatus, systems and methods of the prior art with regards to dealing with contaminant build up.
BRIEF DESCRIPTION OF THE DRAWINGSEmbodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 is a front perspective view of one embodiment of the present invention;
FIG. 2 is a front perspective view of the embodiment ofFIG. 1 shown placed on a skid beside a fuel tank and a container;
FIG. 3 is a sectioned, front perspective view of the embodiment ofFIG. 1;
FIG. 4 is a sectioned, front perspective view of the embodiment ofFIG. 1;
FIG. 5 is a sectioned, front perspective view of the embodiment ofFIG. 1;
FIG. 6 is a sectioned, rear perspective view of the embodiment ofFIG. 1;
FIG. 7 is a top perspective view of the embodiment ofFIG. 1; and
FIG. 8 is a sectioned, side perspective view of the embodiment ofFIG. 1;
FIG. 9 is a front view of the embodiment ofFIG. 1;
FIG. 10 is another front perspective view of the embodiment ofFIG. 1;
FIG. 11 is a perspective view inside the container of the embodiment ofFIG. 1 showing placement of a generator and washer/dryer unit inside therein;
FIG. 12 is a perspective view inside the container of the embodiment ofFIG. 1 showing a closer view of the washer/dryer unit inside therein;
FIGS. 13-20fare various perspective and sectioned perspective views of another embodiment of the present invention;
FIGS. 21-25 are various perspective and sectioned perspective views (FIG. 22) of yet another embodiment of the present invention; and
FIG. 26 is a perspective view of yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSThe following description is of a preferred embodiment by way of example only and without limitation to the combination of features necessary for carrying the invention into effect. Reference is to be had to the Figures in which identical reference numbers identify similar components. The drawing figures are not necessarily to scale and certain features are shown in schematic form in the interest of clarity and conciseness.
Referring now in detail to the accompanying drawings, there is illustrated an exemplary embodiment of apparatus, method and system according to the present invention, the apparatus generally referred to by thenumeral10.
Referring now toFIGS. 1-12, thefluid treatment apparatus10 for treating contaminated fluid (not shown) comprises abase member12 and aperipheral containment wall14, each preferably made of plate steel. Preferably, the outside of theperipheral containment wall14 is insulated (which is preferably a two-inch thick R10 insulation). More preferably, the peripheral wall, and any insulation, is covered by ½ inch thick arena board (also known as puck board) or other high density polyethylene material. Advantageously, the insulation and arena board prevent heat loss through the peripheral wall and function to keep the peripheral wall cool to the touch (thereby easing any safety concerns that might otherwise exist due to hot fluid or boiling waste water that may be present inside the apparatus10).
Even more preferably, theapparatus10, is mounted on a supportingplatform16, which could be a skid. By using askid16 formounting apparatus10, additional components of the system of the present invention, such as afuel tank18 and electric generator19 (shown placed inside a container17) to provide the necessary power, can be mounted together on theplatform16, and the system is made mobile.
In the embodiment ofFIGS. 1-12, thebase member12 andperipheral containment wall14 each contain and define two distinct regions with distinct functionality with respect to contaminated fluid treatment, namely anevaporation region20 and aboiler region22. Preferably, the top of theevaporation region20 is substantially open to the atmosphere (to facilitate evaporation of fluids that may be within said region) while the boiler region is a substantially closed vessel having only limited apertures that function as inlet and outlet, as further described below.
More preferably, theboiler region22 is wholly within theevaporation region20, as shown in the embodiment ofFIGS. 1-12. Yet even more preferably, the top of theboiler region22 is below the top of theevaporation region20. In the embodiment ofFIGS. 1-12, the top of the boiler region is three (3) feet high (from the base member12) while the peripheral containment wall is seven (7) feet tall. However, it is contemplated that in an alternate embodiment (not shown), theboiler region22 is only partially within theevaporation region20.
In a preferred embodiment, thebase member12 andperipheral containment wall14 define a total volume of 7.9 m3with theevaporation region20 having a volume of 6.8 m3and theboiler region22 having a volume of 1.1 m3. Preferably theevaporation region20 is generally enclosed with a mesh or grate type cover to allow vapors to escape the evaporation region20 (in the typical fashion of the prior art noted above) while preventing workers, tools and debris from accidentally falling into theevaporation region20. Even more preferably, one or more sealed valved connection points23 are provided in theperipheral containment wall14 to allow sealed connection of conventional vacuum truck hoses (not shown) between theapparatus10 and a vacuum truck (not shown), thereby facilitating either the filling with, or draining of, contaminated fluid into, or from, theevaporation region20.
Theevaporation region20 andboiler region22 are separated by a dividingmember24 which is also preferably made of plate steel and prevent flow or transfer of contaminated fluid between saidregions20 and22. In the embodiment ofFIGS. 1-12, the dividingmember24 comprises a bottom base24b, aperipheral wall24pand atop cover24t, wherein a portion of thebase member12 and a portion of theperipheral containment wall14 also function as a portion of the dividing member's bottom base24bandperipheral wall24prespectively (as more clearly shown inFIGS. 3,4 and6). In other words, a portion of thebase member12 is coterminous or coincident with the bottom base24band a portion of theperipheral containment wall14 is coterminous or coincident with a portion of theperipheral wall24p.
Preferably, a removable and re-sealable service ormanhole cover24cis provided to facilitate easy periodic maintenance of theboiler region22 when the apparatus is not in operation (saidcover24cbeing normally closed and sealed, so as to prevent the flow or transfer of contaminated fluid between saidregions20 and22).
In another embodiment (not shown), the dividingmember24 is comprised of a bottom base24b, aperipheral wall24pand atop cover24tthat are entirely separate and distinct from thebase member12 andperipheral containment wall14. In this alternate embodiment the dividingmember24 fully encloses and defines the boiler region, is placed within theevaporation region20 and supported up off of thebase member12 by means of legs. In yet another embodiment (not shown), the dividingmember24 is a generally cylindrical member defining theboiler region22.
At least oneinlet24iand one outlet24oare provided to enable introduction of contaminated fluid into the boiler region22 (viainlet24i) and to allow evaporated water (and steam) to exit to the atmosphere (via outlet24o). Fluid transfer means26 are provided to transfer contaminated fluid from theevaporation region20 to theboiler region22. Fluid level control means28 are provided to ensure that a sufficient air space remains within theboiler region22 to allow for the boiling of contaminated fluid while said fluids are in theboiler region22.
Preferably, theinlet24iand outlet24oare two (2) inch diameter openings. More preferably, anexhaust pipe30 is provided to direct evaporated water (and steam) from the outlet24oto the atmosphere. Even more preferably, theexhaust pipe30 is steel and makes multiple passes within theevaporation region20 before exiting to the atmosphere (seeFIGS. 5 and 7), to allow for heat transfer from the evaporating water (and steam) to any contaminated fluid that may be in the evaporatingregion20.
In the embodiment ofFIGS. 1-12, fluid transfer means26 comprises a fluid outlet14oin a portion of theperipheral wall14 that is not coterminous or coincident with theperipheral wall24pof the dividingmember24, an electricfluid transfer pump26p, andfluid lines261 connecting the intake of thefluid transfer pump26pto fluid outlet14oand connecting the output of thefluid transfer pump26pto theinlet24iof the dividingmember24. Preferably fluid outlet14ois screened to reduce or prevent the entry of solids into the fluid transfer means26 and, subsequently, theboiler region22.
To enable heating of the contents in theboiler region22, such as contaminated fluid, theapparatus10 is provided with heating means32. In the preferred embodiment ofFIGS. 1-12, the heating means32 areelectric heating elements32eof the conventional “stab-in” type sealably inserted throughperipheral wall24p(and peripheral containment wall14) through heating apertures34. In another embodiment (not shown), the contents of theboiler region22 are heated in a conventional manner with heating means32 comprising steam lines that run through the inside of saidregion22. In another embodiment (also not shown), the contents of theboiler region22 are heated by hot exhaust gases passing through exhaust piping placed within saidregion22, said hot exhaust gases originating from a burner (in a fashion similar to that described in the patent application by Page) and exiting via an exhaust manifold.
In the embodiment ofFIGS. 1-12, fluid level control means28 comprises one or more float operated switches50 positioned inside theboiler region22 to control the fluid transfer means26, which includesfluid transfer pump26p, to ensure that the contaminated fluid is kept near a predetermined level inside boiler region, said predetermined fluid level being above the top of the heating means32 (so as not to expose the heating means to the outside atmosphere), but preferably still low enough to ensure that a sufficient air space remains within theboiler region22 to allow for the boiling of contaminated fluid.
In another embodiment (not shown), the fluid transfer means26 is a simple gravity drain pipe between theevaporator region20 and theboiler region22 and the fluid level control means28 comprises one or more sight glasses (through theperipheral wall24pand peripheral containment wall14) that allow an operator to view the fluid level inside theboiler region22. In this embodiment, the fluid level control means28 further comprises one or more valves that an operator of theapparatus10 can actuate to control fluid flow through the fluid transfer means26, so as to allow fluid flow through said fluid transfer means26 (for example by gravity) and into the boiler region22 (for example, when fluid level in theboiler region22 is lower than desired), visually determine when said predetermined level is reached (by looking through the one or more sight glasses), and then actuating the one or more valves to stop the fluid flow through the fluid transfer means26.
Preferably the contaminated fluid treatment system of the present invention further comprises anelectric generator19 to provide the electric power for the fluid transfer means27, the and heating elements32. More preferably, theelectric generator19 is a diesel powered generator and the contaminated fluid treatment system of the present invention further comprises afuel tank18 suitable to hold a quantity of diesel fuel. A suitable electric generator is a Caterpillar™ model 3406 engine w/300 kW generator.
Even more preferably, the contaminated fluid treatment system of the present invention further comprises acontainer17 and theelectric generator19 is placed inside the container, thereby keeping it shielded from the outside elements and weather. Yet even more preferably, the contaminated fluid treatment system of the present invention further comprises an electric washer/dryer unit40, saidunit40 also being placed inside thecontainer17. Advantageously, the contaminated fluid treatment system of the present invention will not only treat contaminated fluids, but also provide convenient washer/dryer capabilities for individuals that are working on, or near, theapparatus10. More advantageously, waste water output from the washer can be conveniently directed into the evaporation region22 (e.g. by means of conventional hose or pipe) where it can be treated by the apparatus.
During operation, and with reference to the preferred embodiment shown inFIGS. 1-12, contaminated fluid is placed in theevaporation region20, such as via transfer hose placed simply over the top of the peripheral containment wall or via one or more of the sealed valved connection points23 (if so present). Some of the contaminated fluid is then transferred from theevaporation region20, via the fluid transfer means26, to theboiler region22 until the predetermined level is reached, at which point heating means32 are actuated to effect boiling of the contaminated fluid inside theboiler region22. The boiled off gases (typically steam) exit from theboiler region22, via outlet24oandexhaust pipe30, to the atmosphere. When a sufficient quantify of contaminated fluid is boiled off from inside theboiler region22, fluid level control means28 actuate the fluid transfer means26 to bring the level of contaminated fluid within theboiler region22 to near the pre-determined level.
Advantageously, by limiting theboiler region22 to a smaller volume of the apparatus (in the embodiment ofFIGS. 1-12, to 1.1 m3of the total 7.9 m3volume of the apparatus), by substantially enclosing theboiler region22 with the dividingmember24 and by only providing a small outlet24ofor the exiting of boiled off gases theapparatus10 of the present invention is able to bring the contaminated fluid (that is inside the boiler region22) to a boil much quicker than the devices of the prior art. Using the embodiment ofFIGS. 1-12, starting with contaminated fluid at a temperature of approximately 15 C and filling theboiler region22 to the predetermined level, the inventor was able to reach boiling point in under one (1) hour.
More advantageously, by positioning theboiler region22 is at least partially within the apparatus and theevaporation region20, the heat energy that is traditionally lost to the atmosphere (when using a traditional boiler) is simply transferred to within theevaporation region20 where it acts to speed up evaporation of the contaminated fluid that is within saidevaporation region20. Using the embodiment ofFIGS. 1-12, wherein theboiler region22 is fully within theapparatus10 and below the typical level of contaminated fluid in the evaporation region20 (i.e. having a substantial volume of contaminated fluid level placed above the boiler region22), the inventor has observed that theapparatus10 will return anywhere from 12 m3to 16 m3of water to the atmosphere by both evaporation from theevaporation region20 and boiling from the boilingregion22.
Even more advantageously, any solid contaminates that may be present in the contaminated fluid will simply settle to the bottom of theevaporation region20, and/or will be screened by the screened outlet14o, thereby reducing or eliminating contaminant build up on the heating means32 that has traditionally plagued the devices of the prior art. Yet even more advantageously, descaling or contaminant removal chemicals, can be added to boiler region22 (either viamanhole cover24c, prior to operations) or through fluid transfer means26. Advantageously, because theboiler region22 is separate from theevaporation region20, less of such chemical is needed to maintain optimal effective concentrations.
Additional EmbodimentsThe additional embodiment shown inFIGS. 13-20fis substantially similar to the embodiment ofFIGS. 1-12, but the configuration of the fluid transfer means26 is different, as further described below.
In addition to a providing a first fluid outlet14o(in a portion of theperipheral wall14 that is not coterminous or coincident with theperipheral wall24pof the dividing member24), asecond fluid outlet14pis provided in a portion of theperipheral wall14 that is coterminous with theperipheral wall24pof the dividingmember24, so that fluid may be withdrawn from either the evaporation region20 (via outlet14o) or the boiler region22 (viaoutlet14p). In this embodiment,inlet24iis positioned at a level that is higher than the level of secondfluid outlet14pand additional valving is provided to thefluid lines261 to allow an operator to select from where thefluid transfer pump26p(not shown inFIGS. 13-20a, but seeFIGS. 20b-20f) draws its intake fluid, i.e. from theevaporation region20 via first fluid outlet14oor from the boiler region viasecond fluid outlet14p(or both). Preferably, fluid output fromfluid transfer pump26pis directed, via a short section ofpipe nozzles26n, over theheating elements32e(thereby preventing or reducing settlement of contaminants or scaling of minerals over saidelements32e).
More preferably, achemical compartment26c(having asealable opening26s) is provided wherein saidcompartment26cis in fluid communication with the fluid lines from thesecond fluid outlet14p, so as to allow an operator to easily insert a quantity of treatment chemicals (such as a descaler) into the fluid lines (throughsealable opening26s) and recirculate the fluid within theboiler region22 to dissolve such chemicals and distribute same over theheating elements32e.
Yet even more preferably, afilter screening box26bhaving a sealable, removable top, and a screen element (not shown) provided within, is provided along the intake portion of the fluid lines261. Advantageously, the screen element reduces or prevents entry of solids into thefluid transfer pump26pand, subsequently, theboiler region22. More advantageously, since thescreening box26bhas a sealable, removable top, the screen element can be easily removed to be cleaned or replaced.
Now referring to the embodiment shown inFIGS. 21-25, this embodiment is substantially similar to the embodiment ofFIGS. 1-12, but wherein thegenerator19 is a diesel powered generator, having anexhaust19e, and which further comprises aheat exchanger60 positioned adjacent and above theapparatus10. Preferably,heat exchanger60 is a simple cylindrical vessel made of steel and having an interior space or volume61, aninlet60iand an outlet60o. In this embodiment, the exhaust30 (from outlet24o) is directed into the interior space61, whilediesel exhaust19eis sealably routed through the said interior space61, preferably in a co-axial alignment as shown in theFIGS. 21-25 (i.e.heat exchanger60 is sealably positioned around a section of the exterior of thediesel exhaust19e). Preferably the exterior of thediesel exhaust19ewhich is outside of theheat exchanger60 is covered with a conventional heat insulating material, so as to provide for maximum heat transfer from the generator's19 exhaust to the interior61 of theheat exchanger60. Even more preferably, theheat exchanger60 is likewise covered with a conventional heat insulating material.
Advantageously, the evaporated water (and steam) that exits the outlet24oand passes throughexhaust30 is directed to the interior space61 wherein some of it then condenses and subsequently absorbs additional heat from thediesel exhaust19econverting it into steam once again. Preferably, this reheated condensed water is then directed back into theevaporation region20 of theapparatus10 via outlet60oand second exhaust section30o(seeFIGS. 23 and 25), thereby capturing some of the heat from thegenerator30 that otherwise would have be lost to the atmosphere and adding that to the contaminated fluid in theevaporation region20 and/or by further evaporating some of the condensed water out the outlet60o, thereby further increasing the overall evaporation rate and efficiency of theapparatus10. In another embodiment, outlet60ois positioned high up on theheat exchanger60 and functions as a simple exhaust opening for steam.
In either of these embodiments, and during operation, the interior space61 is allowed to partially fill with condensed water over time and the heat exchanger then functions as a secondary boiler region, powered by heat energy from thegenerator30.
Now referring to the embodiment shown inFIG. 26, this embodiment is nearly identical to the embodiment ofFIGS. 1-12, butexhaust30 directed downward back over top of theevaporation region20, preferably over top of the mesh or grate type cover, to allow any condensed (but still hot) water to fall easily back into said evaporation region20 (rather than be sprayed violently upward), while still allowing for any steam to escape to the atmosphere. Advantageously, all such condensed water is directed into theevaporation region20, rather than outside theapparatus10, and thereby the heat energy within such condensed water will be added to the contaminated fluids within theevaporation region20, aiding the overall evaporation thereof.
In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite article “a” before a claim feature does not exclude more than one of the features being present.
Those of ordinary skill in the art will appreciate that various modifications to the invention as described herein will be possible without falling outside the scope of the invention.