One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.

A separator system and method may provide a four-way separator that may separate a material and remove a hazardous material. The hazardous material may include gas and sand that may be removed by the four-way separator. The separator system and method may further provide a main unit that may include three chambers or recirculation hoppers, an auger sand extractor, and a strap tank. The separator system and method may provide a faster rig-up time and may be exclusively driven by hydraulics.

A separator system and method may provide a four-way separator that may separate a material and remove a hazardous material. The hazardous material may include gas and sand that may be removed by the four-way separator. The separator system and method may further provide a main unit that may include three chambers or recirculation hoppers, an auger sand extractor, and a strap tank. The separator system and method may provide a faster rig-up time and may be exclusively driven by hydraulics.

One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.

One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.

A method and system for separating a suspension into solid and fluid components. The suspension is centrifuged about a substantially vertical axis of rotation to concentrate solid components in a first lower flow stream and fluid components in a first upper flow stream. The first upper flow stream may be centrifuged about a substantially vertical axis of rotation to concentrate solid components in a second lower flow stream and fluid components in a second upper flow stream. The first lower flow stream, the second lower flow stream, or both, may be centrifuged about a substantially horizontal axis of rotation to separate water from stackable dry tailings. The method and system may be applied to separation of tailings or other suspensions.

A method and system for separating a suspension into solid and fluid components. The suspension is centrifuged about a substantially vertical axis of rotation to concentrate solid components in a first lower flow stream and fluid components in a first upper flow stream. The first upper flow stream may be centrifuged about a substantially vertical axis of rotation to concentrate solid components in a second lower flow stream and fluid components in a second upper flow stream. The first lower flow stream, the second lower flow stream, or both, may be centrifuged about a substantially horizontal axis of rotation to separate water from stackable dry tailings. The method and system may be applied to separation of tailings or other suspensions.

A method and system for separating a suspension into solid and fluid components. The suspension is centrifuged about a substantially vertical axis of rotation to concentrate solid components in a first lower flow stream and fluid components in a first upper flow stream. The first upper flow stream may be centrifuged about a substantially vertical axis of rotation to concentrate solid components in a second lower flow stream and fluid components in a second upper flow stream. The first lower flow stream, the second lower flow stream, or both, may be centrifuged about a substantially horizontal axis of rotation to separate water from stackable dry tailings. The method and system may be applied to separation of tailings or other suspensions.