System for separating solids from a fluid stream

A system for separating solids from a fluid stream. The system includes a first separator device mounted to a container. The container includes a settling compartment and baffle plate module, with the initial settling compartment receiving the fluid from the first separator device. The fluid stream proceeds through the baffle plate module. The solids within the fluid stream will descend to the bottom of the container. A spiral blade is positioned at the bottom of the container, with the spiral blade adapted to convey solids to a first pump member. The speed of rotation of the spiral blade may be varied. The first pump member discharges the slurry to a second separator device. The second separator device will discharge the separated fluid stream into the baffle plate module. In one embodiment, the first separator device is a linear shaker and the second separator device is a cyclone separator and linear shaker mounted in tandem. The fluid exiting the baffle plate module may be directed into a mixing compartment, with the mixing compartment being part of the container. A method of separating solids from a fluid stream is also disclosed.

BACKGROUND OF THE INVENTION

This invention relates to a system for treating fluid streams. More particularly, but not by way of limitation, this invention relates to a system and method for separating solids from a fluid stream.

In industrial applications, a fluid stream may contain solids. The solids may be suspended in solution. The particle sizes may range from larger diameter solids to extremely small diameter solids. As those of ordinary skill in the art will recognize, it is desirable to separate the solids from the fluid. For instance, environmental regulations may require that operators separate the solids from a slurry. Additionally, the operator may wish to reuse the base fluid, and hence, the fluid must be purged of solids.

As an example in the drilling industry, the well being drilled contains cuttings from the subterranean well bore. The fluid being used to drill the well is an expensive, chemically enhanced fluid. Therefore, operators wish to salvage the base fluid for reuse.

Regardless of the specific application, there is a need for a system and method to separate solids from fluid streams. Prior art devices suffer from many deficiencies. Prior art systems do not allow for adequate separation of solids from the fluid. The present systems are not packaged in an efficient and well-organized manner. The prior art systems are bulky and can't be transported from site to site in a single package. The present invention allows the packaging of the system on a frame that can be integrated with a trailer allowing for portability and mobility. Therefore, there is a need for a system and method to efficiently handle and separate solids from a fluid stream. There is also a need to add bulk materials to a recently separated fluid stream. These needs, as well as many other needs, will be met by the novel invention herein disclosed.

SUMMARY OF THE INVENTION

A system for separating solids from a fluid stream is disclosed. The system comprises a first shaker adapted to a container, and a settling tank positioned to receive the liquid discharged from the first shaker. The system will also include a first baffle module positioned at the output of the settling tank, with the first baffle module having a discharge opening. The fluid stream proceeds through the container in a first direction. A spiral blade is positioned at the bottom of the container, with the spiral blade adapted to convey the solids in a second direction. The spiral blade will have a controller member that varies the speed of rotation of the spiral blade.

A first pump member is provided, with the first pump member receiving the solids from the spiral blade, along with a first cyclone device that receives the discharge from the first pump member outlet and delivers a separated fluid stream to the initial settling compartment. The solids are discharged to a linear shaker. The linear shaker discharges the separated fluid back into baffle plate module via the open top of the container. In the preferred embodiment, the first baffle module comprises a plurality of baffle plates titled at an angle between 45 degrees to 70 degrees.

Additionally, the system may contain a second pump member that has an input line operatively associated to the bottom of the container to receive the solids and an output line operatively associated with a second tandem cyclone device and linear shaker. The liquid output from the cyclone device is channeled to the initial settling compartment and the solids output from the cyclone device is channeled to the screen of the linear shaker. The collected solids from the screen of the linear shaker is collected to a bin and the fluid falls through the screen and into the baffle plate module.

The system may also comprise a first weir positioned at the first baffle module and a second baffle module positioned adjacent the first baffle module. Additionally, the container may include a mixing compartment operatively connected to the discharge line from the baffle plate modules, the mixing compartment having a hopper and a mixing blade disposed therein. In the preferred embodiment, the container is mounted to a base frame having a set of wheels for mobile transportation. A pump member is operatively associated with the mixing compartment, with the pump member having a suction line from within the mixing container and a discharge line within the mixing compartment.

A method of filtering a fluid containing solids is also disclosed. The method includes flowing the fluid into a first separating means for separating the fluid from the solids and channeling the first cut fluid into an initial settling compartment of a container. Next, the fluid is channeled into a second compartment, with the second compartment containing a plurality of baffle plates. Some of the solids remaining in solution will strike the baffle plates, which in turn will cause the solids to settle to the bottom of the container.

The method further includes conveying the solids to a first discharge pump and discharging the slurry to a second separating means for separating the fluid from the solids, and wherein the solids are further separated from the fluid. Next, the fluid is discharged into the second compartment which in turn will cause the solids to travel through the baffle plates thereby causing the suspended solids to strike the baffle plates. Some of the solids remaining in solution will settle to the bottom of the container and will in turn be conveyed to the first discharge pump. The solids can then be discharged to the second separating means thereby further separating the fluid from the solids. The fluid is exited from the container, and in particular, the fluid stream is exited from the baffle plate compartment.

In one embodiment, the first separating means comprises a linear shaker and the method includes collecting the solids into a bin. Additionally, the second separating means comprises a cyclone separator in tandem with a linear shaker device and the method includes collecting the solids in the bin. The third separating means may comprise a cyclone separator in tandem with a linear shaker means and the method includes collecting the solids into the bin.

In one embodiment, the step of conveying the solids to the first discharge pump includes providing an auger blade placed in the bottom of the container and rotating the auger blade so that the solids are pushed to an inlet for the first discharge pump. The spiral blade can be rotated at a variable speed in order to vary the solids concentration of the slurry to the cyclone separators. In the preferred embodiment, the baffle plates are disposed at an angel of between 45 degrees to 70 degrees. Additionally, the method may further comprise mixing an additive and/or bulk material to the fluid within a mixing compartment. The method may also include suctioning from either the container or mixing compartment and pumping back into the mixing compartment in order to mix the fluid stream with an additive.

An advantage of the present invention includes having a modular design wherein a component of the system may be added or removed from the system. Another advantage is the system may be transported easily from one location to another location. For instance, the frame may be lifted via a crane onto vessels, barges, flat beds, etc. Also, the frame may include wheels so that the entire system can be transported via a vehicle such as a truck.

Another advantage is that the novel system and method will remove solids from five (5) microns and larger in some applications. Still yet another advantage is that the system allows for redundancies in that the fluid stream is introduced to multiple separation devices such as the linear shaker, weir, baffles, cyclone separators, settling tanks, etc. Additionally, the fluid stream can be continuously recycled through the system until the desired level of filtration is achieved.

Further, it is desirable to have the solids thus collected to be essentially fluid-free. Another advantage is that the solids thus recovered contain very little in-situ fluid.

A feature of the present invention includes having a linear shaker that separates large diameter solids from the fluid stream. Another feature is the option to use other types of shakers, such as orbital shakers that can also separate small diameter solids from the fluid stream. Yet another feature is the mixing compartment that can be added to the system for the mixing of bulk materials and/or additives to the fluid stream.

Still yet another feature includes use of an auger type of device for conveying the solids to a pump member. In the preferred embodiment, the auger type of device is a spiral blade without the shaft. The speed of the rotation of the auger blade can be varied depending on the nature of the slurry and the desired process rate of the fluid stream. Thus, a feature includes decreasing or increasing the rotation rate of the spiral blade in order to meet processing rate goals. Another feature includes use of baffles in a baffle module, with the baffle plates being tilted to maximize the impact of the suspended solids during fluid flow as well as to provide the proper orientation for fluid flow through the container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now toFIG. 1, a schematic diagram of the preferred embodiment of the present invention will now be described. The system2seen inFIG. 1includes a container seen generally at4. The container4has generally a bottom6, two side walls, an open top, and two end walls. The two side walls and bottom6are configured in a “V” bottom shape as is well understood by those of ordinary skill in the art.

In a first compartment within the container4, there is contained an initial settling compartment8. The initial settling compartment8has situated above it the linear shaker10, and wherein the linear shaker originally receives the fluid stream. The linear shaker10is commercially available from Fluid Systems, Inc. under the name Linear Shaker. The linear shaker10is sometimes referred to as the scalping shaker since it makes the initial cut i.e. initially scalps the fluid stream of solids. It should be noted that the general fluid flow or solids flow through the system2is denoted by the flow arrows.

The fluid stream initially flowing over the scalping shaker10will have the solids suspended therein. The fluid stream may have originated from an oil and gas well bore, a directional bore hole being drilled for highway and/or bridge construction, waste streams from industrial applications, waste water treatment, tank cleaning, utility construction, etc. The invention can be used for any application where the operator wishes to separate and segregate the solids from a fluid stream.

The scalping shaker10will make an initial cut of the solids from the fluid stream. As those of ordinary skill will appreciate, the shaker10has a dual output, with the first output being primarily solids and the second output being primarily the fluid stream. The larger solids and debris are screened and discarded off the side of the tank to a bin11. Nevertheless, the fluid stream from the second output will continue to have solids suspended therein. As seen inFIG. 1, the solids screened with the shakers are denoted by the arrows AA. The fluid which falls through the screen is denoted by the arrows BB.

As those of ordinary skill in the art will appreciate, separation techniques using shakers and cyclone separators are efficient but not perfect. In other words, by running the fluid streams through each separator means, a portion of the solids is removed during each cut. The larger diameter solids are removed first, followed by successively smaller diameter solids. The system herein disclosed allows for certain redundancies in order to achieve a desired level of separation.

In the embodiment depicted inFIG. 1, the container4will also contain an underflow weir12positioned within the container, with the underflow weir12having an opening extending from the tank bottom6to the weir12that is two feet wide. Thus, the fluid will travel through the space indicated by the numeral14. The baffle plate module, which is seen generally at16, is positioned to receive the fluid stream from the initial settling compartment8. The baffle plate module16comprises a plurality of baffle plates seen generally inFIG. 9as plates16a,16b,16c,16d,16e,16f,16g,16h,16i. The baffle plates are tilted at a preferred angle of between 45 degrees to 70 degrees relative to the horizontal ground reference level, with a most preferred angle of 60 degrees as seen inFIG. 1. The baffle plates are tilted so that as the fluid stream flows through the container, the suspended solids will strike the baffle plates, decreasing the velocity of the solids and allowing gravity to force the solids to the bottom6. As shown inFIG. 1, the baffle plates are tilted in the direction of the fluid flow through the container4. The solids which fall to the bottom may be referred to as a slurry since the solids still contain an in-situ fluid.

FIG. 1depicts the second baffle plate module22that is arranged immediately following the first baffle plate module16. As illustrated inFIG. 9, the baffle plate module22contains a plurality of baffle plates:22a,22b,22c,22d,22e,22f,22g,22h,22i. In the preferred embodiment, the baffle plates22a-22iare tilted from 45 degrees to 70 degrees, with a most preferred angle of 60 degrees, similar to the baffle plates16a-16i.

Returning toFIG. 1, the baffle plate modules16and20may be manufactured independently and then inserted into the container. The baffle plate modules16,20can then be attached to the container via conventional methods such as welding means, nuts and bolts means, etc. Also included in the embodiment shown inFIG. 1is the overflow weir24, with the overflow weir24having an opening at its top end, which in the embodiment shown inFIG. 1, the opening is approximately four feet wide. The fluid flow will occur through the opening area denoted by the numeral26. The opening22in turn leads to the mixing compartment that will be described later in the specification.

The bottom6contains a means for conveying30the solids to an exit line32. In the preferred embodiment, the conveying means30will be an auger, and in the most preferred embodiment, the conveying means30is an auger blade without the inner shaft i.e. spiral blade. The shaftless spiral blade is commercially available from Martin Sprocket & Gear, Inc. under the name Shaftless Screw Conveyor. Hence, with the rotation of the blade via motor33, the solids are advanced to the exit32. Additionally, in the preferred embodiment the motor33will be controlled by a variable frequency drive (VFD) so that the speed of rotation may be varied. Thus, the operator may vary the speed of rotation so that the spiral blades may convey more solids to pumps36and38(in the case of increasing rotation speed), or alternatively convey less solids to pumps36and38(in the case of decreasing rotation speed). In other words, by increasing rotation, more solids are delivered to the cyclones via pumps36and38, and by decreasing rotation, less solids are delivered to the cyclones via pumps36and38. The operator may vary the speed according to the particular processing rate needs and system requirements of specific separation jobs. In the preferred embodiment, the motor is an electric motor that is commercially available from Marathon Inc. under the name Electric Motor.

As those of ordinary skill in the art will recognize, the fluid and solids collected from the exit32may be referred to as a slurry. It is desirable to separate the fluid from the solids. A dual object of the present invention is to produce solids that are essentially free of water and produce a fluid that is essentially free of solids.

In accordance with the teaching of this invention, the slurry being forced from the exit32are directed to a separating means34, which in the preferred embodiment comprises a bank of hydrocyclones34aand a linear shaker34b. The hydrocyclone is commercially available from Krebs Engineering, Inc. under the name Cyclone, and as noted earlier, the linear shaker34is commercially available from Fluid Systems, Inc.

Thus, the pump36will receive the mixture of solids and fluid and pump it to the separator means34via the output line36awherein the separator means34will separate the larger solids and debris that are screened and discarded to the bin11. It should be noted that the tandem cyclone34aand linear shaker34boperation will be described in greater detail later in the application.

The liquid output from the cyclone separator means34ais directed back into the container4via the line164a, into trough seen generally at37, and into initial settling compartment8. With reference to the linear shaker34b, the fluid denoted by the BB arrows that falls through the shaker screen is directed into the top open area of the container4and in turn into the baffle plate modules. Therefore, the fluid is continuously cycled through the process, as noted earlier. The pump36is commercially available from Mission Inc. under the name Centrifugal Pump. In the preferred embodiment, the pumps are driven by an electric motor, and therefore, the pumps with the operatively associated driver motors may be referred to as electric pumps. The electric motor is commercially available from Marathon Inc. under the name Electric Motor. It should be noted, however, that it is within the scope of the present invention to have hydraulic powered pump means and/or diesel powered pump means.

A second electric pump38is also shown, with the second pump38being essentially identical to the first pump36. The operator may choose pumps with specific capacities. As by example and for illustration purposes only, pump36may be a six inch suction and a five inch discharge and pump38may be a six inch suction and a five inch discharge. The second pump38is added so that the output capacity is increased in the case where the quantity and processing rate of the fluid stream is important. In other words, when the output rate from the system2needs to be increased, the second pump38can be utilized to increase the processing rate. The second pump38receives as an intake from the point denoted at38awhich is downstream of the intake for first pump36. At the point38a, the solids tend to be smaller in diameter since the solids are collected at a point (38a) in the container where the larger solids have already been separated.

The second pump38will pump the slurry to the second separator means40that includes the tandem cyclone separator40band the linear shaker40a. The separator means40will process the fluid stream in a similar manner as with the separator means34. The liquid output from the cyclone separator means40bis directed back into the container4via line164b, the trough37and into initial settling compartment8. With the reference to the linear shaker40a, the fluid (denoted by the BB arrows) that falls through the shaker screen is directed into the top open area of the container4, and in turn, into the baffle plate modules. Therefore, the fluid is continuously cycled through the process, as noted earlier

As noted inFIG. 1, pump36receives the slurry from exit32and discharges to the separator means34via discharge line36a. The pump38receives the slurry from exit38aand discharges to the separator means40via discharge line44.

The flow of the fluid stream enters through the scalping shaker10as denoted by the arrow46. The fluid that flows through the screen of shaker10is denoted by the arrows BB. The arrows within container4represent the general fluid stream flow. As solids are knocked and separated from the fluid within the baffle plate module, the solids settle to the bottom and the conveyor means moves the slurry as denoted by the arrow50. Note that the fluid flow is generally opposite the direction of the slurry flow.

Once the fluid stream has been processed through the container4, the fluid stream will exit the overflow weir24via the opening26as denoted by the arrow52. The overflow weir24will direct the fluid stream into the mixing compartment54. The mixing compartment54will contain mixing blades. The mixing hopper56is also operatively associated with the mixing compartment54, with the mixing hopper56allowing for the introduction of bulk materials, chemical additives, and so on as is well understood by those of ordinary skill in the art. The mixing compartment54has contained therein a pair of mixing propellers98,100for mixing additives and/or bulk material, for instance, into the fluid stream. The additives can be added via the mix hopper56wherein the mix hopper56is fed into the line82that in turn discharges into the mixing compartment54.

A pump means58will be operatively associated with a first intake line60, with the first intake line being operatively associated with the container at the second end adjacent the overflow weir24. The pump means58is commercially available from Mission Inc. under the name Centrifugal Pump. The intake line60suctions from the fluid stream that has been processed through the system. The pump means58will have a second intake line62, with the intake line62being positioned to suction from the mixing compartment54.

The pump means58will have a first discharge line64, with the first discharge line leading into the mixing compartment54. The first discharge line64will have operatively associated therewith output jet nozzles66which are commercially available from Halco Inc. under the name Mud Guns. Thus, the pump means58will be able to suction from the container via line60essentially clean fluid and pump into the mixing compartment via line64, with the mud guns66allowing for the jet mixing of the fluid stream within the compartment54. The pump58will also be able to pump from the mixing compartment and then discharge through the mud guns66.

A valve means68for opening and closing the line60is included as well as a valve means70for opening and closing the line64. A second discharge line72may be included, with the line72having a valve means74for opening and closing the line72. The line72may discharge to a storage bin, for instance.

The system2will also contain the electric pump means76, with the pump means76having a suction intake line78that suctions from inside the mixing compartment54. The pump means76is commercially available from Mission Inc. under the name Centrifugal Pump. The pump means76will have a discharge line that branches into three separate lines, namely a first discharge line80(same as line64?) that leads to the mud guns66previously described, a second discharge line82that leads to the mixing hopper56, a third discharge line83to the mixing compartment and discharge line83to the mixing compartment and discharge line84. The valve means86is included for directing the discharge stream to line64, or to simply close the line. The discharge line84contains valve means88for opening and closing line84and discharging to a storage bin, for instance. Valve means89is included for opening and closing line82.

Referring now toFIG. 2, a side view of the preferred embodiment fromFIG. 1will now be described. It should be noted that like numerals appearing in the various figures will refer to like components. As noted earlier, the container4consist of a V-shaped vessel4, with the scalping shaker10mounted above the initial settling compartment8. The first baffle plate module16and second baffle plate module22are positioned within the vessel4. From the second baffle plate module22, the fluid stream will exit via the exit26(not shown) into mixing compartment54as previously described.

The slurry that is being collected at the bottom of the vessel will be conveyed via the conveying means30(not shown inFIG. 2) for conveying the solids from one end to the other end, which in the preferred embodiment is a spiral blade, as noted earlier, and is similar to an auger without the inner shaft.

FIG. 2also depicts the first electric pump means36that collects the slurry exited from the bottom of the vessel via the conveyor means. Hence, the pump means discharges to the line36awhich in turn leads to the hydrocyclone separator34a(also referred to as cyclone separator). As noted earlier, the cyclone separator34ais commercially available from Krebs Engineers, Inc. under the name Krebs Cyclone.

As is understood by those of ordinary skill in the art, the cyclone separator34areceives the slurry and will separate the solids from the fluid within the slurry. The cyclone separator works particularly well in separating sand and silt from fluid streams. The underflow or solids discharged out of the cyclone is then screened by the linear shaker34bin order to dewater or dry the discharged solids before they are discarded off the side of the tank to the bin11. The overflow or fluid discharge out of the cyclone34ais discharged into the trough37that carries it back to a discharge point underneath the linear shaker10which in turn is delivered to the initial settling compartment8. Thus, the solids are disposed of to a bin11while the fluid is conveyed back to the vessel, and in particular, back into the baffle plate modules16,22.

In the embodiment illustrated, the mixing compartment54is integrated onto the same frame together with the vessel4.

The embodiment shown inFIG. 2also contains the electric pump means76that pumps to the line64or line82. The pump76may also be used to pump from the mixing compartment54via line84in the event the operator wishes to pump the fluid stream out of the mixing compartment54.

The system has as a frame106to which all of the previously mentioned components are attached. As part of the frame, a set of wheel means108for transporting the system may be included. The frame may also include a trailer hitch device (shown generally at110), with the trailer hitch device being capable of use with a vehicle (such as an 18-wheeler) so that the entire system may be hauled from one location to another location. In another embodiment, components may be attached to a frame, and the frame can be lifted with a crane or winch truck, so that the system may be transported via a ship or vessel in remote environments. As noted earlier, an advantage of the present system is the modularity of the system and the ability to transport the system in a package that is compact and condensed.

Also included will be the stairs111that an operator can use to mount the system.FIG. 2also depicts the hand railings112for use by individuals while working, inspecting, monitoring, and/or repairing the system.

With reference toFIG. 3, a top view of the preferred embodiment depicted inFIG. 2will now be described. The scalping shaker10will make a first separation (cut) of solids from the fluid stream. The fluid will then descend from the wire mesh screen130of shaker10to the settling compartment8. As noted earlier, the fluid flows to the first baffle plate module16and then into the second baffle plate module22.

The solids will segregate to the bottom as previously described. Thus, the pumps38and36will pump the slurry to the cyclones34aand40bwhich will act to further separate the solids from the fluid stream. The liquid output from the cyclone34awill be fed via line164ato the trough37back into the vessel for continuous processing. The liquid output from the cyclone40bwill be fed via line164bto the trough37back into the vessel for continuous processing. The solids from the cyclone34awill be directed to the linear shaker34a, and in particular to the wire mesh screen132for dewatering the solids. The solids from the cyclone40bwill be directed to the linear shaker40a, and in particular with the wire mesh screen134for dewatering the solids.

FIG. 3also illustrates the placement of the mixing compartment54. As shown, the mixing hopper56is placed above the mixing compartment54for positioning the entry of any additives into the compartment. The additives enter the hopper56and then the mixer136with blades98,100will mix the components as necessary. The eurodrive mixer136is commercially available from Del Corporation under the name Mixer. An advantage of the present invention is that fluid that is cleaned as per the novel method can then be used as the mixing fluid within the mixing compartment54.

InFIG. 4, the drawing illustrates the system ofFIG. 2in a front view. Thus,FIG. 4illustrates the pair of cones that make up the cyclone separators40band the linear shaker40a. The eurodrive mixer136is depicted positioned on top of the mixing compartment54. The mixing hopper56is shown, along with the discharge line82. The pump76is shown having the discharge line82extending therefrom. The pump motor138is shown, with the pump motor being an electric drive in the most preferred embodiment.FIG. 4also depicts the wheels108, stairs111, and handrails112for a walk way are also included.

Referring now toFIG. 5, a perspective view of the preferred embodiment ofFIG. 2will now be described. TheFIG. 5depicts the scalping shaker10that is positioned above the initial settling tank8. The fluid stream then flows into the first baffle plate module16and into the second baffle plate module22as previously noted. In the preferred embodiment, the conveyor means will be rotated via an electric motor33so that the speed of rotation of the motor's shaft can be varied which in turn will vary the speed of rotation of the spiral blade. By varying the speed of rotation of the spiral blade, the concentration of solids conveyed by the spiral blade can vary. The fluid containing the solids will be delivered to the cyclone separator34avia the pump36and the pump38(pumps36and38are not shown in this view) will pump the slurry to cyclone separator40bas noted earlier.

Once the fluid stream exits from the baffle plate module22, the operator may direct the fluid stream into the mixing compartment54. The fluid stream exiting the second baffle plate module22is essentially free of suspended solids. Generally, the system will remove solids from five (5) microns and larger from the fluid system.

Hence, the operator may wish to condition the fluid by adding certain material so that the fluid stream has certain desirable properties. For instance, if the operator is using the fluid stream as a drilling fluid, the operator may wish to add chemical additives to inhibit the swelling of clays, or to simply weight the fluid so that the column of fluid within the well bore exerts a greater hydrostatic pressure. Regardless of the specific application, the operator may mix the bulk material and/or additives by pouring the additives into the hopper. The fluid stream can be channeled into the mix compartment54via the pump means58. It should be noted thatFIG. 5depicts the pump means58and the electric drive motor58athat drives the pump means58as is well understood by those of ordinary skill in the art. The intake line60is shown for pump58along with the output line64and the valve74. Pump76can intake from line78and discharge to either line64, line84, or line82. Valve means86will direct flow to line64.

The linear shaker10will now be described.FIG. 6is an illustration of the linear shaker10. Basically, the scalping shaker10will receive a discharge of the slurry onto the wire screen130, with the screen being a certain mesh i.e. opening. As understood by those of ordinary skill in the art, the shaker screen is vibrated thereby knocking and shaking the slurry so that the solids are caught on the top side of the screen and the fluid falls below. The screen is vibrated and oscillated at high frequencies as is well understood by those of ordinary skill in the art. In the preferred embodiment, the discharge is in two parts: the first part is the solids caught by the wire mesh screen with the flow off the screen130being denoted by the arrow AA, and wherein the solids are funneled to a bin; in the second part, the fluid stream falls through the wire mesh screen denoted by the arrow BB, and wherein the fluid stream can then be directed back into the baffle plate module. The frame of the shaker120is mounted via conventional means, such as welding or bolting, to the frame107of the system, with the chassis of the shaker having spring leg mounts144to attach the shaker and adsorb the vibrations as is well understood by those of ordinary skill in the art.

InFIG. 7, the cyclone34ais shown. As shown, a pair of cones, namely146,148are depicted. In accordance with the teachings of this invention, the multiple cones may be used depending on the desired flow rate being processed. Some embodiments will use a dozen cones. In the alternative, only a single cone may be used. Some factors in deciding the number and size of cones employed includes the processing rate, the desired separation diameter of the solids, the nature of the solids, etc. Hence, it is within the scope of this invention that a bank of cones may be used with an individual linear shaker.

Generally, the fluid stream with embedded solids enters through the inlets150via the line36a. The fluid stream is injected into the cone under pressure. As is well understood by those of ordinary skill in the art, the cone shape container results in a centrifugal force created by the incoming fluid stream. The effect is to force solids to the inner wall of the cyclone. The cleaned liquid from the center of the swirling liquid mass flows out of the top section152,154of the cyclone, and the solids spin downward to the outlets156,158. In the design of the present invention, the solids (denoted by the arrows160) discharge to the wire mesh screens of the linear shakers as previously described. The fluid (denoted by arrow162) is directed back into the vessel via the discharge line164a, with the discharge line leading to the trough37.

FIG. 8is a cross-sectional view of the system taken along line8-8ofFIG. 2. Thus, the cyclone40bis shown with the discharge line164bdischarging fluid (arrow162) to the trough37, with representative small diameter solids seen in the trough37. The fluid with some suspended solids within the tilted baffle plate module22is also shown.FIG. 8also depicts the fluid (denoted by arrow BB) that has fallen through the screen of the shaker40ainto the open top area of vessel which leads to the baffle plate module. The spiral blade30is also shown disposed at the bottom of the V-shaped container4. The solids AA is shown being dispensed from the shaker40awhich will be deposited to the bin. The discharge line44from pump38is also shown. The container4mounted on the frame106is also depicted.

FIG. 9depicts a partial cross-sectional view of the system taken along line9-9ofFIG. 3. This view depicts the discharge line36afrom pump36to the cyclone34aand the discharge line44from pump38to the cyclone40b. The baffle plates of module16are denoted by the numerals16a,16b,16c,16d,16e,16f,16g,16h,16i. The second baffle plate module22is also illustrated, with the baffle plates being denoted by the numerals22a,22b,22c,22d,22e,22f,22g,22h,22i. The line64which contains the mud guns66is also shown. The shaftless spiral blade30is also pictured.

The intake line62which is inside the mixing compartment54is shown, with the intake line62being connected to the pump58(not shown inFIG. 9). Within the mixing compartment54is the mixing blades98,100that is driven by mixer136. The mixing guns66are operatively associated with the discharge line64. The open area26from the overflow weir24allows the fluid stream to enter the compartment54, as previously stated. The mixing hopper56is also depicted.

One of the features of the present invention is the modularity of the components allows for multiple shakers and cones to be placed upon the vessel4. The rate at which the operator seeks to clean a fluid stream will, at least in part, determine the number of separating means that are ultimately employed. Hence, with very large processing volumes, the operator can place a scalping shaker and two tandem cyclone-shakers (as shown in theFIGS. 1 through 9of this application). Alternatively, the operator can place a scalping shaker and three tandem cyclone/shakers. In another option, the operator can place a scalping shaker and only a single tandem cyclone/shaker.

As an example of the number of separators and pumps required, the cyclone separator pump may be sized to feed a bank of cyclones capable of handling a flow rate of 2000 gallons per minute (gpm). If more than 1500 gpm is required however, it is recommended that a third linear shaker,40a, be used in order to split the cyclones so that they discharge over two linear shakers in order to sufficiently dewater the underflow. If flow rates greater than 2000 gpm are desired then another feed HCFP2-pump38can be installed directly behind feed HCFP1 pump36and feed a second bank of hydrocyclones,40b, capable of making a particle size cut that is the same or finer than cyclone34a. An important feature to the cleaning efficiency of the system is the ratio of cleaning rate to flow rate through the system. If the fluid stream is pumped to linear shaker10at a rate of 500 gpm and is processed through the hydrocyclones34aand40bat a rate of 2000 gpm, then the cleaning to flow ratio is 4:1. The system can be set up to maximize the cleaning to flow ratio simply by increasing the number of cyclones and linear shakers and properly sizing the feed pumps.

A second embodiment is shown inFIG. 10, which is the most preferred embodiment of the present invention. This second embodiment ofFIG. 10, like the embodiment ofFIGS. 1 through 9, has applications for oil and gas well drilling, utility construction, waste water treatment, tank cleaning, waste minimization, dredging, tunneling, etc. In short, any process requiring the removal of heavy solids from a fluid stream.

In the preferred embodiment ofFIG. 10, the fluid stream enters tank4through linear shaker10where larger solids and debris are screened and discarded off the side of the tank. Any fluid and solids passing through the screen on linear shaker10enter tank4and must flow under underflow weir/“possum belly”12. Screw conveyor (shaftless or with shaft)30conveys any solids that settle to the bottom of tank4at this point in the opposite direction of the fluid stream flow to hydrocylcone feed pump36suction. Any solids which stay in suspension and continue on with the fluid stream enter the tilted plate baffle system (16and22) which forces the solids to settle to the bottom of tank4by the solids striking the tilted plates, decreasing their velocity and allowing gravity to force them to the bottom so that they are left behind by the fluid stream. When these solids settle to the bottom of tank4, screw conveyor (shaftless or with shaft)30conveys them back to hydrocylcone feed pump36suction. Hydrocylcone feed pump36pumps the settled solids slurry to hydrocyclones34a. Hydrocyclones34ais a bank of hydrocyclones that has been properly sized to remove the undesirable solids from the fluid stream. The underflow or solids discharge out of hydrocyclones34ais then screened by linear shaker34bin order to dewater or dry the discharge solids before they are discarded off the side of the tank. The overflow or fluid discharge out of hydrocyclones34ais discharged into a pipe that carries it back to a “possum belly” that fills and overflows over the tilted plate baffle system (16and22). Any suspended solids not removed on the first pass through hydrocyclones34awill settle, screw conveyor (shaftless or with shaft)30will convey them to hydrocylcone feed pump36suction, and hydrocylcone feed pump36will pump them to hydrocyclones34a. Any solids remaining will continue in this cycle until they are finally removed by hydrocyclones34a, screened by linear shaker34b, and discarded off the side of the tank.

Typically, lighter solids will take longer to settle; therefore, the suction of hydrocyclone feed pump38is located farther down in the flow stream, past underflow weir/“possum belly” in order to remove these lighter, finer solids. Hydrocyclone feed pump38pumps the settled slurry to hydrocyclones40ais a second bank of hydrocyclones properly sized to remove the finer solids left in the fluid stream. The underflow of hydrocyclones40ais then screened by linear shaker40a, dewatered, and discarded off the side of the tank. The overflow of hydrocyclones40ais discharged into a pipe and is carried back to the same “possum belly” as the overflow of hydrocyclones34aand flows through the tilted plate baffle system (16and22) again.

The fluid stream, which continues to flow through tilted plate baffle system (16and22) to the end of tank4opposite the location of linear shaker10, may exit tank4by one of two methods chosen by the operator. In the first method, the flow stream exits tank4by overflowing overflow weir26into mixing/chemical treatment tank54. As mixing/chemical treatment tank54fills with the clean fluid from tank4, then mixing pump76, mixing hopper56, mixer136, and mud guns66can be used to mix additional fluid in the case of drilling mud or they can be used to chemically treat the fluid in the case of tank cleaning where further treatment of the fluid by a centrifuge may be required. Once mixing and/or treatment has taken place transfer pump (58) may be used to transfer the fluid from mixing/chemical treatment tank54to wherever the operator may desire. The second method by which the cleaned fluid may exit tank4is by being pumped by transfer pump (58) into mixing/chemical treatment tank54through mud guns66. Once mixing/chemical treatment tank54fills, clean fluid will overflow overflow weir26back into tank4. Mixing pump76, mixing hopper56, mixer136, and mud guns66may be used to mix additional fluid or chemically treat the clean fluid as in the first method. Transfer Pump76or a remote portable pump may be utilized to transfer the clean fluid from mixing/chemical treatment tank54to wherever the operator may desire.

As noted earlier, the key to the cleaning efficiency of the system is the ratio of cleaning rate to flow rate through the system. As per the teaching of this inventor, if the fluid stream is pumped to linear shaker10at a rate of 500 gpm and is processed through the hydrocyclones at a rate of 2000 gpm then the cleaning to flow ratio is 4:1. The system can be set up to maximize the cleaning to flow ratio simply by increasing the number of hydrocyclones and linear shakers and properly sizing the feed pumps. Systems capable of flow rates in excess of 3000 gpm are often utilized in large dredging applications.

Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention that is intended to be limited only by the scope of the appended claims and any equivalents thereof.