System and method for processing oil-based mud cuttings

Abstract

A cuttings processing system for treating cuttings produced while drilling wells using a drilling mud containing a hydrocarbon and a method for using the same are disclosed. The processing system can include a fan, a solids removal system, a heater, and a spin flash drying chamber. The fan can be configured to circulate the vapor within the system. The solids removal system can be configured to remove particulates from the vapor to provide filtered vapor. A heater is provided to heat the filtered vapor into the superheated region. The heater can be associated with the solids removal system to receive the filtered vapor therefrom. The drying chamber is configured to receive the cuttings. The drying chamber is connected to the heater to receive the superheated and filtered vapor therefrom to promote the emitting of the vapor from the cuttings. The drying chamber is connected to the solids removal system to convey the vapor and dried particulates thereto to form a substantially closed loop.

What is claimed is:  
     
         1 . A cuttings processing system for treating cuttings produced during the drilling of a well which contain hydrocarbons, the system comprising: 
 a spin flash drying chamber, the drying chamber configured to receive the cuttings.    
     
     
         2 . The cuttings processing system according to  claim 1  wherein the cuttings emit a vapor, the system further comprising: 
 a fan, the fan configured to circulate the vapor within the system.  
 
     
     
         3 . The cuttings processing system according to  claim 2  further comprising: 
 a solids removal system configured to remove particulates from the vapor to provide filtered vapor.  
 
     
     
         4 . The cuttings processing system according to  claim 3  further comprising: 
 a heater for heating the filtered vapor into the superheated region, the heater associated with the filter device to receive the filtered vapor therefrom.  
 
     
     
         5 . The cuttings processing system according to  claim 4  wherein the drying chamber is connected to the heater to receive the superheated and filtered vapor therefrom and the drying chamber is connected to the solids removal system to convey the vapor thereto.  
     
     
         6 . The cuttings processing system according to  claim 5  further comprising: 
 a feed vat for storing cuttings, the feed vat connected to the drying chambers, via a conveying device for transporting the cuttings to the drying chamber.  
 
     
     
         7 . The cuttings processing system according to  claim 6  wherein the conveying device includes a pump.  
     
     
         8 . The cuttings processing system according to  claim 6  wherein the feed vat includes an agitator.  
     
     
         9 . The cuttings processing system according to  claim 5  further comprising: 
 a collection system for receiving at least a portion of the vapor, the collection system including a condenser for condensing the vapor into a condensate.  
 
     
     
         10 . The cuttings processing system according to  claim 9  wherein the condenser indirectly cools the vapor.  
     
     
         11 . The cuttings processing system according to  claim 10  wherein the condenser includes a heat exchanger, a pump, and a coolant, the pump and the heat exchanger arranged to circulate the coolant through the condenser.  
     
     
         12 . The cuttings processing system according to  claim 11  wherein the condenser further includes an expansion tank connected to the heat exchanger and the pump.  
     
     
         13 . The cuttings processing system according to  claim 9  wherein the collection system includes a decanter, which receives condensate from the condenser.  
     
     
         14 . The cuttings processing system according to  claim 13  wherein the decanter includes a lower portion and an upper portion, and the collection system further includes a first pump and a second pump, the first and second pumps being connected to the decanter, the first pump disposed to pump condensate from the upper portion of the decanter, and the second pump disposed to pump condensate from the lower portion of the decanter.  
     
     
         15 . The cuttings processing system according to  claim 5  further comprising: 
 a control panel configured to operate the system.  
 
     
     
         16 . The cuttings processing system according to  claim 5  further comprising: 
 a container for housing the fan, the solids removal system, the heater, and the spin flash drying chamber.  
 
     
     
         17 . The cuttings processing system according to  claim 5  wherein the solids removal system includes at least one cyclone collection device.  
     
     
         18 . The cuttings processing system according to  claim 17  wherein the at least one cyclone is two cyclones connected in parallel to the drying chamber.  
     
     
         19 . The cuttings processing system according to  claim 17  wherein the solids removal system includes a fines filter for removing fines from the vapor.  
     
     
         20 . The cuttings processing system according to  claim 18  wherein the solids removal system includes a fines filter for removing fines from the vapor, the fines filter being connected to the outlet of the at least one cyclone.  
     
     
         21 . The cuttings processing system according to  claim 5  wherein the heater indirectly heats the vapor.  
     
     
         22 . The cuttings processing system according to  claim 22  wherein the heater includes a flue-gas re-circulation system.  
     
     
         23 . The cuttings processing system according to  claim 22  wherein the heater includes a fan and a burner.  
     
     
         24 . The cuttings processing system according to  claim 5  wherein the spin flash drying chamber includes an agitator.  
     
     
         25 . A process for treating oil-based cuttings which emit vapor, the process comprising: 
 drying the cuttings in a spin flash drying chamber to vaporize the hydrocarbons associated with the cuttings.    
     
     
         26 . The process according to  claim 25  further comprising: 
 removing the dried particulates from the vapor.  
 
     
     
         27 . The process according to  claim 26  wherein the removal step includes removing fines from the vapor.  
     
     
         28 . The process according to  claim 26  further comprising: 
 conveying superheated vapor to the spin flash drying chamber.  
 
     
     
         29 . The process according to  claim 28  further comprising: 
 storing the cuttings in a feed vat connected to the drying chamber; and  
 conveying the cuttings from the feed vat to the drying chamber.  
 
     
     
         30 . The process according to  claim 29  further comprising: 
 condensing at least a portion of the vapor to form a condensate.  
 
     
     
         31 . The process according to  claim 30  wherein the condensing step includes indirectly cooling the vapor.  
     
     
         32 . The process according to  claim 30  wherein the condensate includes at least a portion of hydrocarbons and at least a portion of water, the process further comprising: 
 collecting the condensate; and  
 separating the hydrocarbons from the water.  
 
     
     
         33 . A system for processing cuttings produced during the drilling of a well using a hydrocarbon containing drilling fluid, the system comprising: 
 a heater for producing superheated vapors;    a spin flash drying chamber for removing any hydrocarbons or water from the cuttings;    a solids removal system for separating the dried cuttings particles from the vapor; and    a collection system for isolating and separating the hydrocarbons from the vapor.    
     
     
         34 . The system of  claim 33 , wherein the solids removal system includes one or more cyclones.  
     
     
         35 . The system of  claim 33 , wherein the collection system includes a condenser.  
     
     
         36 . A system for processing hydrocarbon containing drilling muds, the system comprising: 
 a heater for producing superheated vapors;    a spin flash drying chamber for drying the solids contained in the mud to remove any hydrocarbons or water from the solids;    a solids removal system for separating the dried solids from the vapor; and    a collection system for isolating and separating the hydrocarbons from the vapor.    
     
     
         37 . The system of  claim 36 , wherein the solids removal system includes one or more cyclones.  
     
     
         38 . The system of  claim 36 , wherein the collection system includes a condenser.  
     
     
         39 . A method of processing hydrocarbon-containing cuttings produced during the drilling of a well using a hydrocarbon-containing drilling fluid, the method comprising: 
 feeding the cuttings to a spin flash drying chamber;    feeding superheated steam to the drying chamber to vaporize hydrocarbons contained in or on the cuttings and to dry the solids contained in the cuttings;    feeding the vaporized hydrocarbons and dried solids to a solids removal system to isolate the dried solids from the vapor;    feeding at least a part of the vapor to a collection system to collect the hydrocarbons contained in the vapor; and    feeding at least a part of the vapor to the heater to be superheated for return to the spin flash drying chamber.    
     
     
         40 . The method of  claim 39 , wherein solids are removed from the vapor using one or more cyclones.  
     
     
         41 . The method of  claim 39 , wherein the hydrocarbons are removed from the vapor using a condenser contained in the collection system.  
     
     
         42 . A method of processing hydrocarbon containing drilling muds, the method comprising: 
 feeding drilling mud to a spin flash drying chamber;    feeding superheated steam to the drying chamber to vaporize hydrocarbons contained in or on the drilling mud and to dry the solids contained in the drilling mud;    feeding the vaporized hydrocarbons and dried solids to a solids removal system to isolate the dried solids from the vapor;    feeding at least a part of the vapor to a collection system to collect the hydrocarbons contained in the vapor; and    feeding at least a part of the vapor to the heater to be superheated for return to the spin flash drying chamber.    
     
     
         43 . The method of  claim 42 , wherein solids are removed from the vapor using one or more cyclones.  
     
     
         44 . The method of  claim 42 , wherein the hydrocarbons are removed from the vapor using a condenser contained in the collection system.  
     
     
         45 . A system for processing volatile hydrocarbon-containing solids, the system comprising: 
 a heater for producing superheated vapors;    a spin flash drying chamber for drying the volatile hydrocarbon-containing solids to remove any hydrocarbons or water from the solids;    a solids removal system for separating the dried solids from the vapor; and    a collection system for isolating and separating the hydrocarbons from the vapor.    
     
     
         46 . The system of  claim 36 , wherein the solids removal system includes one or more cyclones.  
     
     
         47 . The system of  claim 36 , wherein the collection system includes a condenser.  
     
     
         48 . A method of processing volatile hydrocarbon-containing solids, the method comprising: 
 feeding the volatile hydrocarbon-containing solids to a spin flash drying chamber;    feeding superheated steam to the drying chamber to vaporize hydrocarbons contained in or on the solids and to dry the solids contained in the cuttings;    feeding the vaporized hydrocarbons and dried solids to a solids removal system to isolate the dried solids from the vapor;    feeding at least a part of the vapor to a collection system to collect the hydrocarbons contained in the vapor; and    feeding at least a part of the vapor to the heater to be superheated for return to the spin flash drying chamber.    
     
     
         49 . The method of  claim 48 , wherein solids are removed from the vapor using one or more cyclones.  
     
     
         50 . The method of  claim 48 , wherein the hydrocarbons are removed from the vapor using a condenser contained in the collection system.  
     
     
         51 . A cuttings processing system for treating cuttings produced during the drilling of a well which contain hydrocarbons, the system comprising: 
 a spin flash drying chamber, the drying chamber configured to receive the cuttings; and    a container system for substantially housing the processing system, the container system including at least one frame.    
     
     
         52 . The system of  claim 51 , wherein each frame of the containerized system has a total weight of about 15,000 pounds or less.