Abstract:
Automated process, conditioning and treatment apparatus and methods are disclosed that are particularly well adapted for closed loop systems using or producing aqueous effluence with varying amounts of suspended solids therein, the apparatus and methods directed to separation of the solids from the effluence and thus cleaning of the centrate. The apparatus includes a mass flow rate meter, liquid polymer injector, and a controller for receiving the monitored rate from the meter and performing analysis to optimize the rate of injection of liquid polymer. The injector is monitored to further optimize the injection rate.

Description:
RELATED APPLICATION 
     This Application is a division of now U.S. patent application Ser. No. 08/900,925 filed Jul. 25, 1997 by the inventors named in this Application and entitled Automated Effluence Conditioning and Treatment now U.S. Pat. No. 6,110,382. 
    
    
     FIELD OF THE INVENTION 
     This invention is related to effluence treatment apparatus, and, more particularly, relates to liquid polymer conditioning and treatment apparatus for aqueous effluence. 
     BACKGROUND OF THE INVENTION 
     Cleaning and recycling of aqueous based effluence from various mining, manufacturing and/or municipal facilities is handled in a variety of ways. For example, outflow from oil well drilling (as well as other mining processes) is directed to shallow settling ponds. This approach is unsightly, potentially hazardous, and involves usage of large amounts of water. 
     In response to such concerns, closed loop drilling systems are used which process the outflow on site using polymer flocculants and other chemical substances. Constant monitoring of these operations, in addition to personnel for operating the systems, is required however, thus adding to the costs associated with extraction. Close attention to monitoring is required (and thus skilled system attendants) to assure proper dosages of polymer flocculant to avoid incomplete removal of solids (under dosage) or the waste, expense and potential for solids restablization effect (and return to active drilling fluids jeopardizing mud chemistry and the drilling operation and tools themselves) inherent in over dosage. 
     While composition monitors, as well as closed loop drilling fluid processing apparatus, are knowing (see, for example, U.S. Pat. Nos. 5,103,181, 5,145,256 and 5,171,090), further improvement could thus be utilized. 
     SUMMARY OF THE INVENTION 
     This invention provides apparatus and methods for automated effluence conditioning and treatment. The apparatus is particularly well adapted for processing drilling fluids (mud), for example in closed loop (pitless) drilling systems, to facilitate recovery and recycling of water in the effluence (for reuse in the system) and the suspended solids therein (for storage, transport, disposal or resale). The automation of process monitoring and effluence conditioning and treatment provides reliable on-site effluence processing at little added labor cost. 
     The apparatus includes a conduit for conducting flow of the effluence and a sensing mechanism at the conduit providing an output indicative of mass flow rate of the drilling fluid conducted through the conduit. An injection pump injects polymer material into the flow of drilling fluid under the control of a microprocessor or other controller connected with the sensing mechanism and the pump. The rate of injection is calculated at the controller to provide a preselected polymer conditioning of the fluid output from the apparatus at the sensed mass flow rate. 
     The rate of polymer injection is self adjustable by provision of a second sensing mechanism downstream of the injection pump providing an output indicative of injection rate of the liquid polymer by the injection pump. The controller is connected to receive this output and, responsive thereto, provide a control signal to the injection pump to adjust pumping rate and thereby rate of injection of the liquid polymer into the conduit based on mass flow rate of the suspended solids in the effluence flowing through the conduit and actual injection rate of the pump. 
     The method of this invention includes the steps of conducting a flow of an aqueous effluence having solids suspended therein, monitoring the conducted flow and indicating mass flow rate of the conducted flow of the aqueous effluence, and determining likely mass flow rate of the suspended solids in the conducted flow from the indicated mass flow rate of the conducted flow of the aqueous effluence. A control signal indicative of a desired rate of liquid polymer injection into the conducted flow based at least in part on the determined likely mass flow rate of the suspended solids is generated and utilized to drive a mechanism for injecting liquid polymer into the conducted flow at the desired injection rate. 
     Further conditioning and treatment apparatus and method steps are provided by this invention to control and optimize pH of the effluence, effluence conditioning rate and weight control, and coagulant insertion into the flow of the effluence. 
     It is therefore an object of this invention to provide apparatus and methods for automated process monitoring, conditioning and treatment of effluence such as drilling fluids. 
     It is another object of this invention to provide automated injection control and on the fly adjustment for injecting polymer material at selected treatment rates into an aqueous effluence having varying amounts of suspended solids therein. 
     It is still another object of this invention to provide automated process control and drilling fluid conditioning apparatus and methods for closed loop drilling operations. 
     It is still another object of this invention to provide reliable, low cost apparatus and methods for automated process monitoring, conditioning and treatment of effluence to facilitate recovery and recycling of water in the effluence (for reuse in the system) and suspended solids therein (for storage, transport, disposal or resale). 
     It is yet another object of this invention to provide an apparatus for automated treatment of drilling fluid with polymer material to provide a preselected polymer conditioning of the fluid output from the apparatus, the apparatus including a conduit for conducting flow of the drilling fluid, sensing means at the conduit providing an output indicative of mass flow rate of the drilling fluid conducted through the conduit, injecting means at the conduit including a pump for injecting the polymer material into the flow of drilling fluid, and control means connected with the sensing means and the pump of the injecting means for receiving the output from the sensing means and, responsive thereto, operating the pump to cause injection of an amount of the polymer material into the flow of drilling fluid calculated at the control means to provide the preselected polymer conditioning of the fluid output from the apparatus. 
     It is yet another object of this invention to provide a self adjusting apparatus for automated liquid polymer conditioning of an aqueous effluence having varying amounts of suspended solids therein to prepare the effluence for treatment to remove the solids, the apparatus including a conduit for conducting a flow of the aqueous effluence, a supply line connected with the conduit for conducting a flow of the liquid polymer, first sensing means at the conduit providing an output indicative of flow rate of the aqueous effluence and density of the aqueous effluence, a controllable injection pump connected at the supply line, second sensing means downstream of the controllable injection pump providing an output indicative of injection rate of the liquid polymer from the supply line into the conduit by the controllable injection pump, and control means connected with the first and second sensing means and the controllable injection pump for receiving the outputs from the first and second sensing means and, responsive thereto, providing a control signal output to the controllable injection pump to adjust pumping rate and thereby rate of injection of the liquid polymer into the conduit based on mass flow rate of the suspended solids in the aqueous effluence flowing through the conduit and sensed injection rate of the injection pump. 
     It is still another object of this invention to provide a method for liquid polymer conditioning of an aqueous effluence having varying amounts of suspended solids therein to prepare the effluence for treatment to remove the solids including the steps of conducting a flow of the aqueous effluence, monitoring the conducted flow and indicating mass flow rate of the conducted flow of the aqueous effluence, determining likely mass flow rate of the suspended solids in the conducted flow from the indicated mass flow rate of the conducted flow of the aqueous effluence, generating a control signal indicative of a desired rate of liquid polymer injection into the conducted flow based at least in part on the determined likely mass flow rate of the suspended solids, and utilizing the generated control signal to drive a mechanism for injecting liquid polymer into the conducted flow at the desired injection rate. 
     With these and other objects in view, which will become apparent to one skilled in the art as the description proceeds, this invention resides in the novel construction, combination, arrangement of parts and method substantially as hereinafter described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiment of the herein disclosed invention are meant to be included as come within the scope of the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings illustrate a complete embodiment of the invention according to the best mode so far devised for the practical application of the principles thereof, and in which: 
     FIG. 1 is a block diagram showing the apparatus of this invention in an effluence treating system; 
     FIG. 2 is a detailed block diagram of the apparatus of this invention; 
     FIG. 3 is a flow diagram illustrating automated control operations of this invention performed for effluence conditioning and treatment with a polymer material; 
     FIGS. 4A and 4B are flow diagrams illustrating automated pH control operations of this invention performed for effluence conditioning and treatment; and 
     FIGS. 5A and 5B are flow diagrams illustrating automated conditioning rate and effluence weight control functions of this invention. 
    
    
     DESCRIPTION OF THE INVENTION 
     Conditioning, treatment and process control apparatus  11  of this invention is shown for use in conjunction with a closed loop drilling system in FIG. 1, the apparatus for drilling fluid, or mud, chemistry process control and achieving a selected drilling mud conditioning to enhance the removal and recovery of suspended solids therein (referring to the drawings, as this description proceeds fluid conduits will be indicated by dual lining and information and signal lines from and to apparatus  11  will be indicated by single lining). The closed loop system includes drilling rig  13  at well  15 , and drilling mud formation and storage tank system  17  having an outlet to pump  19  for moving the drilling mud to the well in the drilling process. 
     Effluence returning from the well is first processed at shaker  21  to remove the heavier solids from the outflow and is then removed to mud tank system  17  for reuse. Also included in the closed loop system is a polymer processing and storage unit  23  providing liquid polymer flocculent for use with the apparatus of this invention (for example, including a mixer for preparing liquid polymer from dry polymer), mixing unit  25  for processing the liquid flocculent into the drilling fluid, and centrifuge  27 , including motor  29 , for removal of the floc and solids from the effluence and providing clean centrate (water) outlet  31  for use in mud makeup at tank system  17 . Acid and coagulant storage units  33  and  35  provide various system chemicals known to such processes for use at apparatus  11 . 
     Apparatus  11  includes electro-mechanical monitoring, conditioning and treatment units  37  and process controller  39  (for example a CHESSELL MULTIPOINT recorder and processor by Eurotherm Recorders, Inc., or other microprocessor, personal computer or the like, though plural processors and/or various analogue controllers could also be utilized). User input interface unit or units  41  (for example a key board and monitor), storage memory (disk, tape, or internal) and recorder (strip recorders, printers or the like) unit or units  43 , and communication interface  45  (modem, transmitter/receiver units or the like) are also provided. Bypass return conduit  47  to tank system  17  carries drilling mud back to the tank system under some circumstances as hereinafter described. 
     Pump  19 , units  23 ,  25 ,  27 ,  41 ,  43  and  45  are all connected with controller  39  and are preferably directly monitored and controlled thereat. 
     Turning now to FIG. 2, monitoring, conditioning and treatment units  37  include several process and effluence conditioning and treatment stages operated and controlled by controller  39 . Drilling fluid from tank system  17  is directed through conduit  49  by variable speed feed pump  51 , the operational speed (i.e., pumping rate) of which is controlled by motor  53 . Fluid passes to motor controlled variable aperture valve  55  and, unless valve  55  is completely closed, through mass flow rate meter or meter grouping  57 . Some or all of the drilling fluid flow may be directed by valve  55  through conduit  59  and motor controlled variable aperture valve  61  to conduit  47  for return to mud tank system  17 . Such two valve control is preferred for control of mud weight in the system as hereinafter detailed. 
     Meter  57  may be a single instrument, such as a Coriolus meter (which is preferred, for example a MODEL CMF 300 mass flow and density sensor by MICROMOTION, INC.), or separate instruments, such as a flow meter and a densitometer. In either case, the instrument or instruments provide as an output to controller  39  signals representing flow rate (e.g., gallons per minute) and density (e.g., pounds per gallon) of the aqueous effluence and suspended solids passing the instrument (the primary variables at this stage). The instrument or instruments may provide other signal pairs, for example representing mass flow rate (e.g., pounds per minute) and flow rate or velocity (e.g., feet per second), so long as the primary variables can be derived from these other signal pairs at controller  39 . These signals may be either analog or digital outputs, depending upon the instrument or instruments utilized. 
     The drilling fluid then passes out to mixing (or flocculating) unit  25  (after injection of liquid polymer into the flow) and to centrifuge  27  for separation of the solids/floc from the centrate. A portion of the flow from mixing unit  25  is directed through conduit loop  63  (by a variable speed processor controlled progressive cavity pump through a slip stream junction and suction valve, for example) to an optical floc evaluation cell  65 . 
     Cell  65  provides an image of floc formation to its onboard processing unit  67  for evaluation. The onboard processing unit includes its own user interface and will provide an output (a digital signal/value) indicative of the quality of floc formation at that stage in the flow to controller  39 . Such an instrument may be, for example, the FLOCTRONIC flocsonde by Passavant-Werke AG. After passage through cell  65 , the portion of the flow returns via a slip stream junction and discharge valve to the main flow. 
     Liquid polymer from polymer processing and storage unit  23  is selectively injected (under control of controller  39  as hereinafter described) into the main effluence flow by injection pump  69  operated by controllable variable speed motor  71 . Injection pump output flow rate is measured by flow meter  73  (for example, a FISHER-ROSEMOUNT magnetic flow meter by Rosemount Incorporated with a 4 to 20 mA output signal indicative of a value in gallons per minute), meter  73  providing a measured output rate signal to controller  39  (either digital or analog signal depending upon the type of instrument selected). 
     Acid for pH conditioning of the effluence is selectively injected from acid storage unit  33  into the main effluence flow by injection pump  75  operated by controllable variable speed motor  77  (responsive to control signals from controller  39 ). Controlled injection rates of acid are computed at controller  39  with reference to pH value input signals (for example, 4 to 20 mA analog signals) received from incoming and outgoing pH probes  79  and  81 , respectively (for example, a Model 40 wet tap-type pH probe by Innovative Sensors, Inc. may be utilized). Coagulant, likewise, is selectively injectable by injection pump  83  operated by controllable variable speed motor  85  in response to a selected user value (injection rate) input at user input unit  41 . 
     Control of the various process control, conditioning and treatment stages will be described with reference to FIGS. 3,  4 A and B, and  5 A and B. In FIG. 3, describing process control at controller  39  of introduction of liquid polymer flocculent into the effluence utilizing apparatus  11  of this invention, controller  39  inputs the signals from the measurement of mass flow rate at meter  57 , a numerical value from user input interface unit  41 , and injection pump  69  flow rate measured at meter  73 . Controller  39  converts the input signals to its internal representation of numbers. 
     The density of water constant (8.33 pounds per gallon) is subtracted from the measured density of the effluence. The remainder value represents the mass of solids suspended in the flow. The remainder density (e.g., pounds per gallon) is then multiplied by the flow rate (e.g., gallons per minute) to get the likely mass flow rate (e.g., pounds per minute) of the solids in the effluence. 
     The inputs from user input unit  41  (operator adjustment to desired ratio of liquid polymer flocculant to suspended solids in the effluence, allowing for use of polymers from various manufacturers or the like) and polymer to solids ratios suggested by various polymer manufacturers and stored and retrieved from memory unit  43  are utilized to calculate an ideal injection rate of liquid polymer flocculant into the flow. This ratio (for example, expressed as a 4 to 20 mA signal) is subject to recomputation based upon the floc evaluation input from floc evaluation unit  65 / 67  (expressed as a 4 to 20 mA correction signal, for example). The likely mass flow rate is then multiplied by the output ratio to provide an injection rate control signal to controllable motor  71  operating polymer injection pump  69  (for example, a 4 to 20 milliamp analog control signal). 
     As may be appreciated, this operation (as do those hereinafter described) takes place on the fly and is subject to almost constant recalculation and process adjustment. Since the output of pump  69  may not be in precise conformance with the control signal, the actual injection rate (the flow rate at the point of injection) of polymer flocculant into the main effluence flow as sensed at meter  73  is input to controller  39 . The actual injection rate is subtracted from the calculated injection rate control signal to achieve a numerical representation of the injection rate error. This error is multiplied by a gain constant (to prevent overcorrection) and then added to the calculated injection rate control signal for self adjustment of the injection rate output control signal. 
     In FIGS. 4A and 4B, pH level control processes are described (a closed loop, proportional control, system). Typically, for example, it is desired to bring drilling fluid into the range of pH=6 to pH=8. Incoming pH value from probe  79  is input to controller  39  which, responsive thereto, calculates a required acid injection amount based on desired variable pH setting (from input unit  41  and/or values stored in memory  43 ) and the then present effluence flow volume signal from meter  57 . An analog injection rate output signal (from 4 to 20 mA) is provided for controllable motor  77  operation of acid injection pump  75 . The input pH value from probe  81  is representative of the chemical residual in the effluence stream after the chemical reaction (i.e., after acid injection) is completed and is utilized for output signal adjustment. The acid feed rate is proportional to the deviation from the ideal injection rate, so the farther from the ideal setpoint, the more acid is added. The closer to the setpoint, the less acid is added. 
     A measured value output, proportional to the probes&#39; measurement, is utilized for recording. A control output increases or decreases according to the control action to adjust pump  75  output to maintain the desired setpoint. Since simple proportional control results in over-injection, a proportional-integral-derivative controller (PID) is employed, which considers the deviation from the setpoint and also takes into account both the rate of change and the time required to bring the process into control in adjusting the pump output. 
     Controller  39  first calculates the mass flow rate of suspended solids in the effluence as previously discussed. The upstream reading from probe  79  is converted to a ratio of acid to effluence. The ideal flow rate of acid is then calculated by multiplying the ratio times the mass flow rate of suspended solids. To this is added (or subtracted) the result of similar calculation performed using input of downstream probe  81  multiplied by the volume (flow rate) input from meter  57 . 
     The conversion of pH signal to the ratio of acid required (FIG. 4B) is accomplished by subtracting the neutral pH=7 from the measured pH. The resulting number is used to determine if the effluence sensed is basic (pH&gt;7) and needs more acid injected, or acidic (ph&lt;7) and needs less acid injected. The amount of acid to be added (or subtracted) is calculated by further subtracting 7, exponentiating the result to the base  10  (this will result in a number or ratio between 0 and 1), and then correcting the ratio by dividing by the acid percentage. 
     For example, if pH is measured at 14, corresponding to 1 molar sodium hydroxide, after subtracting 7 twice a value of 0 is obtained. Ten to the zero power is 1. Thus the ratio is one gallon of pure, or 1 molar, hydrochloric acid to one gallon of sodium hydroxide. If 36% hydrochloric acid is being used, 100/36, or about 3 gallons, of 36% hydrochloric acid would be needed to neutralize one gallon of pure sodium hydroxide. Of course, in a more realistic scenario, if a pH of only 10 is measured, the ratio for 36% acid would drop to about 3 gallons of acid to every 10,000 gallons of effluence. 
     Turning to FIGS. 5A and 5B, a signal indicative of motor torque from motor  29  (in amps) is input to controller  39 . In this way, the controller can be apprised of the ability of centrifuge  27  to keep up with the flow through apparatus  11 . If the torque is exceeding the maximum safe work rate for the centrifuge, a control signal to motor  53  for proportionally slowing system feed pump  51  is issued. If the torque is within its maximum safe work rate, the system throughput as measured at meter  57  is compared with the desired processing rate (as input by a user at interface unit  41 ), and, if less, feed pump  51  is proportionally sped up. 
     Weight of drilling fluid in tank system  17  is controlled by computing the weight of the effluence from the signals input from meter  57  (FIG.  5 B). The selected weight (from user input unit  41 ) is compared. If the weight measured is greater than desired, motor controlled valve  55  is proportionally opened and valve  61  proportionally closed, so that more drilling fluid is processed (and thus solids removed). If the weight measured is less than desired, a reverse operation of the valves is signalled from that just described, so that more of the effluence is returned to the tank system without solids removal. These comparisons and adjustments are continued until the desired weight is achieved. 
     The apparatus of this invention is provided with means of off-site communication ( 45 ) for both data acquisition and process control. Records of all activity of the apparatus over time may be kept and retrieved periodically from memory or recording units  43 . 
     As may be appreciated from the foregoing description, automated yet flexible process control and effluence conditioning and treatment is provided by this invention, with the invention being particularly well adapted to closed loop systems as might be utilized in drilling operations, for example.