Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM, METHOD AND APPARATUS FOR TREATING MINING BYPRODUCTS
FIELD OF THE INVENTION
[0001] The present invention relates generally to field of oil and gas
production and,
more particularly, to a system, method and apparatus for treating mining
byproducts.
BACKGROUND OF THE INVENTION
[0002] Hydrocarbon production starts with mining. Either surface mining with
large
cranes and trucks used for oil sands mining or drilling a well to mine the
hydrocarbons in
a subsurface formation. In either case, byproducts from mining, drilling,
completing
and/or producing hydrocarbons range from drill cuttings to frack flowback
water to
produced water and huge volumes of tailings in the case of oil sands surface
mining
(collectively referred to as "mining byproducts").
[0003] Solvents and/or valuable drilling fluids (collectively referred to as
"mining
fluids") are used in the mining or drilling process to, among other things,
provide
hydrostatic pressure, cool and clean the drill bit, carry out drill cuttings
(e.g., rock, soil,
sand, etc.), and suspend the drill cuttings when the drill is not active. The
cost of most
drilling fluids is directly proportional to the cost of crude oil. Hence, oil
based muds
("OBM") are predominantly diesel, and synthetic based muds ("SBM") are
synthetic oils
similar to Shell Rotella . For example, formate drilling fluids manufactured
by Cabot
Corporation are extremely expensive but are environmentally safe, do not
contain solids
and can be used within high temperature and high pressure formations.
Likewise,
synthetic based drilling fluids are commonly employed for offshore drilling
because the
drill cuttings can be discharged overboard as long as the Fluid Retention On
Cuttings
("ROC") is less than what is required by regulations.
[0004] The mixture of mining fluids and mining byproducts that exit the mine
or well
also contain hydrocarbons. This mixture is typically processed by a solids
control system
(e.g., shale shakers, mud gas separators, desanders, desilters, degassers,
cleaners, etc.) to
substantially separate the mining fluids and hydrocarbons from the mining
byproducts.
But these solids control systems do not remove all of the mining fluids and
hydrocarbons
from the mining byproducts. As a result, these valuable mining fluids and
hydrocarbons
may end up in a tailings pond, the bottom of the ocean or shipped to a
Treatment,
Recovery and Disposal ("TRD") facility.
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[0005] Vertical Centrifuges are commonly employed offshore for reducing the
ROC to
below discharge limits. However, Loss Circulation Material ("LCM") and cement
cannot
be effectively treated in a vertical centrifuge. It clogs the centrifuge and
it must be shut
down and cleaned, thus it is usually bypassed during cementing operations or
when a
LCM Pill is used to prevent losing circulation and fluids into the formation.
Another
treatment system uses thermal desorption units, which are are bulky and have
many
moving parts. Likewise, thermal desorption units typically employ indirect
heating,
which is inefficient when compared to direct heating.
[0006] Air dryers and friction dryers, such as Schlumberger's (M-I Swaco)
Hammermill are commonly employed, but neither have been successful at
recovering
base fluids. Why? Both dryer types comminute the cuttings into very fine
powders
which makes it difficult to separate the base fluid from the fine cuttings.
Likewise, air
dryers can produce an explosive mixture since drilling fluids contain fuels
(diesel,
synthetic oil, etc). Although Schlumberger markets a Zero Discharge thermal
desorption
TPS system, the system still only achieves a removal of Total Percent
Hydrocarbons
(TPH) of less than 0.5%. Finally, the U.S. Department Of Energy's Drilling
Waste
Management Information System discloses many different thermal technologies
for
treating drilling waste.
[0007] When the price of crude oil was low, a ROC near the limits was not
perceived
as a problem. However, with new regulations pushing lower ROC limits in
addition to
high crude oil prices, recovering mining fluids from the mining byproducts has
become a
priority and is now an environmentally sustainable goal for many oil and gas
companies.
Moreover, the cost of some mining fluids, such as formate drilling fluids
containing
Cesium, makes recovering these mining fluids from the mining byproducts very
desirable
both ecomonically and ecologically.
[0008] Other problems associated with the production of oil and gas resources
include
the fact it is very common for oil production wells to reach the end of their
life, while
there is still a substantial amount of oil in place (0IP) within the
formation. Production
superintendents, Geologists and Engineers may then to decide whether to shut
in the well
or stimulate the well using enhanced oil recovery (EOR) methods ranging from
water
flooding to steam flooding to injection of carbon dioxide and injection of
solvents.
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[0009] Likewise, even during peak production of a well, a well may have to be
shut in
due to paraffin plugging the production tubing. This can cause several
problems ranging
from reduced production to parting or breaking of the sucker rod connected to
the surface
pump jack. Another problem associated with most oil and gas wells is produced
water.
When the water reaches the surface it is separated from the oil or gas and
then must be
treated prior to final disposition.
[0010] Recently, primarily due to high crude oil prices many exploration
companies
are turning to unconventional heavy oil resources (API < 22) such as oil sand
bitumen, oil
shale kerogen as well as heavy oil itself Canada contains the largest known
oil sand
reserves estimated at over 1 trillion recoverable barrels of bitumen.
Likewise, the largest
known unconventional petroleum or hydrocarbon resource can be found in the
Green
River Formation in Colorado, Wyoming and Utah. Worldwide oil shale reserves
are
estimated around 2.9-3.3 trillion barrels of shale oil while the Green River
Formation
reserves alone are estimated to contain between 1.5-2.6 trillion barrels.
[0011] However, emerging issues with respect to the renewed interest in oil
shale
development range from water resources, to green house gas emissions to basic
infrastructure needs. Likewise, the Canadian oil sands has its own problems
ranging from
very large tailings ponds to a lack of upgrading capacity for the bitumen
recovered from
the oil sands. In addition, the steam assisted gravity drainage (SAGD) process
utilizes
copious amounts of energy to produce steam. Two problems associated with
producing
steam are first the source of water and removing its contaminants that may be
deposited
upon boiler tube walls and second recovering the latent heat within the steam
when
injected downhole.
[0012] The problem is indirect heat transfer. Heat is transferred via
radiation,
convection and conduction. Indeed, SAGD evaporators and boilers transfer heat
via
radiation, convection and conduction. Although the flame in the boiler
transfers heat via
radiation and convection to boiler tubes, heat transfer through boiler tubes
is solely via
thermal conduction. And the impediment to reducing production costs at SAGD
facilities
is heat transfer via thermal conduction through boiler tubes.
[0013] When the heat transfer surface of the boiler tubes becomes coated with
contaminants, for example silica, then heat transfer is reduced and the boiler
and/or
evaporator must be shut down for maintenance. At SAGD facilities this is a
common
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problem, especially with silica, and is now being viewed as non-sustainable.
The silica is
produced with the oil sand. Hence, sand contamination via volatile silica
compound
evaporation, as well as volatile organic compounds ("VOCs") is an inherit
problem in
current EOR operations utilizing traditional water treatment methods with
boilers and
once through steam generation equipment.
[0014] Therefore, a need exists for systems, methods and apparatuses to
recover
mining fluids, provide enhanced oil recovery and treat produced water.
SUMMARY OF THE INVENTION
[0015] The present invention provides a system, method and apparatus for
recovering
mining fluids from mining byproducts. Moreover, the present invention can
couple the
recovery of valuable mining fluids with the production of clean water using a
steam
plasma. Furthermore, the present invention can melt the mining byproducts,
such as
sand, clays, cuttings and salts, to produce an inert material. As a result,
the present
invention may reduce or eliminate the legacy cradle to grave liability for
operators.
[0016] In addition, one embodiment of the present invention can crack
abundantly
available natural gas to hydrogen and carbon, and then use the hydrogen as a
plasma gas
in a counter current fashion for melting cuttings and recovering fluids would
allow for
ZERO or reduced diesel and/or natural gas engine emissions. This truly opens
door for
Green Drilling and Green Completion. The hydrogen can be compressed and stored
onsite for the completion phase or used during drilling operations to reduce
diesel
emissions by leaning out the diesel engine using hydrogen. The present
invention,
therefore, couples oil and gas water treatment with the recovery of valuable
resources
such as, hydrocarbons, drilling fluids, synthetic gas ("syngas"), hydrogen and
clean
water. All of which can be accomplished in a closed loop system.
[0017] In addition, the present invention provides a system, method and
apparatus for
upgrading or partial upgrading heavy oil to lighter oil in situ and/or at the
wellhead.
[0018] The present invention also provides a system, method and apparatus for
recycling all of the water used in oil and gas production in a very effective
manner while
reducing or eliminating environmental impacts such as air emissions, for
example
burning of fossil fuels to recover fossil fuels.
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[0019] For example, the present invention provides a plasma system that
includes an
oil/water separator, an input of a pump connected to the oil/water separator,
a first three-
way valve connected to the input of the pump, a glow discharge cell having a
input
connected to an output of the pump and a bottom inlet/outlet connected to the
first three-
way valve, and a plasma arc torch. The plasma arc torch includes a cylindrical
vessel
having a first end and a second end, a first tangential inlet/outlet connected
to or
proximate to the first end, a second tangential inlet/outlet connected to or
proximate to the
second end, an electrode housing connected to the first end of the cylindrical
vessel such
that a first electrode is (a) aligned with a longitudinal axis of the
cylindrical vessel, and
to (b) extends into the cylindrical vessel, and a hollow electrode nozzle
connected to the
second end of the cylindrical vessel such that a centerline of the hollow
electrode nozzle
is aligned with the longitudinal axis of the cylindrical vessel, the hollow
electrode nozzle
having a first end disposed within the cylindrical vessel and a second end
disposed
outside the cylindrical vessel. A second three-way valve is connected to a top
outlet of
the glow discharge cell the first tangential inlet/outlet of the plasma arc
torch. A
compressor is connected between the second three-way valve and the first
tangential
inlet/outlet of the plasma arc torch. A third three-way valve is connected to
the second
tangential inlet/outlet of the plasma arc torch. A fourth three-way valve is
connected to
the third three-way valve. A cyclone separator has a tangential inlet
connected to the
third three-way valve, an underflow connected to the fourth three-way valve
and an
overflow connected to the compressor. A fifth three-way valve is connected to
the fourth
three-way valve. A pump is connected to the first three-way valve and the
fifth three-way
valve.
100201 The present invention provides an electrolysis system that includes an
oil/water
separator, an input of a pump connected to the oil/water separator, a first
three-way valve
connected to the input of the pump, and a glow discharge cell having a input
connected to
an output of the pump, a bottom inlet/outlet connected to the first three-way
valve, a top
gas outlet connected to a top of a hollow electrode.
[0021] The present invention provides a plasma system that includes an
oil/water
separator and a plasma arc torch having a cylindrical vessel having a first
end and a
second end, a first tangential inlet/outlet connected to or proximate to the
first end, a
second tangential inlet/outlet connected to or proximate to the second end, an
electrode
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housing connected to the first end of the cylindrical vessel such that a first
electrode is (a)
aligned with a longitudinal axis of the cylindrical vessel, and (b) extends
into the
cylindrical vessel, and a hollow electrode nozzle connected to the second end
of the
cylindrical vessel such that a centerline of the hollow electrode nozzle is
aligned with the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a first end
disposed within the cylindrical vessel and a second end disposed outside the
cylindrical
vessel. A pump has an input connected to the oil/water separator, and an
output
connected to the second tangential inlet/outlet of the plasma arc torch. A
three-way valve
is connected to the input of the pump and the hollow electrode nozzle of the
plasma arc
torch.
[0022] The present invention provides a plasma system that includes an
oil/water
separator and a first and second plasma arc torch. Each plasma arc torch
includes a
cylindrical vessel having a first end and a second end, a first tangential
inlet/outlet
connected to or proximate to the first end, a second tangential inlet/outlet
connected to or
proximate to the second end, an electrode housing connected to the first end
of the
cylindrical vessel such that a first electrode is (a) aligned with a
longitudinal axis of the
cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow
electrode
nozzle connected to the second end of the cylindrical vessel such that a
centerline of the
hollow electrode nozzle is aligned with the longitudinal axis of the
cylindrical vessel, the
hollow electrode nozzle having a first end disposed within the cylindrical
vessel and a
second end disposed outside the cylindrical vessel. A pump has an input
connected to the
oil/water separator, and an output connected to the second tangential
inlet/outlet of the
first plasma arc torch. A four-way valve is connected to the input of the pump
and the
hollow electrode nozzle of the first plasma arc torch. A compressor is
connected between
the first tangential inlet/outlet of the first plasma arc torch and the first
tangential
inlet/outlet of the second plasma arc torch. An eductor is connected to the
hollow
electrode nozzle of the second plasma arc torch and the four-way valve. A
three-way
valve is connected to the second tangential inlet/outlet of the second plasma
arc torch and
an input to the compressor.
[0023] The present invention provides a plasma system that includes a plasma
arc torch
having a cylindrical vessel having a first end and a second end, a first
tangential
inlet/outlet connected to or proximate to the first end, a second tangential
inlet/outlet
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connected to or proximate to the second end, an electrode housing connected to
the first
end of the cylindrical vessel such that a first electrode is (a) aligned with
a longitudinal
axis of the cylindrical vessel, and (b) extends into the cylindrical vessel,
and a hollow
electrode nozzle connected to the second end of the cylindrical vessel such
that a
centerline of the hollow electrode nozzle is aligned with the longitudinal
axis of the
cylindrical vessel, the hollow electrode nozzle having a first end disposed
within the
cylindrical vessel and a second end disposed outside the cylindrical vessel. A
first three-
way valve is connected to the hollow electrode nozzle of the plasma arc torch
and the first
tangential inlet/outlet of the plasma arc torch. A second three-way valve is
connected the
first tangential inlet/outlet of the plasma arc torch. A third three-way valve
is connected
to the second three-way valve. A glow discharge cell has a input connected to
second
tangential inlet/outlet of the plasma arc torch and an output of a hollow
electrode
connected to the third three-way valve. A fourth three-way valve is connected
to a gas
outlet of the glow discharge cell and the second three-way valve. A thermal
oxidizer is
connected to the first three-way valve, the fourth three-way valve, the third
three-way
valve and an input of the hollow electrode of the glow discharge cell.
[0024] The present invention provides a plasma system that includes a first
and second
plasma arc torch. Each plasma arc torch includes a cylindrical vessel having a
first end
and a second end, a first tangential inlet/outlet connected to or proximate to
the first end,
a second tangential inlet/outlet connected to or proximate to the second end,
an electrode
housing connected to the first end of the cylindrical vessel such that a first
electrode is (a)
aligned with a longitudinal axis of the cylindrical vessel, and (b) extends
into the
cylindrical vessel, and a hollow electrode nozzle connected to the second end
of the
cylindrical vessel such that a centerline of the hollow electrode nozzle is
aligned with the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a first end
disposed within the cylindrical vessel and a second end disposed outside the
cylindrical
vessel. A floatation cell is connected between the second tangential
inlet/outlet of the
first plasma arc torch and the first tangential inlet/outlet of the second
plasma arc torch. A
three-way valve is connected to a floats/skim outlet of the flotation cell and
the hollow
electrode nozzle of the second plasma arc torch. A booster pump is connected
to the
three-way valve. A volute inlet valve is connected to the booster pump. A
graphite
electrode plug valve is connected to the hollow electrode nozzle of the first
plasma arc
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torch. A pump volute is connected to the graphite electrode plug valve and the
volute
inlet valve. An electrode feeder is connected to the pump volute.
[0025] The present invention provides a plasma system that includes a first
and second
plasma arc torch. Each plasma arc torch includes a cylindrical vessel having a
first end
and a second end, a first tangential inlet/outlet connected to or proximate to
the first end,
a second tangential inlet/outlet connected to or proximate to the second end,
an electrode
housing connected to the first end of the cylindrical vessel such that a first
electrode is (a)
aligned with a longitudinal axis of the cylindrical vessel, and (b) extends
into the
cylindrical vessel, and a hollow electrode nozzle connected to the second end
of the
cylindrical vessel such that a centerline of the hollow electrode nozzle is
aligned with the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a first end
disposed within the cylindrical vessel and a second end disposed outside the
cylindrical
vessel. A thickener is connected between the second tangential inlet/outlet of
the first
plasma arc torch and the first tangential inlet/outlet of the second plasma
arc torch. A
three-way valve is connected to a bottom of the thickener, the hollow
electrode nozzle of
the first plasma arc torch and the hollow electrode nozzle of the second
plasma arc torch.
[0026] The present invention provides a plasma system that includes a pump, a
first
three-way valve connected to the input of the pump, a glow discharge cell
having a input
connected to an output of the pump and a bottom inlet/outlet connected to the
first three-
way valve and a plasma arc torch. The plasma arc torch includes a cylindrical
vessel
having a first end and a second end, a first tangential inlet/outlet connected
to or
proximate to the first end, a second tangential inlet/outlet connected to or
proximate to the
second end, an electrode housing connected to the first end of the cylindrical
vessel such
that a first electrode is (a) aligned with a longitudinal axis of the
cylindrical vessel, and
(b) extends into the cylindrical vessel, and a hollow electrode nozzle
connected to the
second end of the cylindrical vessel such that a centerline of the hollow
electrode nozzle
is aligned with the longitudinal axis of the cylindrical vessel, the hollow
electrode nozzle
having a first end disposed within the cylindrical vessel and a second end
disposed
outside the cylindrical vessel. A second three-way valve is connected to a top
outlet of
the glow discharge cell the first tangential inlet/outlet of the plasma arc
torch. A
compressor is connected between the second three-way valve and the first
tangential
inlet/outlet of the plasma arc torch. A booster pump is connected to a volute
inlet valve.
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A graphite electrode plug valve is connected to the hollow electrode nozzle of
the plasma
arc torch. A pump volute is connected to the graphite electrode plug valve and
the volute
inlet valve. An electrode feeder is connected to the pump volute.
[0027] The present invention provides a plasma treatment system that includes
a
plasma arc torch and a screw feed unit. The plasma arc torch includes a
cylindrical vessel
having a first end and a second end, a first tangential inlet/outlet connected
to or
proximate to the first end, a second tangential inlet/outlet connected to or
proximate to the
second end, an electrode housing connected to the first end of the cylindrical
vessel such
that a first electrode is (a) aligned with a longitudinal axis of the
cylindrical vessel, and
(b) extends into the cylindrical vessel, and a hollow electrode nozzle
connected to the
second end of the cylindrical vessel such that a centerline of the hollow
electrode nozzle
is aligned with the longitudinal axis of the cylindrical vessel, the hollow
electrode nozzle
having a first end disposed within the cylindrical vessel and a second end
disposed
outside the cylindrical vessel. The screw feed unit has an inlet and an
outlet, the outlet
aligned with the centerline and proximate to the hollow electrode nozzle.
[0028] Moreover, the present invention provides a plasma treatment system that
includes a plasma arc torch, a screw feeder, a filter screen, a tee and a high
temperature
vessel. The plasma arc torch includes a cylindrical vessel having a first end
and a second
end, a first tangential inlet/outlet connected to or proximate to the first
end, a second
tangential inlet/outlet connected to or proximate to the second end, an
electrode housing
connected to the first end of the cylindrical vessel such that a first
electrode is (a) aligned
with a longitudinal axis of the cylindrical vessel, and (b) extends into the
cylindrical
vessel, and a hollow electrode nozzle connected to the second end of the
cylindrical
vessel such that a centerline of the hollow electrode nozzle is aligned with
the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a first end
disposed within the cylindrical vessel and a second end disposed outside the
cylindrical
vessel. The screw feeder has an inlet and an outlet, the outlet aligned with
the centerline
of the hollow electrode nozzle. The filter screen is attached to the outlet of
the screw
feeder, aligned with the centerline of the hollow electrode nozzle and
extending
proximate to the hollow electrode nozzle. The tee is attached to the outlet of
the screw
feeder and enclosing a portion of the filter screen proximate to the screw
feeder. The
high temperature vessel is connected to the plasma arc torch and the tee such
that the
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hollow electrode nozzle is attached to or extends into the high temperature
vessel and the
filter screen extends into the high temperature vessel.
[0029] Furthermore, the present invention provides a method for treating a
material using
a plasma arc torch and a screw feed unit. In its simplest form, the plasma arc
torch
includes a cylindrical vessel having a first end and a second end, a first
tangential
inlet/outlet connected to or proximate to the first end, a second tangential
inlet/outlet
connected to or proximate to the second end, an electrode housing connected to
the first
end of the cylindrical vessel such that a first electrode is (a) aligned with
a longitudinal
axis of the cylindrical vessel, and (b) extends into the cylindrical vessel,
and a hollow
electrode nozzle connected to the second end of the cylindrical vessel such
that a
centerline of the hollow electrode nozzle is aligned with the longitudinal
axis of the
cylindrical vessel, the hollow electrode nozzle having a first end disposed
within the
cylindrical vessel and a second end disposed outside the cylindrical vessel.
The screw
feed unit has an inlet and an outlet, the outlet aligned with the centerline
and proximate to
the hollow electrode nozzle. A steam is supplied to the first tangential
inlet/outlet and an
electrical arc is created between the first electrode and the hollow electrode
nozzle. The
material (e.g., a mining byproduct containing a mining fluid, etc.) is
provided to the inlet
of the screw feed unit and the material is treated by moving the material
through the
outlet of the screw feed unit towards a steam plasma exiting the hollow
electrode nozzle
using the screw feed unit. The treatment produces a fluid (e.g., a recovered
mining fluid
such as a recovered drilling fluid, etc.) and an inert vitrified slag (e.g.,
an inert vitrified
mining byproduct slag such as an inert vitrified drill cuttings, etc.).
[0029.1] In accordance with a first aspect of the present invention, there is
provided a
plasma treatment system comprising:
a plasma arc torch comprising:
a cylindrical vessel having a first end and a second end,
a first tangential inlet/outlet connected to or proximate to the first end,
a second tangential inlet/outlet connected to or proximate to the second
end,
an electrode housing connected to the first end of the cylindrical vessel
such that a first electrode is (a) aligned with a longitudinal axis of the
cylindrical
vessel, and (b) extends into the cylindrical vessel, and
CA 02901496 2016-04-14
a hollow electrode nozzle connected to the second end of the cylindrical
vessel such that a centerline of the hollow electrode nozzle is aligned with
the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a
first end disposed within the cylindrical vessel and a second end disposed
outside
the cylindrical vessel;
a screw feeder having an inlet and an outlet, the outlet aligned with the
centerline
of the hollow electrode nozzle;
a filter screen attached to the outlet of the screw feeder, aligned with the
centerline
of the hollow electrode nozzle and extending proximate to the hollow electrode
nozzle;
to a tee attached to the outlet of the screw feeder and enclosing a
portion of the filter
screen proximate to the screw feeder; and
a high temperature vessel connected to the plasma arc torch and the tee such
that the
hollow electrode nozzle is attached to or extends into the high temperature
vessel and the
filter screen extends into the high temperature vessel.
[0029.2] In accordance with another aspect, there is provided a method for
treating a
material comprising the steps of:
providing a plasma arc torch and a screw feed unit;
the plasma arc torch comprising a cylindrical vessel having a first end and a
second end, a first tangential inlet/outlet connected to or proximate to the
first end, a
second tangential inlet/outlet connected to or proximate to the second end, an
electrode
housing connected to the first end of the cylindrical vessel such that a first
electrode is (a)
aligned with a longitudinal axis of the cylindrical vessel, and (b) extends
into the
cylindrical vessel, and a hollow electrode nozzle connected to the second end
of the
cylindrical vessel such that a centerline of the hollow electrode nozzle is
aligned with the
longitudinal axis of the cylindrical vessel, the hollow electrode nozzle
having a first end
disposed within the cylindrical vessel and a second end disposed outside the
cylindrical
vessel;
the screw feed unit having an inlet and an outlet, the outlet aligned with the
centerline and proximate to the hollow electrode nozzle;
supplying a steam into the first tangential inlet/outlet;
creating an electrical arc between the first electrode and the hollow
electrode
nozzle;
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providing the material to the inlet of the screw feed unit; and
treating the material by moving the material through the outlet of the screw
feed
unit towards a steam plasma exiting the hollow electrode nozzle using the
screw feed
unit.
[0030] The present invention is described in detail below with reference to
the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and further advantages of the invention may be better
understood by
referring to the following description in conjunction with the accompanying
drawings, in
which:
FIGURE 1 is a diagram of a plasma arc torch in accordance with one embodiment
of the present invention;
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FIGURE 2 is a cross-sectional view comparing and contrasting a solid oxide
cell
to a liquid electrolyte cell in accordance with one embodiment of the present
invention;
FIGURE 3 is a graph showing an operating curve a glow discharge cell in
accordance with one embodiment of the present invention;
FIGURE 4 is a cross-sectional view of a glow discharge cell in accordance with
one embodiment of the present invention;
FIGURE 5 is a cross-sectional view of a glow discharge cell in accordance with
another embodiment of the present invention;
FIGURE 6 is a cross-sectional view of a Solid Oxide Plasma Arc Torch System in
accordance with another embodiment of the present invention;
FIGURE 7 is a cross-sectional view of a Solid Oxide Plasma Arc Torch System in
accordance with another embodiment of the present invention;
FIGURE 8 is a cross-sectional view of a Solid Oxide Transferred Arc Plasma
Torch in accordance with another embodiment of the present invention;
FIGURE 9 is a cross-sectional view of a Solid Oxide Non-Transferred Arc Plasma
Torch in accordance with another embodiment of the present invention;
FIGURE 10 is a table showing the results of the tailings pond water and solids
analysis treated with one embodiment of the present invention;
FIGURE 11 is a cross-sectional view of a Multi-Mode Plasma Arc Torch in
accordance with another embodiment of the present invention;
FIGURE 12 is illustrates a second electrode for use with the Multi-Mode Plasma
Arc Torch in accordance with another embodiment of the present invention;
FIGURES 13A-13F are cross-sectional views of various shapes for the hollow
electrode nozzle in accordance with another embodiment of the present
invention;
FIGURE 14 is a cross-sectional view of an anode nozzle flange mounted
assembly for the Multi-Mode Plasma Arc Torch in accordance with another
embodiment
of the present invention;
FIGURE 15 is a cross-sectional view of dual first electrode configuration in
accordance with another embodiment of the present invention;
FIGURE 16 illustrates a first electrode positions to operate a Multi-Mode
Plasma
Arc Torch in accordance with another embodiment of the present invention;
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FIGURE 17 is a block diagram of a system for operating the Multi-Mode Plasma
Arc Torch in five different modes in accordance with another embodiment of the
present
invention;
FIGURE 18 is a diagram of a Multi-Mode Plasma Arc Torch with various
attachment devices in accordance with another embodiment of the present
invention;
FIGURE 19 is a diagram of a Multi-Mode Plasma Arc Torch with various
attachment devices in accordance with another embodiment of the present
invention;
FIGURE 20 is a system, method and apparatus for continuously feeding
electrodes within a cyclone reactor in accordance with another embodiment of
the present
invention;
FIGURE 21A discloses top injection of microwaves into a cyclone reactor while
FIGURE 21B discloses side injection of microwaves into the cyclone in
accordance with
another embodiment of the present invention;
FIGURE 22 discloses a system, method and apparatus for co-injecting
microwaves and filter cake directly into the whirling plasma in accordance
with another
embodiment of the present invention;
FIGURE 23 discloses the co-injected microwaves and filter cake may be fed
directly in the plasma which then flows into the cyclone separator and allows
for
pretreating the filter coke prior to injection into cyclone separator in
accordance with
another embodiment of the present invention;
FIGURE 24 discloses a system, method and apparatus for injecting the plasma
from the ArcWhirl Torch 100 directly into the eye of a cyclone separator in
accordance
with another embodiment of the present invention;
FIGURE 25 discloses feed material such as filter cake or petroleum cake may be
injected into the cyclone separator via a tangential entry in accordance with
another
embodiment of the present invention;
FIGURE 26 discloses a system, method and apparatus for continuous operation of
the Plasma ArcWhirl torch in accordance with another embodiment of the
present
invention;
FIGURE 27 discloses a means for adding additional EMR and heat to the gas
stream exiting V3 by heating the anode nozzle with an induction coil in
accordance with
another embodiment of the present invention;
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FIGURE 28 discloses two ArcWhirls in series to form a unique system for
operating
two identical multi-mode plasma torches in different modes in accordance with
another
embodiment of the present invention;
FIGURE 29 discloses another configuration using two ArcWhirls piped in series
that
can be operated in different modes based upon the application and desired end
products in
accordance with another embodiment of the present invention;
FIGURE 30 discloses a means for combusting and/or quenching the products
produced
from the multi-mode Plasma ArcWhirl Torch in accordance with another
embodiment of the
present invention;
FIGURE 31 discloses a means for countercurrent flowing material to be treated
via an
auger and stinger electrode aligned along the longitudinal axis of the multi-
mode ArcWhirl
Torch in accordance with another embodiment of the present invention;
FIGURE 32A discloses a unique configuration similar to the ArcWhirl Torch of
FIGURE 1 utilizing the electrode and piston configuration as shown in FIGURE
14 that can be
operated as a blowback torch in accordance with another embodiment of the
present invention;
FIGURE 32B discloses a system that can be powered with two separate power
supplies
by replacing the spring with a hydraulic/pneumatic port and electrically
isolating the electrode
piston from the electrode rod in accordance with another embodiment of the
present invention;
FIGURES 33A and 33B allow for operation with alternating current ("AC") by
electrically connecting the three electrodes, electrode rod, electrode piston
and electrode nozzle
to Li, L2 and L3 respectively of a three wire power cable to an AC source
located on the surface
in accordance with another embodiment of the present invention;
FIGURES 34 and 35 disclose a liquid resistor using the multi-mode ArcWhirl
Torch
100 as a resistor within a series circuit in accordance with another
embodiment of the present
invention;
FIGURE 36 discloses a unique system, method and apparatus for enhanced oil
recovery
in accordance with another embodiment of the present invention;
FIGURE 37 discloses a three phase AC Plasma ArcWhirl downhole tool that may
also
be used for downhole steam generation for EOR or for plasma drilling in
accordance with
another embodiment of the present invention;
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FIGURE 38 discloses a novel material treating system that uses Variable Plasma
Resistors(VPR) wired in parallel with a large ArcWhirl Torch in accordance
with
another embodiment of the present invention;
FIGURE 39 discloses a system, method and apparatus for retrofitting and
converting a carbon arc gouging torch into an ArcWhirl Torch in accordance
with
another embodiment of the present invention;
FIGURE 40 discloses a unique system, method and apparatus for using the
Coanda Effect to wrap plasma around a graphite electrode in accordance with
another
embodiment of the present invention;
FIGURE 41 discloses another system, method and apparatus for using the Coanda
Effect to transfer an electrical arc to a graphite electrode thus sustaining
and confining the
plasma in accordance with another embodiment of the present invention;
FIGURE 42 discloses a counter current steam plasma system in accordance with
one embodiment of the present invention;
FIGURE 43 is a block diagram of a closed loop mining waste steam plasma
system in accordance with another embodiment of the present invention;
FIGURE 44 is a block diagram of a closed loop mining waste steam plasma
system in accordance with another embodiment of the present invention;
FIGURES 45-49 are diagrams of various steam plasma treatment systems using
various types of screw feeders in accordance with the present invention;
FIGURE 50 is a flow chart of a method for treating a material in accordance
with
various embodiments of the present invention;
FIGURE 51 is a cross-sectional view of a Solid Oxide Glow Discharge Cell and
Plasma Arc Torch Enhanced Oil Recovery System in accordance with another
embodiment of the present invention;
FIGURE 52 is a cross-sectional view of a Solid Oxide Glow Discharge Cell
Enhanced Oil Recovery System in accordance with another embodiment of the
present
invention;
FIGURE 53 is a cross-sectional view of an ArcWhirl Glow Discharge Cell
Enhanced Oil Recovery System in accordance with another embodiment of the
present
invention;
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FIGURE 54 is a cross-sectional view of an ArcWhirl Glow Discharge Cell and
ArcWhirl Plasma Torch Enhanced Oil Recovery System in accordance with another
embodiment of the present invention;
FIGURE 55 is a cross-sectional view of an ArcWhirl Plasma Torch and Solid
Oxide Glow Discharge Cell Enhanced Oil Recovery System in accordance with
another
embodiment of the present invention;
FIGURE 56 is a cross-sectional view of Dual ArcWhirl Plasma Torches and a
Flotation Cell System in accordance with another embodiment of the present
invention;
FIGURE 57 is a cross-sectional view of Dual ArcWhirl Plasma Torches and a
Thickener System in accordance with another embodiment of the present
invention; and
FIGURE 58 is a cross-sectional view of a SOGD ArcWhirl Upgrader in
accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[00321 While the making and using of various embodiments of the present
invention are
discussed in detail below, it should be appreciated that the present invention
provides
many applicable inventive concepts that can be embodied in a wide variety of
specific
contexts. The specific embodiments discussed herein are merely illustrative of
specific
ways to make and use the invention and do not delimit the scope of the
invention.
[0033] Now referring to FIGURE 1, a plasma arc torch 100 in accordance with
one
embodiment of the present invention is shown. The plasma arc torch 100 is a
modified
version of the ARC WHIRL device disclosed in U.S. Patent No. 7,422,695 that
produces
unexpected results. More specifically, by attaching a discharge volute 102 to
the bottom
of the vessel 104, closing off the vortex finder, replacing the bottom
electrode with a
hollow electrode nozzle 106, an electrical arc can be maintained while
discharging
plasma 108 through the hollow electrode nozzle 106 regardless of how much gas
(e.g.,
air), fluid (e.g., water) or steam 110 is injected into plasma arc torch 100.
In addition,
when a valve (not shown) is connected to the discharge volute 102, the mass
flow of
plasma 108 discharged from the hollow electrode nozzle 106 can be controlled
by
throttling the valve (not shown) while adjusting the position of the first
electrode 112
using the linear actuator 114.
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[0034] As a result, plasma arc torch 100 includes a cylindrical vessel 104
having a first
end 116 and a second end 118. A tangential inlet 120 is connected to or
proximate to the
first end 116 and a tangential outlet 136 (discharge volute) is connected to
or proximate to
the second end 118. An electrode housing 122 is connected to the first end 116
of the
cylindrical vessel 104 such that a first electrode 112 is aligned with the
longitudinal axis
124 of the cylindrical vessel 104, extends into the cylindrical vessel 104,
and can be
moved along the longitudinal axis 124. Moreover, a linear actuator 114 is
connected to
the first electrode 112 to adjust the position of the first electrode 112
within the
cylindrical vessel 104 along the longitudinal axis of the cylindrical vessel
124 as
indicated by arrows 126. The hollow electrode nozzle 106 is connected to the
second end
118 of the cylindrical vessel 104 such that the centerline of the hollow
electrode nozzle
106 is aligned with the longitudinal axis 124 of the cylindrical vessel 104.
The shape of
the hollow portion 128 of the hollow electrode nozzle 106 can be cylindrical
or conical.
Moreover, the hollow electrode nozzle 106 can extend to the second end 118 of
the
cylindrical vessel 104 or extend into the cylindrical vessel 104 as shown. As
shown in
FIGURE 1, the tangential inlet 120 is volute attached to the first end 116 of
the
cylindrical vessel 104, the tangential outlet 136 is a volute attached to the
second end 118
of the cylindrical vessel 104, the electrode housing 122 is connected to the
inlet volute
120, and the hollow electrode nozzle 106 (cylindrical configuration) is
connected to the
discharge volute 102. Note that the plasma arc torch 100 is not shown to
scale.
[0035] A power supply 130 is electrically connected to the plasma arc torch
100 such
that the first electrode 112 serves as the cathode and the hollow electrode
nozzle 106
serves as the anode. The voltage, power and type of the power supply 130 is
dependant
upon the size, configuration and function of the plasma arc torch 100. A gas
(e.g., air),
fluid (e.g., water) or steam 110 is introduced into the tangential inlet 120
to form a vortex
132 within the cylindrical vessel 104 and exit through the tangential outlet
136 as
discharge 134. The vortex 132 confines the plasma 108 within in the vessel 104
by the
inertia (inertial confinement as opposed to magnetic confinement) caused by
the angular
momentum of the vortex, whirling, cyclonic or swirling flow of the gas (e.g.,
air), fluid
(e.g., water) or steam 110 around the interior of the cylindrical vessel 104.
During
startup, the linear actuator 114 moves the first electrode 112 into contact
with the hollow
electrode nozzle 106 and then draws the first electrode 112 back to create an
electrical arc
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which forms the plasma 108 that is discharged through the hollow electrode
nozzle 106.
During operation, the linear actuator 114 can adjust the position of the first
electrode 112
to change the plasma 108 discharge or account for extended use of the first
electrode 112.
Note an inductively coupled induction coil can be added to the various
components of the
Steam Plasma Unit as described herein.
[0036] Referring now to FIGURE 2, a cross-sectional view comparing and
contrasting
a solid oxide cell 200 to a liquid electrolyte cell 250 in accordance with one
embodiment
of the present invention is shown. An experiment was conducted using the
Liquid
Electrolyte Cell 250. A carbon cathode 202 was connected a linear actuator 204
in order
1() to
raise and lower the cathode 202 into a carbon anode crucible 206. An ESAB ESP
150
DC power supply rated at 150 amps and an open circuit voltage ("OCV") of 370
VDC
was used for the test. The power supply was "tricked out" in order to operate
at OCV.
[0037] In order to determine the sheath glow discharge length on the cathode
202 as
well as measure amps and volts the power supply was turned on and then the
linear
actuator 204 was used to lower the cathode 202 into an electrolyte solution of
water and
baking soda. Although a steady glow discharge could be obtained the voltage
and amps
were too erratic to record. Likewise, the power supply constantly surged and
pulsed due
to erratic current flow. As soon as the cathode 202 was lowered too deep, the
glow
discharge ceased and the cell went into an electrolysis mode. In addition,
since boiling
would occur quite rapidly and the electrolyte would foam up and go over the
sides of the
carbon crucible 206, foundry sand was added reduce the foam in the crucible
206.
[0038] The 8" diameter anode crucible 206 was filled with sand and the
electrolyte was
added to the crucible. Power was turned on and the cathode 202 was lowered
into the
sand and electrolyte. Unexpectedly, a glow discharge was formed immediately,
but this
time it appeared to spread out laterally from the cathode 202. A large amount
of steam
was produced such that it could not be seen how far the glow discharge had
extended
through the sand.
[0039] Next, the sand was replaced with commonly available clear floral
marbles.
When the cathode 202 was lowered into the marbles and baking soda/water
solution, the
electrolyte began to slowly boil. As soon as the electrolyte began to boil a
glow
discharge spider web could be seen throughout the marbles as shown the Solid
Oxide Cell
200. Although this was completely unexpected at a much lower voltage than what
has
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been disclosed and published, what was completely unexpected is that the DC
power
supply did not surge, pulse or operate erratically in any way. A graph showing
an
operating curve for a glow discharge cell in accordance with the present
invention is
shown in FIGURE 3 based on various tests. The data is completely different
from what is
currently published with respect to glow discharge graphs and curves developed
from
currently known electro-plasma, plasma electrolysis or glow discharge
reactors. Glow
discharge cells can evaporate or concentrate liquids while generating steam.
[0040] Now referring to FIGURE 4, a cross-sectional view of a glow discharge
cell
400 in accordance with one embodiment of the present invention is shown. The
glow
discharge cell 400 includes an electrically conductive cylindrical vessel 402
having a first
end 404 and a second end 406, and at least one inlet 408 and one outlet 410. A
hollow
electrode 412 is aligned with a longitudinal axis of the cylindrical vessel
402 and extends
at least from the first end 404 to the second end 406 of the cylindrical
vessel 402. The
hollow electrode 412 also has an inlet 414 and an outlet 416. A first
insulator 418 seals
the first end 404 of the cylindrical vessel 402 around the hollow electrode
412 and
maintains a substantially equidistant gap 420 between the cylindrical vessel
402 and the
hollow electrode 412. A second insulator 422 seals the second end 406 of the
cylindrical
vessel 402 around the hollow electrode 412 and maintains the substantially
equidistant
gap 420 between the cylindrical vessel 402 and the hollow electrode 412. A non-
conductive granular material 424 is disposed within the gap 420, wherein the
non-
conductive granular material 424 (a) allows an electrically conductive fluid
to flow
between the cylindrical vessel 402 and the hollow electrode 412, and (b)
prevents
electrical arcing between the cylindrical vessel 402 and the hollow electrode
412 during a
electric glow discharge. The electric glow discharge is created whenever: (a)
the glow
discharge cell 400 is connected to an electrical power source such that the
cylindrical
vessel 402 is an anode and the hollow electrode 412 is a cathode, and (b) the
electrically
conductive fluid is introduced into the gap 420.
[0041] The vessel 402 can be made of stainless steel and the hollow electrode
can be
made of carbon. The non-conductive granular material 424 can be marbles,
ceramic
beads, molecular sieve media, sand, limestone, activated carbon, zeolite,
zirconium,
alumina, rock salt, nut shell or wood chips. The electrical power supply can
operate in a
range from 50 to 500 volts DC, or a range of 200 to 400 volts DC. The cathode
412 can
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reach a temperature of at least 500 C, at least 1000 C, or at least 2000 C
during the
electric glow discharge. The electrically conductive fluid comprises water,
produced
water, wastewater, tailings pond water, or other suitable fluid. The
electrically
conductive fluid can be created by adding an electrolyte, such as baking soda,
Nahcolite,
lime, sodium chloride, ammonium sulfate, sodium sulfate or carbonic acid, to a
fluid.
[0042] Referring now to FIGURE 5, a cross-sectional view of a glow discharge
cell
500 in accordance with another embodiment of the present invention is shown.
The glow
discharge cell 500 includes an electrically conductive cylindrical vessel 402
having a first
end 404 and a closed second end 502, an inlet proximate 408 to the first end
404, and an
outlet 410 centered in the closed second end 502. A hollow electrode 504 is
aligned with
a longitudinal axis of the cylindrical vessel and extends at least from the
first end 404 into
the cylindrical vessel 402. The hollow electrode 504 has an inlet 414 and an
outlet 416.
A first insulator 418 seals the first end 404 of the cylindrical vessel 402
around the
hollow electrode 504 and maintains a substantially equidistant gap 420 between
the
cylindrical vessel 402 and the hollow electrode 504. A non-conductive granular
material
424 is disposed within the gap 420, wherein the non-conductive granular
material 424 (a)
allows an electrically conductive fluid to flow between the cylindrical vessel
402 and the
hollow electrode 504, and (b) prevents electrical arcing between the
cylindrical vessel
402 and the hollow electrode 504 during a electric glow discharge. The
electric glow
discharge is created whenever: (a) the glow discharge cell 500 is connected to
an
electrical power source such that the cylindrical vessel 402 is an anode and
the hollow
electrode 504 is a cathode, and (b) the electrically conductive fluid is
introduced into the
gap 420.
[0043] Note that the configuration of the glow discharge cell 500 shown in
FIGURES
4 and 5 can be varied as illustrated in U.S. Patent Application Serial No.
18/486,626 filed
on March 14, 2014 and entitled "High Temperature Electrolysis Glow Discharge
Device." Such variations can be used as any of the glow discharges cells 500
referenced
throughout this specification and figures.
[0044] The following examples will demonstrate the capabilities, usefulness
and
completely unobvious and unexpected results.
[0045] EXAMPLE 1 - BLACK LIQUOR
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[0046] Now referring to FIGURE 6, a cross-sectional view of a Solid Oxide
Plasma
Arc Torch System 600 in accordance with another embodiment of the present
invention is
shown. A plasma arc torch 100 is connected to the cell 500 via an eductor 602.
Once
again the cell 500 was filled with a baking soda and water solution. A pump
was
connected to the first volute 31 of the plasma arc torch 100 via a 3-way valve
604 and the
eductor 602. The eductor 602 pulled a vacuum on the cell 500. The plasma
exiting from
the plasma arc torch 100 dramatically increased in size. Hence, a non-
condensable gas B
was produced within the cell 500. The color of the arc within the plasma arc
torch 100
when viewed through the sightglass 33 changed colors due to the gases produced
from
the HiTemperTm cell 500. Next, the 3-way valve 604 was adjusted to allow air
and water
F to flow into the first volute 31 of plasma arc torch 100. The additional
mass flow
increased the plasma G exiting from the plasma arc torch 100. Several pieces
of stainless
steel round bar were placed at the tip of the plasma G and melted to
demonstrate the
systems capabilities. Likewise, wood was carbonized by placing it within the
plasma
stream G. Thereafter the plasma G exiting from the plasma torch 100 was
directed into
cyclone separator 610. The water and gases I exiting from the plasma arc torch
100 via
second volute 34 flowed into a hydrocyclone 608 via a valve 606. This allowed
for rapid
mixing and scrubbing of gases with the water in order to reduce the discharge
of any
hazardous contaminants.
[0047] A sample of black liquor with 16% solids obtained from a pulp and paper
mill
was charged to the glow discharge cell 500 in a sufficient volume to cover the
floral
marbles 424. In contrast to other glow discharge or electro plasma systems the
solid
oxide glow discharge cell does not require preheating of the electrolyte. The
ESAB ESP
150 power supply was turned on and the volts and amps were recorded by hand.
Referring briefly to FIGURE 3, as soon as the power was turned on to the cell
500, the
amp meter pegged out at 150. Hence, the name of the ESAB power supply - ESP
150. It
is rated at 150 amps. The voltage was steady between 90 and 100 VDC. As soon
as
boiling occurred the voltage steadily climbed to OCV (370 VDC) while the amps
dropped
to 75.
[0048] The glow discharge cell 500 was operated until the amps fell almost to
zero.
Even at very low amps of less than 10 the voltage appeared to be locked on at
370 VDC.
The cell 500 was allowed to cool and then opened to examine the marbles 424.
It was
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surprising that there was no visible liquid left in the cell 500 but all of
the marbles 424
were coated or coked with a black residue. The marbles 424 with the black
residue were
shipped off for analysis. The residue was in the bottom of the container and
had come off
of the marbles 424 during shipping. The analysis is listed in the table below,
which
demonstrates a novel method for concentrating black liquor and coking
organics. With a
starting solids concentration of 16%, the solids were concentrated to 94.26%
with only
one evaporation step. Note that the sulfur ("S") stayed in the residue and did
not exit the
cell 500.
Total Solids % 94.26
Ash %/ODS 83.64
ICP metal scan: results are reported on ODS basis
Metal Scan Unit F80015
Aluminum, Al mg/kg 3590*
Arsenic, As mg/kg <50
Barium, Ba mg/kg 2240*
Boron, B mg/kg 60
Cadmium, Cd mg/kg 2
Calcium, Ca mg/kg 29100*
Chromium, Cr mg/kg 31
Cobalt, Co mg/kg <5
Copper, Cu mg/kg 19
Iron, Fe mg/kg 686*
Lead, Pb mg/kg <20
Lithium, Li mg/kg 10
Magnesium, Mg mg/kg 1710*
Manganese, Mn mg/kg 46.2
Molybdenum, Mo mg/kg 40
Nickel, Ni mg/kg <100
Phosphorus, P mg/kg 35
Potassium, K mg/kg 7890
Silicon, Si mg/kg 157000*
Sodium, Na mg/kg 102000
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Strontium, Sr mg/kg <20
Sulfur, S mg/kg 27200*
Titanium, Ti mg/kg 4
Vanadium, V mg/kg 1.7
Zinc, Zn mg/kg 20
Table - Black Liquor Results
This method can be used for concentrating black liquor from pulp, paper and
fiber mills
for subsequent recaustizing.
[0049] As can be seen in FIGURE 3, if all of the liquid evaporates from the
cell 500
and it is operated only with a solid electrolyte, electrical arc over from the
cathode to
anode may occur. This has been tested in which case a hole was blown through
the
stainless steel vessel 402. Electrical arc over can easily be prevented by (1)
monitoring
the liquid level in the cell and do not allow it to run dry, and (2)
monitoring the amps
(Low amps = Low liquid level). If electrical arc over is desirable or the cell
must be
designed to take an arc over, then the vessel 402 should be constructed of
carbon.
[0050] EXAMPLE 2 ¨ ARCWHIRL PLASMA TORCH ATTACHED TO SOLID
OXIDE CELL
[0051] Referring now to FIGURE 7, a cross-sectional view of a Solid Oxide
Plasma
Arc Torch System 700 in accordance with another embodiment of the present
invention is
shown. A plasma arc torch 100 is connected to the cell 500 via an eductor 602.
Once
again the cell 500 was filled with a baking soda and water solution. Pump 23
recirculates
the baking soda and water solution from the outlet 416 of the hollow electrode
504 to the
inlet 408 of the cell 500. A pump 22 was connected to the first volute 31 of
the plasma
arc torch 100 via a 3-way valve 604 and the eductor 602. An air compressor 21
was used
to introduce air into the 3-way valve 604 along with water F from the pump 22.
The
pump 22 was turned on and water F flowed into the first volute 31 of the
plasma arc torch
100 and through a full view site glass 33 and exited the torch 30 via a second
volute 34.
The plasma arc torch 100 was started by pushing a carbon cathode rod (-NEG) 32
to
touch and dead short to a positive carbon anode (+POS) 35. A very small plasma
G
exited out of the anode 35. Next, the High Temperature Plasma Electrolysis
Reactor
(Cell) 500 was started in order to produce a plasma gas B. Once again at the
onset of
boiling voltage climbed to OCV (370 VDC) and a gas began flowing to the plasma
arc
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torch 100. The eductor 602 pulled a vacuum on the cell 500. The plasma G
exiting from
the plasma arc torch 100 dramatically increased in size. Hence, a non-
condensable gas B
was produced within the cell 500. The color of the arc within the plasma arc
torch 100
when viewed through the sightglass 33 changed colors due to the gases produced
from
the HiTemperTm cell 500. Next, the 3-way valve 604 was adjusted to allow air
from
compressor 21 and water from pump 22 to flow into the plasma arc torch 100.
The
additional mass flow increased the plasma G exiting from the plasma arc torch
100.
Several pieces of stainless steel round bar were placed at the tip of the
plasma G and
melted to demonstrate the systems capabilities. Likewise, wood was carbonized
by
placing it within the plasma stream G. The water and gases exiting from the
plasma arc
torch 100 via volute 34 flowed into a hydrocyclone 608. This allowed for rapid
mixing
and scrubbing of gases with the water in order to reduce the discharge of any
hazardous
contaminants.
[0052] Next, the system was shut down and a second cyclone separator 610 was
attached to the plasma arc torch 100 as shown in FIGURE 1. Once again the
Solid Oxide
Plasma Arc Torch System was turned on and a plasma G could be seen circulating
within
the cyclone separator 610. Within the eye or vortex of the whirling plasma G
was a
central core devoid of any visible plasma.
[0053] The cyclone separator 610 was removed to conduct another test. To
determine
the capabilities of the Solid Oxide Plasma Arc Torch System as shown in FIGURE
6, the
pump 22 was turned off and the system was operated only on air provided by
compressor
21 and gases B produced from the solid oxide cell 500. Next, 3-way valve 606
was
slowly closed in order to force all of the gases through the arc to form a
large plasma G
exiting from the hollow carbon anode 35.
[0054] Next, the 3-way valve 604 was slowly closed to shut the flow of air to
the
plasma arc torch 100. What happened was completely unexpected. The intensity
of the
light from the sightglass 33 increased dramatically and a brilliant plasma was
discharged
from the plasma arc torch 100. When viewed with a welding shield the arc was
blown
out of the plasma arc torch 100 and wrapped back around to the anode 35. Thus,
the
Solid Oxide Plasma Arc Torch System will produce a gas and a plasma suitable
for
welding, melting, cutting, spraying and chemical reactions such as pyrolysis,
gasification
and water gas shift reaction.
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[0055] EXAMPLE 3- PHOSPHOGYPSUM POND WATER
[0056] The phosphate industry has truly left a legacy in Florida, Louisiana
and Texas
that will take years to cleanup ¨ gypsum stacks and pond water. On top of
every stack is
a pond. Pond water is recirculated from the pond back down to the plant and
slurried
with gypsum to go up the stack and allow the gypsum to settle out in the pond.
This
cycle continues and the gypsum stack increases in height. The gypsum is
produced as a
byproduct from the ore extraction process.
[0057] There are two major environmental issues with every gyp stack. First,
the pond
water has a very low pH. It cannot be discharged without neutralization.
Second, the
phosphogypsum contains a slight amount of radon. Thus, it cannot be used or
recycled to
other industries. The excess water in combination with ammonia contamination
produced
during the production of P205 fertilizers such as diammonium phosphate ("DAP")
and
monammonium phosphate ("MAP") must be treated prior to discharge. The excess
pond
water contains about 2% phosphate a valuable commodity.
[0058] A sample of pond water was obtained from a Houston phosphate fertilizer
company. The pond water was charged to the solid oxide cell 500. The Solid
Oxide
Plasma Arc Torch System was configured as shown in FIGURE 6. The 3-way valve
606
was adjusted to flow only air into the plasma arc torch 100 while pulling a
vacuum on cell
500 via eductor 602. The hollow anode 35 was blocked in order to maximize the
flow of
gases I to hydrocyclone 608 that had a closed bottom with a small collection
vessel. The
hydrocyclone 608 was immersed in a tank in order to cool and recover
condensable gases.
[0059] The results are disclosed in FIGURE 10 ¨ Tailings Pond Water Results.
The
goal of the test was to demonstrate that the Solid Oxide Glow Discharge Cell
could
concentrate up the tailings pond water. Turning now to cycles of
concentration, the
percent P205 was concentrated up by a factor of 4 for a final concentration of
8.72% in
the bottom of the HiTemperTm cell 500. The beginning sample as shown in the
picture is
a colorless, slightly cloudy liquid. The bottoms or concentrate recovered from
the
HiTemper cell 500 was a dark green liquid with sediment. The sediment was
filtered and
are reported as SOLIDS (Retained on Whatmann #40 filter paper). The percent
SO4
recovered as a solid increased from 3.35% to 13.6% for a cycles of
concentration of 4.
However, the percent Na recovered as a solid increased from 0.44% to 13.67%
for a
cycles of concentration of 31.
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[0060] The solid oxide or solid electrolyte 424 used in the cell 500 were
floral marbles
(Sodium Oxide). Floral marbles are made of sodium glass. Not being bound by
theory it
is believed that the marbles were partially dissolved by the phosphoric acid
in
combination with the high temperature glow discharge. Chromate and Molydemun
cycled up and remained in solution due to forming a sacrificial anode from the
stainless
steel vessel 402. Note: Due to the short height of the cell carryover occurred
due to
pulling a vacuum on the cell 500 with eductor 602. In the first run (row 1
HiTemper) of
FIGURE 10 very little fluorine went overhead. That had been a concern from the
beginning that fluorine would go over head. Likewise about 38% of the ammonia
went
overhead. It was believed that all of the ammonia would flash and go overhead.
[0061] A method has been disclosed for concentrating P205 from tailings pond
for
subsequent recovery as a valuable commodity acid and fertilizer.
[0062] Now, returning back to the black liquor sample, not being bound by
theory it is
believed that the black liquor can be recaustisized by simply using CaO or
limestone as
the solid oxide electrolyte 424 within the cell 500. Those who are skilled in
the art of
producing pulp and paper will truly understand the benefits and cost savings
of not
having to run a lime kiln. However, if the concentrated black liquor must be
gasified or
thermally oxidized to remove all carbon species, the marbles 424 can be
treated with the
plasma arc torch 100. Referring back to FIGURE 6, the marbles 424 coated with
the
concentrated black liquor or the concentrated black liquor only is injected
between the
plasma arc torch 100 and the cyclone separator 610. This will convert the
black liquor
into a green liquor or maybe a white liquor. The marbles 424 may be flowed
into the
plasma arc torch nozzle 31 and quenched in the whirling lime water and
discharged via
volute 34 into hydrocyclone 608 for separation and recovery of both white
liquor and the
marbles 424. The lime will react with the Na0 to form caustic and an insoluble
calcium
carbonate precipitate.
[0063] EXAMPLE 4 ¨ EVAPORATION, VAPOR COMPRESSION AND STEAM
GENERATION FOR EOR AND INDUSTRIAL STEAM USERS
[0064] Turning to FIGURE 4, several oilfield wastewaters were evaporated in
the cell
400. In order to enhance evaporation the suction side of a vapor compressor
(not shown)
can be connected to upper outlet 410. The discharge of the vapor compressor
would be
connected to 416. Not being bound by theory, it is believed that alloys such
as Kanthal0
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manufactured by the Kanthal corporation may survive the intense effects of
the cell as a
tubular cathode 412, thus allowing for a novel steam generator with a
superheater by
flowing the discharge of the vapor compressor through the tubular cathode 412.
Such an
apparatus, method and process would be widely used throughout the upstream oil
and gas
industry in order to treat oilfield produced water and frac flowback.
[0065] Several different stainless steel tubulars were tested within the cell
500 as the
cathode 12. In comparison to the sheath glow discharge the tubulars did not
melt. In
fact, when the tubulars were pulled out, a marking was noticed at every point
a marble
was in contact with the tube.
[0066] This gives rise to a completely new method for using glow discharge to
treat
metals.
[0067] EXAMPLE 5¨ TREATING TUBES, BARS, RODS, PIPE OR WIRE.
[0068] There are many different companies applying glow discharge to treat
metal.
However, many have companies have failed miserably due to arcing over and
melting the
material to be coated, treated or descaled. The problem with not being able to
control
voltage leads to spikes. By simply adding sand or any solid oxide to the cell
and feeding
the tube cathode 12 through the cell 500 as configured in FIGURE 2, the tube,
rod, pipe,
bars or wire can be treated at a very high feed rate.
[0069] EXAMPLE 6¨ SOLID OXIDE PLASMA ARC TORCH
[0070] There truly exists a need for a very simple plasma torch that can be
operated
with dirty or highly polluted water such as sewage flushed directly from a
toilet which
may contain toilet paper, feminine napkins, fecal matter, pathogens, urine and
pharmaceuticals. A plasma torch system that could operate on the
aforementioned waters
could potentially dramatically affect the wastewater infrastructure and future
costs of
maintaining collection systems, lift stations and wastewater treatment
facilities.
[0071] By converting the contaminated wastewater to a gas and using the gas as
a
plasma gas could also alleviate several other growing concerns ¨ municipal
solid waste
going to landfills, grass clippings and tree trimmings, medical waste,
chemical waste,
refinery tank bottoms, oilfield wastes such as drill cuttings and typical
everyday
household garbage. A simple torch system which could handle both solid waste
and
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liquids or that could heat a process fluid while gasifying biomass or coal or
that could use
a wastewater to produce a plasma cutting gas would change many industries
overnight.
[0072] One industry in particular is the metals industry. The metals industry
requires a
tremendous amount of energy and exotic gases for heating, melting, welding,
cutting and
machining.
[0073] Turning now to FIGURES 8 and 9, a truly novel plasma torch 800 will be
disclosed in accordance with the preferred embodiments of the present
invention. First,
the Solid Oxide Plasma Torch is constructed by coupling the plasma arc torch
100 to the
cell 500. The plasma arc torch volute 31 and electrode 32 are detached from
the eductor
602 and sightglass 33. The plasma arc torch volute 31 and electrode assembly
32 are
attached to the cell 500 vessel 402. The sightglass 33 is replaced with a
concentric type
reducer 33. It is understood that the electrode 32 is electrically isolated
from the volute
31 and vessel 402. The electrode 32 is connected to a linear actuator (not
shown) in order
to strike the arc.
[0074] Continuous Operation of the Solid Oxide Transferred Arc Plasma Torch
800 as
shown in FIGURE 8 will now be disclosed for cutting or melting an electrically
conductive workpiece. A fluid is flowed into the suction side of the pump and
into the
cell 500. The pump is stopped. A first power supply PS1 is turned on thus
energizing the
cell 500. As soon as the cell 500 goes into glow discharge and a gas is
produced valve 16
opens allowing the gas to enter into the volute 31. The volute 31 imparts a
whirl flow to
the gas. A switch 60 is positioned such that a second power supply PS2 is
connected to
the workpiece and the ¨negative side of PS2 is connected to the ¨negative of
PS1 which
is connected to the centered cathode 504 of the cell 500. The entire torch is
lowered so
that an electrically conductive nozzle 13-C touches and is grounded to the
workpiece.
PS2 is now energized and the torch is raised from the workpiece. An arc is
formed
between cathode 504 and the workpiece.
[0075] Centering the Arc ¨ If the arc must be centered for cutting purposes,
then PS2's
¨negative lead would be attached to the lead of switch 60 that goes to the
electrode 32.
Although a series of switches are not shown for this operation, it will be
understood that
in lieu of manually switching the negative lead from PS2 an electrical switch
similar to 60
could be used for automation purposes. The +positive lead would simply go to
the
workpiece as shown. A smaller electrode 32 would be used such that it could
slide into
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and through the hollow cathode 504 in order to touch the workpiece and strike
an arc.
The electrically conductive nozzle 802 would be replaced with a non-conducting
shield
nozzle. This setup allows for precision cutting using just wastewater and no
other gases.
[0076] Turning to FIGURE 9, the Solid Oxide Non-Transferred Arc Plasma Torch
800
is used primarily for melting, gasifying and heating materials while using a
contaminated
fluid as the plasma gas. Switch 60 is adjusted such that PS2 +lead feeds
electrode 32.
Once again electrode 32 is now operated as the anode. It must be electrically
isolated
from vessel 402. When gas begins to flow by opening valve 16 the volute 31
imparts a
spin or whirl flow to the gas. The anode 32 is lowered to touch the centered
cathode 504.
An arc is formed between the cathode 32 and anode 504. The anode may be hollow
and a
wire may be fed through the anode 504 for plasma spraying, welding or
initiating the arc.
[0077] The entire torch is regeneratively cooled with its own gases thus
enhancing
efficiency. Likewise, a waste fluid is used as the plasma gas which reduces
disposal and
treatment costs. Finally, the plasma may be used for gasifying coal, biomass
or
producing copious amounts of syngas by steam reforming natural gas with the
hydrogen
and steam plasma.
[0078] Both FIGURE 8 and 9 have clearly demonstrated a novel Solid Oxide
Plasma
Arc Torch that couples the efficiencies of high temperature electrolysis with
the
capabilities of both transferred and non-transferred arc plasma torches.
[0079] EXAMPLE 7¨ MULTI-MODE PLASMA ARC TORCH
[0080] Now referring to FIGURE 11, a multi-mode plasma arc torch 1100 in
accordance with one embodiment of the present invention is shown. The multi-
mode
plasma arc torch 1100 is a plasma arc torch 100 of FIGURE 1 that is modified
to include
some of the attributes of the glow discharge cell 500 of FIGURE 5. The multi-
mode
plasma arc torch 1100 includes a cylindrical vessel 104 having a first end 116
and a
second end 118. A tangential inlet 120 is connected to or proximate to the
second end
118 and a tangential outlet 136 is connected to or proximate to the first end
116. An
electrode housing 122 is connected to the first end 116 of the cylindrical
vessel 104 such
that a first electrode 112 is aligned with the longitudinal axis 124 of the
cylindrical vessel
104, extends into the cylindrical vessel 104, and can be moved along the
longitudinal axis
124. Moreover, a linear actuator 114 is connected to the first electrode 112
to adjust the
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position of the first electrode 112 within the cylindrical vessel 104 along
the longitudinal
axis of the cylindrical vessel 124 as indicated by arrows 126. The hollow
electrode
nozzle 106 is connected to the second end 118 of the cylindrical vessel 104
such that the
centerline of the hollow electrode nozzle 106 is aligned with the longitudinal
axis 124 of
the cylindrical vessel 104. In the embodiment shown, the tangential inlet 120
is volute
attached to the second end 118 of the cylindrical vessel 104, the tangential
outlet 136 is a
volute attached to the first end 116 of the cylindrical vessel 104, the
electrode housing
122 is connected to the outlet volute 102, and the hollow electrode nozzle 106
(cylindrical
configuration) is connected to the inlet volute 120. Note that the multi-mode
plasma arc
torch 1100 is not shown to scale.
[0081] A substantially equidistant gap 420 is maintained between the
cylindrical vessel
402 and the hollow electrode nozzle 106. In some embodiments, a non-conductive
granular material 424 is disposed within the gap 420, wherein an optional non-
conductive
granular material 424 allows an electrically conductive fluid to flow between
the
cylindrical vessel 402 and the hollow electrode nozzle 106. In other
embodiments, the
non-conductive granular material 424 is not used. Note that using the non-
conductive
granular material 424 improves the efficiency of the device by increasing the
contact
surface area for the fluid, but is not required. If the cylindrical vessel 402
is metallic, the
non-conductive granular material 424 can prevent electrical arcing between the
cylindrical vessel 402 and the hollow electrode nozzle 106 during a electric
glow
discharge. The shape of the hollow portion 128 of the hollow electrode nozzle
106 can be
varied as needed to provide the desired operational results as shown in
FIGURES 13A-F
and 16. Other shapes can be used.
[0082] A power supply 130 is electrically connected to the multi-mode plasma
arc
torch 1100 such that the first electrode 112 serves as the cathode and the
hollow electrode
nozzle 106 serves as the anode. The voltage, power and type of the power
supply 130 are
dependent upon the size, configuration and function of the multi-mode plasma
arc torch
1100.
[0083] In some embodiments, a second electrode 1102 and second linear actuator
1110
can be added as an (+) anode, such as a graphite electrode, along the
longitudinal axis 124
to dead short to the first electrode 112 (-) cathode. This configuration
allows for
continuous feed of electrodes 112 and 1102 for continuous duty operation
and/or to
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increase the life of the anode nozzle 106. Like the first electrode 112, the
second
electrode 1102 can be moved in either direction along the longitudinal axis
124 using the
second linear actuator 1110 as shown by arrow 126b. Furthermore, as shown in
FIGURE
12, the second electrode 1102 allows for operating in a plasma arc mode by
dead shorting
the first electrode 112 and the second electrode 1102 together and then
separating them to
draw the arc.
[0084] Referring now to FIGURES 13A-13F, various examples of shapes for the
hollow electrode nozzle 106 are shown. FIGURE 13A shows a straight hollow
electrode
nozzle 106a. FIGURE 13B shows a straight hollow electrode nozzle flange 106b.
FIGURE 13C shows a tapered hollow electrode nozzle 106c. FIGURE 13D shows a
tapered hollow electrode nozzle flange 106d. FIGURE 13E shows a hollow
electrode
nozzle counterbore flange 106e. FIGURE 13F shows a hollow electrode nozzle
counterbore exterior tapered flange 106f Note that FIGURE 12 shows a hollow
electrode nozzle counterbore 106. Other shapes can be used as will be
appreciated by
those skilled in the art. FIGURE 14 shows a method for securing the (+) hollow
electrode nozzle 106 to the volute of plasma arc torch 100 or 1100 using
flanges 1402a,
1402b as a coupling means. It will be understood that any type of coupler that
will hold
and secure the (+) hollow electrode nozzle 106 will suffice for use in the
present
invention. Likewise, using couplers or flanges on both sides of the (+) hollow
electrode
nozzle 106 allows for it to be flipped and used as a protruding or reducer
type coupling
nozzle.
[0085] Now referring to FIGURE 15, a diagram of a dual first electrode 1500 in
accordance with another embodiment of the present invention is shown. The dual
first
electrode 1500 is a combination of the first electrode 112 and a larger
diameter, but
shorter, third electrode 1502 that is either electrically connected to the
first electrode 112
or the power supply 130 (same polarity as the first electrode 112). The third
electrode
1502 can be moved up and down independently from the first electrode 112 as
indicated
by arrows 126c. Moreover, the third electrode 1502 can be physically connected
to the
first electrode 112. The third electrode 1502 provides additional electrode
surface area to
enhance the process.
[0086] Referring now to FIGURES 11 and 16, a fluid, slurry, liquid/gas mixture
or
other pumpable material 1104 is introduced into the tangential inlet 120 to a
desired fluid
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level 1106, which can vary based on the desired operational results, within
the cylindrical
vessel 104. Note that the actual level will typically fluctuate during
operation. During
startup, the linear actuator 114 moves the first electrode 112 into contact
with the hollow
electrode nozzle 106 or the second electrode 1102 and then either leaves the
first
electrode 112 there (dead short resistive heating mode 1600) or draws the
first electrode
112 back a specified distance yet remains below the desired fluid level 1106.
The linear
actuator 114 can adjust the position of the first electrode 112 to operate the
multi-mode
plasma arc torch 1100 in a dead short resistive mode 1600, a submerged arc
mode 1602,
an electrolysis mode 1604 or a glow discharge mode 1606. As the fluid 1104 is
heated in
accordance with one of these four operating modes, gases or steam 1108 will
rise and exit
through tangential outlet 136. The fluid 1104 can be recirculated by allowing
the fluid
1104 to flow through the hollow electrode nozzle 106 and reenter the
cylindrical vessel
104 via tangential inlet 120. Note that the fifth operating mode is the plasma
arc mode as
described and shown in FIGURE 1.
[0087] Referring now to FIGURE 17, a diagram of a system 1700 to operate the
plasma arc torch 100 or 1100 in five operating modes in accordance with the
present
invention is show. The system 1700 includes a plasma arc torch 100 or 1100, 3
three-
way valves 1702a, 1702b, 1702c and a pump and/or compressor 1704. The first
three-
way valve 1702a is connected to the inlet/outlet (depends on the operating
mode) located
at the first end 116 of the plasma arc torch 100 or 1100, and has a first
valve inlet/outlet
(depends on the operating mode) 1708a. The second three-way valve 1702b is
connected
to the inlet/outlet (depends on the operating mode) located at the second end
118 of the
plasma arc torch 100 or 1100, and has a second valve inlet/outlet (depends on
the
operating mode) 1708b. The third three-way valve 1702c is connected to the
exterior end
of the hollow electrode nozzle 106, and has a third valve inlet/outlet
(depends on the
operating mode) 1708c. Each of the three-way valves 1702a, 1702b, 1702c are
connected
to the discharge 1706 of the pump and/or compressor 1704. The fluid, slurry,
liquid/gas
mixture or other pumpable/compressable material 1104 enters the suction 1710
of the
pump and/or compressor 1704. The three-way valves 1702 are adjusted to operate
the
plasma arc torch 100 or 1100 in the five modes, while adjusting the first
electrode 112
with the linear actuator 114.
[0088] Operating Mode 1: Plasma Arc
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a. Compressed and/or pressurized fluid 1104 from a
pump/compressor 1704
is flowed into three-way valve 1702a and then into plasma arc torch 100 or
1100.
b. Three-way valve 1702b is fully open to allow fluid to flow out
of plasma
arc torch 100 or 1100 and to outlet 1708b.
c. Three-way valve 1702c is fully open to flow to outlet 1708c.
d. Ensure (-) first electrode 112 is dead shorted to (+) hollow
electrode
nozzle 106.
e. Ensure whirl glow is established.
f. Turn power supply 130 ON.
g. Using linear Actuator 114 pull back the (-) first electrode 112 to
establish
and arc.
h. Arc is transferred from (-) to (+).
i. Whirling gas flowing through (+) hollow electrode nozzle 106 forms a
plasma.
j. Very small plasma may be discharged through outlet 1708c.
k. Three-way valve 1702b may be throttled to increase/decrease plasma flow
through (+) hollow electrode nozzle 106 and outlet 1708c.
1. Three-way valve 1702b may be shut to flow all fluid into (+)
hollow
electrode nozzle 106 and outlet 1708c.
[0089] Operating Mode 2: Resistive Heating
a. Compressed and/or pressurized fluid 1104 from a
pump/compressor 1704
is flowed into three-way valve 1702b and then into plasma arc torch 100 or
1100
b. Three-way valve 1702a is fully open to flow out of plasma arc torch 100
or 1100 and to outlet 1708a.
c. Three-way valve 1702b is throttled to allow fluid to flow into plasma
arc
torch 100 or 1100 very slowly.
d. Three-way valve 1702c is shut.
e. The (-) first electrode 112 is dead shorted to (+) hollow electrode
Nozzle
106.
f. Power supply 130 is turned ON.
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g. Resistive mode begins.
h. Vapors exit through three-way valve 1702a and outlet 1708a
[0090] Operating Mode 3: Submerged Arc
a. Valves remain aligned as in Operating Mode 2 above.
b. Power supply 130 is still ON.
c. The (-) first electrode 112 is slowly within drawn from (+)
hollow
electrode nozzle 106.
d. The system shifts from resistive heating to submerged arc
mode.
e. Three-way valve 1702c may be opened to allow pressurized fluid
from
pump/compressor 1704 to flow through (+) hollow electrode nozzle 106
and into plasma arc torch 100 or 1100.
f. Vapors exit the plasma arc torch 100 or 1100 through outlet
1708a.
[0091] Operating Mode 4: Electrolysis
a. Valves remain aligned as in Operating Mode 2 above.
b. Power supply 130 is still ON.
c. The (-) first electrode 112 is slowly within drawn further from (+)
hollow
electrode nozzle 106 using linear actuator 114.
d. The system shifts from submerged arc to electrolysis mode.
[0092] Operating Mode 5: Glow Discharge
a. Valves remain aligned as in Operating Mode 2 above.
b. Power supply 130 is still ON.
c. The (-) first electrode 112 is slowly within drawn further
from (+) hollow
electrode nozzle 106 using linear actuator 114.
d. Monitor the power supply 130 voltage.
e. When the voltage increases to open circuit voltage ("OCV"), the system
is
operating in glow discharge mode.
f. The amps will decrease.
g. Three-way valve 1702b and three-way valve 1702c may be
adjusted to
allow pressurized flow to enter plasma arc torch 100 or 1100 either
through three-way valve 1702b or three-way valve 1702c, and/or three-
way valve 1702b and three-way valve 1702c aligned for fluid flow
recirculation using pump/compressor 1704.
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h. Vapors exit from plasma arc torch 100 or 1100 and out of
outlet 1708a.
[0093] As shown in FIGURE 18 and 19, the plasma arc torch 100 or 1100 can be
adapted for use in many applications by attaching various devices 1802 to the
exterior of
the hollow electrode nozzle 106 or the three-way valve 1702c. For example, a
partial list
of attachments 1802 include a cyclone separator 1802a (inlet, vortex
collector, overflow
or underflow), volute 1802b, pump/compressor 1802c, filter screen 1802d,
ejector/eductor 1802e, cross 1802f, screw feeder 1802g, valve 1802h, tee
1802i, electrode
& linear actuator 1802j, wave guide 1802k or RF coil 18021 that may be
attached alone or
in any combination thereof to the (+) anode nozzle 106. Other devices 1802 may
include,
but is not limited to a vessel, flange, cover, hatch, electrode stinger,
injector, screw press,
auger, ram feeder, mixer, extruder, T-fired boiler, coker drum, gasifier,
pipe, conduit,
tubing, submerged melting furnace, rotary kiln, rocket nozzle, thermal
oxidizer, cyclone
combustor, precombustion chamber, ice screw-in cylinder, turbine combustor,
pulse
detonation engine, combustion exhaust pipe/stack, thermal oxidizer, flare,
water tank, raw
sewage pipe, wastewater influent/effluent piping/conduit, anaerobic digester
influent/effluent piping, sludge press/centrifuge inlet/outlet piping, potable
water piping
point of use or point of entry, water storage tank, CNC cutting/welding table,
direct
contact water heater, wet gas chlorine line/pipe, O&G wellhead, O&G produced
water
piping, ship ballast water line, engine fuel line, froth flotation
inlet/outlet, conduit
extending inside tank/vessel, submerged inside tank/vessel, porous tube, wedge
wire
screen, well screen, filter, activated carbon filter, ceramic filter, cat
cracker catalyst
recycle line, hospital vacuum suction pump, cooling tower piping, steam
separator,
superheater, boiler water feedwater piping, RO reject piping, vacuum chamber
inlet/outlet, graywater discharge piping, ship ballast water inlet/outlet
piping, bilge water
inlet/outlet piping, toilet discharge piping, grinder/shredder/macerator
discharge piping,
and/or kitchen sink garbage disposer outlet piping, nuclear reactor
containment building
for hydrogen mitigation (hydrogen igniter), infrared heating element/piping,
charge
heater, furnace and/or coke calciner. It will be understood that the coupling
means to
attach the device 1802 to the hollow anode nozzle 106 may be selected from any
type of
coupling device know in the art, ranging from flanges, quick connectors,
welding in
addition to using the cyclone separator with quick connectors such as sanitary
type
clamps.
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[0094] FIGURE 19 demonstrates how some of the devices 1802 may be connected to
the plasma arc torch 100. System 1900 is a plasma arc torch 100 or 1100 having
a
cyclone separator 1802a attached to the exterior of the hollow anode nozzle
106 and a
volute 1802b attached to the cyclone separator 1802a. System 1902 is a plasma
arc torch
100 or 1100 having a filter screen 1802d attached to the exterior of the
hollow anode
nozzle 106. System 1904 is a plasma arc torch 100 or 1100 having an
ejector/eductor
1802e attached to the exterior of the hollow anode nozzle 106. System 1906 is
a plasma
arc torch 100 or 1100 having a tee 1802i attached to the exterior of the
hollow anode
nozzle 106 and a screw feeder 1802g attached to the tee 1802i. System 1908 is
a plasma
arc torch 100 or 1100 having a tee 1802i attached to the exterior of the
hollow anode
nozzle 106, and an auger 1914 and a cyclone separator 1802a attached to the
tee 1802i.
System 1910 is a plasma arc torch 100 or 1100 having a tee 1802i attached to
the exterior
of the hollow anode nozzle 106 and an anode electrode with linear actuator
1802j
attached to the tee 1802i. As also referred to in FIGURE 12, the anode
electrode 1102
with linear actuator 1802j in combination with the anode nozzle 106 form a
stopper valve
that allows the flow in/out of the (+) anode nozzle to be controlled.
[0095] The present invention's plasma arc torch 100 has been tested in the
five modes
and operated with various attachments coupled to the (+) anode nozzle. The
results of
these tests will now be described.
[0096] Steam Plasma Arc Mode
[0097] Referring to FIGURE 17, three-way valves 1702a and 11702b were
connected
to the tangential inlet 118 and tangential outlet 136 of the plasma arc torch
100 disclosed
in FIGURE 1. During testing with the three-way valve 1702b attached as shown,
when
the valve 1702b is fully closed, the plasma 108 of FIGURE 1 was discharged
from the
plasma arc torch 100 and was measured with an optical pyrometer. With the
gases
produced from the cell 500 as shown in FIGURES 6 and 7, the plasma 108
temperature
was measured at +3,000 C (+5,400 F). With only air, the plasma 108 was
measured at
+2,100 C (+3,800 F). The system was operated with a ceramic tee 1802i attached
to the
plasma arc torch 100. Likewise, a filter screen 1802d was attached to the
plasma arc
torch 100. Wood pellets produced with a pelletizer were placed in the filter
screen 1802d
prior to attaching to the plasma arc torch 100. The steam plasma fully
carbonized the
wood pellets. The plasma arc torch 100 with an attached filter screen 1802d is
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particularly useful for remote and/or stand alone water treatment and black
water (raw
sewage) applications.
[0098] Resistive Heating/Dead Short Mode
[0099] The plasma arc torch 100 or 1100 is started by dead-shorting the
cathode 112 to
the anode nozzle 106 with power supply 130 in the off position. Next, the
vessel 104 is
partially filled by jogging the pump 1704. Next the power supply 130 is turned
on
allowing the system to operate in a resistive heating mode. The benefit to
this system is
preventing the formation of gases such as chlorine if sodium chloride is
present within the
water and/or wastewater. The fluid, water and/or wastewater is heat treated
which is
commonly referred to as pasteurization.
[00100] Submerged Arc Oxidation And Combustion Mode
[00101] If the system is to be operated in a submerged arc mode, the cathode
112 is
simply withdrawn from the anode nozzle 106. A submerged arc will be formed
instantly.
This will produce non-condensible gases such as hydrogen and oxygen by
splitting water.
In order to aid in forming a gas vortex around the arc gases such as but not
limited to
methane, butane, propane, air, oxygen, nitrogen, argon, hydrogen, carbon
dioxide, argon,
biogas and/or ozone or any combination thereof can be added between the pump
and inlet
1702a or 1702b with an injector (not shown). However, it is well known that
hydrogen
peroxide will convert to oxygen and water when irradiated with UV light. Thus,
the
plasma arc torch 100 or 1100 will convert hydrogen peroxide to free radicals
and oxygen
for operation as an advanced oxidation system.
[00102] On the other hand, the present invention's submerged arc mode is
ideally
suited for submerged combustion. It is well known that submerged combustion is
very
efficient for heating fluids. Likewise, it is well known and understood that
gases and
condensates are produced along with heavy oil from oil and gas wells. In
addition, the oil
sands froth flotation process produces tailings and wastewater with residual
solvent and
bitumen. The remaining fossil fuels left in produced water and/or froth
flotation
processes can be advantageously used in the present invention. Since the
plasma arc
torch 100 or 1100 is a cyclone separator then the lighter hydrocarbons will
report to the
plasma center. Consequently by sparging air into the plasma arc torch 100 or
1100 it can
be operated as a submerged arc combustor.
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[00103] For example, to ensure that the arc is not extinguished a second
electrode 1102
can be added to the plasma arc torch 100 or 1100 as shown in system 1910
(FIGURE 19).
Air and/or an air/fuel mixture can be flowed into the tee 1802i and converted
into a
rotating plasma arc flame. The fluid to be heated will enter into one volute
while exiting
the other volute in combination with hot combusted gases. On the other hand,
the air/fuel
may be added to the fluid entering into the plasma arc torch 100 or 1100.
Three-way
valve 1702b would be shut. Thus, the mixture of combusted gases and water
would flow
through the anode nozzle and exit out of the tee 1802i. A volute 1802b or
cyclone
separator 1802a may be used in lieu of the tee 1802i. If a cyclone separator
1802a is
used, then the plasma arc torch 100 or 1100 can be operated as a torch while
shooting a
plasma into the vortex of the whirlpool of water within the cyclone separator
1802a. The
benefit of the second (+) electrode 1102 is to ensure that the arc remains
centered and is
not blown out. The discharge from the tee 1802i, volute 1802b or cyclone
separator
1802a would be flowed into a tank (not shown) or stand pipe thus allowing
complete
mixture and transfer of heat from the non-condensible gas bubbles to the
water/fluid.
[00104] Electrolysis Mode
[00105] In order to transition to an electrolysis mode the electrode 112 is
withdrawn a
predetermined distance from the anode nozzle 106 or anode electrode 1102. This
distance is easily determined by recording the amps and volts of the power
supply as
shown by the GRAPH in FIGURE 3. The liquid level 1106 is held constant by
flowing
liquid into the plasma arc torch 100 or 1100 by jogging the pump 1704 or using
a variable
speed drive pump to maintain a constant liquid level.
[00106] Although not shown, a grounding clamp can be secured to the vessel 104
in
order to maintain an equidistant gap 420 between the vessel 104 and cathode
112,
provided the vessel is constructed of an electrically conducted material.
However, the
equidistant gap 420 can be maintained between the anode nozzle 106 and cathode
112
and electrically isolating the vessel 104 for safety purposes. Glass and/or
ceramic lined
vessels and piping are common throughout many industries.
[00107] By operating in an electrolysis mode this allows for the production of
oxidants
in particularly sodium hypochlorite (bleach), if sodium chloride is present or
added to the
water. Bleach is commonly used on offshore production platforms for
disinfecting
sponsoon water, potable water and raw sewage. Since electrolysis is occurring
between
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and within the equidistance gap 420 between the (+) anode nozzle 106 and (-)
cathode
electrode 112 the present invention overcomes the problems associated with
electrolyzers
used on production platforms as well as ships for ballast water disinfection.
[00108] By installing two or more plasma arc torches 100 or 1100, one can be
operated
in a submerged arc combustion mode, while the other is operated in an
electrolysis mode.
The submerged plasma arc combustor 1910 would be configured as shown in FIGURE
19
with a tee 1802i and electrode 1802j and an air ejector would siphon the
hydrogen
generated from the plasma arc torch 100 or 1100. Another benefit for using the
plasma
arc torch 100 or 1100 in a combustion mode is that the Ultraviolet ("UV")
Light produced
from the plasma arc and the electrodes will dechlorinate the water thus
eliminating adding
a reducing agent to the water.
[00109] A simple but effective raw sewage system can be constructed by
attaching the
plasma arc torch 100 or 1100 to a common filter vessel in which the filter
screen would
be coupled directly to the plasma arc torch 100 or 1100. Referring to FIGURE
19 the
plasma arc torch 100 or 1100 is coupled to the filter screen 1802d in system
1902. The
filter screen 1802d is then inserted into a common filter vessel up to the
filter screen
1802d flange. The plasma arc torch 100 or 1100 is operated in an electrolysis
mode
allowing the raw sewage to flow through the anode nozzle and into the filter
screen.
Solids would be trapped in the filter screen.
[00110] The filter screen can be cleaned by several methods. First the screen
can
simply be backwashed. Second the screen can be cleaned by simply placing the
plasma
arc torch 100 or 1100 in a plasma arc mode and either steam reforming the
solids or
incinerating the solids using an air plasma. However, a third mode can be used
which
allows for a combination of back washing and glow discharge.
[00111] Glow Discharge Mode
[00112] To transition to glow discharge mode, the liquid level 1106 is
decreased by
throttling three-way valve 1702b until the plasma arc torch 100 or 1100 goes
into glow
discharge. This is easily determined by watching volts and amps. When in glow
discharge the power supply voltage will be at or near open circuit voltage.
However, to
rapidly transition from electrolysis to glow discharge the cathode electrode
is extracted
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until the power supply is at OCV. This can be determined by viewing the glow
discharge
thru a sight glass or watching the voltage meter.
[00113] This novel feature also allows for fail safe operation. If the pump
1704 is
turned off or fluid flow is stopped then all of the water will be blown down
through the
anode nozzle 106 of the plasma arc torch 100 or 1100. Electrical flow will
stop and thus
the system will not produce any gases such as hydrogen.
[00114] To control the liquid level a variable speed drive pump in combination
with
three-way valve 1702c may be used to control the liquid level to maintain and
operate in
a glow discharge mode. Another fail safe feature, such as a spring, can be
added to the
linear actuator such that the system fails with the cathode fully withdrawn.
[00115] The mode of operation can be reversed from glow discharge to
electrolysis to
arc and then to resistive heating. By simply starting with the cathode 112
above the water
level 1106 within the vessel 104, then slowly lowering the cathode 112 to
touch the
surface of the liquid, the plasma arc torch 100 or 1100 will immediately go
into glow
discharge mode. Continually lowering the cathode 112 will shift the system to
electrolysis then to arc then to resistive heating.
[00116] Now to operate the plasma arc torch 100 or 1100 as a plasma torch,
water/liquid flow may be reversed and blowdown three-way valve 1702c is fully
opened
to allow the plasma to discharge from the plasma arc torch 100 or 1100. Adding
an
anode electrode 1102 will aid in maintaining an arc. However, if a sufficient
amount of
gas in entrained in the water and a gas vortex is formed, the water/liquid can
be flowed
through the plasma arc torch 100 or 1100 in a plasma arc mode.
[00117] Although no granular media is needed for this configuration it will be
understood that granular media may be added to enhance performance. Likewise,
what
has not been previously disclosed is that this configuration always for
purging the vessel
and removing the granular media by reversing the flow through the system.
Referring to
FIGURE 1 outlet 136 is used as the inlet and inlet 120 is used as the outlet.
This
configuration will work for any fluid whether it is more dense or less dense
than water
and/or the liquid flowing through the system. If the material density is
greater than the
liquid the granular material will flow through 120. If the material is less
dense then the
liquid then it will flow through the nozzle.
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[00118] In particularly, remote applications that are in dire need of a
solution are
potable water treatment and black water (raw sewage) treatment. For example,
remote
water and wastewater applications can be found on offshore drilling rigs,
offshore
production platforms, ships, cabins, base camps, military posts/camps, small
villages in
desert and/or arid environments and many developing countries that do not have
centralized water and wastewater treatment facilities. Another remote
application is
electricity produced from wind and solar farms. Likewise, oil and gas wells
that are not
placed in production such as stranded gas can be considered a remote
application. Also,
after a natural disaster, such as a hurricane or tsunami basic services such
as garbage/trash
collection, water treatment and wastewater treatment facilities may be
destroyed, thus
there is a dire need for water disinfection as well as raw sewage treatment in
addition to
handling the buildup of trash.
[00119] The inventor of the present invention has tested this configuration
with an
ESAB EPW 360 power supply. The EPW 360 is a "Chopper" type DC power supply
operating at a frequency of 18,000 Hertz. The above described configuration
held voltage
at an extremely steady state. The discharge 134 was throttled with a valve.
Whether the
valve was open, shut or throttled the voltage remained rock steady. Likewise,
the EPW
360 current control potentiometer was turned down to less than 30 amps and the
electrodes were positioned to hold 80 volts. This equates to a power rating of
about 2,400
watts. The EPW 360 is rated at 360 amps with an open circuit voltage of 360
VDC. At a
maximum power rating of 129,600 watts DC, then: 129,600 2,400 = 54.
[00120] Consequently, the plasma arc torch 100 of the present invention
clearly
demonstrated a turn down rate of 54 without any additional electronic
controls, such as a
secondary high frequency power supply. That is virtually unheard of within the
plasma
torch world. For example, Pyrogensis markets a 25 kw torch operated in the
range of 8-
25kW (A 3:1 turn down ratio). Furthermore the present invention's plasma arc
torch 100
does not require any cooling water. The Pyrogensis torch requires cooling with
deionized
water. Deionized ("DI") water is used because the DI water is flowed first
into one
electrode then into the shield or another part of the torch. Consequently, DI
water is used
to avoid conducting electricity from the cathode to the anode via the cooling
media. In
addition, heat rejection is another impediment for using an indirectly cooled
plasma torch.
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An indirectly cooled plasma torch may reject upwards of 30% of the total input
power
into the cooling fluid.
[00121] The plasma arc torch 100 as disclosed in FIGURES 1, 6, 7 is a
liquid/gas
separator and extreme steam superheater forming an ionized steam/hydrogen
plasma
when coupled to the glow discharge cell 500 and/or any steam source. As
disclosed in
FIGURES 6 and 7, the plasma arc torch 100 can easily be controlled by
manipulating
valves 604 and 606. Moreover, the plasma arc torch 100 as shown in FIGURE 1 is
similar to a blow-back torch. For example the (-) negative electrode 112 will
dead short
and shut flow through the (+) anode nozzle 106 by adjusting the linear
actuator 114.
However, by adding control valve 604 to the discharge 134, this allows for the
plasma arc
torch 100 to be operated in a resistive heating mode.
[00122] Now referring to FIGURE 20, a system, method and apparatus for
continuously feeding electrodes within a cyclone reactor is shown. For
example,
electrode feeder A feeds in-line and countercurrent to the first electrode
along the
longitudinal axis of ArcWhirl 100. On the other hand, electrodes may be fed
perpendicular to one another as shown by Electrode Feeder B. It will be
understood that
only one multi-mode torch 100 may be necessary for processing feed material
which has
been pretreated such as quenched filter cake from a heavy oil, bitumen or
petroleum coke
gasifier. Likewise, petroleum coke from a delayed coker can easily be plasma
steam
reformed with the system, method and apparatus of the present invention.
[00123] A preferred method for pretreating high moisture filter cake from an
oil sands
gasifier is with Electromagnetic Radiation (EMR). Specifically, the preferred
EMR is
within the Radio Frequency spectrum and more specifically within the microwave
range.
In particular, the ideal frequencies range from 915 MHz to 2.45 GHz.
[00124] It is well known and well understood that polar material will absorb
microwaves as well as ionized gases, for example plasma. An ideal reactor for
enhancing
plasma and/or coupling to plasma and material to be treated is disclosed in
FIGURE 22.
FIGURE 21A discloses top injection of microwaves into a cyclone reactor while
FIGURE 21B discloses side injection of microwaves into the cyclone.
[00125] Returning to FIGURE 6, the ideal cyclone separator 606 for the present
invention is disclosed in FIGURE 20 and FIGURE 21. In particular FIGURE 21
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discloses a multi-entry or multi-exit cyclone that incorporates 4
inlets/outlets to stabilize
the rotating WHIRL of fluid.
[00126] In addition, referring to the tangential entry volutes disclosed as
the first end
116 and second end 118 of FIGURE 1, an ideal whirl generator, commonly
referred to as
a vortex generator or cyclone separator, is disclosed in FIGURES 21A and 21B.
The
multiple inlets/outlets allow for stabilizing the whirl without forming a
pressure gradient
typical on single entry cyclones. In addition, many cyclones utilize an
involute for
enhancing separation of matter. However, the involute feed housing is prone to
erosion at
the wall fluid curve interface. On the other hand, the present invention uses
the velocity
of fluid jets impinging on one another to prevent wall erosion while also
eliminating a
pressure gradient. A single entry cyclone separator produces a pressure
gradient with a
whipping tail of less dense fluid exiting and whipping 180 out from the inlet
of the
cyclone separator. In many applications the pressure gradient may not affect
the
operation of the cyclone.
[00127] However, when stabilizing and centering an arc is critical then
producing a
pressure gradient can lead to destabilizing the whirling center of plasma.
Consequently,
the arc may be extinguished or in a worse case scenario the arc may be pushed
away from
the anode nozzle and transferred to the wall or vessel. This could result in
melting the
reactor vessel. Hence, a ceramic electrical insulator is used as shown in
FIGURES 20
and 21.
[00128] When the multiple inlet/outlet ceramic cyclone shown in FIGURE 21 is
used
as the cyclone 601 as shown in the FIGURE 6, the plasma injected into the
cyclone can
be enhanced and coupled to with RF energy. However, it is critical that the
ceramic be
permeable or transparent to EMR within microwave frequency range from 915 Mhz
to
2450 Mhz (2.45 GHz). It will be understood that the microwaves may be injected
directly into the eye of the whirling fluid or through the side of the ceramic
that is
transparent to microwaves. The shell of the vessel should be made of microwave
blocking or opaque material.
[00129] FIGURE 22 discloses a system, method and apparatus for co-injecting
microwaves and filter cake directly into the whirling plasma. The microwaves
will
pretreat the material prior to entering into the eye of the whirling fluid. A
waveguide
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directs the microwaves perpendicular to the travel of the filter cake. A screw
feeder
pushes the material directly into the eye of the plasma.
[00130] Turning now to FIGURE 23, the co-injected microwaves and filter cake
may
be fed directly in the plasma which then flows into the cyclone separator and
allows for
pretreating the filter coke prior to injection into cyclone separator 100.
[00131] FIGURE 24 discloses a system, method and apparatus for injecting the
plasma
from the ArcWhirl Torch 100 directly into the eye of a cyclone separator.
Feed
material, such as filter cake, is pretreated first with EMR within the radio
frequency range
specifically within the microwave frequency range, then injected directly into
the hot
1() ionized plasma gas stream using a conveyance means such as a screw
feeder. A quench
fluid may be used for quenching the reaction between plasma and the feed
material.
[00132] Turning now to FIGURE 25 while referring to FIGURE 21, feed material
such
as filter cake or petroleum cake may be injected into the cyclone separator
via a tangential
entry. Likewise, feed material may be pretreated with microwaves prior to
injection into
the plasma.
[00133] FIGURE 26 discloses a system, method and apparatus for continuous
operation of the Plasma ArcWhirl torch. By installing a second anode
electrode and
linear actuator the arc can be transferred from the first electrode of 100 to
anode nozzle
and then to the anode electrode. This allows for an extremely high turn down
rate.
[00134] EXAMPLE 8 - ARCWHIRL TORCH WITH ANODE ELECTRODE,
LINEAR ACTUATOR
[00135] The following example with unexpected results will clearly demonstrate
a
novel and unobvious multi-mode plasma torch. The ArcWhirl Torch as shown in
FIGURE 1 and FIGURE 11 was electrically connected to an ESAB ESP150 plasma arc
power supply ("PS"). The ESP150 PS was modified to operate in a load bank mode
similar to a dead short. The ArcWhirl Torch of FIGURE 1 operated with voltage
spikes
which is typical of non-transferred arc torches due to the arc dancing around
the anode
nozzle. The minimum amps required to sustain an arc was 50 amps.
[00136] However, when an additional anode electrode 1102 was added as
disclosed in
FIGURE lithe current potentiometer was rotated to its minimum position at a
current
load of less than 30 amps. With a welders helmet with a #13 shield the arc was
visibly
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seen and was indeed transferred between the carbon gouging electrodes. The arc
was
maintained in a steady state. Once again this allows for an unlimited flow
rate of fluid
through the anode nozzle without extinguishing the arc.
[00137] EXAMPLE 9 - HYBRID MICROWAVE PRETREATMENT ARCWHIRL
TORCH FOR CALCINING AND STEAM REFORMING PETROLEUM COKE
[00138] Petroleum coke in the form of a pressed filter cake with a moisture
content of
85% produced from an oil sands gasifier was fired with an air ArcWhirl plasma
torch as
shown in FIGURE 6 utilizing the multi-inlet/outlet cyclone of FIGURE 20 and
21. The
coke glowed to red heat within seconds but acted as a thermal insulator.
However, as the
pet coke particles broke off from the large piece, particle to particle
collision comminuted
the large piece. The smaller particles glowed red hot instantly when exposed
to the air
plasma. Thus, this gives rise to a system, method and apparatus for treating
pet coke
produced with delayed cokers in refineries and filter cake produced from
quenching
syngas produced from gasifying oil sand bitumen.
[00139] Next, the pet coke was placed inside an induction coil powered by an
Ambrel
50/30 EKOHEAT Induction Power Supply. The EKOHEAT PS is rated at:
Max Power (kW) 50
Frequency (kHz) 15-45
Line Voltage (Vac) 360 - 520, three phase
Input Max (kVA) 58
The RF within the above frequency range did not couple to the pet coke. The
pet coke
was transparent to EMR within the 15-45 kHz frequency range.
[00140] Next, a sample from the same pet coke batch containing vanadium and
nickel
was placed in a standard microwave oven operating at a frequency of 2.45 GHz.
Within
seconds of energizing the microwave oven, arcs and sparks flashed within the
oven
producing bright white flashes of light. The oven was operated for 15 seconds.
After
opening the door the pet coke was fluctuating and flickering with red hot
spots.
[00141] The sample was then crushed and placed back into the microwave oven.
What
occurred next was completely unexpected when compared and contrasted to the
first
sample. The pet coke began to turn red hot then burst into an orange flame.
Within
seconds the orange flame transitioned to a blue flame.
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[00142] Another test was performed by placing a Pyrex cover over the sample
to
eliminate air. The pet coke sample with the cover was placed back in the
microwave
oven and irradiated for 15 seconds. An initial orange flame was observed for
only a few
seconds then extinguished and the pet coke began to glow red hot in the
absence of
oxygen.
[00143] The sample was taken out of the microwave and allowed to air cool for
2
hours. However, after 2 hours, particles were still glowing red hot within the
crushed pet
coke sample.
[00144] This microwave pretreatment process step prior to injection into a
plasma
torch gives rise to an entirely new system, method and apparatus for
calcining, oxidizing
and steam reforming. Quite simply by coupling microwaves to pet coke and
allowing any
leakage of microwaves to irradiate the plasma arc allows for a highly
efficient and nearly
leak free Hyrbrid Microwave Plasma Torch. In its simplest explanation any form
of pet
coke including coal may be used as a susceptor to ignite and sustain plasma.
The addition
of steam plasma to the pretreated red hot pet coke allows for a system for
producing
copious amounts of hydrogen and/or syngas.
[00145] EXAMPLE 10 - HYBRID MICROWAVE GLOW DISCHARGE
STEAM/HYDROGEN WATER GAS SYSTEM
[00146] As previously disclosed the pet coke was heated to red hot with only
microwaves. Likewise, copious amounts of steam/hydrogen can be generated with
the
solid oxide high temperature glow discharge cell as disclosed in FIGURES 4 and
5.
Consequently, this gives rise to an entirely unobvious and unique system for
processing
petroleum coke based upon the desired end product.
[00147] Returning back to FIGURES 22-26 steam and hydrogen can be produced
with
the ArcWhirl when operated in a Glow Discharge Mode. The steam/H2 mixture
exits
nozzle V3 and immediately comes into contact with red hot coke irradiated with
microwaves. Thus, this novel process is a unique way for producing Water Gas,
for
example:
H20 + C ¨> H2 + CO (AH = +131 kJ/mol)
[00148] In the event a steam plasma is required then the Multi-Mode ArcWhirl
Torch
is switched to the plasma arc mode. Another multi-mode ArcWhirl Torch
operated in a
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glow discharge mode would be placed upstream to produce steam/H2 for the
ArcWhirl
operated in a plasma arc mode.
[00149] This configuration is disclosed in FIGURE 6 wherein ArcWhirl 100 and
Cyclone 610 are replaced with any one of the configurations disclosed in
FIGURES 20
thru 27. The attachment devices selected from FIGURE 18 would be the microwave
waveguide, screw feeder (auger) and cyclone as retrofits to FIGURE 6 in order
to carry
out the present invention.
[00150] FIGURE 27 discloses a means for adding additional EMR and heat to the
gas
stream exiting V3 by heating the anode nozzle with an induction coil. This
allows for
preserving the anode nozzle and simply using RF energy to heat the graphite
nozzle.
[00151] FIGURE 28 discloses two ArcWhirls in series to form a unique system
for
operating two identical multi-mode plasma torches in different modes.
[00152] FIGURE 29 discloses another configuration using two ArcWhirls piped
in
series that can be operated in different modes based upon the application and
desired end
products.
[00153] FIGURE 30 discloses a means for combusting and/or quenching the
products
produced from the multi-mode Plasma ArcWhirl Torch. By attaching the ArcWhirl
Torch 100 to a peripheral jet eductor/ejector, products may be quenched when a
quench
fluid is flowed into the second compressor and/or pump. However, the syngas
can be
thermally oxidized or combusted by flowing air into the peripheral jet
eductor/ejector via
the second compressor. An extremely hot flame will exit the peripheral jet
eductor at a
very high velocity that can be used for thrust, heating and rotational energy.
[00154] FIGURE 31 discloses a means for countercurrent flowing material to be
treated via an auger and stinger electrode aligned along the longitudinal axis
of the multi-
mode ArcWhirl Torch. Returning to FIGURE 11 and Example 8, the additional
stinger
electrode allows for high turn down rates. The peripheral jet eductor/ejector
allows for
rapid quenching or thermal oxidation based upon the desired solution. Once
again,
although not shown, microwaves can be introduced into the stinger tube to
pretreat
material, for example pet coke, prior to injection into the steam plasma or
just steam if
operated in a Glow Discharge Cell ("GDC") GDC mode.
[00155] EXAMPLE 11 - BLOWBACK ARC WHIRL TORCH
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[00156] FIGURE 32A discloses a unique configuration similar to the ArcWhirl
Torch 100 of
FIGURE 1 utilizing the electrode and piston configuration as shown in FIGURE
15 that can be
operated as a blowback torch. Blowback plasma torches are well known and well
understood.
By including a spring behind the piston, this keeps the electrode piston in
contact with the
electrode nozzle for operating in a dead short. Although not shown, the
electrode rod may be
controlled separately with a linear actuator. When it is necessary to operate
in another mode, the
valve on the tangential exit is throttled, thus forcing the electrode piston
to move away from the
electrode nozzle. If for example, air or steam is flowed into the torch, then
a plasma arc will be
formed between the electrode rod, electrode nozzle and electrode plasma.
[00157] As previously disclosed, the major problem with blowback torches and
all other
plasma torches is a lack of throttling the plasma gas. The gas is regulated
prior to entry into the
torch. However, the present invention's blowback torch regulates the gas on
the discharge
tangential exit. Consequently, this allows for high turn down rates. Likewise,
the electrode
piston allows for operating in any mode previously described ¨ resistance
heating, plasma arc,
glow discharge, electrolysis and submerged arc.
[00158] Referring now to FIGURE 32B, by replacing the spring with a
hydraulic/pneumatic
port and electrically isolating the electrode piston from the electrode rod,
the system can be
powered with two separate power supplies. Thus, this allows the same system to
be operated in
separate multi-modes. For example, by adding another electrode rod 1102 as
shown in FIGURE
11 to the discharge of the electrode nozzle, then the electrode nozzle and
electrode piston can be
operated in a glow discharge mode by utilizing an electrolyte while the two
electrode rods can be
operated in a plasma arc mode to convert the steam/H2 mixture into a steam/H,
plasma. This
configuration does not require a solid oxide between the equidistant gap.
[00159] EXAMPLE 12- THREE PHASE AC ARC WHIRL TORCH
[00160] Thus far the present invention has been disclosed with the use of a
DC power supply.
However, the invention as disclosed in FIGURES 33A and 33B allows for
operation with
alternating current ("AC") by electrically connecting the three electrodes,
electrode rod, electrode
piston and electrode nozzle to Li, L2 and L3 respectively of a three wire
power cable to an AC
source located on the surface.
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[00161] EXAMPLE 13 - MULTI-MODE PLASMA RESISTOR
[00162] FIGURE 34 discloses a novel and unobvious liquid resistor using the
multi-
mode ArcWhirl Torch 100 as a resistor within a series circuit. Liquid
resistors are well
known and well understood. Likewise, resistive wire type resistors are well
known and
well understood.
[00163] Wire Resistors typically produce waste heat. Likewise, liquid
resistors
produce steam and/or hot water as waste heat. Power supplies incorporating
resistors
normally are not designed to make use of the waste heat. However, the present
invention
has clearly shown that the multi-mode torch can make steam/H2 from an
electrolyte.
Likewise, when the ArcWhirl Torch 100 is operated in a glow discharge mode it
operates in a very predictable manner. For example, an ESAB ESP 150 has been
operated with ArcWhirl Torch 100 and the device shown in FIGURES 4 and 5.
When
operated as a Glow Discharge Cell ("GDC") the only necessary control parameter
is a
pump or a linear actuator or combination of both.
[00164] Referring to the graph in FIGURE 3, liquid level determines current
flow
(amps). Likewise, electrode depth for the ArcWhirl Configuration as shown in
FIGURE
12 would determine current flow and voltage. Controlling liquid level and
electrode
depth would give precise control for varying resistance, by varying voltage
and current.
Hence, the use of the present invention as a variable resistor with the
ability to recover
heat by using the steam/H2 mixture as the plasma gas in a separate ArcWhirl
Torch 100
or for general heating purposes.
[00165] EXAMPLE 14 - VARIABLE PLASMA RESISTOR FOR HEAT,
HYDROGEN AND 380 VDC BUILDINGS
[00166] An exemplary use for the present invention's Variable Plasma Resistor
("VPR") is for rectifying three phase AC to 380 VDC. Turning now to FIGURE 35,
the
Variable Plasma Resistor can be placed in parallel with a load in particular a
380 VDC
load. By allowing the water to run at a low level within the VPR when
operating in a
steady state as a GDC only a small of amount of current is used, thus
producing a small
amount of heat for hotel services while providing full current load to a
building. When
more heat is required water is added to the VPR, thus increasing steam/H2
production but
reducing the available current to the 380 VDC Building.
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[00167] EXAMPLE 15 - DOWNHOLE ENHANCED OIL RECOVERY WITH
VARIABLE PLASMA RESISTOR HEATER
[00168] FIGURE 36 discloses a unique system, method and apparatus for enhanced
oil
recovery. Returning back to Example 4 the GDC of FIGURE 4 and 5 discloses a
surface
method for generating steam for enhanced oil recovery ("EOR"). The device is
well
suited for surface production of steam using DC power. DC electrical leads
from the
power supply to the ArcWhirl Torch are limited in length due to voltage drop.
[00169] However, when diodes (rectifier) are packaged with the GDC of the
present
invention the downhole heating tool may be small enough in diameter to insert
within the
well bore. Thus, widely available downhole power cable available from GE,
Boret and
Schlumberger can be used to provide AC power to the integrated Rectifier
Variable
Resistor Plasma Heater. Likewise, by selecting the appropriate electrolyte for
the
formation, hydrogen, steam and CO2 can be produced for maintaining pressure
within the
formation by producing a non-condensible gas.
[00170] EXAMPLE 16- PLASMA DRILLING IN PLASMA ARC WHIRL MODE
[00171] The configuration as shown is FIGURE 36 can be used to produce a true
plasma arc downhole. First, steam would be produced on the surface with a
separate
GDC and then the steam would be flowed downhole into the Plasma ArcWhirl Tool
for
plasma drilling. This allows for eliminating the entire mud system commonly
found on
drilling rigs by melting the formation and producing a slag that results in
90% volume
reduction from original hole volume. In previous testing, the inventor of the
present
invention melted drill cuttings and achieved a 90% volume reduction.
Consequently, the
molten slag would form a ceramic type casing. The ideal ArcWhirl design may
be the
blowback piston or pneumatic/hydraulic piston as shown in FIGURES 32 and 33.
[00172] FIGURE 37 discloses a three phase AC Plasma ArcWhirl downhole tool
that
may also be used for downhole steam generation for EOR or for plasma drilling.
The
ArcWhirl shown in FIGURE 33B can operate with three phase AC power. Likewise,
FIGURE 11 can be configured to be operated with three phase AC power.
[00173] FIGURE 38 discloses a novel material treating system that uses
Variable
Plasma Resistors (VPR) wired in parallel with a large ArcWhirl Torch. The
bulk of the
DC current would flow into the carbon electrode 112 and carbon electrode
nozzle(not
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shown) while VPR-1 through VPR-4 are wired in parallel with the carbon
electrode 112
and nozzle butoperated individually to produce steam, hydrogen, disinfected
water,
ozone, air plasma, oxygen plasma and hot water that may be discharged into the
large
ArcWhirl Torch are discharged through their respective outlets.
[00174] EXAMPLE 17 - PLASMA ARCWHIRL KIT FOR CONVERTING
CARBON ARC GOUGING TORCH INTO PLASMA TORCH/WELDER
[00175] FIGURE 39 discloses a system, method and apparatus for retrofitting
and
converting a carbon arc gouging torch into an ArcWhirl Torch. The carbon arc
gouging
torch with the Plasma ArcWhirl Retrofit kit can now be operated in multi-
modes for
carbon arc gouging, plasma gouging, plasma welding, plasma marking, plasma
spraying,
plasma coating and plasma cutting applications.
[00176] Turning now to FIGURE 39, a carbon arc gouging torch such as an Arcair
N7500 System is coupled to the ArcWhirl First End 116 via the Arcair torch
head
nozzle. Consequently, the Arcair Gouging Torch then becomes both the
electrode
housing 122 and the linear actuator 114 for the ArcWhirl 100.
[00177] The Plasma ArcWhirl conversion kit now allows for a standard off-the-
shelf
carbon arc gouging torch to be operated as a non-transferred plasma arc torch,
plasma
welder, plasma sprayer, plasma cutter and plasma marker. When attached to an
identical
Plasma ArcWhirl that is operated in a glow discharge mode, then the system
can be
operated with a steam/hydrogen plasma. This opens the door for reducing the
costs for
cutting risers off castings, plasma steam/hydrogen cutting thick plate steel
and aluminum,
steam plasma preheating ladles, steam plasma heat treating and steam plasma
reforming.
[00178] In addition, the Plasma ArcWhirl Gouging and Welding Torch can be
operated as an inert Steam/Hydrogen Plasma Welder. For example, the carbon
electrode
would be replaced with a tungsten electrode. The plasma arc would be
constricted with
the steam/hydrogen gas. The Plasma ArcWhirl torch differs from all other
plasma
torches by using the discharge valve to throttle the gas going through the
nozzle. This
allows for an extremely high turn down rate while also allowing for welding or
cutting
based upon the velocity of the plasma gas exiting from the nozzle. Quite
simply, to weld
the throttling valve would be fully open thus allowing for a low velocity
plasma jet
exiting from the nozzle. To plasma cut, the throttle would be shut thus
forcing all of the
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gas through the nozzle to produce an extremely high velocity plasma jet for
severing and
blowing slag out of the way.
[00179] EXAMPLE 18 - ARC WHIRL COANDA EFFECT PLASMA
[00180] FIGURE 40 discloses a unique system, method and apparatus for using
the
Coanda Effect to wrap plasma around a graphite electrode. The Coanda Effect is
the
tendency of a fluid jet to be attracted to a nearby surface. The principle was
named after
Romanian aerodynamics pioneer Henri Coanda, who was the first to recognize the
practical application of the phenomenon in aircraft development. Dual
ArcWhirls
Torches 100 couple the arc to a graphite electrode thus allowing for 24/7
operation with
an extremely steady voltage. The plasma wraps around the graphite electrode
and enters
into the coanda plasma gap 39108. Material to be treated is fed directly into
the plasma
gap 39108.
[00181] FIGURE 41 discloses another system, method and apparatus for using the
Coanda Effect to transfer an electrical arc to a graphite electrode thus
sustaining and
confining the plasma. Although two ArcWhirl torches are shown it will be
understood
that only one torch is necessary to operate as a Coanda Effect Plasma System.
The
ArcWhirl Torch arc attaches itself to the central graphite electrode while
the plasma
wraps around the electrode. Thus, this allows for feeding a large central
electrode and
smaller electrodes within the torch for continuous duty operation.
[00182] EXAMPLE 19 - RECOVERING MINING FLUIDS FROM MINING
BYPRODUCTS
[00183] Turning now to FIGURE 42, an embodiment of the Steam Plasma Unit of
FIGURE 1 is disclosed as a counter current plasma system 4200 showing a graph
with a
temperature vs. phase graph. A plasma torch 100 is attached to a feed unit
4202. The
plasma torch 100 may be selected from a DC arc torch, AC arc torch, microwave
torch,
inductively coupled plasma torch and/or any combination thereof The feed unit
4202
may be selected from a screw press, hydraulic press, an auger with a well
screen, a
concrete pump with a sintered metal screen and/or any means for conveying
solid
material while separating fluids from the solids. As shown, the feed unit 4202
includes
filter screen 1802d attached to the output of a screw feeder 1802g where a
portion of the
filter screen 1802d is enclosed within a tee 1802i. The longitudinal axis 124
of the
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plasma torch 100 is preferably aligned with a longitudinal axis of the feed
unit 4202.
Mining byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g.,
drilling fluids,
etc.) (collectively 4204) are feed into the inlet 4206 of the feed unit 4202
where the screw
feeder 1802g pushes the mining byproducts towards the nozzle 106 of the plasma
torch
100.
[00184] Steam 4208 is flowed into the tangential inlet 120 of the Plasma
ArcWhirl
torch 100 where the steam 4208 is converted to a steam plasma 4210 and exits
through
the nozzle 106. It is well known that there are 4 states of matter ¨ solid,
liquid, gas and
plasma. The graph 4200 discloses the phases the steam plasma 4210 goes through
as it
contacts the byproducts (e.g., drill cuttings, etc.) containing mining fluids
(e.g., drilling
fluids, etc.) (collectively 4204) that are flowed counter current to the steam
plasma 4210.
As the steam 4208 enters into the ArcWhirl Torch 100 through the tangential
inlet 120,
the steam 4208 traverses around, through and forms a Plasma Arc ("PA"). The
ionized
gas exiting from the nozzle 106 is a Steam Plasma ("SP") 4210. As shown in
FIGURES
17-18, 22-27, 30-31 and 39 a valve may be attached to the tangential exit 136
of the
ArcWhirl Torch 100. This allows for throttling and controlling the amount of
Steam
Plasma 4210 exiting from the nozzle 106. Consequently, this allows for a 100:1
turn
down rate of the system. Furthermore, the tangential exit 136 allows for
backflowing
mining byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g.,
drilling fluids,
etc.) (collectively 4204) all the way into the ArcWhirl Torch 100. This
feature sets the
Plasma ArcWhirl Torch apart from all other plasma torches currently being
marketed
and sold today. The ArcWhirl Torch can also be operated as a steam/water
quench
reactor.
[00185] As the Steam Plasma 4210 traverses through the filter screen 1802d and
directly contacts the mining byproducts (e.g., drill cuttings, etc.)
containing mining fluids
(e.g., drilling fluids, etc.) (collectively 4204), the Steam Plasma 4210 gives
up some of its
heat and its temperature is reduced to form Super Heated Steam ("SS"). As the
Super
Heated Steam flows counter current to the mining byproducts (e.g., drill
cuttings, etc.)
containing mining fluids (e.g., drilling fluids, etc.) (collectively 4204)
through the filter
screen 1892d into tee 1802i, the Super Heated Steam continues to give up heat
and is
converted to Wet Steam ("WS"). The Wet Steam then gives up its last remaining
available latent heat and may condense to Hot Water ("HW"). By pulling a
vacuum on
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the discharge exit 4212 of the tee 1802i, the Hot Water washes the mining
fluids (e.g.,
drilling fluids, etc.) from the mining byproducts (e.g., drill cuttings, etc.)
without cracking
the base fluids to light ends. This is very important for the recovery and
reuse of the base
fluids. The mining fluids (e.g., drilling fluids, etc.) and Hot Water 4214
exit through the
discharge exit 4212 of the tee 1802i. The steam plasma 4210 continues to
process or
"incinerate" the mining byproducts (e.g., drill cuttings, etc.) such that the
processed
byproducts (e.g., drill cuttings, etc.) 4216 are inert and substantially
reduced in volume
and either fall through the filter screen 1802d or exit the end of the filter
screen 1802d.
[00186] Now referring to FIGURE 43, a block diagram of a Closed Loop Drilling
Fluids Recovery System, Method and Apparatus 4300 is shown in accordance with
one
embodiment of the present invention. Mining fluids, Hydrocarbons and Mining
Byproducts 4302 from a drilling rig mud system and/or shaker room 4304 report
to a
shale shaker 4306. Mining Fluids 4308 are returned to the drilling rig mud
system 4304
while cuttings (mining byproducts with residual mining fluids and
hydrocarbons) 4204
fall from the shaker 4306 and into a mud/cuttings pump/conveyor system 4310.
The
pump/conveyor system 4310 may be a cement/concrete pump, centrifugal pump,
progressive cavity pump, screw conveyor, auger, eductor, ejector, ram feeder,
pneumatic
conveyor and/or any conveyance means for transporting the cuttings (mining
byproducts
with residual mining fluids and hydrocarbons) 4204 from the shaker 4306 to the
counter
current plasma system 4200. Alternatively, water 4312 or recovered mining
fluids and/or
water 4314 can be added to the cuttings (mining byproducts with residual
mining fluids
and hydrocarbons) 4204 to form a slurry 4316 to flow the materials through the
counter
current plasma system 4200 more easily.
[00187] The counter current plasma system 4200 produces recovered mining fluid
and
hot water 4214, which reports back to the drilling rig mud system 4304 and/or
is used as a
motive fluid 4314 in the mud/cuttings pump/conveyor 4310 for producing a
slurry 4316
for transport back to the plasma system 4200. The recovered mining fluid and
hot water
4214 may also undergo further processing and/or separation 4316 in which case
the
recovered mining fluid 4318 can be stored or sent back to the drilling rig mud
system
4304. The plasma system 4200 heats and melts the mining byproducts or cuttings
producing a molten slag 4216 that is quenched in a water quench system 4320.
Ideal
fluids for the water quench system 4320 are frack flowback 4322a from a well
that has
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been hydraulically fractured and/or produced water 4322b from a producing
well, but
other sources can be used. This allows for recovering and recycling water in
lieu of
injection into a disposal well. Gases (e.g., inert gases, hydrogen, syngas,
etc.) from a gas
source 4324 may also be injected into the plasma system 4200.
[00188] An inert vitrified slag 4326 is removed from the water quench unit or
vessel
(quencher) 4320 that may be used in construction and metallurgical
applications, such as
roads on the farm, ranch or property where the well is drilled. The slag 4326
may be
suitable for grinding and use as a cement additive for cementing the well.
Likewise,
another alternative use for the slag 4326 may be as a proppant or proppant
ingredient.
Hence, the slag 4326 is a fully fired ceramic material. Thus, the use of the
slag 4326 as a
cement or proppant additive allows for returning the material back into the
well. It will
be understood that frack flowback 4322a and/or produced water 4322b contains
insoluble
salts/chlorides. Thus, the quench water can be concentrated and thus only
concentrated
brine 4328 will need to be disposed of via an injection well. This will reduce
transportation costs.
[00189] The water quench unit or vessel (quencher) 4320 can be rated for
pressure.
Thus, a mixture of steam and/or hot water 4208 can be produced within the
quench vessel
4320. This allows for flowing hot water, steam and/or a combination of both to
the
plasma system 4200 and/or to the cooler/condenser 4330. It will be understood
that the
cooler/condenser 4330 may use any fluid available as the heat exchange fluid.
Clean
water 4332 exits from the cooler/condenser 4330 for reuse and recycle as drill
water
and/or frac water.
[00190] FIGURE 44 is another embodiment of the present invention's plasma
system
4400 disclosing a High Temperature Vessel 4402 for holding vitrified molten
solids 4216.
The operation of the counter current plasma torch 100, filter screen 1802d,
screw feeder
1802g and a tee 1802i were described in reference to FIGURE 42. The mining
fluids and
hot water 4214 flow out of the outlet of the tee 1802i into a primary
separation system
4404, which separates the recovered mining fluids from the water. The
extracted mining
fluids 4318 can be further separated into a recovered mining fluids (product)
4318 and
gases (e.g., hydrogen) 4406 using a degasser 4408. The recovered mining fluids
(product) 4318 can be fed back to the mud system or stored. The gases 4406 can
then be
used to upgrade the fuels sources for diesel engine, gas turbines, boiler,
thermal oxidizers,
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etc. The water from the primary separation system 4404 is feed to a pump or
compressor
4410 to be used as the motive fluid for eductor 4412.
[00191] The high temperature vessel 4402 collects the vitrified solids 4216
dropping
from the filter screen 1802d and allows steam and gases to be extracted to
three-way gas
recirculation valve 4414. The eductor 4412 is used to quench and recover heat
from the
vitrified solids 4216. The resulting vitrified solids slurry 4416 is flowed
into the glow
discharge system 500 of FIGURE 5. The glow discharge system 500 produces steam
and
hydrogen 4418, which are used as the motive gas for thenno-compressor 4420
connected
to the tangential inlet 120 of the counter current plasma torch 100. The
cooled vitrified
solids 4216 exit the bottom of the glow discharge system 500 Steam and gases
from the
three-way gas recirculation valve 4414 are fed to the thermo-compressor 4420
and/or the
feed stream 4204 to the screw feeder 1802g. Hydrogen form the glow discharge
cell 500
can also be co-fed with diesel and/or natural gas to engines to reduce
combustion
emissions via lean combustion.
[00192] FIGURE 45 is another embodiment of the present invention 4500. Hollow
shaft
screw presses 4502 are well known and well understood. Although a screen for
separating solids from liquids is not shown, it will be understood that one
can be installed
in the system 4500. Within the hollow shaft a stinger electrode 4504 is
installed for
continuous 24/7 operation of the ArcWhirl torch 100. This configuration
allows for
feeding the first electrode 112 and the stinger electrode 4504 towards one
another.
Likewise, this configuration allows for transferring the arc from the nozzle
106 to the
stinger electrode 4504 and thus centering the arc between the electrodes.
Thus, it is
extremely difficult to "BLOW" out the arc because the arc is confined between
the
electrodes. Drill cuttings or other mining byproducts are introduced into the
feeder inlet
4506 and pressed towards the plasma generated by the arc in the Are Whirl
torch 100.
As previously disclosed the drill cuttings may be backflowed directly into the
ArcWhirl
torch 100.
[00193] Various other steam plasma embodiments using different types of screw
feeders
are shown in FIGURES 46-49. FIGURE 46 shows an embodiment 4600 of the present
invention wherein a Salsnes Filter 4602 by Trojan UV (see U.S. Patent No.
6,942,786) is
attached to the ArcWhirl torch 100. A glow discharge system 400 of FIGURE 4
is
CA 02901496 2016-04-14
attached between an outlet of the Salsnes Filter 4602 and the tangential inlet
120 of the
ArcWhirl torch 100.
[001941 Similarly, FIGURE 47 shows an embodiment 4700 of the present invention
wherein a Salsnes Filter 4602 by Trojan UV (see U.S. Patent No. 6,942,786) is
attached
to the ArcWhirl torch 100. A glow discharge system 500 of FIGURE 5 has an
inlet
attached a pump 4702 connected to an outlet of the Salsnes Filter 4602 and an
outlet
attached to a compressor 4704, which is connected to an eductor 4706. A mixer
4708 is
also attached between an outlet (filtered wastewater) of the Salsnes Filter
4602 and the
glow discharge system 500 to mix oxidant with the filtered wastewater to
produce the
effluent. The exhaust from the Salsnes Filter 4706 is vented and flowed to the
eductor
4706 to be injected into the tangential inlet 120 of the ArcWhirl torch 100.
The exhaust
from the tangential outlet 136 of the ArcWhirl torch 100 is flowed to the
effluent.
[001951 FIGURE 48 shows an embodiment 4800 of the present invention in which a
Screen Washing Monster Auger 4802 (see U.S. Patent No. 7,081,171) is attached
to a tee
1802i connected to the ArcWhirl torch 100. A glow discharge system 400 of
FIGURE 4
is attached between an outlet of the Screen Washing Monster Auger 4802 and the
tangential inlet 120 of the ArcWhirl torch 100. The Screen Washing Monster
Auger
4802 separates material to be processed into fluids and solids. The fluids are
fed and
mixed with rock salt or sea water to form an electrolyte that is then fed into
the glow
discharge system 400. The glow discharge system 400 produces bleach and steam.
The
steam is input into the tangential inlet 120 of the ArcWhirl torch 100. The
solids are
pushed up into the tee 1802i where the plasma from the ArcWhirl torch 100
reacts with
and vitrifies the solids.
[001961 Similarly FIGURE 49 shows an embodiment 4900 of the present invention
in
which a Screen Washing Monster Auger 4902 (see U.S. Patent No. 7,081,171) is
attached
to a curved tee 1802i connected to the ArcWhirl torch 100. A glow discharge
system
400 of -FIGURE 4 is attached between an outlet of the Screen Washing Monster
Auger
4802 and the tangential inlet 120 of the ArcWhirl torch 100. The Screen
Washing
Monster Auger 4802 separates material to be processed into fluids and solids.
The fluids
are fed into the glow discharge system 400. The glow discharge system 400
produces
effluent and steam. The steam is input into the tangential inlet 120 of the
ArcWhirl
torch 100. The plasma 108 from the ArcWhirl torch 100 reacts with and
vitrifies the
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solids producing syngas. A stinger electrode 4904 is installed for continuous
24/7
operation of the ArcWhirl torch 100. This configuration allows for feeding
the first
electrode 112 and the stinger electrode 4904 towards one another. Likewise,
this
configuration allows for transferring the arc from the nozzle 106 to the
stinger electrode
4904 and thus centering the arc between the electrodes. Thus, it is extremely
difficult to
"BLOW" out the arc because the arc is confined between the electrodes.
[00197] As illustrated in FIGURES 42-49 and shown in FIGURE 50, the present
invention provides a method 5000 for treating a material. A plasma arc torch
and a screw
feed unit are provided in block 5002, which can be any of the embodiments
shown in
FIGURES 1, 11 and 42-49, any combinations thereof, or modifications recognized
by
those skilled in the art. In its simplest form, the plasma arc torch includes
a cylindrical
vessel having a first end and a second end, a first tangential inlet/outlet
connected to or
proximate to the first end, a second tangential inlet/outlet connected to or
proximate to the
second end, an electrode housing connected to the first end of the cylindrical
vessel such
that a first electrode is (a) aligned with a longitudinal axis of the
cylindrical vessel, and
(b) extends into the cylindrical vessel, and a hollow electrode nozzle
connected to the
second end of the cylindrical vessel such that a centerline of the hollow
electrode nozzle
is aligned with the longitudinal axis of the cylindrical vessel, the hollow
electrode nozzle
having a first end disposed within the cylindrical vessel and a second end
disposed
outside the cylindrical vessel. The screw feed unit has an inlet and an
outlet, the outlet
aligned with the centerline and proximate to the hollow electrode nozzle. A
steam is
supplied to the first tangential inlet/outlet in block 5004. An electrical arc
is created
between the first electrode and the hollow electrode nozzle in block 5006. The
material
(e.g., a mining byproduct containing a mining fluid, etc.) is provided to the
inlet of the
screw feed unit in block 5008. The material is treated by moving the material
through the
outlet of the screw feed unit towards a steam plasma exiting the hollow
electrode nozzle
using the screw feed unit in block 5010. The treatment produces a fluid (e.g.,
a recovered
mining fluid such as a recovered drilling fluid, etc.) and an inert vitrified
slag (e.g., an
inert vitrified mining byproduct slag such as an inert vitrified drill
cuttings, etc.).
[00198] Other steps may include, but are not limited to: (a) injecting a gas
into the
steam before the steam is supplied into the first tangential inlet/outlet; (b)
pumping or
conveying the material to inlet of the screw feed unit; (c) quenching the
vitrified material
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with water, frac flowback or produced water; (d) quenching the vitrified
material
produces the steam that is fed into the first tangential inlet/outlet; (e)
separating the fluid
into a recovered fluid and water; and/or (f) producing the steam using a glow
discharge
system. Additional steps are apparent to those skilled in the art in light of
FIGURES 42-
49.
[00199] EXAMPLE 20- ENHANCED OIL RECOVERY FOR HEAVY OIL
[00200] An impediment to reducing production costs at SAGD facilities is heat
transfer
via thermal conduction through boiler tubes. The problem is indirect heat
transfer. Heat
is transferred via radiation, convection and conduction. Indeed, SAGD
evaporators and
boilers transfer heat via radiation, convection and conduction. Although the
flame in the
boiler transfers heat via radiation and convection to boiler tubes, heat
transfer through
boiler tubes is solely via thermal conduction.
[00201] When the heat transfer surface of the boiler tubes becomes coated with
contaminants, for example silica, then heat transfer is reduced and the boiler
and/or
evaporator must be shut down for maintenance. At SAGD facilities this is a
common
problem, especially with silica, and is now being viewed as non-sustainable.
The silica is
produced with the oil sand. Hence, sand contamination via volatile silica
compound
evaporation, as well as volatile organic compounds ("VOCs") is an inherit
problem in
current EOR operations utilizing traditional water treatment methods with
boilers and
once through steam generation equipment.
[00202] If a non-plugging evaporator, boiler, steam generator and/or system,
method or
apparatus could use the water straight from the oil/water separator and
produce 100%
quality or superheated steam, then this eliminates the need and operating
costs associated
with water treatment and fossil fueled fired once through steam generators and
boilers.
Simply put it reduces the production costs of existing SAGD facilities as well
as Capital
Expenses for new facilities.
[00203] Furthermore, if the same system could be operated on just electricity,
especially from renewable resources such as wind, solar, hydro or even
biomass, then this
allows for reduced, zero air emissions and/or carbon neutral operations.
Furthermore, if
the same all electrical system is capable of producing hydrogen, then this
opens the door
for upgrading at the wellhead and/or in situ. Thus, the true impetus is not
oil at
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$60/barrel, but producing higher quality oil at the wellhead without the
associated
problems and costs for operating a large water treatment facility as well as a
large
up grader.
[00204] The present invention provides a glow discharge electrode evaporator
and/or
boiler that can operate with produced water directly from an oil/water
separator.
Moreover, the present invention provides an electrode evaporator and/or boiler
coupled to
a plasma superheater for producing very high quality steam (approximately
100%) and
hydrogen.
[00205] SAGD facilities refer to saturated or wet steam as steam that is less
than 100%
quality. For example, 85% quality steam in their words is steam that is 85%
vapor and
15% moisture and/or water. On the other hand, 100% steam is just vapor with no
moisture/water. The term, superheated steam, is rarely used or heard of in
SAGD
operations. Likewise another term commonly used in SAGD operations is Steam to
Oil
Ratio ("SOR"). SOR is the most relied upon number for calculating and
predicting
profitable operations based upon the price of crude oil. Simply put, the cost
to produce
steam is based upon water treatment and current fuel prices. And utilizing
natural gas to
produce bitumen from oil sands is no longer feasible for many reasons.
[00206] If the water treatment plant can be eliminated and fuel costs reduced
or
eliminated then this opens the door to a more sustainable SAGD plant. If the
only
residual waste is brine, then this helps eliminate the costs associated with
hauling and
disposal of waste.
[00207] Upgrading is another major obstacle with production of heavy oil.
Heavy oil
requires upgrading to decrease the viscosity in order to produce a marketable
"CRUDE
OIL" that can be refined in modern day refineries. Upgraders are very
expensive to
construct, maintain and operate. The upgrading spread similar to the term
"CRACK
SPREAD" is the value of the incoming raw product, for example bitumen, to the
value of
the upgraded bitumen ¨ synthetic crude oil. It is the Upgrading Spread that
allows for
heavy oil producers to undertake a massive construction project such as an
Upgrader.
[00208] Although an upgrader will produce a pipeline quality synthetic crude,
the
downside to COKING crude oil is the production of coke. And coke cannot be
moved
through a pipeline. Thus, this is a stranded byproduct that if could be used
in an EOR
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process as fuel would change the game with respect to using clean burning
natural gas for
producing heavy oil.
[00209] Turning now to FIGURE 51, SOGD Plasma EOR, while referring to
FIGURES 1, 4, 5, 6 and 7, and specifically units 100, 400, 500, 600 and 700,
an all
electrical system is disclosed for Enhanced Oil Recovery of Heavy Oil.
Produced water
A from an oil/water separator 5102 is flowed into a Glow Discharge Cell
("GDC") Pump
5104 then into the Solid Oxide High Temperature Glow Discharge Electrolysis
Cell 500.
The Cell 500 may be configured as shown in FIGURES 4, 5 or 52. A very good
granular
media 424 for Enhanced Oil Recover is petroleum coke, commonly referred to as
"petcoke". The petcoke may be used in a green or calcined state.
[00210] Petroleum coke is produced through the thermal decomposition of heavy
petroleum process streams and residues. The three most common feedstocks used
in
coking operations are: (1) reduced crude (vacuum residue); (2) thermal tar;
and (3) decant
oil (catalytically cracked clarified oil) (Onder and Bagdoyan, 1993). These
feedstocks are
heated to thermal cracking temperatures and pressures (485 to 505 C at 400
kPa) that
create petroleum liquid and gas product streams. The material remaining from
this
process is a solid concentrated carbon material, petroleum coke (Ellis and
Paul, 2000b;
EC, 2003). Additional information on petcoke can be found in: (1) the American
Petroleum Institute's report to the EPA entitled "Petroleum Coke Category
Analysis and
Hazard Characterization" (December 28, 2007) at
http://www.epa.gov/hpv/pubs/summaries/ptrlcoke/c12563a2.pdf; (2) an EPA report
on
the low level toxicity of Petroleum Coke at
http ://www. ep a . gov/chemrtk/hpvis/hazchar/C ategory Petroleum%20Coke June
2011 .pd
f; and (3) a NASA report entitled "ELECTRICAL PROPERTIES OF PETROLEUM
COKE FROM PIPELINE CRUDE OIL" (September 1976) at
http ://ntrs .nas a. gov/archive/nas a/casi.ntrs .nasa . gov/19760024217
1976024217 .p df.
[00211] U.S. Patent No. 8,087,460 discloses a process for RESISTIVE heating
oil
shale in situ using petroleum coke as a resistor between two electrodes and/or
electrical
conductors. In addition, the specification states in part, "As an alternative,
international
patent publication WO 2005/010320 teaches the use of electrically conductive
fractures to
heat the oil shale. A heating element is constructed by forming wellbores and
then
hydraulically fracturing the oil shale formation around the wellbores. The
fractures are
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filled with an electrically conductive material which forms the heating
element. Calcined
petroleum coke is an exemplary suitable conductant material. Preferably, the
fractures are
created in a vertical orientation extending from horizontal wellbores.
Electricity may be
conducted through the conductive fractures from the heel to the toe of each
well. The
electrical circuit may be completed by an additional horizontal well that
intersects one or
more of the vertical fractures near the toe to supply the opposite electrical
polarity. The
WO 2005/010320 process creates an "in situ toaster" that artificially matures
oil shale
through the application of electric heat. Thermal conduction heats the oil
shale to
conversion temperatures in excess of 300 C., causing artificial maturation."
[00212] The present invention can use green or calcined petroleum coke as the
GRANULAR MEDIA 424.
[00213] Returning back to FIGURE 51, a gas mixture B, consisting mainly of
steam
with small amounts of hydrogen and other non-condensible gases ("NCGs"), is
generated
within the Cell 500. Liquids are blown down from Cell 500 through a 3-way
valve 5106.
Liquids C can be recirculated to the suction side of the GDC Pump 5104 and/or
liquids D
can be flowed into the suction of a blowdown pump 5108. The NCGs produced
within
the Cell 500 are based upon the ions within the produced water in addition to
electrolytes
added to the water. For example, if sodium carbonate and/or bicarbonate are
present,
then the NCGs produced may be hydrogen and carbon dioxide. In addition,
volatile
material within the green petcoke 424 will produce additional gases. Likewise,
the high
temperature glow discharge will steam reform the petcoke near the cathode,
thus
enhancing the production of syngas.
[00214] In addition, electrolytes, such as sulfuric acid, may be added to
change the
composition of the gas produced within the Cell 500. The Cell 500 may be
operated as
an evaporator with the vapor compressor 5110 by flowing the gases E via a 3-
way valve
5112 to the compressor 5110. On the other hand, the Cell 500 may be operated
as a
boiler using a high pressure feedwater GDC pump and opening the 3-way valve
5112 to
flow as gas B bypassing the vapor compressor 5110 21. However, it will be
understood
that the Cell 500 can be operated as a hybrid evaporator boiler using both the
vapor
compressor and the pump.
[00215] From Cell 500, the gases E and/or B are then flowed into the Plasma
ArcWhirl
Torch 100. The vapors are superheated and then converted to a steam/NCGs
plasma G
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then discharged into the injection well 5114 for EOR. An eductor 5116,
hereinafter to
mean and include but not limited to a thermocompressor, ejector, injector,
mixer, and
desuperheater may be attached to the plasma G discharge. The eductor 5116 may
be
attached such that either fluids X or G are the motive fluid. The operation
and use of
eductors are well known and well understood thus need no further explanation.
[00216] Optical pyrometer measurements of the steam/hydrogen plasma G were
taken
when sodium carbonate was used as the electrolyte within the GDC 500.
Temperatures
were measured at +3,000 C (+5,400 F). Consequently, back mixing concentrated
blowdown D via the Blowdown pump 5108 by aligning valves 5118 and 5120 allow
for
ZERO discharge into the disposal well.
[00217] The plasma arc torch of the present invention can be throttled with a
valve.
This is completely unheard of within the plasma cutting industry. By placing a
valve
5122 on the discharge volute of the ArcWhirl Torch 100, the amount of fluid
flowing
through the anode nozzle 106 as shown in FIGURE 1 can be adjusted from 0 to
100%.
Thus, the ArcWhirl Plasma Torch as disclosed in FIGURE 1 has an infinite
turndown
ratio. With the proper power supply it can be operated in a resistive heating
mode by
simply dead shorting the cathode 112 to the anode nozzle 106 thus shutting
flow through
the hollow portion 128 of the anode nozzle 106. As a result, all of the fluid
will exit the
Torch 100 tangentially via volute 102 through outlet 118 as the discharge 134.
[00218] Once again with the proper power supply, the ArcWhirl Torch can be
operated in a resistive heating mode. Thus, any fluid closely approaching
and/or touching
the anode 106 and/or cathode 112 will be heated with EMR emitted from the
resistive
element as well as via conduction and convection by heating gases and/or
fluids near the
resistive element. It will be understood, that if the ArcWhirl Torch 100 is
to be operated
in a continuous resistive heating mode, then the anode 106 should be
electrically isolated
from the vessel 104 and volute 102. Resistive heating is also commonly
referred to as
Joule Heating.
[00219] As previously disclosed 100% steam quality is crucial for lowering the
SOR in
SAGD facilities. The Plasma ArcWhirl Torch as disclosed in FIGURE 1 is a
liquid/gas
separator and extreme steam superheater that can be controlled with the linear
actuator
and the 3-way valve 606 attached to the Tangential Exit. As previously
disclosed when
the linear actuator 114 moves as shown by arrow 126 the cathode electrode 112
towards
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the anode nozzle 106, it is dead-shorted to the anode nozzle 106. Thus, no
fluid will flow
through the nozzle 106. The combination of the cathode electrode 112 and anode
nozzle
106 form a valve. When dead shorted the valve is in the closed position. When
the linear
actuator 114 moves the cathode electrode 112 away from the anode nozzle 106,
the valve
opens. As previously disclosed, when in the closed and dead short position,
the power
supply is turned ON. Once again, the dead short causes resistive heating of
the
electrodes. When the cathode electrode 112 is moved away from the anode nozzle
106
and an arc is formed between the cathode 112 and anode 106. If fluid is
discharged 134
from the Tangential Outlet 118, then a very small plasma 108 will be
discharged from the
anode nozzle 106.
[00220] Now returning back to FIGURE 51, a 3-way valve 5122 is connected to
the
Tangential Outlet 118 of the ArcWhirl Torch 100. During testing with the 3-
way valve
5122 attached as shown, when the valve 5122 is fully closed, the plasma 108
was
discharged from the ArcWhirl Torch 100 and measured with an optical
pyrometer. With
the gases produced from the Cell 500, the plasma 108 was measured at +3,000 C
(+5,400 F). With only air, the plasma 108 was measured at +2,100 C (+3,800 F).
The
system as shown in 700 was operated with a ceramic eductor 5116. The ceramic
eductor
5166 was actually a ceramic TEE provided by Bausch Ceramics. However, the
velocity
of the plasma G was sufficient to pull a vacuum through the perpendicular
entrance of the
TEE, thus it operated as an eductor. To date the ceramic TEE has not cracked
and has
survived both rapid heating and cooling without any signs of deterioration.
[00221] The present invention provides a high quality steam (approximately
100%) for
EOR. If the operator desires to reduce the temperature of the steam plasma 108
shown in
FIGURE 1 and shown as G in FIGURE 51, the power supply amps and/or volts can
be
adjusted in addition to opening 3-way valve 5122 to discharge as a gas I to
cyclone
separator 5124 or a gas H and drawn back into the plasma G with an injection
eductor
5116. However, if maximum steam quality, for example an extreme steam plasma G
is
required, then the 3-way valve 5122 will be shut. In order to reduce the
temperature of
the steam injected into the well and increase mass flow, then blowdown liquid
stream D
may be mixed with the plasma steam/NCGs plasma G. This will eliminate disposal
into
an injection well by using a 3-way valve 5118. The blowdown pump 5108 ensures
that
the liquid G is pressurized and can be used as the motive fluid X for the
eductor 5116. An
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ideal injection eductor 5116 for this application is a peripheral jet eductor,
for example
the PeriJet Eductor manufactured by Derbyshire Machine, Philadelphia, PA. It
will be
understood that plasma G may be used as the motive fluid for the eductor 5166
by using a
single jet eductor. If blowdown G from the Cell 500 must be discharged into
the disposal
well 5126, then the 3-way valve 520 would be opened for injection into the
disposal well.
A 3-way valve 5120 may be opened to allow fluid underflow K from the cyclone
separator 5124 to flow into the eductor 5116. Overflow I from the cyclone
separator
5124 would flow into the gas E entering into the compressor 5110.
[00222] The Plasma ArcWhirl Torch 100 has nearly an infinite turndown. For
example, by adjusting 3-way valve 5122, the amount of fluids going through the
Anode
Nozzle 106 as shown in FIGURE 1 and converted to plasma G can be from 0% to
100%
of total flow into the ArcWhirl Torch 100. Referring to FIGURES 1 and 51, the
ArcWhirl Torch 100 may be started and operated in accordance with the
following steps:
1. 3-way valve 5122 is fully opened to allow discharge through the second
volute.
2. The Cathode Electrode is dead shorted to the Anode acting as a valve to
prevent flow entering into the Anode Nozzle.
3. When Steam/NCGs flow into the ArcWhirl is established, the power
supply is turned on and the Cathode Electrode is slowly withdrawn establishing
an arc
between the Cathode and Anode.
4. Voltage will increase as the distance between the cathode and anode
increases.
5. Amps can be adjusted with the power supply's potentiometer.
6. Next, the 3-way valve 5122 is slowly closed so that all of the
steam/NCGs
must flow through the anode nozzle.
7. The 3-way valve 5122, the cathode position and distance from the anode,
and the potentiometer can be adjusted to infinitely control the volume and
temperature of
the Steam/NCGs Plasma G discharged from the ArcWhirl Torch.
[00223] A unique and unobvious method will be demonstrated for production of
heavy
oil with renewable energy and petcoke. Renewable energy may be in the form of
solar,
wind, hydro and/or biomass. Biomass would be converted to Plasma BioCharTM and
syngas would be provided lean combustion (see U.S. Patent No. 8,074,439). In
addition,
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any waste material, such as Municipal Solid Waste could be converted to a fuel
and
energy for use in the present invention. Furthermore, Coke produced from
upgrading
bitumen would be an ideal fuel for lean combustion with the present invention.
Likewise,
as previously stated Coke is an ideal granular media 424 for use in the GDC
Cell.
However, it will be understood that granular petcoke can be directly injected
into the
Plasma G with the eductor 5116 and thus steam reformed as traveling down the
Injection
Well 5114.
[00224] On the other hand, the coke could be plasma steam reformed. By adding
oxygen to the syngas it would be combusted and produce high temperature steam
and
carbon dioxide ("CO2"). Once again, the steam and CO2 would be flowed into the
injection well 5114 for EOR. A very good configuration for adding coke and
oxygen to
the coupling plasma steam reforming with oxy combustion is the Plasma Whirl
Reactor
disclosed in U.S. Patent No. 7,622,693. By placing three or more torches on a
reactor, the
plasma will be confined and allow for complete gasification and oxy combustion
of the
coke. The oxygen may be reduced in order to produce only syngas.
[00225] Turning now to FIGURE 52 ¨ SOGD CELL FOR EOR ¨ the entire water
treatment train as well as the once through steam generator and/or boiler as
disclosed in
the prior art can be eliminated by utilizing the Enhanced Oil Recovery system,
method
and apparatus of the present disclosure. Oil and water from the production
well is fed to
an oil & water separator 5200 where the oil is separated from the oily water.
The oily
water is fed into the inlet 408 of the Glow Discharge Cell 400 using pump
5201. Petcoke
is used as a fuel for many industries. Many oil companies are advocating it as
means for
sequestering carbon. However, by using Petcoke as the granular media 424 in
the Glow
Discharge Cell 400 a portion of the Petcoke will be steam reformed and
converted to a
non-condensible gas. Likewise, as an oxidant selected but not limited to air,
oxygen,
hydrogen peroxide, ozone may be added to the oily water via the recirculation
line 5202
or directly into the inlet 408 of the vessel 402 by means known in the art.
[00226] The oxidant will react with the syngas formed from steam reforming the
petcoke 424. Consequently, makeup petcoke will have to be added to the replace
the
granular petcoke 424. This eliminates the need for removal of the granular
media petcoke
424 from the vessel. The metals within the petcoke, such as nickel and
vanadium may be
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coated to the cathode tubular 412 and/or may be discharged via outlet 410 and
blown
down via 3-way valve 5204 for recovery as valuable metals.
[00227] Not being bound by theory, it is believed that the sulfur within the
petcoke 424
will be converted to sulfur trioxide and then to sulfuric acid and/or sodium
sulfate. Thus,
another valuable commodity may be recovered with the GDC 400 as disclosed
herein.
[00228] For EOR purposes the gas exiting from 410 is looped around and flowed
5206
directly into the cathode tubular 412. As previously disclosed the cathode
tubular 412
will glow at temperatures exceeding 1000 C and upwards of the melting point of
many
metals. However, the typical temperature of the gases exiting the GDC 400 is
based upon
the pressure within the GDC 400. For example, when operating under one
atmosphere
using baking soda as the electrolyte and gravel as the granular media 424 the
temperature
is at or slightly above 100 C. Not being bound by theory, it is believed that
the
temperature increase above the standard boiling point is do in part to the
production of
oxygen and hydrogen within the GDC 400 and thus releasing additional heat upon
oxidation. This gives rise to operating the GDC 400 as a submerged combustor
by using
petcoke 424 as the granular material and superheating the gases 5206 with the
tubular
cathode 412. The gases 5206 will flow down through the tubular and become a
superheated gas and flowed into the injection well for EOR purposes.
[00229] Referring to FIGURE 53 ¨ ArcWhirl GD Cell for EOR ¨ the ArcWhirl 100
has been tested and operated as a glow discharge electrolysis cell without
granular media.
By closely comparing and contrasting FIGURE 1 with FIGURE 4 and FIGURE 5, the
only difference between the three systems is the means in which material is
flowed into
each system, straight or tangentially and the lack of a moveable electrode.
Oil and water
from the production well is fed to an oil & water separator 5200 where the oil
is separated
from the oily water. The oily water is fed into the inlet 408 of the Glow
Discharge Cell
400 using pump 5201. As previously described, the Plasma ArcWhirl Torch can
easily
be configured and operated in 4 different modes for EOR: (1) Resistive
Heating; (2) Arc;
(3) Electrolysis, and/or (4) Glow Discharge.
[00230] The Plasma ArcWhirl can be configured and operated in any of the
aforementioned modes simply requires valving and/or a manifold (not shown) for
changing the outlet 134 as shown in FIGURE 1 to be the inlet 120 as shown in
FIGURE
12. Now by cycling valve 5302 from shut to open, the ArcWhirl GDC will be
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demonstrated for operating in all 4 modes. Likewise, but not shown a valve
would be
attached to outlet 118.
[00231] The ArcWhirl GDC is started by dead-shorting the cathode to the anode
with
power supply in the off position. Next, the vessel is partially filled by
jogging the pump.
And the power supply is turned on allowing the system to operate in a
resistive heating
mode. The benefit to this system is preventing the formation of gases such as
chlorine if
sodium chloride is present within the oily water. Saturated gases will exit
outlet 118 as a
discharge 5304 to another ArcWhirl Torch or GDC for superheating or to a
boiler and/or
to the injection well.
[00232] If the system is to be operated in an Arc Mode, the cathode is simply
withdrawn from the anode. A submerged arc will be formed instantly. This will
produced noncondensible gases such as hydrogen and oxygen by splitting water.
In order
to aid in forming a gas vortex around the arc gases such as but not limited to
methane,
butane, propane, air, oxygen, nitrogen, argon, hydrogen, carbon dioxide,
argon, biogas
and/or ozone or any combination thereof can be added between the pump and
inlet 120
with an injector (not shown). However, it is well known that hydrogen peroxide
will
convert to oxygen and water when irradiated with UV light. Thus, the ArcWhirl
will
convert hydrogen peroxide to free radicals and oxygen. In addition, it is well
known that
gases and condensates are produced along with heavy oil. Thus, a portion of
the gases
can be flowed into the ArcWhirl GDC for forming a plasma vortex. The present
invention has clearly demonstrated a system, method and apparatus for
operating a
plasma torch in an Arc mode as well as transitioning from a resistive heating
mode an arc
mode.
[00233] In order to transition to an electrolysis mode the electrode is
withdrawn a
predetermined distance from the anode. This distance is easily determined by
recording
the amps and volts of the power supply as shown by the GRAPH in FIGURE 3. The
liquid level is held constant by flowing liquid into the ArcWhirl GDC by
jogging the
pump or using a variable speed drive pump to maintain a constant liquid level.
Although
not shown in FIGURE 53, a grounding clamp can be secured to the vessel in
order to
maintain an equidistant gap between the vessel and cathode, provided the
vessel is
constructed of an electrically conducted material. However, the equidistant
gap can be
maintained between the anode and cathode and electrically isolating the vessel
for safety
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purposes. Glass and/or ceramic lined vessels and piping are common throughout
many
industries.
[00234] To transition to Glow Discharge, the distance between the cathode and
anode
is increased until the ArcWhirl GDC goes into glow discharge. This is easily
determined by watching volts and amps. When in glow discharge the power supply
voltage will be at or near open circuit voltage. However, to rapidly
transition from
Electrolysis to Glow Discharge the valve 5302 is opened to allow the ArcWhirl
GDC
100 to blowdown the liquid to adjust the level for glow discharge. This novel
feature also
allows for FAIL SAFE OPERATION. If the pump is turned off and all of the water
is
blowndown from the ArcWhirl GDC, then the system will not produce any gases.
Likewise, a variable speed drive pump may be used to control the liquid level
to maintain
and operate in a glow discharge mode. Another failsafe feature, such as a
spring, can be
added to the linear actuator such that the system fails with the cathode fully
withdrawn.
[00235] Note that the mode of operation can be reversed from Glow Discharge to
Electrolysis to Arc and then to Resistive Heating. By simply starting with the
cathode
above the water level within the vessel, then slowly lowering the cathode to
touch the
surface of the liquid, the ArcWhirl GDC will immediately go into glow
discharge mode.
Continually lowering the cathode will shift the system to electrolysis then to
arc then to
resistive heating.
[00236] Now to operate the ArcWhirl GDC as a plasma torch, water/liquid flow
is
reversed and blowdown valve 5302 is opened to allow the plasma to discharge
from the
ArcWhirl GDC. However, if a sufficient amount of gas in entrained in the
water and a
gas vortex is formed, the water/liquid can be flowed through the ArcWhirl GDC
100.
However, if outlet 118 is obstructed or a downstream valve is shut, then all
of the
liquid/water will be flowed through the anode nozzle. The mode of operation,
resistive
heating, arc, electrolysis or glow discharge will be determined based upon the
electrical
conductivity of the water/liquid.
[00237] Although no granular media is needed for this configuration it will be
understood that granular media may be added to enhance performance. Likewise,
what
has not been previously disclosed is that this configuration always for
purging the vessel
and removing the granular media by reversing the flow through the system,
outlet 118 is
used as the inlet and inlet 120 is used as the outlet. This configuration will
work for any
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whether it is more dense or less dense than water and/or the liquid flowing
through the
system. If the material density is greater than the liquid the granular
material will flow
through 120. If the material is less dense then the liquid then it will flow
the nozzle.
[00238] Now referring to FIGURE 54 ¨ Dual ArcWhirls0 for EOR ¨ a second
ArcWhirl Plasma Torch 100 can be placed in series and/or parallel with the
ArcWhirl
GDC 500 for operation as a complete system 5400. It will be understood that
both units
are piped series such that either one is the GDC while the other is the Plasma
Torch
and/or both are operated in parallel as Glow Discharge Cells or Plasma
Torches.
Manifolds, valves and headers are very common that allow for operation of
filters, pumps
and equipment in parallel and/or series.
[00239] The Dual ArcWhirl System 5400 is extremely useful for EOR, especially
SAGD applications because standard High Pressure and Low Pressure Steam
Separators
can be modified and converted to the ArcWhirl GDC 500 and the ArcWhirl
Plasma
Torch 100. By adding the Vapor Compressor between the GDC 500 and Torch 100,
the
gases from exit 5402 can be compressed to injection well pressure
requirements. Once
again the Torch 100 is controlled by means of a discharge valve 5404 connected
to a
compressor recirculation line. In addition, discharge through nozzle 5406 from
the GDC
500 unit can be flowed via a 4-way manifold 5408 to the pump recirculation, or
as
blowdown to an injection well or to the eductor for mixing with the Plasma
5410 and
discharge into the injection well. Mixing with the plasma thus allows for a
ZERO
DISCHARGE SYSTEM and not just a ZERO LIQUID DISCHARGE system.
[00240] EXAMPLE 21 ¨ O&G WATER TREATMENT ¨ PRODUCED WATER,
FRAC FLOWBACK, TAILINGS WATER AND REFINERY WASTEWATER
[00241] There are many applications within the Oil & Gas ("O&G") industry that
do
require steam injection. For example, produced water from producing wells and
the
current major problem of frac flowback. The frac flowback wastewater problem
must be
addressed with a simple solution. In contrast, existing systems are
complicated and
expensive.
[00242] Turning now to FIGURE 55, by coupling the present invention with the
current inventor's Plasma Thermal Oxidizer, U.S. Patent No. 8,074,439 the
costs for
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treating frac flowback and/or produced water can be reduced by using Petcoke
and/or
activated carbon as the granular media 424 in the GDC 400.
[00243] A MIX (mixture) of Gas, Fluid (produced water, frac flowback) and/or
Fuel
and/or any combination thereof is flowed into the inlet of the ArcWhirl 100.
The MIX
is exposed to Wave Energy. Once again, the plasma 108 is discharged from the
anode
nozzle and into the Thermal Oxidizer of U.S. Patent No. 8,074,439. The mixture
is
discharged B from the ArcWhirl 100 and is flowed into the Glow Discharge Cell
400. A
good granular media 424 is selected from a carbon containing material such as
activated
carbon, nutshell, woodchips, biochar and/or petcoke. The GDC 400 granular
media will
trap and filter organics and solids within the mixture. The mixture exits as a
Gas through
a Gas OUTLET and/or as liquid via a Liquid OUTLET. The Gas can be flowed via a
3-
way valve to a mixing valve and/or to the compressor of the Thermal Oxidizer.
The
compressed GAS flows through a 3-way throttle valve for feed into the plasma
108 or
recycled back into the ArcWhirl 100.
[00244] The gas entering into the Mixing Valve may flow back into the INLET of
the
ArcWhirl 100. Next, as disclosed in U.S. Patent No. 8,074,439 an oxidant is
combined
with a hot plasma for lean combustion in the thermal oxidizer, Plasma Rocket
of FIGURE
7, the pump or for converting hot gases to rotational energy. Returning back
to FIGURE
16 of the present invention while viewing the Recuperators of U.S. Patent No.
8,074,439
and comparing it to the GDC 400, by flowing the oxidant through the hot
tubular cathode
the GDC 400 is indeed operated as a recuperator. The Hot Oxidanat E exits
through the
outlet and to an OXIDANT 3-way valve. The oxidant may flow to the mixing valve
and
to the Gas 3-Way valve or to the Inlet of the ArcWhirl 100. However, in
ordinary
operations the oxidant will be flowed from the Oxidant 3-way valve to the
Thermal
Oxidizer Cyclone and/or combustion chamber of U.S. Patent No. 8,074,439.
[00245] It was thoroughly disclosed that the exhaust from the turbochargers of
U.S.
Patent No. 8,074,439 could be discharged directly into water. Consequently,
this allows
for submerged heating of water by discharging the exhaust of the turbine of
the
turbocharger underwater by adding an exhaust pipe to the turbine. This can be
done in a
final pretreatment process of the Liquid Outlet of the GDC 400 of FIGURE 55 of
the
present invention. The present invention of FIGURE 55 has disclosed a novel
process for
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treating oily wastewater such as produced water, frac flowback, tailings water
from Oil
Sands Surface Mining, SAGD water and Refinery Wastewater.
[00246] Turning now to FIGURE 56 - Dual ArcWhirl Flotation ¨ the present
invention is ideally suited for adapting to a flotation cell. Flotation cells
such as a
Dissolved Air Flotation ("DAF"), Induced Gas Flotation ("IGF") and/or Froth
Flotation
Cell are common amongst many industries. DAFs are common in the wastewater
treatment industry. IGFs are common in refineries, O&G Production Platforms
and O&G
gathering facilities/pads. Froth Flotation Cells are common in the metals and
minerals
industries. Likewise, Froth Flotation Cells are used extensively within the
Oil Sands
surface mining industry.
[00247] The present invention dramatically improves the performance of a
flotation
cell by adding a First ArcWhirl for production of UV Light, oxidants such as
Ozone and
also for operation as a submerged thermal oxidizer. For example by adding an
oxidant
such as air or oxygen to the FLUID 110 inlet, this will help push hydrophobic
contaminants such as hydrocarbons to the arc. The rotating gaseous mixture of
hydrocarbons and oxidants around the arc will form a plasma and will be
combusted
within the Whirlpool formed by the rotating water. Hence, the name ArcWhirl .
The
mixture comprising water, solids and hot combustion gases is then discharged
directly
into the Flotation Cell. Floats and Skims are collected in a Collection Header
and
discharged into a 3-way valve. The floats/skims may then be recycled back to
the
ArcWhirl UV/OZONE Oxidizer or to a second ArcWhirl Submerged Thermal
Oxidizer. Once again as previously disclosed the plasma 108 from the second
ArcWhirl
may be discharged into the thermal oxidizer of U.S. Patent No. 8,074,439.
[00248] However, the floats/skims can be boosted in pressure with a booster
pump and
discharged into a Graphite Electrode Plug Valve. The Plug Valve assembly is
unique to
the ArcWhirl Plasma Torch in that it allows for continuous feeding of
electrodes. Thus,
the plasma torch does not need to be shut down for replacing electrodes as is
common
with all other electrode type plasma torches. The electrode feeder consists of
a feeder
housing in which a traction feeder grips a second electrode.
[00249] By adding a second electrode in addition to the anode nozzle, the arc
is fully
stabilized by not having to attach itself to the anode nozzle. All non-
transferred arc
plasma torches are limited in operation and power based upon the volume and
velocity of
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the gas flowing through the nozzle. This is easily explained by blowing unto
any flame in
particular a candle. Blow too hard and the candle goes out. However, by arcing
directly
within the center of the vortex and between two electrodes, this allows for
continuous
operation with unlimited fluid/gas flows. Hence, the use of a pump volute will
introduce
the floats/skims into the ArcWhirl 100 tangentially thus enhancing the vortex
and
WHIRL flow. It will be understood that the pump volute will be oriented in the
same
direction as the volute for the FLUID 110 inlet.
[00250] Returning now to the traction feeder, it operates similar to any track
type
conveyor belt system. By pushing the tracks together to compress against the
electrode
the tracks move the electrode in and out based upon the direction of the
tracks. As
previously disclosed graphite electrodes are screwed together similar to drill
pipe found
throughout the oil and gas industry. Likewise, a coiled tubing rig can be used
that
includes a traction drive system that is common throughout the Coiled Tubing
Drilling
Industry. The metal tubing would be used as a sacrificial anode. This allows
for the
introduction of micronized iron. When ozone and/or hydrogen peroxide are
combined
with micronized iron, in particular ferric oxide, a reaction known occurs
which forms a
very powerful oxidant known as the hydroxyl radical. This reaction is commonly
referred to as Fenton's Reagent.
[00251] The electrode can be electrically connected to the anode lead cable
via
common DC brushes used on DC motors and/or generators. The anode lead is
coupled to
the housing via a power feed thru. For safety measures, a motor for driving
the traction
drive system can be an air or pneumatically operated motor. The traction drive
electrode
feeder of the present invention can also be used for the cathode. However, it
will be
understood that the traction feeder must be electrically isolated form the
feeder housing
and should be electrically isolated from the electrode.
[00252] The ArcWhirl Submerged Thermal Oxidizer may also include the traction
drive electrode feeder of the present invention. The purpose of the second
ArcWhirl is
to ensure that contaminants are removed below permit discharge levels or to
within limits
for recycling and reuse of the water. The second ArcWhirl polishes the water
prior to
reuse.
[00253] Referring to FIGURE 57 ¨ Dual ArcWhirl Thickener ¨ the ArcWhirl is
attached to a thickener commonly employed within the oil sands mining
industry.
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Tailings water may still contain extraction solvents such as naptha and/or
asphaltenes and
must be removed from the tailings prior to discharge into the tailings pond.
However, for
reuse and/or recycling the water the solvent must be removed from the water.
Thus, this
complicates the solution, because the solvent will be left with either the
water and/or
tailings.
[00254] However, the present invention provides a unique system, method and
apparatus for solving the water recycling and tailings drying problem. The oil
sands
tailings pond problem is well known and is a legacy problem that if not solved
will make
surface mining unsustainable for several reasons. First, the withdrawal of
large volumes
of water from the Athabasca River is not sustainable. Second, a portion of the
valuable
resource bitumen, stays with the tailings and is not recovered from the ponds.
[00255] Returning back to FIGURE 57, by operating the ArcWhirl as submerged
combustors the solvent and bitumen remaining with the water and tailings can
be
combusted to heat the water. Likewise as previously disclosed, the air plasma
operates at
well over 4,000 F, thus allowing for melting and vitrifying the sand. By
dumping the
vitrified glass back into the water, this allows for recovering energy into
melting the
glass. Thus, the present invention produces hot water for recycling and an
inert glass
particle thus eliminating tailings ponds all together.
[00256] The present invention produces unexpected results in that petcoke can
be fed
into the ArcWhirl with the oxidant. Since the density of petcoke will allow
reporting to
the plasma vortex, then this allows for submerged combustion. Likewise,
another ideal
and near perfect feed point for the petcoke is through the anode nozzle or
through a
hollow cathode. Why is this a great petcoke feed location? Simply put, the
petcoke is
calcined by the extreme temperature of the carbon arc and then it becomes
electrically
conductive. Thus, the petcoke becomes the consumable electrode within the
ArcWhirl .
In addition, as the petcoke is steam reformed, then combusted it adds a
tremendous
amount of heat to the Fluid 110 entering into the ArcWhirl . The present
invention gives
rise to a new and undisclosed use for petcoke as both a consumable electrode
as well as
providing heat for submerged combustion for treating water.
[00257] A feed mechanism for the petcoke is shown in FIGURE 56. The petcoke is
slurried fed by injection into the suction of the Booster Pump via
recirculation through an
eductor. The petcoke slurry is then fed directly into the anode nozzle.
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[00258] EXAMPLE 22¨ SOGD ARC WHIRL UPGRADER FOR HEAVY OIL
[00259] Referring now to FIGURE 58 ¨ SOGD ArcWhirl Upgrader - petcoke is
produced by upgrading heavy oil. Thus, using petcoke to enhance upgrading by
gasifying
and/or steam reforming the petcoke by using it as the granular media 424 for
the GDC
500 helps eliminate the problem of petcoke disposal. In addition, it provides
the needed
hydrogen for upgrading. Moreover, since both the GDC 500 and the ArcWhirl
Plasma
Torch Upgrader 100 operate with DC power, the system, method and apparatus as
disclosed in FIGURE 19 is ideal for renewable energy regions. For example,
solar
irradiation in the Middle East and North Africa ("MENA") is sufficient to
drive a plasma
EOR and Well Head Upgrader for daytime operations while using petcoke for
night time
operations. The use of natural gas for EOR and upgrading is not perceived as
sustainable.
If the price of natural gas rises, the field will be shut in.
[00260] Referring to both FIGURE 5 land FIGURE 58 jointly, the EOR system of
FIGURE 51 can be operated on Solar and Wind power for recovering the oil,
while the
Upgrader as disclosed in FIGURE 58 can upgrade the heavy oil at the well head
or on the
pad. In FIGURE 51, a heavy oil booster pump would supply heavy oil to the
Graphite
Electrode Plug Valve assembly. Steam and Hydrogen produced in the GDC 500,
using
petcoke as the granular material 424, would be compressed then flowed in the
ArcWhirl
Upgrader 100. An oxidant such as oxygen may be used to partially combust the
heavy oil
to reduce electrical power to the ArcWhirl 100. The high pressure and very
hot
Upgraded Oil would flow into a cyclone flash separator. The gas oil would be
separated
from the heavy fractions and condensed as a synthetic oil.
[00261] Returning to FIGURE 51, while also referring to the submerged
combustion
ArcWhirl Apparatus of FIGURES 56 and 57 the utilization of Petcoke as the
granular
media 424 allows for a unique system, method and apparatus for EOR with steam,
nitrogen and carbon dioxide. By adding air stoichiometrically into GDC 500,
the
compressor inlet via the 3-way valve, the hydrogen and carbon dioxide produced
from the
GDC 500 will be combusted in the ArcWhirl 100. Thus, very little or no oxygen
will be
flow downhole into the injection well. The present inventions EOR system
allows for
injection of steam, hydrogen, nitrogen, carbon dioxide or a combination
thereof by simply
adding AIR or an oxidant into the system.
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[00262] The present invention as disclosed in FIGURE 58 was operated with
woodchips and an auger feeder in lieu of a booster pump. A mixture of steam
and
hydrogen produced by the GDC 500 was flowed into the ArcWhirl 100 forming a
steam
plasma in excess of 3,000 C (5,400 F). The results from the test clearly
demonstrate that
the system is not only capable of upgrading heavy oil, but also capable of
producing a
syngas suitable for Fischer Tropschs ("FT") Fuels. Thus, this allows for a
micro-refinery
to be installed at the wellhead or on the pad.
[00263] Heavy oil contains copious amounts of sulfur. The GDC 500 will produce
caustic soda for scrubbing H2S and sulfur species produced in the ArcWhirl
Upgrader.
However, the ideal electrolyte is weak sulfuric acid. Not being bound by
theory, it is
believed that the H2S will be converted to sulfur trioxide by operating
several ArcWhirl
GDC 100 systems as shown in FIGURE 14 as Hot Gas Cleanup systems in a glow
discharge, electrolysis or arc mode.
[00264] Sulfuric acid is a good electrolyte for the glow discharge cell of the
present
invention because electrical conductivity does not decrease with increasing
concentration.
It is the only electrolyte that provides that benefit for use in the present
invention.
Consequently, the present invention also includes a system, method and
apparatus for
disposal of large sulfur piles from heavy oil upgrading by manufacturing
sulfuric acid.
[00265] Wood has been carbonized with the Plasma ArcWhirl Torch 100 using a
plasma gas generated from the Glow Discharge Cell 500 configured as shown in
FIGURE
7. In addition, recent testing has shown that the gases exiting from the
Plasma ArcWhirl
Torch 100 using baking soda within the Glow Discharge Cell 500 as the plasma
gas
produced a plasma G temperature of 2,900 C (5,250 F) as measured with an
optical
pyrometer. Likewise, sawdust was flowed directly into the steam/hydrogen
plasma G and
were formed producing syngas with a composition shown in the following SYNGAS
TABLE:
Component Sample 1 Sample 2 Sample 3
Concentration % Concentration % Concentration %
H2 38.702591 23.993687 31.965783
02 7.603821 3.777238 5.671720
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N2 5.730443 4.424545 4.803373
CH4 1.042843 3.770582 2.923456
CO 9.465042 14.879737 10.633168
CO2 30.015818 33.110154 32.207613
1-12/C0 4.08/1 1.61/1 3.01/1
[00266] The syngas produced from the present invention is now ready for lean
combustion with the Plasma ArcWhirl Turbine as disclosed in US Patent No.
8,074,439.
Likewise, it will be understood that the syngas can be converted to liquid
biofuels using a
Fischer Tropschs catalyst or any suitable process and/or catalyst that will
convert syngas
to liquid fuels. On the other hand, the syngas may be mixed with the Oil and
upgraded to
meet pipeline quality oil standards.
[00267] Syngas and/or a hot gas and char are produced from the Plasma ArcWhirl
Torch's plasma plume G. The hot syngas and/or hot gas is used to rotate a
turbine that is
connected to a compressor, pump, generator and/or mixer. Referring to U.S.
Patent No.
8,074,439, the Plasma ArcWhirl Turbine '439 may be operated in a lean
combustion
mode to simply drive a turbocharger for providing compression via the vapor
compressor
5110 as disclosed in FIGURE 51.
[00268] The System 700 as shown in FIGURE 7 rated at 35 kw was operated at
only 9
kw-hr for plasma steam reforming woodchips for conversion to Plasma BioCharTM.
By
simply using the Plasma Plume of 100 to gasify woodchips, the carbon in the
wood is
sequestered as a usable form of BioCharim for water treatment. The off-gas
temperature
was measured at over 900 C and dumped directly into a recirculating water
bath. The
total process demonstrated that for every 1 kw of out of the wall power, 2 kw
of energy
could be recovered within the water as hot water.
[00269] The Biochar produced from the present invention was visually analyzed
and
determined to be a suitable BioCharTM for water treatment purposes.
Consequently, as
previously disclosed the Plasma BioCharTM could be used as the media for the
glow
discharge cell 400 or 500 as shown in FIGURES 4-9 and 51-58 of the present
invention.
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BioCharTM makes and excellent water filtration aid and can be used in
conjunction with
the petcoke.
[00270] The foregoing description of the apparatus and methods of the
invention in
preferred and alternative embodiments and variations, and the foregoing
examples of
processes for which the invention may be beneficially used, are intended to be
illustrative
and not for purpose of limitation. The invention is susceptible to still
further variations
and alternative embodiments within the full scope of the invention, recited in
the
following claims.
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