Drilling fluid treatment process and system

Abstract

Methods and apparatus for treating fluid streams containing solids are described herein. One method includes mixing a fluid stream containing solids, or a material derived from the fluid stream containing solids, with a flocculant agent, a coagulant agent, or both to form a mixture; routing the mixture to a high efficiency separator to yield a solids stream and a liquid stream; and routing the solids stream to an electro-osmotic filter press to form a solid filter cake. The fluid stream can be a water-based stream or a non-aqueous stream.

1 . A method of treating a water-based stream containing solids, the method comprising:
 mixing the water-based stream containing solids, or a material derived from the water-based stream containing solids, with a flocculant agent, a coagulant agent, or both to form a mixture;   routing the mixture to a high efficiency separator to yield a solids stream and a liquid stream; and   routing the solids stream to an electro-osmotic filter press to form a solid filter cake.   
     
     
         2 . The method of  claim 1 , further comprising mixing the mixture using a vessel and mixing the mixture using an in-line mixer. 
     
     
         3 . The method of  claim 1 , further comprising routing at least a portion of the water-based stream containing solids to a bulk separator and forming the material derived from the water-based stream from an effluent of the bulk separator. 
     
     
         4 . The method of  claim 1 , further comprising controlling operation of the high efficiency separator by flowing a diluent into the mixture. 
     
     
         5 . A method of treating a fluid stream containing solids, the method comprising:
 mixing the fluid stream containing solids, or a material derived from the fluid stream containing solids, with a flocculant agent, a coagulant agent, or both to form a mixture;   routing the mixture to a high efficiency separator to yield a solids stream and a liquid stream;   determining whether the fluid stream containing solids is a water-based stream, determining whether the liquid stream is a water stream, or both; and   where the fluid stream containing solids is a water-based stream, the liquid stream is a water stream, or both, routing the solids stream to an electro-osmotic filter press to form a compressed solid material.   
     
     
         6 . The method of  claim 5 , further comprising operating a diverter to route the solids stream to the electro-osmotic filter press. 
     
     
         7 . The method of  claim 6 , further comprising, where the fluid stream containing solids is a non-aqueous stream, the liquid stream is a non-aqueous stream, or both, operating the diverter to route the solids stream away from the electro-osmotic filter press. 
     
     
         8 . The method of  claim 5 , wherein the compressed solid material is a cake. 
     
     
         9 . The method of  claim 5 , further comprising mixing the mixture using a mixing vessel, an in-line mixer, or both. 
     
     
         10 . The method of  claim 5 , further comprising controlling operation of the high efficiency separator by flowing a diluent into the mixture. 
     
     
         11 . A system for processing drilling fluids comprising:
 a bulk separator containing an effluent;   a mixing vessel in fluid communication with the bulk separator such that the mixing vessel can receive at least a portion of the effluent and wherein the mixing vessel is configured to receive a mixing agent whereby the effluent and the mixing agent combine to become a mixture;   a drying module wherein the drying module comprises;
 a high efficiency separator configured to receive at least a portion of the mixture wherein the high efficiency separator separates the mixture into a solid stream and a liquid stream; and 
 a press mechanism in fluid communication with the high efficiency separator and configured to receive the solid stream, wherein the press mechanism compresses the solid stream into a compressed solid material and a solid-free liquid. 
   
     
     
         12 . The system for processing drilling fluids of  claim 11 , wherein the mixing agent is a flocculant agent, a coagulant agent or both. 
     
     
         13 . The system for processing drilling fluids of  claim 12 , wherein the high efficiency separator is a centrifuge. 
     
     
         14 . The system for processing drilling fluids of  claim 12 , wherein the press mechanism is an electro-osmotic filter press. 
     
     
         15 . The system for processing drilling fluids of  claim 12 , further comprising
 a first and a second sensor, wherein the first sensor is coupled to the mixing vessel and configured to determine the density of the mixture as it enters the high efficiency separator, and wherein the second sensor is coupled to the high efficiency separator and configured to determine the density of the liquid stream;   a pump configured to pump a diluent stream into the mixture before it enters the high efficiency separator; and   a controller operatively coupled with the first and second sensors and the pump such that a first density signal from the first sensor coordinated with a second density signal from the second sensor can be utilized to determine a target density of the mixture.   
     
     
         16 . The system for processing drilling fluids of  claim 15 , wherein the controller is configured to control the pump wherein the pump can pump diluent into the mixture before it enters the high efficiency separator to generate the target density of the mixture. 
     
     
         17 . The system for processing drilling fluids of  claim 12 , further comprising a solid stream sensor operatively coupled with the high efficiency separator and configured to determine if the solid stream is water-based or non-aqueous. 
     
     
         18 . The system for processing drilling fluids of  claim 17 , further comprising a controller in signal communication with the solid stream sensor and a diverter, wherein if the solid stream is determined to be non-aqueous the diverter can be controlled to an open state and divert the solid stream onto a conveyor system before entering the press mechanism. 
     
     
         19 . The system for processing drilling fluids of  claim 18 , wherein if the solid stream is determined to water-based, the controller can cause the diverter to be in a closed state and divert the solid stream to the press mechanism. 
     
     
         20 . The system for processing drilling fluids of  claim 12 , further comprising an inline mixer disposed between the mixing vessel and the high efficiency separator.