Drilling mud closed loop system, method, process and apparatus for reclamation of drilling mud

Abstract

The present invention is generally directed to a closed loop apparatus, system, process or method adapted for processing drilling mud used in a down hole well drilling process such that any undesirable particulate such as cuttings will be substantially, if not completely separated from the dirty mud while at the same time allowing the recycled drilling mud to be continuously circulated with the drilling mud. In one embodiment, the present invention includes the following components, all in fluid or mud flow communication with one another and with an adjacent drilling rig: at least one clean mud mixing tank, at least one pump system, at least one dirty mud shakers, at least one optional conveyor belt system, at least one recycled mud reclamation tank and one or more filtering centrifugal pumps or centrifuge systems.

I claim: 
     
       1. A closed loop apparatus for reclaiming drilling mud used in a down hole well drilling process with a drilling rig, the apparatus comprising at least one clean mud mixing tank adapted to mix and store clean mud, the clean mud mixing tank being in mud flow communication with the drilling rig through a predefined mud flow communication path, at least one conveyor belt system in mud flow communication with the drilling rig, at least one recycled mud reclamation tank in mud flow communication with the conveyor belt system, one or more pump systems in mud flow communication with the drilling rig and the recycled mud reclamation tank, and one or more centrifuges in mud flow communication with the recycled mud reclamation tank and the clean mud mixing tank, the apparatus adapted to continuously circulate the drilling mud to and from the drilling rig while substantially removing one or more cuttings excavated during the drilling process, the apparatus further comprising one or more dirty mud shakers, each dirty mud shaker adapted to receive dirty mud from the drilling rig and being in mud flow communication with the clean mud mixing tank and the conveyor belt system, each shaker further adapted to partially separate undesired particles from the dirty mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to the clean mud mixing tank and reintroduce the shaker processed mud back into the mud flow communication path. 
     
     
       2. The apparatus of  claim 1  wherein the conveyor belt system is a conveyor belt adapted to receive mud from the mud flow communication path and substantially separate undesired particles from the mud resulting in recycled mud and cuttings, each convey conveyor belt system further adapted to transport the recycled mud to the recycled mud reclamation tank and transport any remaining cuttings to at least one cuttings disposal tank. 
     
     
       3. The apparatus of  claim 2  further including at least a first pressure spray system adapted to selectively dispense fluid which neutralizes or eliminates an undesirable compound in the mud. 
     
     
       4. The apparatus of  claim 2  wherein the conveyor belt is vibrational at one or more points along the conveyor travel path. 
     
     
       5. The apparatus of claim  2  3 wherein the recycled mud reclamation tank is adapted to store recycled mud from the conveyor belt system and allow the recycled mud to be removed from within the tank to a disposal vessel. 
     
     
       6. The apparatus of  claim 5  further including at least one recirculation system in mud flow communication with the recycled mud reclamation tank, each recirculation system adapted to further filtrate the recycled mud within the recycled mud reclamation tank. 
     
     
       7. The apparatus of  claim 6 , each recirculation system comprising at least one centrifuge system adapted to filter out one or more undesirable compounds in the recycled mud and returning return the recycled mud to the recycled mud reclamation tank. 
     
     
       8. The apparatus of  claim 7 , each recirculation system further comprising at least a second spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       9. The apparatus of  claim 2  wherein the recycled mud reclamation tank is further adapted to transport the recycled mud back to the drilling rig through at least one centrifuge system in mud flow communication with the recycled mud reclamation tank, each centrifuge system being adapted to selectively filtrate one or more undesired compounds prior to transmitting the recycled mud to the drilling rig. 
     
     
       10. The apparatus of  claim 1  further including at least a first pressure spray system adapted to selectively spray fluid on the shaker processed mud as it travels on the conveyor belt system in order to further assist the separation of mud from the cuttings. 
     
     
       11. The apparatus of claim  1  6 further comprising at least one centralized computer system in electronic communication with the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, and the recirculation system, the computer system adapted to selectively control the operation of any of the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, or the recirculation system. 
     
     
       12. The apparatus of claim  1  6 further comprising a foundation adapted to retain and, during transport, carry the weight of the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, and the recirculation system. 
     
     
       13. The apparatus of  claim 1  further comprising at least one frac tank, each frac tank adapted to receive, store, and dispense recycled mud which may remain in either the clean mud tank or the recycled mud tank after the down hole well drilling process is completed. 
     
     
       14. A system for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud, the system comprising at least one clean mud mixing tank adapted to mix and store clean mud, at least one conveyor belt system adapted to receive mud from the mud flow communication path and substantially separate undesired particles from the mud in the mud flow communication path resulting in recycled mud and cuttings, at least one recycled mud reclamation tank adapted to store recycled mud from the conveyor belt system, one or more pump systems adapted to selectively assist mud flow travel within the mud flow communication path and one or more centrifuge systems adapted to selectively filtrate one or more undesirable compounds in the drilling mud, each clean mud mixing tank, conveyor belt system, recycled mud reclamation tank, pump system and centrifuge system all being in mud flow communication with the drilling rig through the mud flow communication path, the system adapted to continuously circulate the drilling mud to and from the drilling rig while substantially removing one or more cuttings from the drilling mud excavated during the drilling process. 
     
     
       15. The system of  claim 14  further comprising at least one dirty mud shaker adapted to receive drilling mud from the drilling rig to partially separate undesired particles from the mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to the clean mud mixing tank and reintroduce the shaker processed mud back into the mud flow communication path. 
     
     
       16. The system of  claim 14  wherein the conveyor belt system is a conveyor belt adapted to transport the recycled mud to the recycled mud tank and transport any remaining cuttings to at least one cuttings disposal tank. 
     
     
       17. The system of  claim 16  further including at least a first pressure spray system adapted to selectively spray fluid on the mud as it travels on the conveyor belt system in order to further assist the separation of mud from the cuttings, the first pressure spray system further being adapted to selectively dispense fluid which neutralizes or eliminates an undesirable compound in the mud. 
     
     
       18. The system of  claim 17  further including at least one recirculation system in mud flow communication with the recycled mud reclamation tank, each recirculation system adapted to filtrate the recycled mud within the recycled mud reclamation tank. 
     
     
       19. The system of  claim 17 , each recirculation system further comprising at least one centrifuge adapted to filter out one or more undesirable compounds in the recycled mud and returning the recycled mud to the recycled mud reclamation tank, each recirculation system further comprising at least a second spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       20. The system of  claim 14  wherein the recycled mud reclamation tank is further adapted to transport the recycled mud back to the drilling rig through at least one centrifuge system and at least one pump in mud flow communication with each centrifuge system, each centrifuge system being adapted to selectively filtrate one or more undesired compounds prior to transmitting the recycled mud to the clean mud mixing tank. 
     
     
       21. A closed loop method for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud from a clean mud mixing tank, the method comprising the steps of:
 transporting the drilling mud from the drilling rig to at least one dirty mud shaker, each dirty mud shaker adapted to receive dirty mud from the mud flow communication path, each shaker further adapted to partially separate undesired particles from the drilling mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to at least one the clean mud mixing tank and reintroducing reintroduce the shaker processed mud back into the mud flow communication path; 
 transporting the shaker processed mud from the mud flow communication path to at least one conveyor belt system, each conveyor belt system being adapted to substantially separate undesired particles from the shaker processed mud resulting in recycled mud and cuttings, 
 each conveyor belt system further adapted to transport the recycled mud to at least one the recycled mud tank and transport any remaining cuttings to at least one cuttings disposal tank; 
 transporting the recycled mud within the recycled mud tank to the clean mud mixing tank for use as drilling mud through one or more centrifuge systems, each centrifuge system adapted to selectively filtrate one or more undesired compounds prior to transmitting the recycled mud to the clean mud mixing tank. 
 
     
     
       22. The method of  claim 21  further including the step of introducing at least a one first pressure spray system to the at least one conveyor belt system, the at least one first pressure spray system adapted to selectively spray fluid on the mud as it travels on the conveyor belt system in order to further assist the separation of mud from the cuttings, the at least one first pressure spray system further being adapted to selectively dispense fluid which neutralizes or eliminates an undesirable compound in the mud. 
     
     
       23. The method of  claim 22  further controlling the at least one first pressure spray system to selectively dispense fluid which neutralizes or eliminates an undesirable compound in the mud. 
     
     
       24. The method of  claim 21  further including the steps of utilizing at least one recirculation system in mud flow communication with the recycled mud reclamation tank, each recirculation system adapted to filtrate the recycled mud within the recycled mud reclamation tank. 
     
     
       25. The method of  claim 24 , each recirculation system further comprising at least one centrifuge adapted to filter out one or more undesirable compounds in the recycled mud and returning the recycled mud to the recycled mud reclamation tank. 
     
     
       26. The method of  claim 25  further comprising at least one second spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       27. The method of  claim 21  further including the step of introducing at least one centralized computer system in electronic communication with the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, and the recirculation system, the computer system adapted to selectively control any of the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, or the recirculation system. 
     
     
       28. The method of claim  21  24 further including the step of utilizing a foundation adapted to retain and, during transport, carry the weight of the clean mud mixing tank, the conveyor belt system, the recycled mud reclamation tank, and the recirculation system. 
     
     
       29. The method of  claim 21  further including the step of utilizing at least one fracture tank, each fracture tank adapted to receive, store and dispense recycled mud which may remain in either the clean mud tank or the recycled mud tank after the down hole well drilling process is completed. 
     
     
       30. A closed loop method for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud from at least one clean mud mixing tank, the method comprising the steps of:
 transporting the drilling mud from the drilling rig to at least one dirty mud shaker, each dirty mud shaker adapted to receive dirty mud from the mud flow communication path, each shaker further adapted to partially separate undesired particles from the drilling mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to the clean mud mixing tank and reintroducing the shaker processed mud back into the mud flow communication path; 
 transporting the shaker processed mud from the mud flow communication path to at least one recycled mud reclamation tank, the recycled mud tank further including at least one recirculation system in mud flow communication with the at least one recycled mud reclamation tank and the clean mud mixing tank, each recirculation system adapted to filtrate the shaker processed mud resulting in a recycled mud within the recycled mud reclamation tank and transport the recycled mud to the clean mud mixing tank for use as drilling mud. 
 
     
     
       31. A closed loop method for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud from a clean mud mixing tank, the method comprising the steps of:
 transporting the drilling mud from the drilling rig to at least one recycled mud reclamation tank and transporting any cuttings to at least one cuttings disposal tank; 
 allowing at least one recirculation system within the recycled mud reclamation tank to filtrate the drilling mud resulting in a recycled mud; and 
 transporting the recycled mud within the recycled mud reclamation tank to the drilling rig through the clean mud mixing tank. 
 
     
     
       32. The closed loop method for reclaiming drilling mud of  claim 31 , each recirculation system comprising at least one centrifuge system adapted to filter out one or more undesirable compounds in the recycled mud and returning the recycled mud to the recycled mud reclamation tank. 
     
     
       33. The closed loop method for reclaiming drilling mud of  claim 32 , each recirculation system further comprising at least a spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       34. A process for reclaiming drilling mud used in a down hole well drilling event with a drilling rig, the process comprising the steps of:
 transporting the drilling mud from the drilling rig to at least one recycled mud reclamation tank resulting in recycled mud, the recycled mud reclamation tank being in mud flow communication with the drilling rig; 
 allowing at least one recirculation system within the recycled mud reclamation tank to filtrate the drilling mud resulting in a recycled mud; and 
 transporting the recycled mud within the recycled mud reclamation tank to a clean mud mixing tank for use as drilling mud through one or more centrifuge systems, each centrifuge system adapted to selectively filtrate one or more undesired compounds prior to transmitting the recycled mud to the clean mud mixing tank, the clean mud mixing tank being in mud flow communication with the drilling rig. 
 
     
     
       35. The process of  claim 34  further comprising the steps step of transporting the recycled mud to at least one conveyor belt system adapted to receive mud from the mud flow communication path and substantially separate undesired particles from the recycled mud. 
     
     
       36. The process of  claim 34  further comprising the step of introducing clean mud into the clean mud mixing tank through at least one hopper. 
     
     
       37. The process of  claim 34 , each recirculation system further comprising at least a spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       38. A closed loop method for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud, the method comprising the steps of:
 transporting the drilling mud from the drilling rig to at least one recycled mud reclamation tank, the mud reclamation tank being in mud flow communication with the drilling rig, the mud reclamation tank further comprising at least one recirculation system adapted to filtrate the drilling mud resulting in a recycled mud within the recycled mud reclamation tank; and 
 transporting the recycled mud within the recycled mud reclamation tank to the drilling rig for use as drilling mud through one or more centrifuge systems, each centrifuge system adapted to selectively filtrate one or more undesired compounds prior to transmitting the recycled mud to the drilling rig through the a clean mud mixing tank. 
 
     
     
       39. The method of  claim 38  wherein each recirculation system comprises at least one recycling centrifuge system, each recycling centrifuge system adapted to selectively filtrate one or more undesired compounds from the recycled mud in the recycled mud reclamation tank. 
     
     
       40. The method of  claim 39 , each recirculation system further comprising at least a spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       41. A closed loop apparatus for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having drilling mud, the apparatus being in mud flow communication with the drilling rig forming a mud flow communication path, the apparatus comprising at least one mud reclamation tank and at least one centrifuge system, each mud reclamation tank being in mud flow communication with the drilling rig and the at least one centrifuge system, each mud reclamation tank accepts the drilling mud, filtrates the drilling mud through at least one recirculation system resulting in recycled mud and transports the recycled mud to the at least one centrifuge system, the at least one centrifuge system filters out one or more undesirable compounds in the recycled mud, and returns the recycled mud to the mud flow communication path. 
     
     
       42. The apparatus of  claim 41 , each mud reclamation tank further comprising at least a spray system adapted to selectively dispense fluid adapted to neutralize or eliminate an undesirable compound in the recycled mud. 
     
     
       43. The apparatus of  claim 41 , the at least one recirculation system further comprising at least one centrifuge adapted to filter out one or more undesirable compounds in the recycled mud and returning return the recycled mud to the recycled mud reclamation tank. 
     
     
       44. An entirely closed loop apparatus for reclaiming dirty drilling mud used in a down hole well drilling process with a drilling rig generating the dirty drilling mud, the apparatus being in mud flow communication with the drilling rig defining a mud flow communication path, the apparatus comprising at least one mud reclamation tank and at least one centrifuge system, each mud reclamation tank being in mud flow communication with the drilling rig and the at least one centrifuge system, each mud reclamation tank adapted to receive and store the dirty drilling mud, each mud reclamation tank further comprising at least one recirculation system adapted to stir the dirty drilling mud and prevent undesired compounds in the dirty drilling mud from settling in the mud reclamation tank resulting in recirculated mud, the apparatus further adapted to transport the recirculated mud to the at least one centrifuge system, the at least one centrifuge system adapted to substantially or completely remove one or more undesirable compounds in the recirculated mud resulting in recycled mud, the at least one centrifuge system further adapted to return the recycled mud to the mud flow communication path. 
     
     
       45. The apparatus of claim 44, each recirculation system further comprising one or more pumps being in mud flow communication with each mud reclamation tank, each pump being adapted to assist in the movement of the dirty drilling mud within the mud reclamation tank. 
     
     
       46. The apparatus of claim 45 wherein each pump is a centrifugal pump. 
     
     
       47. The apparatus of claim 45 wherein each pump allows the dirty drilling mud to be transported out of each mud reclamation tank and then to be reinserted into the same mud reclamation tank after flowing through the pump. 
     
     
       48. The apparatus of claim 45, each recirculation system further comprising at least one first sprayer system positioned above the recirculated mud in each mud reclamation tank for spraying the recirculated mud in each mud reclamation tank during the movement of the recycled mud in each mud reclamation tank. 
     
     
       49. The apparatus of claim 44 further comprising one or more dirty mud shakers adapted to receive dirty drilling mud from the drilling rig and being in mud flow communication with a clean mud mixing tank and each mud reclamation tank, each dirty mud shaker being adapted to partially separate one or more undesired particles from the dirty drilling mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to the clean mud mixing tank and reintroduce the shaker processed mud back into the mud flow communication path. 
     
     
       50. The apparatus of claim 44, each recirculation system further comprising one or more centrifugal pumps being in mud flow communication with each mud reclamation tank, each centrifugal pump being adapted to assist in the movement of the dirty drilling mud within the mud reclamation tank, the apparatus further comprising one or more dirty mud shakers adapted to receive dirty drilling mud from the drilling rig and being in mud flow communication with a clean mud mixing tank and each mud reclamation tank, each dirty mud shaker being adapted to partially separate one or more undesired particles from the dirty drilling mud resulting in shaker processed mud and used mud, each shaker further adapted to transport the used mud to the clean mud mixing tank and reintroduce the shaker processed mud back into the mud flow communication path. 
     
     
       51. A closed loop process for reclaiming dirty drilling mud generated from a down hole well drilling process with a drilling rig having a mud flow communication path containing drilling mud, the process comprising the steps of transporting the dirty drilling mud from the drilling rig to at least one recycled mud reclamation tank, each mud reclamation tank being in mud flow communication with the drilling rig and further comprising at least one recirculation system, using the recirculation system to stir the dirty drilling mud in each mud reclamation tank to prevent undesired compounds in the dirty drilling mud from settling within the mud reclamation tank resulting in recirculated mud, transporting the recirculated mud to at least one centrifuge system, the at least one centrifuge system adapted to filter out one or more undesirable particulates in the recirculated mud resulting in recycled mud, and transporting the recycled mud to the mud flow communication path. 
     
     
       52. The process of claim 51, each recirculation system further comprising one or more centrifugal pumps being in mud flow communication with each mud reclamation tank, each centrifugal pump assisting circulation of the dirty drilling mud in the mud reclamation tank to substantially or completely prevent the undesirable particulates in the dirty drilling mud from settling within each mud reclamation tank. 
     
     
       53. The process of claim 52, each recirculation system further comprising at least one sprayer system positioned above the recirculated mud in each mud reclamation tank for spraying the recirculated mud in each mud reclamation tank during the movement of the recycled mud in each mud reclamation tank. 
     
     
       54. A closed loop apparatus for reclaiming drilling mud used in a down hole well drilling process with a drilling rig having dirty drilling mud containing one or more undesirable particulates, the apparatus comprising at least one clean mud mixing tank adapted to mix and store drilling mud used in the down hole well drilling process, the clean mud mixing tank being in mud flow communication with the drilling rig through a predefined mud flow communication path, at least one mud reclamation tank in mud flow communication with the drilling rig, each mud reclamation tank adapted to receive the dirty drilling mud and variously circulate the dirty drilling mud in the mud reclamation tank through at least one recirculation system, each recirculation system adapted to selectively prevent undesired compounds in the dirty drilling mud from settling within the mud reclamation tank, resulting in recirculated mud, and at least one centrifuge in mud flow communication with each mud reclamation tank and each clean mud mixing tank, each centrifuge adapted to receive most, if not all, of the recirculated mud from the mud reclamation tank and selectively remove each undesirable particulates, resulting in recycled mud prior to transmitting the recycled mud to the clean mud mixing tank for use as clean mud in the down hole well drilling process. 
     
     
       55. The apparatus of claim 54, each recirculation system further comprising one or more centrifugal pumps being in mud flow communication with each mud reclamation tank, each centrifugal pump being adapted to assist the circulation of the dirty drilling mud in each mud reclamation tank to substantially or wholly prevent undesirable particulates in the dirty drilling mud from settling within each mud reclamation tank. 
     
     
       56. The apparatus of claim 54, each recirculation system further comprising at least one sprayer system positioned above the recirculated mud in each mud reclamation tank for spraying the recirculated mud in each mud reclamation tank during the movement of the recycled mud in each mud reclamation tank.