Methods and apparatus for counter-current leaching of finely divided solids

Abstract

This disclosure describes systems, methods, and apparatus for counter-current solids leaching. A multi-stage countercurrent leaching chamber can include a top and bottom end, a barren liquor input, two or more regions for countercurrent mixing, and a barren solids output. The input can be configured to receive barren liquor. The two or more regions for countercurrent mixing and separation can be configured to mix and separate liquid and solid phases. The barren solids output can be configured to collect and discharge barren solids from the bottom end of the multi-stage countercurrent leaching chamber. A fluidized bed chamber and clarifier chamber can also be included, where the fluidized bed receives a fluidizable slurry of pregnant solids and the clarifier chamber aids in separating liquids from solids passing from a top of the fluidized bed chamber to the top end of the multi-stage countercurrent leaching chamber.

Claims

1. An apparatus for leaching fine solids, the apparatus comprising: a leaching chamber having: a top end; a bottom end; an input configured to receive a leach or wash solution; one or more regions for mixing and separation of liquid and solid phases; and an output configured to collect and discharge settled solids from the leaching chamber; a fluidized bed chamber with a top and bottom end, wherein the fluidized bed chamber is joined to the leaching chamber; and a clarifier chamber with a top and a bottom end, and joined at its bottom end to the top end of the leaching chamber and the top end of the fluidized bed chamber.

2. The apparatus of claim 1, wherein the fluidized bed chamber includes a pregnant solids input configured to receive a fluidizable slurry of pregnant solids, and wherein the fluidized bed chamber and the leaching chamber are separated by a shared partition wall furnished with an aperture through which solids can move from the fluidized bed chamber and into the leaching chamber.

3. The apparatus of claim 2, wherein said shared partition wall aperture is near a top of said shared partition wall, said aperture configured to allow transfer of solids at uniform mass flux over the area of the aperture, and from the fluidized bed chamber into the top end of the leaching chamber.

4. The apparatus of claim 1, wherein the input is a barren liquor input configured to receive barren liquor in the form of the leach or wash solution, and wherein the liquid and solid phases are countercurrently mixed and separated in the one or more regions for mixing and separation of liquid and solid phases, and the one or more regions further comprises an arrangement of inclined fixed plates.

5. The apparatus of claim 4, wherein said inclined fixed plates are arranged at an angle with a horizontal that is equal to or greater than an angle of repose of solids settling on the fixed plates.

6. The apparatus of claim 4, wherein said inclined fixed plates are affixed in an alternating array on two opposing inside walls of the leaching chamber, and spaced such that solids falling from at least a first of the plates will intercept an upper surface of a plate located below and opposite the at least a first of the plates.

7. The apparatus of claim 6, wherein the solids falling from the at least a first of the plates intercept the upper surface of the plate below the at least a first of the plates at a point on the upper surface of the plate below that is no greater than one-half of a length of the plate below measured from a plate precipice of the plate below.

8. The apparatus of claim 4, wherein given a vertical axis drawn from a bottom end of one of the plates through a point on another plate below and opposing the one of the plates, a distance along this vertical axis between a point where the vertical axis intersects the end of the one of the plates and the point on the another plate is less than 20% of a horizontal distance between the end of the one of the plates and a wall of the leaching chamber opposing the one of the plates.

9. The apparatus of claim 1, wherein the output is a barren solids output comprising a dewatering screw press.

10. The apparatus of claim 9, wherein the dewatering screw press provides barren liquor to the bottom end of the leaching chamber.

11. The apparatus of claim 1, wherein the leaching chamber is a multi-stage countercurrent leaching chamber.

12. The apparatus of claim 11, wherein the output is a barren solids output, and wherein the barren solids output collects and discharges the settled solids or barren solids from the bottom end of the multi-stage countercurrent leaching chamber.

13. The apparatus of claim 11, wherein the fluidized bed chamber is joined at its top end with the top end of the multi-stage countercurrent leaching chamber.

14. The apparatus of claim 1, wherein the output collects and discharges the settled solids from near a bottom end of the leaching chamber.

15. The apparatus of claim 1, wherein the fluidized bed chamber and the leaching chamber are joined within top halves of the fluidized bed chamber and the leaching chamber.

16. A method for leaching fine solids, the method comprising: receiving barren liquor and pregnant solids in a fluidized bed chamber to form a mixture; fluidizing the mixture to form a fluidized mixture that moves within the fluidized bed chamber; the fluidized mixture entering a region within the fluidized bed chamber that is shared with a leaching chamber; receiving a leach or wash solution via an input of the leaching chamber; allowing the pregnant solids to descend within the leaching chamber via gravity; separating solids and liquids via one or more mixing and separating stages of the leaching chamber; collecting and discharging barren solids from the leaching chamber; and collecting and discharging pregnant liquor from a clarifier chamber arranged atop both the fluidized bed and the leaching chamber.

17. The method of claim 16, wherein the region has a larger cross section than a cross section of either the fluidized bed chamber or the leaching chamber alone.

18. The method of claim 16, wherein the leaching chamber is a multi-stage countercurrent leaching chamber.

19. The method of claim 16, wherein the barren liquor and pregnant solids are received near a bottom end of the fluidized bed chamber, and wherein the fluidized bed chamber is joined at its top end with a top end of the leaching chamber.

20. An apparatus for leaching fine solids, the apparatus comprising: a leaching chamber having: a top end; a bottom end; an input configured to receive a leach or wash solution; one or more regions for mixing and separation of liquid and solid phases; and an output configured to collect and discharge settled solids from the leaching chamber; a fluidized bed chamber with a top and bottom end, and joined to the leaching chamber, the fluidized bed chamber including a pregnant solids input configured to receive pregnant solids and fluidizing liquor; and a clarifier chamber with a top and a bottom end, and joined at its bottom end to the top end of the leaching chamber and the top end of the fluidized bed chamber.

Description

BRIEF DESCRIPTION OF FIGURES

(1) Various objects and advantages and a more complete understanding of the present disclosure are apparent and more readily appreciated by referring to the following detailed description when taken in conjunction with the accompanying drawings:

(2) FIG. 1 illustrates one embodiment of a counter-current solids leaching system.

(3) FIG. 2 shows an integrated process flow diagram using the counter-current solids leaching system for treating drill cuttings.

(4) FIG. 3 shows one embodiment of a method for counter-current solids leaching.

DETAILED DESCRIPTION

(5) FIG. 1 shows one embodiment of a counter-current flow, solids leaching system 100 comprised of a multistage leaching chamber 101 fitted with inter-stage thickener plates 102, and separated from a fluidized bed 103 by a vertical overflow weir 106. The leaching chamber 101 and fluidized bed 103 are connected at their upper end to a sedimentation clarifier 105.

(6) Pregnant solids are fed to the lower portion of the fluidized bed 103 where they are fluidized by recycled fluidizing liquor that is introduced to the bottom of the fluidized bed chamber via a fluidizing liquor distributor 104. Those skilled in the art will recognize that the fluidizing liquor distributor 104, without limitation, may be selected from the group consisting of screens, perforated plates, perforated tubes, sintered metal or plastic plates, tuyer plates, bubble cap plates, dense media, and open tubes.

(7) Fluidized solids rise vertically in the fluidized bed 103 and are transported to the region of the top of the overflow weir 106 where the superficial velocity of the fluidizing liquor is reduced below the minimum fluidizing velocity for the solids. The reduction in fluidizing velocity occurs as the fluidized bed expands into the increased cross section provided by the combined leaching chamber 101 and fluidized bed 103.

(8) The clarifier 105 further increases the cross section and reduces the upward component of velocity of the up-welling fluidizing liquor such that all but the finest particles settle by gravity into the leaching chamber 101.

(9) Solids slide down the inclined thickener plates 102 to the plate gaps and fall over the plate precipice in a thin sheet. The downward velocity of the falling sheet is much greater than the Stokes settling velocity of any individual particle in the sheet. The falling sheet of solids is intercepted by counter flowing leach or wash solution, having a substantial horizontal streamline component. The wash water partially fragments the falling sheet of solids and pushes it toward the outside wall of the leaching chamber 101. Near the wall, the wash solution streamline is forced back to upward vertical, creating a shear zone, in the thickener plate gap, between the falling and fragmenting sheet of solids and the rising wash water stream. Some of the falling solids are re-entrained by the upward flow of wash water and are carried into the interstitial volume above the plate.

(10) The interstitial volume above each thickener plate 102 receives solids falling from the plate above and solids re-entrained by the wash water moving through the plate gap from below. In the interstitial volume above the plate, wash water moves in a substantially horizontal streamline across the column, to the opposing gap, and above the bulk of the disbursed solids. This promotes settling and transport of solids down the plate. Sweep flock settling is the predominant mechanism in this region, with larger flocks and particles, carrying finer materials downward to the thickener plate and occluding them in the sheet discharge. In this manner, the concentration of solids in the region above the plate increases until the settling, transport, and sheet discharge reach steady state equilibrium with the sludge solids feed rate. Each stage provides a turbulent contact zone and a quiescent settling zone. Downward transport of particles is not governed by Stokes law, and the solids loading to the pregnant liquor discharge is determined by the dimensions of the sedimentation clarifier 105.

(11) FIG. 2 shows one embodiment of an integrated process flow diagram 200 for employing the counter-current flow solids leaching system 100 to remove dissolved solids from finely divided drilling residues, also referred to as cuttings.

(12) Cuttings feed in the form of dry solids or solids present as paste, sludge, or slurry are fed to a feed pump 201 where they are comingled and mixed with filter cake from a blowback filter 202 before being fed to the previously disclosed counter-current flow solids leaching system 100.

(13) Those skilled in the art will recognize that the feed pump 201, without limitation, may be selected from the group consisting of high-shear mixers, pug mills, mixing tanks, progressive cavity pumps, rotary lobe pumps, flexible impeller pumps, rotary valves, and centrifugal slurry pumps.

(14) Pregnant liquor discharged from the counter-current flow solids leaching system 100 is filtered using a blow-back filter 202 to produce clarified product brine for beneficial use or disposal, plus a thickened filter cake that is recycled to the feed pump 201.

(15) Those skilled in the art will recognize that the blow-back filter 202, without limitation, may be selected from the group consisting of bag filters, belt filters, filter presses, V-Sep filters, sintered metal filters, ceramic filters, deep bed filters, lamella thickeners, sedimentation clarifiers, electro-coagulation clarifiers, and centrifugal clarifiers.

(16) Recycle of pregnant liquor to the feed pump and fluidized bed concentrates soluble salts in the recycled fluid and maximizes the concentration and specific gravity of the product brine. High specific gravity brines have value in the oil field. In addition, high-concentration brines exhibit reduced volume and reduced cost for transportation and off-site disposal via deep well injection.

(17) Settled, barren solids exiting the bottom of the counter-current flow solids leaching system 100 may be dewatered using a dewatering screw press 203 or other dewatering equipment. Dewatering produces a reduced volume, reduced mass, stackable, easily handled and transported solid residue. Water thus removed from the barren solids may be comingled with the leach or wash solution fed to the leaching system 100 in order to reduce the total fresh solution required for operation of the system.

(18) Those skilled in the art will recognize that the dewatering press 203, without limitation, may be selected from the group consisting of dewatering screw presses, belt filters, pressure filters, V-Sep filters, gas displacement dryers, and centrifugal separators.

Operational Experience

(19) A prototype commercial countercurrent solids leaching system as shown in FIG. 2 has been operated on a drilling site in the Williston basin to treat salt water brine mud cuttings and other solid residues derived from horizontal drilling operations in the Bakken formation. The prototype commercial countercurrent solids leaching system demonstrated removal of 98.8% to 99.4% of chlorides from feed materials containing an average of 57,315 mg Cl.sup.−/L, and at feed rates as much as 20% above the system design rating. Treated material exhibited chloride concentrations below the regulatory limit for surface application of 250 mg/kg.

(20) The instant invention has been reduced to practice and successfully demonstrated at the prototype commercial scale throughput of 500 lbm/hr, and with feed material-to-fresh water mass ratios in the range from 1.2 to 4.6. Demonstration testing showed that the prototype countercurrent solids leaching system requires from 43% to 85% less fresh water when compared to conventional leaching techniques base on equivalent throughput and salt removal.