Abstract:
One embodiment of the invention disclosed is an apparatus for separating a solid material from a mixture containing oil, water, clay, sand, soil and drill cuttings. The apparatus comprise a series of processing cells and wash tanks. Hydrocyclonic devices are also used to further purify the solid mixture for disposal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/354,162 filed on Jun. 11, 2011 by the present inventor. 
    
    
     FEDERAL SPONSORED RESEARCH 
     N/A 
     FIELD OF THE INVENTION 
     This invention is related to the field of the treatment of oil, water and sand mixtures and specifically to an improved apparatus and method for the treatment of oil, water, cuttings, sand, soil and clay mixtures. 
     BACKGROUND 
     My issued Canadian patent #2196522 is relevant to this application. This invention has been improved to address the requirements of drilling in shale formations. The invention has been improved to address the cleaning of cuttings, sand, clay, soil and oil and water mixtures in shale drilling operations. 
     SUMMARY OF THE INVENTION 
     In accordance with one embodiment of the invention is an apparatus for separating a solid material from a mixture containing oil, water and solid material. 
     In a further embodiment of the invention the apparatus comprises: a source of a mixture containing oil, water and sold material; a conveying means for conveying the mixture from the source to a first processing cell; means for conveying first cell processed material from the first processing cell to a second processing cell; means for conveying second cell processed material from the second processing cell to a third processing cell; means for conveying third cell processed material from the third processing cell to a fourth processing cell; means for conveying fourth cell processed material from the fourth processing cell to a disposal. 
     The solid mixture or feed stock to be processed by the apparatus comprises drill cuttings and clay particulates from oil and gas drilling operations through a variety of formations including shale formations. 
     A conveyor belt is used to move the feed stock from the source of the feed stock to the first processing cell. 
     In another embodiment of the invention the first processing cell comprises a shaker conveyor disposed above a wash tank. The shaker conveyor separates unwanted material from the mixture and conveys it to a disposal site. A wash tank receives the mixture from the shaker conveyor. The wash tank includes an agitation means; a chemical addition means for adding emulsifying chemicals to the mixture in the wash tank during operation of the agitation means; a water inlet for receiving a continuous flow of clean water into the wash tank; a wash tank outlet for removing a first amount of settled material from the wash tank; and, a first overflow means for transferring a first refined mixture to a settling tank. 
     The settling tank comprises a second settled material outlet for removing a second amount of settled material from the settling tank; and, a second overflow means for transferring a second refined mixture to a transfer tank. The transfer tank comprises a third settled material outlet for removing a third amount of settled material from the transfer tank, a second chemical addition means for adding a first flocculent, a third chemical addition means for adding a second flocculent, water transfer means for transferring clean water from the transfer tank to a storage tank; and, oil transfer means for transferring separated oil from the transfer tank to an oil storage tank. 
     In still a further embodiment of the invention the apparatus comprising a hydrocyclonic separator in communication with the wash tank and the settling tank. The first amount of settled material from the wash tank and the second amount of settled material from the settling tank are transferred to the hydrocyclonic separator for separating water from the first and second amounts of settled material and forming the first cell processed material. The first cell processed material is transferred to the second processing cell. 
     The second cell comprises a second wash tank for receiving the first cell processed material and forming a first cell processed mixture. The second wash tank comprises a second wash tank agitation means; a second wash tank chemical addition means for adding emulsifying chemicals to the first cell processed mixture in the second wash tank during operation of the second agitation means; a second water inlet for receiving a second continuous flow of clean water; a fourth wash tank outlet for removing a fourth amount of settled material from the second wash tank; and, a third overflow means for transferring a third refined mixture to a second settling tank. 
     The second settling tank comprises a fifth settled material outlet for removing a fifth amount of settled material from the second settling tank; and, a fourth overflow means for transferring a fourth refined mixture to a second transfer tank. 
     The second transfer tank comprises a sixth settled material outlet for removing a sixth amount of settled material from the second transfer tank; a fourth chemical addition means for adding the first flocculent; a fifth chemical addition means for adding the second flocculent; a second water transfer means for transferring clean water from the second transfer tank to the water storage tank; and, a second oil transfer means for transferring separated oil from the second transfer tank to the oil storage tank. 
     The apparatus of the invention further comprises a second hydrocyclonic separator in communication with the second wash tank and the second settling tank, wherein the fourth amount of settled material from the second wash tank and the fifth amount of settled material from the second settling tank are transferred to the second hydrocyclonic separator for separating water from the fourth and fifth amounts of settled material and forming the second cell processed material. Means are provided for transferring the second cell processed material to the third processing cell. The third processing cell forms a third cell processed material which is transferred to a fourth processing cell. The fourth processing cell forms a fourth cell processed material. 
     The invention also includes a method for separating a solid material from a mixture containing oil, water and said solid material. The method comprises the following steps: 
     a. obtaining a source of the mixture; 
     b. conveying the mixture from the mixture source to a first processing cell; 
     c. processing the mixture in the first processing cell to form a first cell processed mixture; 
     d. conveying the first cell processed mixture from the first processing cell to a second processing cell; 
     e. processing the first cell processed mixture in the second processing cell to form a second cell processed mixture; 
     f. conveying the second cell processed mixture from the second processing cell to a third processing cell; 
     g. processing the second cell processed mixture in the third processing cell to form a third cell processed mixture; 
     h. conveying the third cell processed mixture from the third processing cell to a fourth processing cell; and, 
     i. processing the third cell processed mixture in the fourth processing cell to form a fourth cell processed mixture. 
     ADVANTAGES 
     Accordingly, several advantages of one or more aspects of the invention are as follows: to provide an apparatus that is able to effectively separate water, oil and solid mixtures for disposal and reprocessing to mitigate pollution associated with traditional disposal method. The invention has a further advantage of being able to process sand, clay, soil and drill cuttings from formations in the field of gas and oil exploration. Specifically, the apparatus and method of the invention can separate oil and water from a mix of solid materials found when drilling through shale formations. Other advantages of one or more aspects of the invention will be apparent from a consideration of the drawings and ensuing description. 
    
    
     
       DRAWINGS 
         FIG. 1  is a schematic view of one embodiment of the invention. 
         FIG. 2  illustrates a separation cell of another embodiment of the invention. 
         FIG. 3  illustrates another separation cell of yet another embodiment of the invention. 
         FIG. 4  illustrates yet another separation cell of another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , there is shown schematically a first separation cell (Cell # 1 ) of one embodiment of the invention  10 . A mixture of water, oil, clay, sand, soil and shale formation cuttings  12  is obtained from shale drilling operations. The mixture is conveyed by a conveyor  14  to a shaker screen where trash and oversize rock is separated from mixture and sent to disposal or further treatment  18 . The graded mixture  20  is delivered to wash tank  22 . Wash tank  22  is an agitation tank having powered agitation means  24  to separate light from heavy particular matter. Suitable chemicals  26  are added  28  to the wash tank  22  to promote separation of oil from the cuttings, clay and other materials. The chemicals are specially formulated to suit the composition of the mixture  12 . The composition of mixture  12  is dependent on the location of the drilling operation. For example, the chemicals added from tank  26  in Oklahoma will be different from the chemicals added in Mexico. Water is also continually added to the wash tank  22 . The water used in the wash tank is recycled water from the process as further described below. Water can also be sourced from a local system  36 . 
     Once the mixture is added to the wash tank  22  the agitation  24  begins and forms a froth emulsion. Heavy cuttings  38  will fall to the bottom of the wash tank. Lighter particles will remain in suspension  40  and the froth will be floating on top of the wash tank. The wash tank is designed so that it continuously receives mixture and water. The wash tank will overflow  42  into settling tank  44  taking with it the oil froth and lighter particles in suspension. The heavy cuttings  38  at the bottom of the wash tank  22  will be pumped out of the wash tank by pump  46  by way of line  48 . The heavy cuttings are transferred to the hydrocyclonic separator  34 . Within the settling tank  44 , heavier particles  50  will settle to the bottom of the tank. They will also be pumped out of the tank by way of line  52  and pump  46  and transferred to the hydrocyclonic separator  34 . Water, oil and lighter particles suspended in water will overflow  52  from the settling tank  44  to the transfer tank  54 . Water and suspended particles  69  within transfer tank  54  will be continually transferred by pump  55  and line  57  to treatment tank  59 . An oil layer  70  will accumulate on the top of the water  69  and will be removed once it accumulates to certain thickness and transferred to tank  66 . 
     In tank  59 , two types of quick settling flocculants are pumped into the treatment tank by way of pump  56  and line  58 . The resulting clarified water is held in tank  62  and then pumped into tank  30  for storage. Separated oil is held in tank  63  and pumped into oil holding tank  66 . 
     The heavier cuttings  38  and heavier particles  50  which have settled to the bottom of wash tank  22  and settling tank  44  respectively are pumped to the hydrocyclonic separator  34  by pump  46 . Vortex separation is used to separate the water from the particulate matter. Clean water  80  is recycled from the separator back to the wash tank  22  by line  84  and pump  85 . Particulate matter  82  which is collected in the hydrocyclonic separator is transferred by way of line  86  to a second separation cell (Cell # 2 ). The material  87  collected at the bottom of the treatment tank  59  is periodically augured out of the tank and transferred  89  to a clean waste disposal site. 
     Referring to  FIG. 2 , there is illustrated a second separation cell  100  (Cell # 2 ) that receives the material from hydrocyclone  34  in Cell # 1  by way of line  86  and pump  91 . The material is transferred into wash tank  102  having agitation means  104 . The material is agitated so that heavier particulate materials  106  will fall to the bottom of the tank  102 . An emulsifier  108  is added to the wash tank  102  by way of pump  110  and line  112 . Emulsifier  108  is formulated specially to suit the composition of the material and helps form a froth of oil and water which floats on the surface of the tank. Water is continually added to the wash tank  102  either from the hydrocyclonic separator  114  by way of line  116 , from an on-site system by way of line  118  and by recycling water from the transfer tank in cell # 3  shown in FIG. # 1 . 
     Froth material and lighter clay particles in suspension will overflow  122  from the wash tank  102  into the settling tank  124 . Heavier material  126  will fall out of suspension and settle to the bottom of the tank  124 . A mixture of oil, water and fine particles will overflow  130  into transfer tank  132  forming a layer of oil  134  and clean water  136 . The oil can be skimmed off of the surface and transferred to oil storage tank  66  by way of line  140  on a periodic basis. The water  136  is transferred by line  142  and pump  143  back to cell # 1  wash tank # 22 . 
     The heavier cuttings  106  and heavier particles  126  which have settled to the bottom of wash tank  102  and settling tank  124  respectively are pumped to the hydrocyclonic separator  114  by pump  158 . Vortex separation is used to separate the water from the particulate matter. Clean water  115  is recycled from the separator  114  back to the wash tank  102  by line  116  pump  117 . Particulate matter  162  which is collected in the hydrocyclonic separator is transferred by way of line  164  to a third separation cell (Cell # 3 ) wash tank  166 . 
     Referring to  FIG. 3 , there is shown Cell # 3  ( 200 ) that receives the material from hydrocyclone  114  in Cell # 2  by way of line  164  and pump  165 . The material is transferred into wash tank  166  having agitation means  168 . The material is agitated so that heavier particulate materials  170  will fall to the bottom of the tank  166 . An emulsifier  108  is added to the wash tank  166  by way of pump  172  and line  174 . Emulsifier  108  is formulated specially to suit the composition of the material and helps form a froth of oil and water which floats on the surface of the tank. Water is continually added to the wash tank  166  either from the hydrocyclonic separator by way of line  178  and pump  180 , from an on-site system by way of line  182  and by recycling water from the transfer tank in cell # 4 . 
     Froth material and lighter particles in suspension will overflow  188  from the wash tank  166  into the settling tank  190 . Heavier material  192  will fall out of suspension and settle to the bottom of the tank  190 . A mixture of oil, water and particles will overflow  194  into transfer tank  198  forming a layer of oil  201  and clean water  202 . The oil can be skimmed off of the surface and transferred to oil storage tank  66  by way of line  204  on a periodic basis. The water  202  is transferred by line  206  and pump  208  back to cell # 2  wash tank # 102 . 
     The heavier cuttings  170  and heavier particles  192  which have settled to the bottom of wash tank  166  and settling tank  190  respectively are pumped to the hydrocyclonic separator  176  by pump  193 . Vortex separation is used to separate the water from the particulate matter. Clean water  177  is recycled from the separator  176  back to the wash tank  166  by line  178  and pump  180 . Particulate matter  179  which is collected in the hydrocyclonic separator  176  is transferred by way of line  402  and pump  404  to a fourth separation cell (Cell # 4 ). 
     Referring to  FIG. 4 , there is shown Cell # 4  ( 400 ) that receives the material from hydrocyclone  176  in Cell # 3  by way of line  402  and pump  404 . The material is transferred into wash tank  406  having agitation means  408 . The material is agitated so that heavier particulate materials  410  will fall to the bottom of the tank  406 . An emulsifier  108  is added to the wash tank  406  by way of pump  412  and line  414 . Emulsifier  108  is formulated specially to suit the composition of the material and helps form a froth of oil and water which floats on the surface of the tank. Water is continually added to the wash tank  406  either from the hydrocyclonic separator  420  by way of line  422  and pump  424  or from an on-site system by way of line  426 . 
     Froth material and lighter particles in suspension will overflow  430  from the wash tank  406  into the settling tank  432 . Heavier material  434  will fall out of suspension and settle to the bottom of the tank  432 . A mixture of oil, water and particles will overflow  450  into transfer tank  452 . By this stage there is no oil on the surface of the water in the transfer tank  452 . The water  454  is transferred by line  456  and pump  458  back to cell # 3  wash tank # 166 . 
     Material  480  that is collected by hydrocyclonic separator  420  is transferred  482  to a clean material storage site. 
     Although the description above contains much specificity, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of the several embodiments. Thus the scope of the invention should be determined by the appended claims and their legal equivalents rather than by any examples given.