Shale-Gas Separator Discharge Diffuser

Abstract

According to one aspect, a diffuser apparatus includes a first pipe having a first plurality of openings formed therein, the first pipe defining a first passageway that is adapted to receive a first portion of debris that is discharged from a well; a first housing within which the first pipe extends, the first housing comprising a first wall and a first outlet formed therein; and a first region formed between the first pipe and the first housing, the first region in communication with the first passageway via the first plurality of openings; wherein the first plurality of openings are circumferentially and axially spaced along the first pipe to pass the first portion of the debris from the first passageway to the first region; and wherein the first outlet is sized such that the first portion of the debris exits the first region via the first outlet.

Claims

1. A discharge diffuser assembly to be disposed above a collection bin, comprising: a plurality of diffuser modules for coupling to a discharge outlet of a shale gas separator and configured to receive a discharge material therefrom, each diffuser module comprising: a conduit having a plurality of openings configured to permit passage of debris components of the discharge material; and a cylindrical housing substantially surrounding the conduit at least along top and two elongated sides and having an axially-disposed elongated outlet positioned below the conduit, the elongated outlet being substantially larger than the plurality of openings to permit passage of the debris components of the discharge material.

2. The discharge diffuser assembly of claim 1, wherein the plurality of diffuser modules are serially-coupled to the discharge outlet and to one another.

3. The discharge diffuser assembly of claim 1, wherein the plurality of diffuser modules have openings of different sizes.

4. The discharge diffuser assembly of claim 1, wherein the plurality of diffuser modules have openings of similar sizes.

5. The discharge diffuser assembly of claim 1, wherein inner diameters of the conduits of the plurality of diffuser modules are dissimilar.

6. The discharge diffuser assembly of claim 1, wherein inner diameters of the conduits of the plurality of diffuser modules are equal.

Description

DESCRIPTION OF FIGURES

[0031] The accompanying drawings facilitate an understanding of the various embodiments.

[0032] FIG. 1 is a diagrammatic illustration of a separator in communication with a well according to an exemplary embodiment, the separator including a discharge line, a diffuser system, and a receptacle.

[0033] FIG. 2 is a perspective view of the discharge line, the diffuser system, and the receptacle of FIG. 1, according to an exemplary embodiment.

[0034] FIG. 3 is an enlarged perspective view of a portion of the discharge line, the diffuser system, and the receptacle of FIG. 2, according to an exemplary embodiment.

[0035] FIG. 4 is a side view of the diffuser system and the receptacle of FIG. 1, according to an exemplary embodiment.

[0036] FIG. 5 is a perspective view of a separator, including a discharge line, a diffuser system, a bypass pipe, and an overflow port, according to another exemplary embodiment.

[0037] FIG. 6A is a side view of another embodiment of the diffuser system of FIG. 1, according to an exemplary embodiment.

[0038] FIG. 6B is another side view of the diffuser system of FIG. 6A, according to an exemplary embodiment.

DETAILED DESCRIPTION

[0039] In an exemplary embodiment and as illustrated in FIG. 1, a shale-gas separator is generally referred to by the reference numeral 10. Generally, the shale-gas separator 10 is adapted to be in air/fluid communication with a well 12 that extends through a formation 14. FIG. 1 illustrates shale debris, dust, gas, and fluid being communicated to the shale-gas separator 10 in a pipe 16. The fluid is typically water, mist, foam, detergent or aerated mud. The shale-gas separator 10 receives the shale-gas-fluid mixture at an intake pipe 18. The intake pipe 18 is secured to and protrudes through a wall of a vessel 20. An optional dust eliminator 22 is illustrated as being directly connected to the intake pipe 18. However, the dust eliminator 22 may also be positioned in-line with the pipe 16. Regardless, the separator 10 separates the debris from the gas and communicates the debris through a discharge line 24 and a diffuser system 26 and into a receptacle 28.

[0040] In an exemplary embodiment, as illustrated in FIGS. 2 and 3 with continuing reference to FIG. 1, the diffuser system 26 is positioned over the receptacle 28 that is a collection bin 29. The diffuser system 26 is in communication with a discharge outlet, or the discharge line 24, of the shale-gas separator 10. The diffuser system 26 may include a first diffuser 30, a second diffuser 32, a third diffuser 34, and a fourth diffuser 36. However, the diffuser system 26 may include any number of diffusers. Generally, the first, second, third, and fourth diffusers 30, 32, 34, and 36 are arranged in series. In other embodiments, diffusers of the diffuser system 26 may be arranged in parallel. In an exemplary embodiment, the collection bin 29 has a longitudinal axis 29a (shown in FIG. 2).

[0041] In an exemplary embodiment, the first diffuser 30 includes a pipe 30a having a plurality of openings 30b formed therein. The pipe 30a defines an inner diameter and an interior passageway. The plurality of openings 30b are circumferentially and axially spaced along the pipe 30a. That is, the plurality of openings 30b may be located anywhere along the length and circumference of the pipe 30a. While the plurality of openings 30b are shown as circles, any variety of shape may be formed, such as, for example, a triangle, a square, a hexagon or any other polygon, an oval, a star, etc. In one or more exemplary embodiments, the area formed by one opening from the plurality of openings is a function of the inner diameter of the pipe 30a. In another exemplary embodiment, the area formed by one opening from the plurality of openings is a function of the number of openings in the plurality of openings 30b, the length of the pipe 30a, and/or the expected velocity of debris that exits from the discharge line 24. For example, the area of the one opening from the plurality of openings may be substantially equal to (within 10%) or less than the cross-sectional area of the inner diameter of the pipe 30a.

[0042] The first diffuser 30 also includes a housing 30c having a tubular or cylindrical wall 30d, a first end cap 30e that extends radially from the wall 30d to the pipe 30a and a second opposing end cap 30f that extends radially from the wall 30d to the pipe 30a. While a cylindrical wall 30d is shown, a cross-section of the housing 30c may form a variety of shapes such as a square, a rectangle, an oval, etc. In an exemplary embodiment, an outlet 30g is formed in the wall 30d of the housing 30c. The outlet 30g may be an oblong or elongated opening that is formed along a length (measured along the longitudinal axis) of the housing 30c.

[0043] The first diffuser 30 also includes a first region 30h formed between the pipe 30a and the housing 30c. In an exemplary embodiment, the first region 30h is an annulus. In an exemplary embodiment, the first and second end caps 30e and 30f at least partially define the first region 30h. In an exemplary embodiment, the first region 30h is in communication with the passageway of the pipe 30a via the first plurality of openings 30b.

[0044] In an exemplary embodiment, each of the second diffuser 32, the third diffuser 34, and the fourth diffuser 36 is substantially similar to the first diffuser 30 and therefore the second diffuser 32, the third diffuser 34, and the fourth diffuser 36 will not be described in further detail. Reference numerals used to refer to the features of each of the second diffuser 32, the third diffuser 34, and the fourth diffuser 36 that are substantially identical to the features of the first diffuser 30 will correspond to the reference numerals used to refer to the features of the first diffuser 30 except that the prefix for the reference numerals used to refer to the features of the first diffuser 30, that is, 30, will be replaced by the prefix of each of the second diffuser 32, the third diffuser 34, and the fourth diffuser 36, that is, 32, 34, and 36. However, in an exemplary embodiment, the inner diameter of the pipe 32a is equal to or less than the inner diameter of the pipe 30a, the inner diameter of the pipe 34a is equal to or less than the inner diameter of the pipe 32a, and the inner diameter of the pipe 36a is equal to or less than the inner diameter of the pipe 34a. That is, the inner diameter of the pipes 30a, 32a, 34a, and 36a progressively decreases along a length of the diffuser system 26 in a direction from a first end of the diffuser system 26 that is coupled to the discharge line 24 and towards an opposing second end of the diffuser system 26. Considering the area of one opening from the plurality of openings 32b, 34b, and 36b is a function of the inner diameter of the pipes 32a, 34a, and 36a, respectively, the area of the one opening from the plurality of openings 32b, 34b, and 36b also progressively decreases. Additionally, a length of the pipe 36a may be less than the length of the housing 36c so that the end cap 36f of the housing may not contact the pipe 36a, as shown in FIGS. 2 and 3. Instead, a capped fitting may be coupled to the end of the pipe 36a and the cap 36f may be a solid circular end cap.

[0045] In an exemplary embodiment, each of the diffusers 30, 32, 34, and 36 is configured to couple to another of the diffusers 30, 32, 34, and 36. That is, each of the diffusers 30, 32, 34, and 36 is modular and can be mixed and matched to form a diffuser system 26 having a variety of lengths. For example, the diffuser system 26 may only include the first diffuser 30 and the second diffuser 32 or may include each of the diffusers 30, 32, 34, and 36 in addition to additional diffusers not shown, depending on, for example, a length of collection bin 29, an expected amount of debris from a well, an expected shale-gas-fluid mixture, and the like. Inner diameters of any additional diffusers can, but are not required to, progressively decrease along a length of the diffuser system 26 in a direction from the first end of the diffuser system 26 that is coupled to the discharge line 24 and towards the opposing second end of the diffuser system 26. The diffusers 30, 32, 34, and 36 may be detachably coupled to another of the diffusers 30, 32, 34, and 36 in a variety of ways. For example, the pipe 30a may have a flanged fitting or be otherwise connected to a flanged fitting that corresponds with a flanged fitting of the pipe 32a. Thus, when the flanged fittings are coupled together, the passageway of the pipe 30a and the passageway of the pipe 32a are in communication. In an exemplary embodiment, the first diffuser 30 is coupled to the discharge line 24 in a similar manner, such as through the use of a flanged fitting. However, a threaded connection, a snap fitting, or other similar type of fittings may be used to couple the diffusers 30, 32, 34, and 36 to one another or to the discharge line 24. As shown, the passageway defined by the pipe 30a is in communication with the discharge line 24; the passageway of the pipe 32a of the second diffuser 32 is in communication with the discharge line 24 via the passageway defined by the pipe 30a; the passageway of the pipe 34a of the third diffuser 34 is in communication with the discharge line 24 via the passageway defined by the pipe 30a and 32a, and so on.

[0046] In an exemplary embodiment, the diffuser system 26 has a longitudinally extending axis 26a. The diffusers 30, 32, 34, and 36 are spaced such that the outlets 30g, 32g, 34g, and 36g are also spaced along the longitudinal axis 26a of the diffuser system 26. In an exemplary embodiment, the system 26 has connectors 40 that secure the system 26 relative to the collection bin 29. The connectors 40 secure the system 26 to a wall of the collection bin 29 at a location that is offset from a center line that generally coincides with the longitudinal axis 29a of the collection bin 29. In an exemplary embodiment, the diffuser system 26 is offset from the center line by a percentage that is between 20-50% of the width of the collection bin 29. Additionally, the connectors 40 secure the system 26 such that the outlets 30g, 32g, 34g, 36g are spaced along the length of the collection bin 29.

[0047] In operation and in an exemplary embodiment, the diffuser system 26 receives debris from the discharge line 24 in the direction indicated by the numeral 42 in FIG. 4. The debris flows into the passageway of the pipe 30a from the discharge line 24. In an exemplary embodiment, a first portion of the debris exits the passageway of the pipe 30a and enters the region 30h via the plurality of openings 30b in the pipe 30a. The first portion of the debris then exits the region 30h via the outlet 30g as indicated by the numeral 44. In an exemplary embodiment, the first portion of the debris exits the outlet 30g at a first velocity. Some of the debris that enters the passageway of the pipe 30a does not exit the passageway via the plurality of openings 30b. Instead, a second portion exits the passageway of the pipe 30a to enter the passageway of the pipe 32a. The second portion of the debris exits the passageway of the pipe 32a and enters the region 32h via the plurality of openings 32b in the pipe 32a. The second portion of the debris then exits the region 32h via the outlet 32g as indicated by the numeral 46. In an exemplary embodiment, the second portion of the debris exits the outlet 32g at a second velocity. This process is repeated such that a third portion of the debris exits the outlet 34g as indicated by the numeral 48 at a third velocity and a fourth portion of the debris, or the remainder of the debris that enters the system 26, exits the outlet 36g as indicated by the numeral 50 at a fourth velocity. In an exemplary embodiment, the progressive reduction of inner diameter of the pipes 30a, 32a, 34a, and 36a, and/or the size of the plurality of openings 30b, 32b, 34b, and 36b balances the air flow within each of the diffusers 30, 32, 34, and 36; encourages the first, second, third, and fourth velocities to be substantially similar (equal to or within 50%); and/or reduces each of the first, second, third, and fourth velocities. For example, the first velocity may be approximately 29 ft/s, the second velocity may be approximately 22 ft/s, the third velocity may be approximately 32 ft/s, and the fourth velocity may be approximately 33 ft/s. Thus, the first, second, third, and fourth velocities are within 50% considering the difference between the fastest velocity (33 ft/s) and the slowest velocity (22 ft/s) is 11 ft/s. In an exemplary embodiment, the variations in the inner diameters of the pipes 30a, 32a, 34a, and 36a, and the size of the plurality of openings 30b, 32b, 34b, and 36b control the air flow passing through the diffuser system 26. Generally, the inner diameter of the pipe 30a is larger than the inner diameter of the pipes 32a, 34a, and 36a because the inner diameter of the pipe 30a is sized to accommodate the sum total airflow rates of the pipes 30a, 32a, 34a, and 36a. Similarly, the inner diameter of the pipe 32a is generally larger than the inner diameter of the pipes 34a and 36a because the pipe 32a is sized to accommodate the sum total airflow rates of the pipes 32a, 34a, and 36a and so on for pipes 34a and 36a. However, and as shown, the inner diameter of the pipes 32a and 34a may be equal. In an exemplary embodiment, when the inner diameter of the pipes 32a and 34a are equal, the area of one opening in the plurality of openings 34b is less than the area of one opening in the plurality of openings 32b. In an exemplary embodiment, the housing 30c reduces the first velocity due to the wall 30d and the end caps 30e and 30f blocking or deflecting the debris that exits the plurality of openings 30b. In an exemplary embodiment, the end caps 30e and/or 30f may block or deflect debris that is exiting the plurality of openings 30b, which also encourages the exit velocities to be substantially similar and/or reduced. Slowing the exit velocities reduces the likelihood of debris ricocheting off a bottom or the wall of the collection bin 29 and into an area outside of the collection bin 29. Slowing the exit velocities may also reduce the likelihood of debris from entering the collection bin 29 with a force sufficient to splash or eject debris, which is already disposed in the collection bin 29, from the collection bin 29 to a location outside the collection bin 29. Thus, the system 26 may prevent or at least reduce the likelihood of the debris damaging or dirtying surrounding equipment, posing a danger to nearby personnel, creating slip hazards, and creating a hazardous air quality condition. In an exemplary embodiment, the spacing of the outlets 30g, 32g, 34g, and 36g along the length of the collection bin 29 encourages the equal distribution of debris along the length of the collection bin 29. This may, in turn, enable the collection bin 29 to collect an additional amount of debris without being emptied or increase the time interval between emptying the collection bin.

[0048] In several exemplary embodiments, the diffuser system 26 reduces the likelihood of ricocheting debris, which in turn, reduces man hours required to clean surrounding equipment, reduces the amount of nearby equipment damaged by ricocheting debris, and ensures that the collection bin 29 is efficiently filled (i.e., debris is distributed along the length of the collection bin 29). Additionally, the connectors 40 secure the diffuser system 26 such that the diffuser system 26 is located near or close to the wall of the collection bin 29 so that a front end loader or other piece of equipment may extend within the collection bin 29 even while the diffuser system 26 extends along the length of the collection bin 29. That is, the diffuser system 26 is located flush against, or close to flush against, the wall of the collection bin 29 and does not interfere with the cleaning out or removal of the debris from the collection bin 29.

[0049] In several exemplary embodiments and as shown in FIG. 4, the receptacle 28 may be one or more shakers and the diffuser system 26 is positioned over the one or more shakers. Specifically, the outlets 30g and 32g may be positioned above an inlet 52 of a first shaker 54 and the outlets 34g and 36g may be positioned above an inlet 56 of a second shaker 58. However, when only the first diffuser 30 and the second diffuser 32 form the diffuser system 26, the outlet 30g may be positioned over an inlet 56 of the first shaker 54 and the outlet 32g may be positioned over the inlet 56 of the second shaker 58 such that the debris exiting the outlet 30g is received in the first shaker 54 and the debris exiting the outlet 32g is received in the second shaker 58. Any number of diffusers and shakers may be combined. In an exemplary embodiment, distributing the debris across a number of shakers may extend the life of at least one of the shakers, extend the time period between maintenance activities for at least one of the shakers, etc.

[0050] In an exemplary embodiment and as illustrated in FIG. 5, the system 26 may be coupled to and in communication with the discharge line 24; a bypass pipe 60 that is in fluid communication with the well 12; and a shale-gas separator overflow port 62. In one or more exemplary embodiments, the pipe 30a is adapted to be coupled to and in communication with any one or more of the discharge line 24; the bypass pipe 60 that is in fluid communication with the well 12; and the shale-gas separator overflow port 62. In an exemplary embodiment, the bypass pipe 60 may be the pipe 16 or be in communication with the pipe 16. Thus, the pipe 30a of the first diffuser 30 may receive debris from the well 12 via any one of the discharge line 24 of a shale-gas separator 10 that is in communication with the well 12; a bypass pipe 60 that is in communication with the well 12; and the overflow port 62 of the shale-gas separator 10.

[0051] In several exemplary embodiments, the debris may be a solid material, such as pieces of shale, fluids such as downhole fluids, gases, and/or dust, etc.

[0052] In an exemplary embodiment, the receptacle 28 may be a collection bin, a dumpster, an intake for a piece of equipment that is adapted to process or store debris that exits the discharge separator system 10 or the well 12, such as, for example, a shaker, or any other similar piece of equipment.

[0053] Exemplary embodiments of the present disclosure can be altered in a variety of ways. For example, and in an exemplary embodiment illustrated in FIGS. 6A and 6B, a double flanged reducer 64 forms a portion of the system 26 and is placed between any two of the diffusers 30, 32, 34, and 36. As shown in FIGS. 6A and 6B, the double flanged reducer 64 is coupled to each of the diffusers 30 and 32. In an exemplary embodiment, a flange 64a on one end portion of the reducer 64 is coupled to the pipe 30a of the diffuser 30 and another flange 64b on an opposing end portion of the reducer 64 is coupled to the pipe 32a of the diffuser 32. That is, and as shown in FIGS. 6A and 6B, the double flanged reducer 64 couples the first pipe 30a to the second pipe 32a such that the first passageway of the first pipe 30a is in communication with the second passageway of the second pipe 32a. Generally, the reducer 64 provides back pressure, which keeps, at least in part, uniformly low discharge velocities thereby at least in part reducing the likelihood of the debris damaging or dirtying surrounding equipment, posing a danger to nearby personnel, creating slip hazards, and creating a hazardous air quality condition. The reducer 64 also provides a transition between the pipes 30a and 32a when the inner diameter of the pipes 30a and 32 are not the same. Moreover, the reducer 64 also provides for proper placement of the outlets 30g, 32g, 34g, and 36g along the length of the diffuser system 26 and/or the collection bin 29. Moreover, as the majority of wear and wash out occurs in the reducer 64, the flanges 64a and 64b allow the reducer 64 itself to be quickly changed out, reducing down time and material cost over changing out one of the diffusers 30, 32, 34, and 36.

[0054] Additionally, and for example, and in one embodiment in which the flow rate and/or velocity of the debris exiting the discharge line 24 or the well 12 is low, the fourth velocity of the debris that exits the outlet 36g may be zero or close to zero. Additionally, in another exemplary embodiment, instead of each diffuser 30, 32, 34, and 36 having an individual housing 30c, 32c, 34c, and 36c, a housing may extend over each of the pipes 30a, 32a, 34a, and 36a with any number of outlets formed in the housing. In another embodiment, the diffuser system 26 may include only the diffuser 30 in which the inner diameter of the pipe 30a remains constant. In an exemplary embodiment, the size of the plurality of openings 30b is progressively reduced, with larger sized openings associated with the first end of the diffuser system 26 that is attached to the discharge line 24 and smaller sized openings associated with the opposing second end. Additionally, an insert having a progressively larger outer diameter may be extended within the passageway of the pipe 30a and from the second end of the diffuser system 26 such that that the insert has an outer diameter at the second end that is larger than the outer diameter that is near the first end. The housing 30c may include a plurality of outlets 30g.

[0055] In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as left and right, front and rear, above and below and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0056] In this specification, the word comprising is to be understood in its open sense, that is, in the sense of including, and thus not limited to its closed sense, that is the sense of consisting only of. A corresponding meaning is to be attributed to the corresponding words comprise, comprised and comprises where they appear.

[0057] In addition, the foregoing describes only some embodiments of the disclosure(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

[0058] Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.