Solid material comminution or disintegration – Processes – Subjecting material to impact by moving comminuting surface
Reexamination Certificate
1999-03-24
2001-05-15
Rosenbaum, Mark (Department: 3725)
Solid material comminution or disintegration
Processes
Subjecting material to impact by moving comminuting surface
C241S073000, C241S189100, C241S195000, C241S197000
Reexamination Certificate
active
06230996
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention relates to drill cuttings remediation systems, and in particular to a pulverizer/grinder, in its principle embodiment, configured to process drilling mud having cuttings therein. The preferred embodiment of the invention teaches a unit having a shaft on a horizontal axis having multiple rotors emanating therefrom, the system surrounded by a cylindrical housing having inner walls situated near the tips of the rotors, each rotor further including first and second, side mounted pulverizing members, the inner wall of the housing, in conjunction with the rotors and the first tips of the mounted pulverizing members, forming the grinding/pulverizing surface.
The upper portion of housing includes input means for the ingress of cuttings, drilling mud, and fluid, the lower portion of the housing further including output means in the form of a cuttings screen having the desired aperture size for the egress of appropriately ground cuttings, particles, and fluid. Included with the system is a specially designed lug which emanates from the inner surface of the upper housing unit, the lug configured to securely communicate with the upper edge of the cuttings screen, securely holding same in place and preventing the buildup of debris thereabouts.
The shaft of the pulverizer/grinder unit is powered by an exterior motor via a coupling, the shaft utilizing a unique seal cartridge for lubrication between the pulverizer housing and pillow block bearings. Further complimenting the design is a unique cuttings blade configuration which optimizes grinding efficiency, providing a carbide, angled, rectilinear design having pulverizing members mounted thereupon.
The present design of the system provides a particularly effective pulverizer/grinder, while requiring little operational supervision, effectively preventing build up of debris within the unit; hence, a self-cleaning system.
The grinder of the present system is designed to be directly fed from a hopper in conjunction with a shell shaker, with the pulverizer/grinder mounted upon a slurry tank for receiving the processed cuttings and fluid. A fluid line from the slurry tank containing the processed grindings and fluid may be re-injected into the well via injection system; a second, recirculation line may run from the slurry tank to the pulverizer/grinder be utilized to provide fluid flow for efficient processing grindings, the rate of recirculation depending upon the operating environment.
In addition to processing drill cuttings, the present system is also particularly suitable for pulverizing other non-metal material in a wet or dry context, including, for example, aggregate for on-site road bed formation.
BACKGROUND OF THE INVENTION
Cuttings remediation is not a new concept in and of itself, various attempts at processing and reinjecting ground cuttings having been tried over the years, yet remediation has only relatively recently been considered a requisite in petroleum exploration, with recognition of the adverse environmental impact of dumped drill cuttings and drilling mud upon environment.
There are two options for disposal other than dumping, which is not environmentally sound and may be illegal in some jurisdictions, namely 1) dumping of the cuttings at a landfill, or 2) reinjection of the cuttings into the well. While drill cuttings are disposed of at designated low hazardous waste landfills, the costs of transportation and disposal are generally prohibitive, especially when the drilling occurs in remote areas.
There is, therefore, a more urgent need than ever for an efficient cuttings remediation system which reintroduces processed cuttings into the well.
A list of patents which may have some pertinence to the present invention include:
U.S. Pat. No.
Inventor
Date of Issue
Grinders/pulverizers:
5400977
Hayles, Jr.
03/28/1995
3993254
Bicik et al
11/23/1976
3957210
Durr
05/18/1976
2991947
Schuyler
07/11/1961
1038886
Hirt
09/17/1912
666404
Wurster
01/22/1901
500582
Jones
07/04/1893
410247
Kimble
09/03/1889
345408
Birge
07/13/1886
Cuttings Processing:
5405223
Sirevag
05/11/1995
5303786
Prestridge et al
04/19/1994
5294061
Van Dijk
03/15/1994
4544032
Echols
10/01/1985
4480702
Keily, Jr.
11/06/1984
4222988
Barthel
09/16/1980
U.S. Pat. No. 1,038,886 issued 1912 teaches a “pulverizer” including a shaft on a horizontal axis having multiple rotors emanating therefrom, the system further surrounded by a cylindrical housing having inner walls having “perforations” situated near the tips of the rotors, each tip further including a “beater”.
U.S. Pat. No. 410,247 issued 1889 teaches an “apparatus for atomizing solid substances” including first and second, horizontally situated shafts having multiple, intermeshing rotors emanating therefrom. See also U.S. Pat. Nos. 500, 582, 345,408, 666,404 and 5,400,977.
U.S. Pat. No. 4,222,988 issued 1980 teaches an “apparatus for removing hydrocarbons from drill cuttings” including milling means in the form of a horizontal shaft (
19
) having a plurality of rotors emanating therefrom (
17
,
20
), the ends of the rotors in close proximity to a cylindrical housing (FIG.
3
). U.S. Pat. Nos. 4,480,702, 5,405,223, 4,544,032, 5,303,032, and 5,294,061 teach drill cuttings processing apparatus; see
FIG. 2
of the '061 patent, which teaches a mill including a rotating shaft having rotors for milling the cuttings, enclosed within a cylindrical housing.
While the above cited prior art teachings teach rotor mills having some similarities when compared to the present invention, none teach the improvements disclosed, nor the operating configuration of the present system. It is averred that prior art drill cuttings remediation systems have traditionally been either expensive to implement, or ineffective in real world operations, requiring continual maintenance and operational supervision, as well as monitoring to prevent clogging or jamming of the unit.
GENERAL SUMMARY DISCUSSION OF THE INVENTION
The present invention contemplates a pulverizer/grinder system for processing drill cuttings for re-injection into the well, providing a pulverizer/grinder system which is relatively simple to operate and maintain, while being cost effective to manufacture and implement.
The pulverizer/grinder of the present system is configured to be used a main component in a drill cuttings remediation system, the pulverizer/grinder designed to be directly fed from the shell shaker, or, alternatively, via hopper to which the shell shaker feeds, with the pulverizer/grinder mounted upon a slurry tank for receiving the processed cuttings and fluid.
The pulverizer/grinder may be operated dry under some conditions, and may, under some conditions, actually perform better dry than with fluid circulation, although for most applications it is advantageous to have fluid present in the pulverizer/grinder, and for this reason a fluid line from the slurry tank is fed back into the pulverizer/grinder to provide fluid flow to aid in the flow of cuttings and particulates through the system.
The present exemplary embodiment of the invention, which has been implemented in the field, includes 18 sets of rotors situated three sets of six rotors equilaterally spaced fashion (thirty degrees), with cutting/grinding carbide or carbide overlaid pulverizing members affixed to the opposing sides of each rotor, the ends of which may also be overlaid with carbide. The exemplary system is rotated at a speed of about 1700-1800 RPM, which, along with the screen size of the pulverizer/grinder chamber may vary according to flow, cuttings properties, requirements, and other environmental criteria.
The housing design of the present system includes a unique means of securing the screen against the housing to prevent detachment of same, comprising a specially designed lug which emanates from the inner surface of the upper housing unit, the lug configured to securely communicate with the upper edge of the cuttings screen, the securement means preventing debris buildup at the securement area.
An exterior
Regard, ltd plc Joseph T.
Rosenbaum Mark
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