Method and apparatus for converting spent water-based drilling muds into fertile indigenous top soil

Abstract

A method and apparatus for converting spent water-based drilling mud into fertile indigenous top soil at a well site or location. The fertile indigenous top soil is produced by the steps of: admixing, at a well site, effective amounts of spent water-based drilling mud, mature compost, organic fertilizer, and top soil from the well site to provide a mixture containing spent water-based drilling mud, from about 30 to about 150 volume percent mature compost, from about 5 to 20 volume percent organic fertilizer, and from about 5 to 20 volume percent top soil from the well site wherein each of the volume percents is based on the volume of the spent water-based drilling mud present in the mixture; stirring the mixture for a period of time effective to form a substantially homogenous mixture; and drying the substantially homogenous mixture so as to provide fertile indigenous top soil possessing similar microbial and enzyme characteristics as the top soil at the well site.

1 . The method for producing fertile indigenous top soil from water-based drilling mud at a well site wherein the fertile indigenous top soil possesses similar microbial and enzyme characteristics as soil at the well site, comprising: 
 admixing, at a well site, effective amounts of spent water-based drilling mud, mature compost, organic fertilizer, and top soil from the well site to provide a mixture containing spent water-based drilling mud, from about 30 to about 150 volume percent mature compost, from about 5 to 20 volume percent organic fertilizer, and from about 5 to 20 volume percent top soil from the well site wherein each of the volume percents is based on the volume of the spent water-based drilling mud present in the mixture;    stirring the mixture for a period of time effective to form a substantially homogenous mixture; and    drying the substantially homogenous mixture so as to provide fertile indigenous top soil possessing similar microbial and enzyme characteristics as the top soil at the well site.    
   
   
       2 . The method of  claim 1  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       3 . The method of  claim 2  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud, to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       4 . The method of  claim 1  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud, to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       5 . The method of  claim 4  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       6 . The method of  claim 5  further comprising injecting an effective amount of air into the substantially homogenous mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spentwater-based drilling mud during conversion of the spent water-based drilling mud into fertile indigenous top soil.  
   
   
       7 . The method of  claim 6  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby provide the fertile indigenous top soil.  
   
   
       8 . The method of  claim 7  wherein the temperature of the air is at least 60° F.  
   
   
       9 . The method of  claim 8  wherein the temperature of the air is from about 70 to about 105° F.  
   
   
       10 . The method of  claim 1  further comprising injecting an effective amount of air into the mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spent water-based drilling mud.  
   
   
       11 . The method of  claim 10  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby as provide the fertile indigenous top soil.  
   
   
       12 . The method of  claim 11  wherein the temperature of the air supply is at least 60° F.  
   
   
       13 . The method of  claim 12  wherein the temperature of the air supply is from about 70 to about 105° F.  
   
   
       14 . The method of  claim 13  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume spent water-based drilling mud, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       15 . The method of  claim 14  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       16 . The method of  claim 15  further comprising introducing an effective amount of water into the mixture to enhance formation of the substantially homogenous mixture and to enhance stirring of the mixture to provide the substantially homogenous mixture.  
   
   
       17 . A fertile indigenous top soil produced at a well site employing spent water-based drilling mud recovered at the well site, the fertile indigenous top soil produced by a method comprising the steps of: 
 admixing effective amounts of spent water-based drilling mud, mature compost, organic fertilizer, and top soil at the well site to provide a mixture containing spent water-based drilling mud, from about 30 to about 150 volume percent mature compost, from about 5 to 20 volume percent organic fertilizer, and from about 5 to 20 volume percent top soil from the well site wherein each of the volume percents is based on the volume of the spent water-based drilling mud present in the mixture;    stirring the mixture for a period of time effective to form a substantially homogenous mixture; and    drying the substantially homogenous mixture so as to produce fertile indigenous top soil possessing similar microbial and enzyme characteristics as the top soil surrounding the well site.    
   
   
       18 . The method of  claim 17  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       19 . The method of  claim 18  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud present, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       20 . The method of  claim 19  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       21 . The method of  claim 20  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       22 . The method of  claim 21  further comprising injecting an effective amount of air into the mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spent water-based drilling mud during conversion of the spent water-based drilling mud into fertile indigenous top soil.  
   
   
       23 . The method of  claim 22  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby provide the fertile indigenous top soil.  
   
   
       24 . The method of  claim 23  wherein the temperature of the air is at least 60° F.  
   
   
       25 . The method of  claim 24  wherein the temperature of the air supply is from about 70 to about 105° F.  
   
   
       26 . The method of  claim 17  further comprising injecting an effective amount of air into the mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spent water-based drilling mud.  
   
   
       27 . The method of  claim 26  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby as provide the fertile indigenous top soil.  
   
   
       28 . The method of  claim 27  wherein the temperature of the air supply is at least 60° F.  
   
   
       29 . The method of  claim 28  wherein the temperature of the air supply is from about 70 to about 105° F.  
   
   
       30 . The method of  claim 29  further comprising admixing from about 5 to about 15 volume percent gypsum, based on the volume spent water-based drilling mud, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       31 . The method of  claim 30  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       32 . A fertile indigenous top soil produced at a well site employing spent water-based drilling mud recovered at the well site, the fertile indigenous top soil produced by a method comprising the steps of: 
 providing an apparatus having a hopper, the hopper provided with at least one compartment having a mixing assembly and at least one air supply conduit for supplying air into the at least one compartment;    moving the apparatus to a position near the well site;    admixing effective amounts of spent water-based drilling mud, mature compost, organic fertilizer, and top soil in the at least one compartment of the hopper to provide a mixture containing spent water-based drilling mud, from about 30 to about 150 volume percent mature compost, from about 5 to 20 volume percent organic fertilizer, and from about 5 to 20 volume percent top soil from the well site wherein each of the volume percents is based on the volume of the spent water-based drilling mud present in the mixture;    activating the mixing assembly so as to stir the mixture for a period of time effective to form a substantially homogenous mixture;    drying the substantially homogenous mixture so as to produce fertile indigenous top soil possessing similar microbial and enzyme characteristics as the top soil surrounding the well site; and    removing the fertile indigenous top soil from the at least one compartment of the hopper.    
   
   
       33 . The method of  claim 32  wherein, in the step of providing the apparatus, the at least one compartment of the hopper is provided with a discharge assembly for removing the fertile indigenous top soil from the at least one first compartment.  
   
   
       34 . The fertile indigenous top soil of  claim 33  wherein the mixture formed in the at least one compartment is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       35 . The fertile indigenous top soil of  claim 34  further comprises admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud present, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       36 . The fertile indigenous top soil of  claim 32  wherein the method further comprises admixing from about 5 to about 15 volume percent gypsum, based on the volume of spent water-based drilling mud, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       37 . The fertile indigenous top soil of  claim 32  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.  
   
   
       38 . The fertile indigenous top soil of  claim 37  wherein the method further comprises injecting an effective amount of air into the mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spent water-based drilling mud.  
   
   
       39 . The fertile indigenous top soil of  claim 38  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby provide the fertile indigenous top soil.  
   
   
       40 . The fertile indigenous top soil of  claim 39  wherein the temperature of the air is at least 60° F.  
   
   
       41 . The fertile indigenous top soil of  claim 40  wherein the temperature of the air supply is from about 70 to about 105° F.  
   
   
       42 . The method of  claim 32  wherein the method further comprises injecting an effective amount of air into the mixture to enhance enzyme and microbial activity on hydrocarbons components present in the spent water-based drilling mud.  
   
   
       43 . The fertile indigenous top soil of  claim 42  wherein the air is injected into the mixture in an amount and at a velocity sufficient to dry the mixture and thereby as provide the fertile indigenous top soil.  
   
   
       44 . The fertile indigenous top soil of  claim 43  wherein the temperature of the air supply is at least 60° F.  
   
   
       45 . The fertile indigenous top soil of  claim 44  wherein the temperature of the air supply is from about 70 to about 105° F.  
   
   
       46 . The fertile indigenous top soil of  claim 45  wherein the method further comprises admixing from about 5 to about 15 volume percent gypsum, based on the volume spent water-based drilling mud, into the mixture so as to break up and reduce adhesive characteristics of clay particles present in the spent water-based drilling mud.  
   
   
       47 . The fertile indigenous top soil of  claim 46  wherein the mixture is maintained at a pH in a range of from about 7 to about 9.5.