Patent ID: 12195358

DETAILED DESCRIPTION

Embodiments of the present disclosure relate generally to a method, apparatus and system for the evaporation of produced water from oil and gas production and other dirty water sources. Embodiments of the present disclosure can be used in the enhanced oil recovery industry in processes such as Hydraulic Fracturing, or any other application which requires large quantities of contaminated water to be treated and/or disposed of.

FIG.1depicts a plan view of a produced water evaporation apparatus and system10, in accordance with embodiments of the present disclosure. Embodiments of the present disclosure can include an above ground storage tank (AST)1. The AST1can include a retaining wall, which defines a perimeter of the AST1. The AST1can be used in oil fields and can come in many sizes. As depicted, the AST1can be approximately 150 feet in diameter, as represented by line B-B, although the AST1can be of a smaller or larger diameter than 150 feet.

The AST1can be erected quickly, sometimes in a matter of days, and can be easily disassembled and moved. The AST1 can be constructed with integrated fluid barriers that include single or multiple linings and/or water retention systems. In some embodiments, the fluid barriers can be plastic liners and/or membranes of considerable strength and durability. The AST1can be enclosed by a fixed or movable roof and/or can be open. In some embodiments, the AST1can be screened in on its exposed surface to resist waterfowl interaction. In some embodiments, the AST1can be equipped with a sound system and/or other systems that are viewed by waterfowl as threatening, to reduce the risk of waterfowl interaction with the contents of the AST1. The AST1can include a second retaining wall2, which may be part of an independent fluid retention system or may be part of one of the fluid barriers already employed in AST1. A retention volume3can be defined between the AST1and the second retaining wall2, which can help to minimize the risk of fluid being spilled or misted from the area enclosed by the AST1, thus preventing contamination of the areas surrounding the AST1.

A network of spray systems can be disposed within a perimeter of the retaining wall that defines the AST1. The network of spray systems can include one or more nozzles that can spray produced water. The number, spacing, and/or configuration of the nozzles can be varied. For example, the one or more nozzles can be configured to have a spray plume shape that includes at least one of a flat fan, mist fan, full cone, hollow cone, among other types of spray plume shapes. As depicted, the AST1can include spray systems4,5,6and7. The spray systems4,5,6, and7can have an infinite combination of flows, heights, and spray plume shapes, as depicted. For ease of illustration, the reference numbers4,5,6, and7point to spray plumes that are produced by nozzles associated with the spray systems. For example, a different fluid flow can be provided to one or more of the spray systems4,5,6, and7, one or more of the spray systems can extend a different height above the AST1, and/or one or more of the spray systems can be configured to have a different spray plume pattern shape. The pattern of fluid flow, height, and/or spray plume pattern shape may or may not repeat in the balance of the spray systems situated at each set of intersecting lines shown inFIG.1and specifically inside the area enclosed by the retaining wall that defines the AST1. Some embodiments of the present disclosure can include a spray plume pattern shape control and altitude control. For example, the spray plume pattern shape and/or altitude of the spray plume can be varied by increasing and/or decreasing a flow and/or pressure of fluid through the one or more nozzles. In the example of the quantity of fluid projection systems and the spray plume or projection control and altitude control of the fluid spray plumes shown inFIGS.1and2, the system and apparatus can evaporate over 1,000 barrels per day of produced water when residing in the Permian Basin. If the diameter of the system and apparatus is reduced by 50% the resulting system and apparatus will evaporate over 500 barrels per day of produced water when residing in the Permian Basin.

Although only spray systems4,5,6,7are labeled inFIG.1, spray systems can be located at the intersection of the vertical lines and horizontal lines located within the perimeter of the AST1. As depicted, the AST1can include 177 spray systems with individual nozzles, however, the number of spray systems (e.g., nozzles) can be greater than or less than 177. In some embodiments, an individual spray system can include one or more nozzles. As further depicted inFIG.1, in some embodiments, the vertical lines (e.g., representative of nozzle spacing in a first direction) can be spaced apart by approximately 10 feet, represented by line C-C, although spacing between nozzles can be closer or further than 10 feet. As further depicted inFIG.1, in some embodiments, the horizontal lines (e.g., representative of nozzle spacing in a second direction) can be spaced apart by approximately 10 feet, represented by line D-D, although spacing between nozzles can be closer or further than 10 feet.

In some embodiments, the AST1can include a plurality of fluid pumping systems8,9,10, and11. In an example, the fluid pumping systems8,9,10, and11can be disposed in a retention area3between the retaining wall that defines the AST1and the second retaining wall2, as depicted. These pumping systems8,9,10, and11can include pumps that are driven by any power source, for example, such as electricity or fossil fuel prime movers including a turbine and/or internal combustion engine. In some embodiments, it is desirable that the pumping systems8,9,10, and11can vary their flow and pressure. For example, the fluid flow and/or pressure generated by the pumping systems8,9,10, and11can be varied to adjust the spray plume pattern shape and/or altitude of the spray plume. In some embodiments, one or more of the pumps associated with the pumping systems8,9,10, and11may be disposed in the retention area3, as shown inFIG.1. In some embodiments, one or more of the pumps associated with the pumping systems8,9,10, and11may be in a more remote area or retention system. It is desirable for the pumping systems8,9,10, and11to draw fluid from a location below the surface water of the AST1, but above the altitude where solids accumulate. This condition is shown inFIG.3, in relation to the representative pump inlet15.FIG.3depicts a close up view of a pump for the produced water apparatus and system, as depicted inFIGS.1and2, in accordance with embodiments of the present disclosure. As depicted, the pump inlet pipe15can be disposed above the bottom of the AST1and can travel through the wall of the AST1and through the second retaining wall2to the intake portion of the pump8. A pump outlet pipe26can be fluidly coupled with the outlet of the pump and extend through the second retaining wall2and the wall of the AST1to a distribution header (e.g., manifold14, as depicted and described in relation toFIG.2). In some embodiments, a fluid tight seal25can be formed between the interface of the pump outlet pipe25and the second retaining wall2. The fluid tight seal25can prevent fluid that has drifted via wind and/or overflowed from the AST1from escaping the area contained by the second retaining wall2. A fluid tight seal25can also be formed between the interface of the pump inlet pipe15and the second retaining wall2, although not labeled. In some embodiments, a pipe support27can be disposed between the second retaining wall2and the pump8, to support the pump inlet pipe15and the pump outlet pipe25.

In some embodiments, the AST1can include a separator12, which can be a hydrocarbon or oil and water separator and/or skimmer. In most cases hydrocarbons which have commercial value are entrained in the produced water being held by the AST1. They continue to separate due to fluid density and other motives in the AST1and are desirable to finally collect and separate out to be used for beneficial purposes. Thus, the separator12can separate hydrocarbons from the produced water being held in the AST1.

FIG.2is a cross-sectional side view of the AST1, along line A-A, depicted inFIG.1, in accordance with embodiments of the present disclosure. As mentioned, the AST1can include spray systems4,5,6and7that utilize nozzles, which in some embodiments can be self-cleaning nozzles, in nature. In some embodiments, the nozzles associated with spray systems4,5,6and7can be air augmented. In some embodiments, spray plume pattern shape and/or an altitude of the spray plume can be altered between the nozzles associated with spray systems4,5,6and7. In some embodiments, the spray plume pattern shape can be adjusted by increasing and/or decreasing a flow and/or pressure of fluid provided to the nozzles associated with spray systems4,5,6and7and/or through use of a nozzle configured to provide a particular spray plume pattern shape.

The pattern produced by the nozzles associated with spray systems4,5,6and7can be repeated as shown with respect to the nozzles associated with spray systems15,16,17and18. In some embodiments, the goal can be to implement a system that maximizes the exposed surface area and temperature difference between the fluid to be evaporated and the wet bulb temperature of the surrounding atmosphere. In order to accomplish this, the particle size of the projected fluid shown emanating from any nozzle can be minimized without creating an environment for clogging and the particles can be large enough to not form a particulate cloud that drifts past the AST1and the retention area3, as depicted inFIG.1. Wind and other environmental conditions can affect the optimum size, shape, height and density of the spray plumes emanating from the nozzles in the AST1. Nozzles that are self-cleaning that can be implemented inFIG.2can include; air atomizing nozzles, axial flow hollow cone nozzles, tangential flow hollow cone nozzles, full cone nozzles, spillback nozzles, laval nozzles and others known to those skilled in the art. The nozzle spray plume may be made up of fluid particles of the predominant diameter of 0.01 to 1 millimeters or more desirably from 0.1 to 0.3 millimeters.

In some embodiments, the nozzle systems and manifold systems shown inFIG.2as spray systems4,5,6,7,15,16,17,18and manifold14can float on top of the produced water or can be fixed to the walls of the AST1, or a combination of both. In an example, one or more manifolds14can be included in the AST1for fluidly coupling the various strings of nozzles together.

As depicted inFIGS.2and3, the AST1can be built on existing soil21. In some embodiments, a compacted foundation22can be disposed under the AST1and any secondary retaining walls (e.g., secondary retaining wall2). As depicted, in some embodiments, the wall of the AST1can be approximately 7 feet tall, however, the wall of the AST1can be shorter or taller than 7 feet. In some embodiments, the secondary retaining wall2can be approximately 12 feet tall, however, the secondary retaining wall can be shorter or taller than 12 feet. In some embodiments, as discussed, the AST1can include a skimmer23and/or an oil/water separator24.

Wind and temperature sensors that relate to wind direction, wind velocity, dry and wet bulb conditions and other meteorological metrics can be used to control the individual nozzle fluid particle size, spray plume shape, spray plume height and density. The particle size can be the size (e.g., diameter) of individual particles that form the spray generated by the one or more nozzles. The spray plume shape can be an overall shape of the spray plume when viewed from the side or from above the spray plume. The spray plume height can be the height of the spray plume above the nozzle and/or above a surface of fluid held in the AST1. The density of the spray plume can be an amount of fluid per volume of the spray plume

In an example, in some embodiments, in response to a velocity of the wind increasing, a fluid particle size can be increased, height, and/or density can be decreased, which can prevent fluid particles from escaping the confines of the AST1and/or the retention area3, while maximizing evaporation. In response to a velocity of the wind decreasing, a fluid particle size can be decreased, height, and/or density can be increased, which can prevent fluid particles from escaping the confines of the AST1and/or the retention area3, while maximizing evaporation. In some embodiments, in response to a wind direction, height, and/or density associated with downwind spray systems can be decreased and/or a fluid particle size associated with the downwind spray systems can be increased, to avoid fluid particles from escaping the confines of the AST1and/or the retention area3. In some embodiments, in response to a difference between a dry and wet bulb condition decreasing, the fluid particle size and height can be increased and a density of the spray plume can be decreased. In response to a difference between a dry and wet bulb condition increasing, the fluid particle size and height can be decreased and a density of the spray plume can be increased. The brine concentration as measured in the AST1may also be factored into the control optimization. In an example, as a concentration of the brine increases, a fluid particle size of the spray plume can be decreased, a height of the spray plume can be increased, and a density of the spray plume can be decreased. In an example, as a concentration of the brine decreases, a fluid particle size of the spray plume can be increased, a height of the spray plume can be decreased, and a density of the spray plume can be increased.

Sectors of nozzles can be controlled by all of the aforementioned parameters to optimize evaporation and minimize over spray into undesirable areas. For ease of illustration, the meteorological measurement systems, brine concentration measurement system and nozzle controllers have been excluded in the figures. One or more microprocessors, chemical sensors, variable speed pumps, solenoid and/or valve banks comprise the inner workings of these control systems that are programmed to react to the changing meteorological conditions and chemical makeup of the process fluid, such as the brine concentration contained in the AST1. For example, the various sensors, pumps, solenoid and/or valve banks can be electrically connected to one or more computers that include a processor and memory that stores instructions that are executable by the processor to perform one or more actions (e.g., control a speed of a pump, etc.).

As further depicted inFIG.2, in some embodiments, the spray systems4,5,6,7,15,16,17,18can be arranged such that the spray plume shape, spray plume height, and/or spray plume particle diameter can be varied for adjacent spray systems. In an example, with reference to a first spray system4and second spray system5, the spray plume height, diameter, and/or particle size of the first spray system4can be greater than the spray plume height, diameter, and/or particle size of the second spray system5. In an example, the spray plume associated with the first spray system4can cause properties of the air that is adjacent to the spray plume to be affected. For example, the spray plume associated with the first spray system4can change the temperature of air that is adjacent to the spray plume due to heat transfer and evaporative effects, for example. Accordingly, the second spray system5can have a smaller spray plume, such that the air into which the smaller spray plume is ejected is not affected by the spray plume associated with the first spray system4. As depicted, the spray systems (e.g., nozzles) can be arranged to vary the spray plume shape of the spray generated by the spray systems, the spray plume height of the spray generated by the spray systems, and/or the spray plume particle diameter of the spray generated by the spray plume nozzles. In some embodiments, as illustrated with the spray systems7and18, a height at which the nozzle is disposed can be varied. As depicted, the spray systems7and18can be disposed higher above the surface of the fluid held by the AST1to ensure that the air surrounding the spray plume is not affected by adjacent spray plumes. In some embodiments, a height of the spray systems (e.g., height at which associated nozzles are disposed) can be increased towards a center of the AST1, as depicted with respect to spray systems7and18. This can help to increase evaporation of the fluid since the fluid falls back a further distance to the fluid surface of the AST1. In addition, wind drift of the fluid outside of the AST1from spray systems7and18can be minimized, because the spray systems7and18are located further towards the center of the AST1, allowing for the fluid to have a greater distance to settle back to the fluid surface of the AST1.

FIG.4depicts a plan view of a produced water evaporation apparatus and system that includes a redundant containment area, in accordance with embodiments of the present disclosure. An additional membrane16can be included to provide another redundant containment area for the fluids in the containment area located within the perimeter of the retaining wall that defines the AST1. In some embodiments, the pumps8,9,10, and11can be located in this example in the additional redundant containment area. In some embodiments, an embankment17or other type of barrier (e.g., retaining wall) can be built to incorporate the fluid and particulate mist retention and sealing characteristics of membrane16, as shown inFIG.4.

FIG.5depicts a plan view of the produced water evaporation apparatus and system that includes nozzle areas, also referred to as AST nozzle sections, that could be independently controlled to be optimized for evaporation under varying meteorological conditions, in accordance with embodiments of the present disclosure. The individual nozzle fluid particle size, spray plume shape, spray plume height and/or density could be varied per section or any combination of sections included in the AST1. An infinite combination of sections and optimizations are possible. As depicted, the number of spray systems (e.g., nozzles) included in each AST nozzle section can vary. For example, AST nozzle section18can have fewer nozzles than the number included in AST nozzle section19, and AST nozzle section19can have fewer nozzles than the number included in AST nozzle section20.

In some embodiments, removable panels in the AST1and containment systems can be constructed to aid in the cleaning process of the solids that will form in the bottom of the system and apparatus. In an example, the removable panels in the AST1can line a floor of the AST1and solids can form on the removable panels. This feature can be exploited in the cleaning process by removing the panels for cleaning. The AST construction with removable panels also allows the quick construction and removal of the apparatus and system for the evaporation of produced water from oil and gas production and other dirty water sources, as described in this disclosure.

In some embodiments, a salt and electrical based chlorination or anti-bacterial chemical solution generating system may be integrated into the fluid system and apparatus described in this disclosure to minimize organic contamination from bacteria and other matters. These anti-bacterial solution generating, electrical charge-based systems such as those used in salt based swimming pools.

Embodiments are described herein of various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments, the scope of which is defined solely by the appended claims.

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment(s) is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment,” or the like, in places throughout the specification, are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional.

Although at least one embodiment for a produced water evaporation system has been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the devices. Joinder references (e.g., affixed, attached, coupled, connected, and the like) are to be construed broadly and can include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relationship to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure can be made without departing from the spirit of the disclosure as defined in the appended claims.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.