Abstract:
The invention provides a method and apparatus of removing contaminants such as salts, hydrocarbon, chemicals, minerals, and metals from materials such as sand, soil, gravel, drill cuttings, and other solids, and reclaiming contaminants and materials for reuse. The invention is scalable in size and capability, economic to construct and operate and reliable in operation and performance. The invention slurries contaminated material with a solution. Transports the slurried material throughout a hydraulic chamber, where the contaminants become more associated with the solution than the material. The invention then separates the processed material and contaminated solution into unique reclaimed components.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This application claims the benefit of Provisional Application No. 61/706,895, filed Sep. 28, 2012. This invention relates to the handling of waste material and the field of environmental reclamation of waste material. More specifically, the invention comprises a method and apparatus of removing contaminants such as salts, hydrocarbon, chemicals, minerals, and metals from materials such as sand, soil, gravel, drill cuttings, and other solids, and reclaiming contaminants and materials for reuse. 
         [0003]    2. Description of the Related Art 
         [0004]    Contaminated materials are a byproduct of Oil and Gas Exploration-Completion-Production-Refining-Transportation, Agriculture, Manufacturing, Construction, Mining, Excavation and other activities. There are numerous devices that attempt to clean contaminated materials. Examples of devices can be found in U.S. Pat. Nos. 4,462,416, 4,546,783, 7,404,903, 8,100,198. Due to the performance, reliability, cost to purchase and operate these devices they are seldom used in industry. Instead, contaminated materials are generally handled through stock piling, transferring to a permitted disposal sites, burial, dilution, dispersion or other methods. Thus, as each day passes, the amount of contaminated material on the earth increases. The present invention provides an efficient, economic, reliability option to remove the contaminants from the materials, reducing the volume of waste and reclaiming the majority of the material for reuse. In addition to making the material ready for reuse, in many instances, once removed from the material, the contaminant can be reclaimed to a useful and valuable product as well. Reducing contaminated material is a desirable outcome for all communities. The need for an affordable, efficient reclamation processes and devices exits. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention provides an apparatus and method for removing salts, hydrocarbon, chemicals, minerals, metals and other contaminants from sand, clay, shale, soil, drill cuttings, gravel and other materials. The invention provides a scalable, efficient, economic process that can be set up as a permanent facility or as a mobile skid mounted unit. 
         [0006]    In one aspect, the invention is a method for removing contaminants comprising oils, salts, chemicals, minerals from materials comprising of sand, clay, shale, soil, drill cuttings, gravel. The inventive method comprises the steps of:
       a. transferring the contaminated material to a feed mechanism;   b. feeding the contaminated material into a slurry device;   c. slurring the contaminated material with a solution, which solution has been designed to efficiently remove the contaminant from the material;   d. transferring the slurred material to a hydraulic chamber, allowing the slurred material to flow throughout the hydraulic chamber, wherein the interaction between the contaminated material and the solution, and the vigorous flowing movement of the slurred material causes some, most or substantially all of the contaminant to become more associated with the solution then the material, the first hydraulic chamber may be in fluid communication with subsequent hydraulic chamber(s) having a similar shape and process as the initial hydraulic chamber;       
 
         [0011]    In another aspect, the invention is a method for reclaiming material and contaminants where sand, clay, shale, soil, drill cuttings, gravel, and other materials are contaminated with salts, hydrocarbon, chemicals, minerals, metals and other contaminants. The inventive method comprises the steps of:
       a. providing a slurry device being supplied with contaminated material and solution;   b. providing a hydraulic chamber in fluid contact with the slurry device;   c. slurring the contaminated material with a solution, which solution has been designed to efficiently remove the contaminant from the material;   d. transferring the slurred material to a hydraulic chamber, allowing the slurred material to flow throughout the hydraulic chamber, wherein the interaction between the contaminated material and the solution, and the vigorous movement of the slurred material causes the contaminant to become more associated with the solution then the material, the first hydraulic chamber may be in fluid communication with subsequent chamber(s) having a similar shape and process as the initial hydraulic chamber;   e. transferring the material, contaminants and solution from the hydraulic chamber to the separation chamber.   f. separating the slurry into material, contaminants and solution   g. collecting the reclaimed material and reclaimed contaminants and solution in separate holding containers as reclaimed components.       
 
         [0019]    In another aspect, the invention is an apparatus for removing contaminants from materials. The inventive apparatus includes a feed mechanism in communication with a slurry device which is in fluid communication with a hydraulic chamber which is in fluid communication with a separation chamber. The feed mechanism is suitable for providing contaminated material into a slurry device wherein the contaminated material is combined with a solution and allowed to flow throughout a hydraulic chamber, wherein the contaminants become more associated with the solution than the material, continuing from the hydraulic chamber into a separation chamber suitable for separating the material from the contaminants and solution. 
         [0020]    In another aspect, the invention is an apparatus for reclaiming materials and contaminants. The inventive apparatus includes a feed mechanism in communication with a slurry device which is in fluid communication with a hydraulic chamber which is in fluid communication with a separation chamber. The feed mechanism is suitable for providing contaminated material into a slurry device wherein the contaminated material is combined with a solution and allowed to flow throughout a hydraulic chamber, wherein the contaminants become more associated with the solution than the material, continuing from the hydraulic chamber into a separation chamber suitable for separating the material, the contaminants and the solution into components and holding the components in unique containers as reclaimed material and contaminants. 
         [0021]    Numerous objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings which illustrate such embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  depicts a schematic of a material and contaminant reclamation system. 
           [0023]      FIG. 2 . depicts a schematic of the Hydraulic Chamber configured with turbulators and a nozzle system. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    As used herein, the term “material” refers to sand, clay, shale, soil, drill cuttings, gravel, and other solids in singular or plurality. The term “contaminate” comprises salts, hydrocarbons, chemicals, minerals, metals and other items in singular or plurality. The term “contaminated material” refers to a solution, compound, or mix comprising material in singular or plurality and contaminate in singular or plurality dissolved, coated, bonded, reacted thereon. The term “solution” refers to a liquid designed to be best suited for the process of removing the contaminant from the material. The term “slurred material” refers to a combination of contaminated material and solution. The term “contaminated solution” refers to a mix of contaminants that have been removed from the material, and the Solution  11 . 
       Concept of Operations 
       [0025]    The depiction in  FIG. 1  provides the concept of operations for a notional system providing contaminated material from sources comprising drilling operations, completion operations, production operations, transportation, refining, storage of oil and natural gas, agriculture, factories, refineries, mining, excavation, construction, spills, leaks, naturally occurring, etc. 
         [0026]    In the concept of operations for the notional system, earthen material, granular to drill cutting in size, soaked and infused with contaminants, comprising hydrocarbon and chlorides, is the contaminated material  10 . Contaminated material  10  is communicated from the source of the contamination to a holding container  101  which is located either at the source site or at a remote facility. 
         [0027]      FIG. 1  depicts Contaminated Material  10  being communicated from Holding Container  101  to Feed Mechanism  400 . Feed Mechanism  400  further communicating the Contaminated Material  10  to the Slurry Device  500 , where the contaminated material  10  is combined with a solution  11 . In the notional system, Pump  304  used to pressurize the solution  11  may be a single pump or a plurality of pumps, and, the Slurry Device  500  may be present in singular or plurality. 
         [0028]    As an alternative to using solution  11  at ambient temperature, bypass  301  is utilized to communicate Solution  11  to Heater  302 , where Solution  11  is heated to a desired temperature prior to being communicated to Slurry Device  500 . The implementation of a heater at this point in the process will be dictated by the physical properties of the Contaminated Material  10  and the specific conditions of the actual site. 
         [0029]    Alternatively, the Contaminated Material  10  is pretreated prior to prior to being communicated to the Feed mechanism  400 . The pretreatment may comprise steps such as the removal of debris, sorting, sizing, immersing, wetting, and heating for the purpose of improving the performance of the process. The pretreatment of Contaminated Material  10  will be dictated by the physical properties of the Contaminated Material  10  and the specific conditions of the actual site. 
         [0030]    At this point in the process, the contaminated material  10  has been combined with a solution  11  to form a slurry. This slurry is a combination of material, contaminants and solution, and is now referred to as Slurred Material  12 . 
         [0031]    The Slurry Device  500  is in fluid communication with the Hydraulic Chamber  600 . The Hydraulic Chamber  600  may be in fluid communication with subsequent hydraulic chambers, in singular or plurality, having similar shape and process as the initial Hydraulic Chamber  600 . The Hydraulic Chamber  600  and subsequent hydraulic chambers provide an area where the Slurred Material  12  moves throughout, wherein the interaction between Contaminated Material  10  and Solution  11 , and the vigorous movement of the Slurred Material  12  causes the contaminant to become more associated with the solution then the material. 
         [0032]    Alternatively, the Hydraulic Chamber  600  performance may be enhanced through the addition of Turbulator surfaces  602  on the interior of the Hydraulic Chamber  600  which impart additional motion onto the Slurred Material  12 . This motion enhances the separation of the contaminant from the material. 
         [0033]    Alternatively, the Hydraulic Chamber  600  performance may be enhanced through the addition of a pressurized Nozzle System  603 . This pressurized Nozzle System  603  is comprised of a Nozzel  603 , in singular or a plurality of nozzles that hydraulically acts on the Slurred Material  12 . The Nozzle  603  may comprise a variety of design types, such as, orifice type, shaped orifice type, surface impingement type, pressure swirl spray type, compound nozzle type, etc. 
         [0034]    The Nozzle System  603  and Turbulator  602  can be added to the Hydraulic Chamber separately, or concurrently, as they independently perform their function. 
         [0035]    Alternatively, Hydraulic Chamber  600  may be in fluid contact with Pump  604  between the Hydraulic Chamber  600  and subsequent hydraulic chambers. Pump  604  serves a multiple purposes, comprising; (1) to pressurize the Slurred Material  12  into subsequent Hydraulic Chambers  600 , (2) to impart a shearing and agitating action on the Slurred Material  12 , and (3) to increase the surface area of the material by breaking up the material into smaller sized particles. 
         [0036]    Alternatively, Hydraulic Chamber  600  may be in fluid contact with Pump  604  between the Hydraulic Chamber  600  and the Separation Chamber  700 . Pump  604  serves a multiple purposes comprising; (1) to pressurize the slurry into the Separation Chamber  700 , (2) to impart a shearing and agitating action on the Slurred Material  12 , and (3) to increase the surface area of the material by breaking up the material into smaller sized particles. 
         [0037]    The Separation Chamber  700  acts on the Slurred Material  12 , dividing it into components comprising Material  13 , Processed Solution  16 , and Processed Contaminates  15 . Material  13  is separated from Slurred Material  12  using a Solid-Liquid Separation Device  701 , such as an oilfield shaker, desand-desilter cones, centrifuge, or a combination of these or similar devices. 
         [0038]    The material  13  moves from the Separation Chamber  700  to a Material Holding Container  102  and stored as reclaimed material. 
         [0039]    In the notional system the mix of Contaminates and Solution  14  is further processed to separate the Processed Contaminants  15  from the Processed Solution  16  using liquid phase separation devices and other technology. 
         [0040]    In the best embodiment of the system, Processed Solution  16  is further treated to remove impurities and moved to Processed Solution tank  105  for reuse as Solution  11 . The Processed Contaminant  15  moves from the Separation Chamber to Processed Contaminant Tank  106  and stored as reclaimed Contaminants. 
       Apparatus 
       [0041]    While each step of the process can be manually adjusted, the preferred embodiment utilizes a computer process to control and coordinate the rate of Contaminated Material  10  fed into the Slurry Device  500  with the rate of Solution  11  moved by Pump  304  into the Slurry Device  500 . 
         [0042]    Referring to the Feed Mechanism  400 , there are numerous suitable methods of transferring Contaminated Material  10  from the Holding Container  101  to the Slurry Device  500 . The most efficient and economical method may vary from facility to facility and will be dictated by the physical properties of the Contaminated Material  100  being processed and the specific site conditions. 
         [0043]    Regarding Solution  11 . The composition of the Solution  11  should be tailored to the Contaminated Material  10  being processed and the end requirements of the process. Test trials performed by the inventor utilized filtered well water and a mixture of filtered well water and surfactants. Other possible constituents of Solution  11  include alcohols, xylenes, peroxides, hydrocarbons, alkalis, oxidizers, petrochemicals, oleochemicals, etc, including combinations that comprise these and other chemicals, minerals and mixtures. 
         [0044]    Referring to the Slurry Device  500 , there are numerous suitable methods that can be used to slurry the Solution  11  with the Contaminated Material  10 . The best embodiment may vary from facility to facility and will be dictated by the physical properties of the Contaminated Material  10  being processed and the specific site conditions. Slurred Material  12  exits the Slurry Device  500  liquid enough to flow fluidly throughout the Hydraulic Chamber  600 . Test trials performed by the inventor were conducted with a venturi type slurry device and a slurry ratio of  1 : 1  Contaminated Material  10  to Solution  11 . The percentage of Solution  11  to Contaminated Material  10  will be dictated by the physical properties of the Contaminated Material  10  being processed. 
         [0045]    FIGS.  1 , 2  depicts an embodiment where the Hydraulic Chamber  600  is cylindrical in shape. As tested, the cylindrical shape provided efficient movement of the Slurred Material throughout the Hydraulic Chamber. It is noted for the purpose of this document, similar results can be achieved using other shapes for the Hydraulic Chamber  600 , such as U shaped channel, V shaped channel, etc, so as long as the shape of the chamber promotes a flowing movement of Slurred Material  12 . 
         [0046]    Referring to  FIG. 1 , the inventive apparatus is depicted with a single Hydraulic Chamber  600 . Given specific site requirements and conditions the apparatus may contain a plurality of Hydraulic Chambers  600 , connected in series or parallel, which are similar in shape and process to the initial Hydraulic Chamber  600 . Hydraulic Chambers  600  in parallel will increase throughput volume. Hydraulic Chambers  600  in series will increase performance of the process. If Hydraulic Chambers  600  are connected in series there will be Pump  604  located between the Hydraulic Chambers  600 . Pump  604  serves a multiple purposes comprising; (1) to pressurize the Slurry Material  12  into subsequent Hydraulic Chambers  600 , (2) to impart a shearing and agitating action on the Slurred Material  12 , and (3) to increase the surface area of the material by breaking up the material into smaller sized particles. 
         [0047]      FIG. 1  depicts one embodiment of the Hydraulic Chamber  600  where the chamber provides for interaction between the Contaminated Material  10  and Solution  11 , now Slurred Material  12 , wherein the interaction between the contaminated material and the solution, and the vigorous movement of the slurred material causes the contaminant to become more associated with the solution then the material.  FIG. 2  depicts another embodiment of the Hydraulic Chamber  600  where Turbulators  602 , in singular or a plurality, are added throughout the length and width of the Hydraulic Chamber  600  to impart a mixing and agitating motion to the slurred material  12 . For the purpose of an example, the motion imparted by the Turbulator  602  on the Slurred Material  12  is similar to that of rapids in a river. This added motion enhances the removal of the contaminant from the material. 
         [0048]      FIG. 2  depicts another embodiment of the Hydraulic Chamber  600  where a pressurized Nozzle System  603  is added to the Hydraulic Chamber  600 . The addition of the Nozzle System  603  serves to assist in moving the Slurred Material  12  throughout the Hydraulic Chamber  600  and to enhance the performance of the process by the increased shearing and agitation imparted on the Contaminated Material  10  carried in the Slurred Material  12 . The increased shearing and agitation assists in the removal of the contaminant from the material. 
         [0049]    The Nozzle System  603  is comprised of a single or preferably a plurality of Nozzles  603 . The Nozzle  603  design may comprises a variety of types, such as, orifice type, shaped orifice type, surface impingement type, pressure swirl spray type, compound nozzle type, etc. The best embodiment will be dictated by the physical properties of the Contaminated Material  10  and the actual site conditions. 
         [0050]    Regarding  FIGS. 2 , Nozzles  603  are positioned around the Hydraulic Section  601  and disposed therethrough. Preferably, a plurality of Nozzles  60311  are disposed on the Hydraulic Chamber  600 . The actual position of Nozzle  603  will be dictated by the physical properties of the Contaminated Material  10  and the actual site conditions. In the best embodiment, the Nozzels contain isolation valves controlling flow to each nozzle position, allowing individual nozzles to be serviced without shutting down the working process. During the field trials performed by the inventor, Pump  606  produce a flow of Nozzel Solution  610  at 1,000 pounds per square inch (psi). 
         [0051]    Nozzle  603  serves to create an impact force on the Slurred Material  12 . 
         [0052]    The Separation Chamber  700  is in fluid communication with the Hydraulic Chamber  600 . 
         [0053]    In one embodiment, the Separation Chamber  700  acts on the Slurred Material  12  exiting the Hydraulic Chamber  600  and serves to separate Material  13  from Contaminated Solution  14 . 
         [0054]    In another embodiment, Contaminated Solution  14  is further processed by the Separation Chamber  700  to separate Processed Contaminants  15  from the Processed Solution  16  using liquid phase separation devices and other technology. 
         [0055]    In another embodiment, Processed Solution  16  is further treated to remove impurities and then moved to Processed Solution tank  105  for reuse as Solution  11 . Processed Contaminants  15  move from Separation Chamber  700  to Processed Contaminants Tank  106  and stored as reclaimed Contaminants. 
         [0056]    In one embodiment an oilfiled “shaker”  701 , in singular or a plurality of shakers, is used to separate the Material  13  from the Contaminated Solution  14 . 
         [0057]    In another embodiment, oilfield “desander” and “desilter” cones are used to separate the Material  13  from the Contaminated Solution  14 . 
         [0058]    In another embodiment, a centrifugal cuttings dryer is used to separate the Material  13  from the Contaminated Solution  14 . 
         [0059]    Depending on the output requirements of the specific application, the Separation Chamber  700  may be comprised of any combination of the Shaker, Desander, Desilter, Centrifigual Cuttings Dryer or other Solid-Liquid, Liquid-Liquid, Solid-Solid separation device. 
         [0060]    The Separation Chamber  700  may contain additional equipment to further process Contaminated Solution  14  after it has been separated from the Material  13 . In the best embodiment, the output from the additional equipment would be Solution  16  and Processed Contaminants  15 . The Processed Solution  16  would be fluidly connected to Holding Containers  105  for reuse or disposal. The Processed Contaminants  15  would be held in Holding Containers  106  for reuse or disposal.