Note: Descriptions are shown in the official language in which they were submitted.
- 1 -
BACKFLOW COLLECTION SYSTEM AND METHOD FOR
RECLAIMING THE SAME
TECHNICAL FIELD
The present disclosure is directed, in general to a receptacle
and more specifically, to a backflow collection receptacle and method
for using the same.
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BACKGROUND
Production of oil and gas (e.g., hydrocarbons) from
subterranean formations is dependent on many factors. These
hydrocarbons must usually migrate through a low permeable
formation matrix to drain into the wellbore. In many
formations, the permeability is so low that it hinders the
well's production rate and overall potential. In other wells,
the near wellbore is damaged during drilling operations and
such damage often results in less than desirable well
productivity. Hydraulic fracturing is a process designed to
enhance the productivity of oil and gas wells or to improve
the injectivity of injection wells.
In the fracturing process, a viscous fluid is injected
into the wellbore at such a rate and pressure as to induce a
crack or fracture in the formation. Once the fracture is
initiated, a propping agent, such as sand (e.g., often
referred to as "frac" sand), is added to the fluid just prior
to entering the wellbore. This sand laden slurry is
continuously injected causing the fracture to propagate or
extend. After the desired amount of proppant has been placed
in the reservoir, pumping is terminated, and the well is shut-
in for some period of time.
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After the pressure is released from the wellbore, the
sand, or at least a significant portion of the sand, remains
within the fractured strata thereby holding the strata in a
substantially fractured state. Accordingly, the oil and gas
is allowed to flow freely. Unfortunately, as the oil and gas
begin to flow it starts to push other unwanted fluids and
gasses, as well as some unwanted particulates from the strata
(including, frac sand, salts, etc.) back to the surface.
A problem arises in how to deal with these unwanted
fluids, gases and particulates. One gas
byproduct of the
fracking process of particular concern is hydrogen sulfide.
Hydrogen sulfide is the chemical compound with the formula
H2S. Hydrogen sulfide is a colorless, very poisonous,
flammable gas with the characteristic foul odor of rotten
eggs. As
hydrogen sulfide is extremely poisonous, and is
often odorless in small concentrations, it is a significant
concern during the collection of the unwanted fluid and
particulates that backflow from the wellbore.
Accordingly, what is needed in the art is apparatus,
and/or associated process, which addresses the aforementioned
problems.
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SUMMARY
To address the above-discussed deficiencies of the prior
art, the present disclosure provides a backflow collection
system. The backflow collection system, in one embodiment,
includes a collection vessel having an upper section and a
lower section, the collection vessel having a side opening
configured to receive backflow from an oil/gas well, as well
as a discharge port proximate an upper end of the upper
section configured to discharge pressurized gas from the
collection vessel. The backflow collection system, in this
embodiment, further includes an auger coupled proximate the
lower section of the collection vessel, the auger configured
to receive solid and liquid matter from a bottom opening in
the lower section of the collection vessel, and when elevated
remove at least a portion of the solid and liquid matter from
the collection vessel, the collection vessel designed such
that when fluid is contained therein it acts as a liquid/gas
seal to prevent the pressurized gas from exiting through the
bottom opening in the lower section of the collection vessel.
Further provided is a method for reclaiming backflow from
a wellbore. The
method, in one embodiment, includes
collecting solid and liquid matter from a wellbore within a
backflow collection system, the backflow collection system
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being similar to the backflow collection system of the
paragraph above. The method further includes operating the
auger in a manner configured to remove at least a portion of
the solid matter from the collection vessel while burning the
5 pressurized gas exiting the discharge port.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present
disclosure, reference is now made to the following
descriptions taken in conjunction with the accompanying
drawings, in which:
Fig. 1 illustrates a collection receptacle in accordance
with the disclosure;
Figs. 2A thru 2E illustrate various views of an elevated
auger including a housing and a flighting;
Fig. 3 illustrates an alternative embodiment of an
elevated auger;
Fig. 4 illustrates yet another alternative embodiment of
an elevated auger; and
Figs. 5-7 illustrate various different views of a
backflow collection system manufactured and operated in
accordance with this disclosure.
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DETAILED DESCRIPTION
Referring initially to Fig. 1, illustrated is a
collection receptacle 100 in accordance with the principles of
the disclosure. The
collection receptacle 100, as those
skilled in the art appreciate, may be used to collect any
number of different types of matter, including solid matter,
liquid matter or a combination thereof. In one particular
embodiment, the collection receptacle is configured to
reclaim, including collecting and dispensing, backflow from a
wellbore. For instance, the collection receptacle could be
configured to reclaim fluid, hydrocarbons, frac sand, salts,
etc., that would backflow from a wellbore after fracturing an
oil and gas strata.
The collection receptacle 100 of Fig. 1 includes an
enclosure 110. The
enclosure 110, in this embodiment, is
configured to collect solid and liquid matter. Moreover, the
enclosure 110 of Fig. 1 includes a first portion 120 and a
second portion 130. The
first portion 120, in this
embodiment, is configured to initially collect the solid and
liquid matter. However, in this embodiment, the first portion
120 has an opening 125 (e.g., weir) in an upper region
thereof. The opening 125, in one embodiment, is configured to
allow excess collected liquid matter to overflow into the
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second portion 130 as the collected solid matter falls to a
bottom of the first portion 120.
In one embodiment, the first portion additionally
includes an emergency opening 127 configured to quickly divert
extreme amounts of collected solid and liquid matter to the
second portion 130. The purpose of the emergency opening 127,
in this embodiment, is to prevent overflow of the collected
liquid and/or solid matter from the enclosure 110 in the event
the opening 125 cannot handle the volume of the incoming solid
and liquid matter. As the emergency opening 127 is
traditionally only used in extreme circumstances, the
positioning of the emergency opening 127 is above the
positioning of the opening 125. Accordingly, the emergency
opening, in this embodiment, will only be employed in extreme
circumstances. In the embodiment of Fig. 1, the opening 125
is located at the rear of the first portion 120, and the
emergency opening 127 is located along the sides of the first
portion 120. Nevertheless, the size, shape and location of
each of the opening 125 and emergency opening 127 may be
tailored on a use-by-use basis.
Located within the enclosure 110, and in this example the
first portion 120, are one or more baffles 140. The baffles
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140, in one example, are used to help direct the solid matter
to the bottom of the first portion 120, among other uses.
The collection receptacle 100 further includes an
elevated auger 150 extending into the enclosure 110, and more
particularly the first portion 120 of the embodiment of Fig.
1. The
auger 150, as would be expected, is configured to
remove one or more contents from the enclosure 110.
Nevertheless, in contrast to well known augers, the auger 150
is configured in such a way as to promote the separation of
the solid matter from the liquid matter located within the
enclosure 110, for example as the solid matter travels up the
auger 150 and out of the enclosure 110.
Specifically, the
auger 150 of Fig. 1 includes a housing and a flighting, and in
this embodiment the housing and flighting are configured in a
manner to promote the aforementioned separation.
Turning briefly to Figs. 2A thru 2D, illustrated are
various views of an elevated auger 200 including a housing 210
and a flighting 220. Fig. 2A illustrates a cutaway view of
the auger 200, whereas Fig. 2B illustrates the flighting 220,
Fig. 2C illustrates a cross-section of the housing 210 taken
through line C-C, and Fig. 2D illustrates a cross-section of
the housing 210 taken through line D-D. In referring to the
embodiment of Figs. 2A thru 2D, the housing 210 has a radius
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rh and the flighting 220 has a lesser radius rf, the difference
in radius configured to promote separation of the solid matter
from the liquid matter. Because of this lesser radius rf of
the flighting 220, the auger 200 creates a solid matter tube
surrounding the flighting 220 as the solid matter is removed
from the enclosure. The
term solid matter tube, as used
herein, is intended to reference a tube like feature using the
solid matter itself as the tube, as opposed to other rigid
materials such as steel, iron, etc. The solid matter tube, a
sand or mud tube in one example, provides a porous means for
the liquid matter to travel back down the auger 200 as the
solid matter travels up the auger 200. Likewise, as the solid
matter travels up the auger 200 it is squeezed by the pressure
of the solid matter tube against the flighting 220, thus
further promoting the separation of the liquid matter.
The degree of difference between the housing radius rh
and the flighting radius rf can be important to the ability of
the auger 200 to promote separation. For instance, in one
embodiment rf is less than about 90 percent of rh. In yet
another embodiment, rf is less than about 75 percent of rh, and
in yet another embodiment, rf is less than about 67 percent of
rh. For example, in the embodiment of Figs. 2A thru 2D, rf
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ranges from about 5 inches to about 7 inches, whereas rhranges
from about 8 to about 9 inches.
It has been acknowledged that certain configurations of
the auger 150 experience issues with the solid matter tube
5 caving in, or sliding back down to the bottom of the first
portion 120. This is particularly evident when the spacing
between the flighting and the housing are large. This is also
particularly evident in the embodiment wherein the centerline
of the housing and centerline of the flighting do not
10 coincide. Based upon this acknowledgment, and substantial
experimentation, it has been recognized that blocks 155 (Fig.
1) may be placed between the flighting and housing at various
positioned along the length thereof. The blocks 155, in this
embodiment, typically extend from the inside wall of the
housing toward the flighting, and in doing so help reduce the
likelihood of the solid matter tube caving in. The blocks
155, in one embodiment, typically extend from the upper most
inner surface of the housing toward the flighting, are located
at one to six different locations, and are not required
between the lower most inner surface of the housing and the
flighting. Other configurations, beyond those just disclose,
might also be used.
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Turning now specifically to Fig. 2B, illustrated is the
flighting 220. The flighting 220, as shown, includes a radius
rf. Likewise, a shaft 230 of the flighting 220 includes a
radius r,. To further promote the separation of the liquid
matter from the solid matter, for example by way of increased
pressing on the solid matter, the "teeth" 240 of the flighting
220 extend only a little way from the shaft. For example, in
one embodiment, rs should be at least about 50 percent of r=.
In an alternative embodiment, rs should be at least about 65
percent of rf, if not at least about 80 percent of rf. For
example, in the embodiment of Fig. 2B, r, ranges from about 3
inches to about 4 inches, whereas rf ranges from about 5
inches to about 7 inches. To further promote separation, the
teeth 240 may include notches therein, for example notches
extending into the teeth 240 about .25 inches to about 1 inch.
Turning now specifically to Figs. 2C and 2D, illustrated
are the cross-sections of the housing 210. As is illustrated
in Fig. 2C, this portion of the housing 210 has a u-shaped
trough cross-section. In contrast, as is illustrated in Fig.
2D, this portion of the housing 210 has a flare-shaped trough
cross-section. Nevertheless, other cross-sections could be
used.
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Turning briefly to Fig. 2E, illustrated is an alternative
cross-sectional shape for the housing 210. In
this
embodiment, as shown, the housing 210 may have a circular
cross-section. In this embodiment, the circular cross-section
might have a radius ranging from about 8 to about 10 inches,
and more particularly about 9 inches. As the radius of the
flighting (rf) is less than the radius of the circular cross-
section of the housing 210, in this embodiment rf ranging from
about 5 to about 7 inches, a solid matter tube will likely
form. It should
be noted that in certain embodiments a
centerline of the flighting will coincide with a centerline of
the circular housing 210. In other embodiments, however, the
centerlines will not coincide. For
example, in one known
embodiment the centerline of the flighting will be closer to a
bottom surface of the housing 210 than an upper surface of the
housing 210. In
this embodiment, the distance between the
flighting and the bottom surface of the housing 210 will be
less than a distance between the flighting and the top surface
of the housing 210.
Turning now to Fig. 3, illustrated is an alternative
embodiment of an elevated auger 300. The auger 300 of Fig. 3,
in contrast to the degree of difference between the housing
radius rh and the flighting radius rf, includes a drain shoot
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315 extending along a bottom surface of a housing 310 thereof.
The drain shoot, regardless of the shape thereof, provides a
pathway for excess fluid to travel back down the auger 300 as
the solid matter travels up the auger 300. Accordingly, in
this embodiment the housing 310 and the flighting 320 may have
a somewhat similar overall shape and radius, but the added
drain shoot 315 promotes the separation of the solid matter
from the liquid matter. Accordingly, excess liquid matter
squeezed from the solid matter travels down the drain shoot
315 as the solid matter travels up the auger 300.
Turning now to Fig. 4, illustrated is an alternative
embodiment of an elevated auger 400. The auger 400 of Fig. 4,
in contrast to the degree of difference between the housing
radius rh and the flighting radius rf, includes a housing 410
having a first portion 413 and a second portion 418 and
surrounding a flighting 420. In this embodiment, the first
portion 413 is located between the second portion 418 and the
flighting 420, and furthermore is perforated to promote the
separation of the solid matter from the liquid matter.
Accordingly, excess liquid matter squeezed from the solid
matter exits the first portion 413 through the perforations
therein, and then travels back down the auger 400 between the
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space separating the first and second portions 413, 418,
respectfully.
Returning back to Fig. 1, the auger 150 includes a gate
160 at a bottom portion thereof. The
gate 160, in this
embodiment, is configured to allow solid matter to exit the
auger 150 when operated in reverse. For
example, certain
situations may exist wherein solid matter remains within the
enclosure 110, but there is a desire to fully empty the auger
150 of any solid matter. In
this situation, the auger 150
could be operated in reverse, thereby emptying the auger 150
of any solid matter. The gate 160, in this example, allows
the auger 150 to rid itself of solid matter without putting
undue stress or torque on the auger 150 and/or its motor.
Accordingly, the gate 160 may be opened when the auger 150 is
run in reverse, and any solid matter within the auger 150 will
be efficiently removed therefrom. In the embodiment shown,
the solid matter exits into the second portion 130 of the
enclosure 110.
The collection receptacle 100 of Fig. 1 further includes
a gas buster 170 located between the enclosure 110 and a
wellbore. The gas buster 170, as expected, is configured to
dissipate energy associated with incoming solid and liquid
matter. In the embodiment of Fig. 1, the gas buster 170 is
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coupled to an upper portion of the enclosure 110, for example
near a rear thereof. The collection receptacle 100 of Fig. 1
further includes one or more wheels 180 coupled to the
enclosure 110. The wheels 180 are configured to allow the
5 collection receptacle 100 to roll from one location to
another.
Likewise, the auger 150 may include one or more
inspection ports 190, for example with hinged covers,
A collection receptacle, such as the collection
receptacle 100 of Fig. 1, may be used for reclaiming backflow
10 from a wellbore. In one embodiment, solid and liquid matter
originally enters the first portion 120 of the enclosure 110
through the gas buster 170. As the solid matter sinks to the
bottom of the first portion 120, the liquid matter (e.g., the
water, salts, and hydrocarbons) float to the top. As the
15 solid and liquid matter continue to fill the first portion 120
of the enclosure 110, the liquid matter begins to flow through
the opening 125 designed therein, to the second portion 130 of
the enclosure 110. Once the solid matter approaches the top
of the first portion 120 where the opening 125 exists, the
first portion 120 will be substantially full of solid matter,
while the second portion 130 of the enclosure 110 will
primarily contain the liquid matter.
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In certain embodiments, it is important that the
revolutions per minute (rpm) of the flighting within the
housing is slow enough to remove the solid matter from the
enclosure, while allowing the liquid matter to be adequately
removed there from.
Accordingly, in direct contrast to
traditional auger systems, the rpm of the flighting is
intentionally kept slow. For example, in one embodiment the
flighting has an rpm of about 15 or less. In
other
embodiments, an rpm of 12 or less provides advantageous
results. In yet another embodiment, an rpm of 8 or less, and
more particularly between about 4 and 8, provides superior
results.
In this scenario, the liquid matter can be easily removed
from the first portion 120 of the enclosure 110 without
further contaminating the solid matter. The solid matter that
exits the top of the auger 150 tends to be only slightly damp.
Moreover, it is believed that this solid matter need not be
decontaminated or reconditioned before being reused or
introduced into the environment. Accordingly, the expense
associated with this decontamination or reconditioning may be
spared.
Turning to Fig. 5, illustrated is a backflow collection
system 500 manufactured in accordance with the disclosure.
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The backflow collection system 500 includes a collection
receptacle 510. The collection receptacle 510 is similar, in
many ways to the collection receptacle 100 illustrated and
discussed above.
Accordingly, no further discussion is
needed.
The backflow collection system 500 further includes a
collection vessel 520 coupled to an auger 560. The collection
vessel 520, in the illustrated embodiment, is configured as a
vertical collection vessel. Such a configuration may be used
to further help separate the solid and liquid matter from the
gasses. The
collection vessel 520, in one embodiment,
includes an upper section 523 and a lower section 528. The
lower section 528, in this embodiment, includes a side opening
530, while the upper section includes a discharge port 535.
The side opening 530, in this embodiment, is configured to
receive backflow from an oil/gas well. For example, the side
opening 530 might comprise a pipe and flange configured to
couple to an oil/gas well and receive backflow therefrom. The
side opening 530 may be positioned at various different
heights along the collection vessel 520. If the side opening
530 is positioned to near the bottom of the collection vessel
520, solid matter entering the collection vessel 520 may plug
the side opening 530. In contrast, if the side opening 530 is
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positioned to near the top of the collection vessel 520, solid
and liquid matter entering the collection vessel 520 may be
pushed out the discharge port 535. The discharge port 535, in
the illustrated embodiment, is configured to discharge
pressurized gas received from the backflow from the oil/gas
well from the collection vessel. One particular gas that may
be discharged, and burned as it exits the discharge port 535,
is hydrogen sulfide.
The auger 560, in the illustrated embodiment, is coupled
proximate the lower section 528 of the collection vessel 520.
The augur 560, in this embodiment, is configured to receive
the solid and liquid matter from a bottom opening 540 in the
lower section 528 of the collection vessel 520. When
the
auger 560 is elevated, and turned on, the auger 560 is
configured to remove at least a portion of the solid and
liquid matter from the collection vessel 520 while allowing
the gasses to remain within the collection vessel 520, or
alternatively exit the discharge port 535 in the upper end of
the upper section 523 of the collection vessel 520. The auger
may include a hoist 565, for example an electric hoist, to
raise and lower the auger 560.
Bottom walls of the lower section 528 of collection
vessel 520 may be slanted (e.g., from vertical) to assist the
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solid matter in exiting the bottom opening 540 into the auger
560. For example, the bottom walls of the lower section 528
might slant at an angle of at least about 45 degrees from
vertical. In an alternative embodiment, bottom walls of the
lower section 528 might slant at an angle of at least about 70
degrees from vertical.
A vibration mechanism 550 may be coupled to at least one
of the collection vessel 520 or the auger 560. The
term
"vibration mechanism", as used herein, encompasses any device
capable of providing vibrations to the collection vessel 520
in such a way as to assist the solid material from exiting the
collection vessel 520 and entering the auger 560. The
vibration mechanism 550, in this embodiment, is configured to
assist the auger 560 receive solid matter from the bottom
opening 540 in the lower section 528 of the collection vessel
520. In the illustrated embodiment, the vibration mechanism
550 is coupled to the lower section 528 of the collection
vessel 520. Nevertheless, the vibration mechanism 550 could
also be coupled to the auger 560. Any
type of vibration
mechanism 550, including pneumatic and electric based
vibration mechanisms, are within the scope of the present
disclosure.
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The collection vessel 520 further includes abrasion plate
545 located on an opposing side of the collection vessel 520
as the side opening 530. The abrasion plate 545 is configured
to receive the brunt of the abrasion/force of the solid and
5 liquid matter as it enters the collection vessel 520. The
abrasion plate 545 is an additional feature added to a typical
collection vessel. In one embodiment, the abrasion plate 545
is replaceable. For example, a second side opening could be
included within the collection vessel, the second side opening
10 directly opposing the side opening 530. In this embodiment,
the abrasion place 545 could be attached to the second side
opening.
Accordingly, the abrasion place could be easily
replaced when needed. The
collection vessel 520 may
additionally include a sight liquid level indicator 557.
15 The backflow collection system 500 may further include a
gas buster 570. The gas buster 570, in this embodiment, is
configured to reduce a velocity of the solid and liquid matter
exiting the oil/gas well and entering the collection vessel
520. The
gas buster 570, in the illustrated embodiment,
20 couples directed to a flange associated with the side opening
530 in the collection vessel 520. Other embodiments exist
wherein the gas buster 570 is not directly coupled to the
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collection vessel 520, but is located more near the oil/gas
well.
Turning briefly to Fig. 6, illustrated is an enlarged
view of the gas buster 570 of Fig. 5. In the
illustrated
embodiment, the gas buster 570 includes a first section 610
and a second section 620. The
first section 610, in this
embodiment, includes a first cross-sectional area that is less
than a second cross-sectional area of the second section 620.
The increasing cross-sectional area of the gas buster 570
(e.g., as it approaches the collection vessel 520) is
configured to reduce the velocity of the solid and liquid
matter exiting the oil/gas well and entering the collection
vessel 520. While the gas buster 570 only includes two steps
in cross-sectional value, other embodiments may exist wherein
three or more steps are used.
The gas buster 570, in the illustrated embodiment,
further includes a first smaller pipe 630 that is encompassed
by a second larger pipe 640. The first smaller pipe 630, in
the illustrated embodiment, includes a plurality of openings
635 spaced along a length thereof. In fact, in the embodiment
of Fig. 6, the openings 635 are sequentially spaced and
rotated along the length of the first smaller pipe 630.
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Returning to Fig. 5, the backflow collection system 500,
in the illustrated embodiment, further includes a choke
manifold 580 positioned between the side opening 530 in the
collection vessel 520 and the oil/gas well. The
choke
manifold 580, in this embodiment, is configured to reduce a
volume of the solid and liquid matter exiting the oil/gas well
and entering the collection vessel 520. Those skilled in the
art understand the various different choke manifolds 580 that
might be used and remain within the purview of the present
disclosure.
The backflow collection system 500, in the illustrated
embodiment, may further include a high pressure sand trap 590
positioned between the side opening 530 in the collection
vessel 520 and the oil/gas well. The high pressure sand trap
590, in this embodiment, is configured to remove a portion of
the solid matter exiting the oil/gas well prior to entering
the collection vessel 520. Those
skilled in the art
understand the various different high pressure sand traps 590
that might be used and remain within the purview of the
present disclosure.
In the illustrated embodiment of Fig. 5, the collection
vessel 520 and the auger 560 are position on a movable trailer
595. Further to the embodiment of Fig. 5, the gas buster 570,
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the choke manifold 580 and the high pressure sand trap 590 are
also located on the movable trailer 595. In the illustrated
embodiment, each of the collection vessel 520, auger 560, gas
buster 570, choke manifold 580 and high pressure sand trap 590
are configured to transition from an operational positions to
transit positions on the movable trailer.
With brief reference to Fig. 7, illustrated are the
collection vessel 520, auger 560, gas buster 570, choke
manifold 580 and high pressure sand trap 590 in their transit
positions. As illustrated, the collection vessel 520, auger
560, gas buster 570, choke manifold 580 and high pressure sand
trap 590 may pivot to transition from the operational position
to the transit position. Other mechanisms, however, could
also be used to help the collection vessel 520, auger 560, gas
buster 570, choke manifold 580 and high pressure sand trap 590
transition from the operational position to the transit
position.
A backflow collection system, such as the backflow
collection system of Figs. 5-7, may be used to reclaim
backflow from a wellbore. This
process may begin by
collecting solid and liquid matter from the wellbore using the
backflow collection system. As the solid and liquid matter,
as well as the gasses, enter the collection vessel, the auger
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may be operated in a manner to remove at least a portion of
the solid matter from the collection vessel, while at the same
time pressurized gas exiting the discharge port is burned.
Although the present disclosure has been described in
detail, those skilled in the art should understand that they
can make various changes, substitutions and alterations herein
without departing from the spirit and scope of the disclosure
in its broadest form.
