US2011174695A1PendingUtilityA1

Processes for recycling sag-d process water and cleaning drill cuttings

44
Assignee: MALCERA L L CPriority: Sep 30, 2008Filed: Sep 30, 2009Published: Jul 21, 2011
Est. expirySep 30, 2028(~2.2 yrs left)· nominal 20-yr term from priority
Inventors:Gordon K. Goldman
B01D 21/26C10G 7/04B01D 17/047B01D 21/009E21B 21/068
44
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Claims

Abstract

A method of treating slop oil and slops from the SAG-D (steam assisted gravity-drainage) very heavy oil-bitumen crude oil production in such locations as Alberta and Saskatchewan provinces in Canada, Russia, Venezuela, Saudi Arabia, and Kern County, Calif., involves mixing the slop oil and slops with chemicals to help separate out water from the slop oil and slops.

Claims

exact text as granted — not AI-modified
1 . A method of recovering water from SAG-D slop oil comprising:
 mixing a first quantity of water with a first quantity of a chemical blend to create a water/chemical mixture, the chemical blend comprising: (i) Malcera 508MM and Malcera 1507A (ii) acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein (iii) Malcera 508MM and acceptable alternatives to Malcera 1507A mentioned herein or (iv) acceptable alternatives to Malcera 508MM mentioned herein and Malcera 1507A;   heating and stirring the water/chemical mixture;   adding to the mixture SAG-D slop oil create a water/chemical/slop oil mixture;   heating the water/chemical/slop oil mixture; and   separating individually the water, the oil, and solids from the water/chemical/slop oil mixture.   
     
     
         2 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred for at least 10 minutes and the water/chemical/slop oil mixture is heated for at least 30 minutes. 
     
     
         3 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred until the mixture reaches about 50-70 degrees C. and the water/chemical/slop oil mixture is heated until the mixture reaches about 50-100 degrees C. 
     
     
         4 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred for about 10-30 minutes and the water/chemical/slop oil mixture is heated for about 30-60 minutes. 
     
     
         5 . The method of  claim 1 , wherein the solids separate out as two phases, one in the form of sand will fall to the bottom of the beaker and the other as clays will rise to form a layer of clays above the water. 
     
     
         6 . The method of  claim 5 , wherein on standing for a period of time the layer of clays falls to the bottom. 
     
     
         7 . The method of  claim 5 , wherein on standing for 60-240 minutes the layer of clays falls to the bottom. 
     
     
         8 . The method of  claim 5 , wherein on standing for 60-120 minutes the layer of clays falls to the bottom. 
     
     
         9 . The method of any prior claim, wherein the chemical blend comprises Malcera 508MM and Malcera 1507A. 
     
     
         10 . The method of  claim 9 , wherein the chemical blend comprises at least 0.010% Malcera 508MM and at least 0.03% Malcera 1507A. 
     
     
         11 . The method of  claim 9 , wherein the chemical blend comprises 0.010-0.25% Malcera 508MM and 0.030-0.5% Malcera 1507A. 
     
     
         12 . The method of  claim 9 , wherein the chemical blend comprises 0.050-0.25% Malcera 508MM and 0.10-0.50% Malcera 1507A. 
     
     
         13 . The method of  claim 9 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM and 0.25-0.40% Malcera 1507A. 
     
     
         14 . The method of  claim 9 , wherein the chemical blend comprises about 0.1% Malcera 508MM and about 0.3% Malcera 1507A. 
     
     
         15 . The method of any one of  claims 1 - 8 , wherein the chemical blend comprises acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein. 
     
     
         16 . The method of  claim 15 , wherein the chemical blend comprises 0.010-0.50% Malcera 508MM alternative and 0.03-0.50% Malcera 1507A alternative. 
     
     
         17 . The method of  claim 15 , wherein the chemical blend comprises 0.05-0.25% Malcera 508MM alternative and 0.1-0.5% Malcera 1507A alternative. 
     
     
         18 . The method of  claim 15 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM alternative and 0.25-0.4% Malcera 1507A alternative. 
     
     
         19 . The method of  claim 15 , wherein the chemical blend comprises about 0.1% Malcera 508MM alternative and about 0.3% Malcera 1507A alternative. 
     
     
         20 . The method of any one of  claims 15 - 19 , wherein the Malcera 508MM alternative comprises a blend of KP140 (TBEP), non-ionic surfactants, and esterified vegetable oils, e.g. methyl and higher alcohol esters of soy bean, corn, or other vegetable oils. 
     
     
         21 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and 0.05-3.0% by volume of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)), wherein,   the first chemical blend comprises at least one blend from the group consisting of Malcera 508MM and a Malcera 508MM alternative, and the second chemical blend comprises at least one blend from the group consisting of Malcera 1507A and a Malcera 1507A alternative.   
     
     
         22 . The process of  claim 21 , wherein about 2.0% of the first chemical blend is used and about 2.0% of the second chemical blend is used. 
     
     
         23 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and 0.15-9.0% by volume of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)), wherein,   the first chemical blend comprises at least one blend from the group consisting of Malcera 508MM and a Malcera 508MM alternative, and the second chemical blend comprises at least one blend from the group consisting of Malcera 1507A and a Malcera 1507A alternative.   
     
     
         24 . The process of  claim 23 , wherein about 2.0% of the first chemical blend is used and about 6.0% of the second chemical blend is used. 
     
     
         25 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and about one to five times as much as the first chemical blend of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)), wherein,   the first chemical blend comprises at least one blend from the group consisting of Malcera 508MM and a Malcera 508MM alternative, and the second chemical blend comprises at least one blend from the group consisting of Malcera 1507A and a Malcera 1507A alternative.   
     
     
         26 . The process of  claim 25 , wherein about 2.0% of the first chemical blend is used. 
     
     
         27 . The process of any one of  claims 21 - 26 , wherein on cooling down to room temperature, the solids begin to settle out by gravity and a top layer of oil looks very homogenous. 
     
     
         28 . The process of any one of  claims 21 - 27 , wherein there are no lumps or rag layers present. 
     
     
         29 . The process of any one of  claims 21 - 28 , wherein the solids are observed to be very white and greyish, indicating the complete absence of any heavy hydrocarbons such as asphaltenes or paraffins. 
     
     
         30 . The process of any one of  claims 21 - 29 , wherein the first chemical blend comprises Malcera 508MM, and the second chemical blend comprises Malcera 1507A. 
     
     
         31 . The process of any one of  claims 21 - 30 , wherein the first chemical blend comprises a Malcera 508MM alternative, and the second chemical blend comprises a Malcera 1507A alternative. 
     
     
         32 . A method of recovering water from SAG-D slop oil comprising:
 mixing a first quantity of water with a first quantity of a chemical blend to create a water/chemical mixture;   heating and stirring the water/chemical mixture for about 20-45 minutes until the mixture reaches about 50-70 degrees C.;   adding to the mixture SAG-D slop oil to create a water/chemical/slop oil mixture;   heating and stirring the water/chemical/slop oil mixture for about 30-60 minutes until the mixture reaches about 50-70 degrees C.;   ceasing stirring and allowing for the water to separate out, and for solids to separate out;   pumping the water off from the solids.   
     
     
         33 . The method of  claim 32 , wherein the solids separate out as two phases, one in the form of sand will fall to the bottom of the beaker and the other as clays will rise to form a layer of clays above the water. 
     
     
         34 . The method of  claim 33 , wherein on standing for 180-240 minutes the layer of clays falls to the bottom. 
     
     
         35 . The method of any prior claim, wherein the chemical blend comprises Malcera 508MM and Malcera 1507A. 
     
     
         36 . The method of  claim 35 , wherein the chemical blend comprises 0.05-0.25% Malcera 508MM and 0.1-0.5% Malcera 1507A. 
     
     
         37 . The method of  claim 35 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM and 0.25-0.4% Malcera 1507A. 
     
     
         38 . The method of  claim 35 , wherein the chemical blend comprises about 0.1% Malcera 508MM and about 0.3% Malcera 1507A. 
     
     
         39 . The method of any one of  claims 32 - 34 , wherein the chemical blend comprises acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein. 
     
     
         40 . The method of  claim 39 , wherein the chemical blend comprises 0.05-0.25% Malcera 508MM alternative and 0.1-0.5% Malcera 1507A alternative. 
     
     
         41 . The method of  claim 39 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM alternative and 0.25-0.4% Malcera 1507A alternative. 
     
     
         42 . The method of  claim 39 , wherein the chemical blend comprises about 0.1% Malcera 508MM alternative and about 0.3% Malcera 1507A alternative. 
     
     
         43 . The method of any one of  claims 39 - 42 , wherein the Malcera 508MM alternative comprises a blend of KP140 (TBEP), non-ionic surfactants, and esterified vegetable oils, e.g. methyl and higher alcohol esters of soy bean, corn, or other vegetable oils. 
     
     
         44 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume (e.g., 2.0%) of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and 0.05-3.0% by volume (e.g., 2.0%) of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)).   
     
     
         45 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume (e.g., 2.0%) of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and 0.15-9.0% by volume (e.g., 6.0%) of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)).   
     
     
         46 . A process for cleaning drill cuttings comprising:
 to a first quantity of OBDC containing solids and oil adding 0.05-3.0% by volume (e.g., 2.0%) of a first chemical blend with stirring and heating to create a mixture of OBDC and chemical blend;   to this mixture adding with stirring and heating a quantity of diluent which is approximately the same as the first quantity and about one to five times as much as the first chemical blend of a second chemical blend to create a diluent/OBDC/chemical mixture;   stirring the diluent/OBDC/chemical mixture for a period of at least one hour at a temperature of not less than 150 and not higher than 185 degrees F. (66-85 degrees C.);   allowing the diluent/OBDC/chemical mixture to cool down to room (ambient) temperature (about 70-90 degrees F. (21-32 degrees C.)).   
     
     
         47 . The process of any one of  claims 44 - 46 , wherein on cooling down to room temperature, the solids begin to settle out by gravity and a top layer of oil looks very homogenous. 
     
     
         48 . The process of any one of  claims 44 - 47 , wherein there are no lumps or rag layers present. 
     
     
         49 . The process of any one of  claims 44 - 48 , wherein the solids are observed to be very white and greyish, indicating the complete absence of any heavy hydrocarbons such as asphaltenes or paraffins. 
     
     
         50 . The process of any one of  claims 44 - 49 , wherein the first chemical blend comprises Malcera 508MM, and the second chemical blend comprises Malcera 1507A. 
     
     
         51 . The process of any one of  claims 44 - 50 , wherein the first chemical blend comprises a Malcera 508MM alternative, and the second chemical blend comprises a Malcera 1507A alternative. 
     
     
         52 . A method of recovering water from SAG-D slop oil comprising:
 mixing a first quantity of water with a first quantity of a chemical blend to create a water/chemical mixture, the chemical blend comprising: (i) Malcera 508MM and Malcera 1507A (ii) acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein (iii) Malcera 508MM and acceptable alternatives to Malcera 1507A mentioned herein or (iv) acceptable alternatives to Malcera 508MM mentioned herein and Malcera 1507A;   heating and stirring the water/chemical mixture;   injecting the water/chemical mixture into a feed line;   adding to the mixture SAG-D slop oil in the feed line to create a water/chemical/slop oil mixture;   heating the water/chemical/slop oil mixture; and   separating individually the water, the oil, and solids from the water/chemical/slop oil mixture.   
     
     
         53 . The method of  claim 52 , wherein the SAG-D slop oil is passed through a screen filter before being added to the water/chemical mixture. 
     
     
         54 . The method of  claim 52 , wherein the water, the oil, and the solids are separated using a centrifuge. 
     
     
         55 . The method of  claim 52 , wherein the water and chemical blend are mixed in a mixing tank before entering the feed line. 
     
     
         56 . The method of  claim 52 , wherein the SAG-D slop oil is in a heated feed tank before entering the feed line. 
     
     
         57 . The method of  claim 52 , wherein the water/chemical/slop oil mixture is heated in a heat exchanger. 
     
     
         58 . The method of  claim 52 , wherein the feed line is passed through a heat exchanger. 
     
     
         59 . The method of  claim 56 , wherein the heated feed tank is about 150 cubic meter capacity. 
     
     
         60 . The method of  claim 52 , wherein the SAG-D slop oil is heated until the mixture reaches about 85° C. 
     
     
         61 . The method of  claim 52 , wherein the water/chemical/slop mixture is heated until the mixture reaches about 95-98° C. 
     
     
         62 . The method of  claim 52 , wherein the water/chemical mixture is heated to until the mixture reaches about 60° C. 
     
     
         63 . The method of  claim 52 , wherein as the water level of the chemical/water mixture goes down, the water level of the mixture was replenished by using a produced water that was previously separated. 
     
     
         64 . The method of  claim 52 , wherein the water, the oil, and the solids are separated into three distinct components using a centrifuge. 
     
     
         65 . The method of any one of  claims 52 - 64 , wherein the method is substantially continuous. 
     
     
         66 . The method of any one of  claims 52 - 64 , wherein the method is continuous. 
     
     
         67 . The method of  claim 52 , wherein the chemical blend comprises at least 0.010% Malcera 508MM and at least 0.03% Malcera 1507A. 
     
     
         68 . The method of  claim 52 , wherein the chemical blend comprises 0.010-0.25% Malcera 508MM or Malcera 508MM alternative and 0.030-0.5% Malcera 1507A or Malcera 1507A alternative. 
     
     
         69 . The method of  claim 52 , wherein the chemical blend comprises 0.050-0.25% Malcera 508MM or Malcera 508MM alternative and 0.10-0.50% Malcera 1507A or Malcera 1507A alternative. 
     
     
         70 . The method of  claim 52 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM or Malcera 508MM alternative and 0.25-0.40% Malcera 1507A or Malcera 1507A alternative. 
     
     
         71 . A method of recovering water from SAG-D slop oil comprising:
 mixing a first quantity of water with a first quantity of a chemical blend to create a water/chemical mixture, the chemical blend comprising: (i) Malcera 508MM and Malcera 1507A (ii) acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein (iii) Malcera 508MM and acceptable alternatives to Malcera 1507A mentioned herein or (iv) acceptable alternatives to Malcera 508MM mentioned herein and Malcera 1507A;   heating and stirring the water/chemical mixture;   adding to the mixture SAG-D slop oil to create a water/chemical/slop oil mixture;   heating and stirring the water/chemical/slop oil mixture;   ceasing stirring and allowing for the water to separate out, and for solids to separate out;   pumping the water off from the solids.   
     
     
         72 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred for at least 10 minutes and the water/chemical/slop oil mixture is heated and stirred for at least 30 minutes. 
     
     
         73 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred until the mixture reaches about 50-70 degrees C. and the water/chemical/slop oil mixture is heated and stirred until the mixture reaches about 50-100 degrees C. 
     
     
         74 . The method of  claim 1 , wherein the water/chemical mixture is heated and stirred for about 10-30 minutes and the water/chemical/slop oil mixture is heated and stirred for about 30-60 minutes. 
     
     
         75 . The method of  claim 1 , wherein the solids separate out as two phases, one in the form of sand will fall to the bottom of the beaker and the other as clays will rise to form a layer of clays above the water. 
     
     
         76 . The method of  claim 5 , wherein on standing for a period of time the layer of clays falls to the bottom. 
     
     
         77 . The method of  claim 5 , wherein on standing for 60-240 minutes the layer of clays falls to the bottom. 
     
     
         78 . The method of  claim 5 , wherein on standing for 60-120 minutes the layer of clays falls to the bottom. 
     
     
         79 . The method of any prior claim, wherein the chemical blend comprises Malcera 508MM and Malcera 1507A. 
     
     
         80 . The method of  claim 1 , wherein the chemical blend comprises at least 0.010% Malcera 508MM and at least 0.03% Malcera 1507A. 
     
     
         81 . The method of  claim 1 , wherein the chemical blend comprises 0.010-0.25% Malcera 508MM and 0.030-0.5% Malcera 1507A. 
     
     
         82 . The method of  claim 1 , wherein the chemical blend comprises 0.050-0.25% Malcera 508MM and 0.10-0.50% Malcera 1507A. 
     
     
         83 . The method of  claim 1 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM and 0.25-0.40% Malcera 1507A. 
     
     
         84 . The method of  claim 1 , wherein the chemical blend comprises about 0.1% Malcera 508MM and about 0.3% Malcera 1507A. 
     
     
         85 . The method of any one of  claims 1 - 8 , wherein the chemical blend comprises acceptable alternatives to Malcera 508MM and Malcera 1507A mentioned herein. 
     
     
         86 . The method of  claim 15 , wherein the chemical blend comprises 0.010-0.50% Malcera 508MM alternative and 0.03-0.50% Malcera 1507A alternative. 
     
     
         87 . The method of  claim 15 , wherein the chemical blend comprises 0.05-0.25% Malcera 508MM alternative and 0.1-0.5% Malcera 1507A alternative. 
     
     
         88 . The method of  claim 15 , wherein the chemical blend comprises 0.075-0.12% Malcera 508MM alternative and 0.25-0.4% Malcera 1507A alternative. 
     
     
         89 . The method of  claim 15 , wherein the chemical blend comprises about 0.1% Malcera 508MM alternative and about 0.3% Malcera 1507A alternative. 
     
     
         90 . The method of any one of  claims 15 - 19 , wherein the Malcera 508MM alternative comprises a blend of KP140 (TBEP), non-ionic surfactants, and esterified vegetable oils, e.g. methyl and higher alcohol esters of soy bean, corn, or other vegetable oils. 
     
     
         91 . The invention(s) substantially as shown and/or described herein.

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