CA3090319A1

CA3090319A1 - Improvements in wastewater evaporation systems

Info

Publication number: CA3090319A1
Application number: CA3090319A
Authority: CA
Inventors: Joshua Curlett; Hugues Wanlin
Original assignee: Cleantek Industries Inc
Current assignee: Cleantek Industries Inc
Priority date: 2017-02-07
Filing date: 2018-02-07
Publication date: 2018-08-16
Also published as: WO2018145205A1

Abstract

The invention relates to methods, systems and apparatus for distributed management of raw water and internal combustion engine (ICE) gas emissions generated during industrial operations. The raw water vaporization system comprises a concentrator tank positioned directly below a vaporization chamber such that material exiting the vaporization chamber via the vaporization chamber outlet impinges with liquid in the concentrator tank. This may reduce maintenance as any particulates or scale formed within the vaporization chamber can fall directly into the liquid contained in the concentrator tank.

Description

IMPROVEMENTS IN WASTEWATER EVAPORATION SYSTEMS
FIELD OF THE INVENTION
[0001] The invention relates to methods, systems and apparatus for distributed management of raw water, heat energy within combustion gas and internal combustion engine (ICE) gas heat and pressure generated during industrial operations. Such operations include but are not limited to oilfield drilling, completions and production operations with mobile, semi-permanent and/or permanent processing units. One aspect of the invention provides a compact, concentrator, vaporizer and demister. The apparatus can be configured in various embodiments and can provide various advantages to operators seeking to vaporize raw water and/or concentrate contaminants within raw water using waste heat and/or pressure from such operations including ICE's and other sources, such as flare stacks, incinerators, steam generators or natural gas turbines. These advantages can include:
a. low maintenance through the design and operation of a system that minimizes scale, particulate, salts and other build-up;
b. minimal new energy input over and above a primary heat source such as an ICE, combustion gas, flare gas or other similar source;
c. minimal pressure drop related to water vaporization and/or entrainment separation;
d. maximization use of available waste pressure and/or heat;
e. effective and maximized use of low grade waste heat not typically suitable or accessible;
f. reduce the release of volatiles and pollutants to the atmosphere;
g. recovery of condensates/concentrates from raw water;
h. reduced capital cost of raw water vaporization equipment;
i. reduced ongoing operating expense due to minimized need for operator oversight;
j. light weight and compact system for remote or satellite installations closer to a heat source;
k. light weight and compact system that can be made with plastics allowing rapid mass production and the ability to custom manufacture various embodiments;
I. a monitoring and reporting system for remote management of many distributed systems within a larger grid;
m. reduced ground level footprint when installed or retrofit to existing oilfield equipment.

[0002] The system may help allow many economical and environmentally positive alternatives over historical raw water management techniques and can substantially limit atmospheric discharge of contaminants entrained within ICE combustion gas.
Advantageously the invention simultaneously facilitates rapid transfer of combustion gas particulate chemicals into the raw water as it concentrates. Another aspect of the invention is an exhaust diversion system to provide energy within exhaust, i.e. heat and pressure, to a dual fluid interaction zone within the system.

[0003] Another aspect of the invention is that due to some of its various features and benefits such as being compact, in-line and/or self-cleaning it can be placed at or near to a waste heat source minimizing the need for ground level footprint. A further aspect of the invention provides an economically viable and environmentally synergistic means of distributed raw water and emissions management to reduce and recycle large volumes of industrial raw water and emissions within localized regions, often remote and stranded from waste management infrastructure, in which both raw water and emissions are generated, are in abundance and are considered waste by-products of industrial operations.
Distributed management of raw water and emissions may be enhanced by networking data from these remote raw water management processing units as a means to ensure that each satellite system in the network can be utilized to its full capacity either by actors within an organization operating within a geographic region or by many organizations operating within a geographic region utilizing each other's raw water processing system.

[0004] An algorithm may be used as a means to communicate data points to those within the network such as individual system run time, raw water processing rates, available or unused capacity of raw water, re-condensed water, heat, pressure, brine, salt, etc., timing and/or availability of upcoming spare capacity, etc. As described herein part of the novelty of the present invention is its simplicity.
BACKGROUND OF THE INVENTION

[0005] There are many examples where vaporization is used to reduce the liquid phase of water solutions containing contaminants for the purpose of concentrating the contaminants for disposal. Often referred to as thermal separation or thermal concentration processes, these processes generally begin with a liquid and end up with a more concentrated but still pump-able concentrate or a dry salt that may be subjected to further processing and/or disposal. In the context of this description, waste water solutions containing dissolved and/or suspended contaminants are referred to as "raw water" or "wastewater". In particular, raw water refers to water solutions containing contaminants, for example, brackish or brine fluid (including sodium, potassium, calcium and other salts) and some particulates. Other contaminants including hydrocarbons (generally 05 and higher), soaps and particulates may also be within the raw water. The concentrations of contaminants within the raw water may range, in the case of salts from about 0 to about 25 wt%, in the case of hydrocarbons from about 0 to about 5 wt%, in the case of soaps from about 0 to about 2 wt%.

[0006] Raw water may be production water from a gas or liquid hydrocarbon production facility where the raw water has been separated from a gas or liquid hydrocarbon production stream. In this instance, the raw water may include connate water, connate water salts and particulates together with hydrocarbons. Raw water may also be raw water from drilling operations including cement water, wash water, contaminated lease water, drilling fluid, water from recovered drilling fluids which may include connate water, connate water salts, emulsifiers/soaps, viscosifying agents, hydrocarbons and particulates and others.

[0007] As is generally known with aqueous concentrator systems, as water vapor is vaporized, the concentrate progressively comprises increasing percentages of the original contaminants in the solution including the salts, hydrocarbons and particulates. Due to the nature of different contaminants, as the solutions become more concentrated, there has been a need for systems and methods that can effectively manage the solutions as the contaminants become more concentrated.

[0008] In the case of dilute solutions containing hydrocarbons, that may include heavy oil, medium oil and light oil fractions, the handling of such solutions must be managed in order to enable operators to collect what might be valuable amounts of these hydrocarbons but also to prevent flammable solutions from being created particularly in locations where heat and oxygen may be present in the concentrator system. For example, a feed or raw water solution with 1%
condensate concentration may result in a 10% (or higher) condensate solution over time as water is vaporized from the solution which may represent a sufficiently valuable volume to warrant collection but also that could become a potentially flammable mixture wherein the hydrocarbons should be removed.

[0009] Similarly, in the case of a brackish wastewater solution having a 1-2% salt concentration or brine wastewater solutions having a 4-20% salt concentration, the solution will become progressively more concentrated with salt up to a point where the solution becomes fully saturated with the salt and will precipitate from the solution. As a result, there has been a need for systems and methods that can effectively manage concentrated salt solutions that do not lead to scaling within the equipment that will require maintenance and/or precipitates that could cause clogging of lines. Moreover, as the solubility of many salts varies as a function of temperature, there has been a need for concentration systems that can maintain consistent temperatures to minimize precipitation issues that may occur as temperatures vary within a system.

[0010] Particulates in a typical wastewater solution may range in size from about 0.2 microns (fine clay or silt particles) to about 500-1,000 microns (sand and gravel particles) and may comprise from about 0 to about 10 wt% of the raw water solution. As with other contaminants, particulates will become more concentrated during the concentration processes.
While larger particles are generally easily removed, finer particles can become increasingly problematic within the concentrating solutions as viscosity increases and increasingly larger particles may become suspended in the solution and can lead to scaling and/or plugging of lines. As such, there has been a need for systems and methods that minimize the effect of particulates.

[0011] In addition, there has also been a need for a system with the capability to concentrate waste water using waste heat and waste pressure, pushed by mechanical force of engine pistons. These can be generated from remote or stranded industrial operations, such as drilling rig operations, and there has been a need to provide further operational and efficiency advantages over systems that use standalone hydrocarbon (e.g. fuels) and/or electric sources as prime energy inputs and that add to the cost of vaporizing and/or processing raw water.

[0012] Further still, there is also a need for a system that is also simultaneously effective in vaporizing water and removing combustion related soot, particulate and combustion chemicals from the combustion gas source of the particular heating source. In other words, heretofore there has been no incentive for mobile treatment of flue gasses on remote or stranded drilling sites because there are local and national exemptions to standard air emission regulations on oil and gas drilling sites related to diesel engine exhaust volume and concentration of discharge within relatively short timeframes. As such, until an economical and functional solution is provided, enabling regulators and operators to insist on change, the cleaning of these collectively large volumes of acid gasses prior to atmospheric discharge will not occur. Accordingly, by marrying the technology for cleaning exhaust gasses with another use such as vaporizing raw water, there is an economic incentive to the operator to take this environmentally responsible action.

[0013] In regards to the emissions from drilling rig operations, in recent years as many as 2,000 rigs have been operating in North America each day with each one consuming on average approximately 3,000 ¨ 9,000 liters per day of diesel fuel within the various power generating machinery. For example, a typical 500kW engine-generator set at a drilling site will exhaust 50 to 120 m3/min whereas a 1200kW engine-generator set produces in the order of 273 m3/min of acid gas exhaust into the environment thereby polluting the environment and wasting the heat and pressure energy contained therein. However, the heat contained within this exhaust is capable of vaporizing up to about 10 cubic meters of water per day depending on average engine load through-out the day. This equates to 95-285 billion cubic meters of uncleaned acid gas discharge from all North American rigs every year and a heat/pressure resource that is otherwise unutilized. As can be imaged when 1200-2500 kW
engine-generator sets are used for these operations, the amount of waste heat and waste pressure are much larger and become substantial sources of free prime mover energy input.

[0014] Thus, there has also been a need for systems that can reduce the amount of exhaust contaminants that may be released to the atmosphere while at the same time using that heat/pressure resource for reducing the total volumes of contaminated waste water that requiring shipping and/or removal from a drilling rig site, in-ground injection or the like.

[0015] Other oilfield operations include heavy oil production through steam injection, including steam assisted gravity drainage (SAGD), and gas production where large quantities of water are utilized within and recovered from heavy oil reservoirs. Water will be recovered from the reservoir with varying contaminants and concentrations of contaminants.
For example, steam injection techniques result in the production of mixtures of produced water (containing sodium and calcium salts inter alia) and hydrocarbons (complex mixtures of heavy and light fractions) and particulates (sand, minerals etc.). While the majority of hydrocarbons are removed from this produced water and the majority of water is recycled for steam production a certain volume of produced water is raw water that is contaminated with a combination of salts, hydrocarbons and particulates. These facilities use one to many dozen steam generators, such as Once-Though Steam Generators and Heat-Recovery Steam Generators (HRSG).
These generators typically have power outputs ranging from 3MW to 250MW. The by-product of the combustion heat utilized by these systems is a low grade heat that is no longer economically usable by current heat exchange technology and which is vented to atmosphere using large chimney stacks. As one example a 50MW Steam Generator may have a 2-3 meter diameter flue stack, downstream of an economizer, which releases flue gas to atmosphere with an approximate temperature of 150 C-200 C. Drawbacks of prior art systems are an inability to utilize this low grade heat. Drawbacks to other prior art systems is they have to bring the heat from 30+ meters up a flue stack to ground level for processing, and by doing so lose more heat.
These latter systems although described as compact are not light nor compact enough satellite installation at the top of the flue stack. Further, even if prior art systems were light and compact, they are prone scale buildup within their systems, requiring ground level operator access for ongoing cleaning and maintenance, which results in ongoing, undesirable operational expense.

[0016] Similarly, at gas production facilities, gas plants or remote compressor stations, where produced gas is recovered at surface and compressed for delivery to pipelines, connate water is recovered with the gas which is substantially raw water. As noted above, this raw water is also a varying mixture of salts, hydrocarbons and particulates and can be produced in volumes of up to several hundred cubic meters of water per day, per single site. There are a variety of engine types and sizes utilized in oilfield operations. These generators and associated engines can vary greatly, but typically range in size and power ratings from about 500kW at a drilling rig to about 2500kW at gas production and compression facilities.
Such engines are typically used to generate power and to drive gas compression systems at gas production facilities. Generally, the temperate of the exhaust gas is about 300-700 C, depending on engine type and engine load.

[0017] At a drilling rig, engines are typically portable systems that are positioned adjacent to drilling equipment whereas at a gas production facility, the engines and compressors are typically permanent or semi-permanent installations. At each operation, each engine is connected to muffler systems to manage noise associated with the engine. Typically, large muffler systems for example paired to a 2,000kW engine-generator set are installed in a vertical orientation adjacent to or above the engine which smaller engines for example 500-1200kW may have a horizontal orientation. Similarly, the temperature of the exhaust gas is about 300-700 C.

[0018] Such engines have variable performance characteristics including varying exhaust pressures, exhaust flow rates/speeds, exhaust temperatures and backpressure tolerances. Table 1 show typical performance characteristics for different engine sizes.

Table 1-Representative Engine Performance Characteristics (not muffled) Engine Exhaust Exhaust Pipe Exhaust Flow Exhaust Push Power Temperature Diameter Rate Backpressure Power Rating (bhp) ( C) (Typical) @100% Max (max) WC (kW) @100% Max Load inches (kPa) Load 600-850 550 5-8" 112 m3/min 40" WC 19 (10 kPa) 1000-1500 400-450 10-16" 221 m3/min 27"WC 25 (7 kPa) 2300-2500 450-500 18-22" 451 m3/min 10-14" WC 19-27 (2.5-3.5 kPa)

[0019]
As can be seen from Table 1, in many cases as an engine becomes larger it is generally less able to tolerate significant backpressure. As a result, there has been a need for raw water vaporization systems that can be adapted to different engines without adversely affecting the performance of that engine to conduct its primary function at a work site.

[0020]
More specifically, there has been a need for an ICE Exhaust gas delivery system that provides any one of or a combination of static, control actuated, flow actuated or pressure actuated control systems that directs and allows ICE exhaust to be effectively used to at least partially shear, boil and/or vaporize raw water while ensuring the maximum backpressure limits as seen by the engine are not exceeded. As can be seen in Table 1, the push pressure of an ICE is significant when utilized for the purpose of shearing, vaporizing and as discussed below can also be used as input pressure for an induced cyclone for demisting entrained water droplets from the exhaust gas. Other various demisting methods may also be employed, including impingement based demisters as are known to those with skill in the art.

[0021]
Furthermore, to further enhance the scope of using different heat sources, there has been a need for low pressure combustion gas delivery systems that, as needed, can be enhanced by additional pressure inducing devices (e.g. blowers).

[0022]
Further still, in order to reduce the capital costs associated with implementing vaporizer systems, there has been a need for compact and relatively light weight vaporizer systems that can be manufactured from plastics whilst operating in hot environments. In addition, to reduce manufacturing costs, such systems can also provide advantages for the installation of vaporizing systems on existing equipment, such as tall chimney stacks. Further, a vaporization and demisting system with non-stick inner surfaces minimizes scale buildup within the system thereby reducing the need for maintenance, as with prior art systems, and allows for remote installation on tall exhaust stack structures.

[0023] Further still, in order to improve the efficiency of vaporization, there has been a need for improved combustion gas velocity modifier, stabilizer, manipulator or generator systems, referred to collectively as an "air knife" system designed to utilize the waste pressure within ICE combustion gas for shearing and vaporizing raw water by mixing/interfacing exhaust gases with raw water. Alternatively, in embodiments where there little or no waste pressure is available, an air knife system may be used in conjunction with a blower, rotor, fan or the like in order to assist with shearing and vaporization of raw water. In various other embodiments an air knife system can be used in conjunction with a demisting cyclone system.

[0024] Further still, there is a need to remove VOCs (Volatile Organic Compounds) from produced water.

[0025] Further still, there is a need to remove barium from produced water.

[0026] Further still, there has been a need for vaporizing systems that in addition to vaporizing raw water are effective as muffler systems for large ICE's. That is, there has been a need for an inline, muffling, self-washing vaporizer that can be placed remotely adjacent to, upstream from or downstream from an existing muffler is desirable.

[0027] Further still, there has been a need for vaporizing and concentrating systems that are effective in reducing the build-up of scale within the systems that require maintenance to remove the scale. There is a particular need for such systems where the raw water being vaporized is continuing to be enriched in contaminants that due to the enrichment are particularly susceptible to precipitation within the system. In particular, there has been a need for vaporizing systems that are effectively and efficiently being continually cleaned during operation.

[0028] Furthermore, there has also been a need for systems that can reduce the amount of exhaust contaminants that may be released to the atmosphere while at the same time reducing the total volumes of contaminated waste water that require shipping and/or removal from an industrial waste generation site.

[0029] Additionally, there is a need for a system for the management, reporting, distribution and/or controlling of many distributed systems within a grid of systems that allows for feedback to a central processing system wherein processing rates, raw water storage, condensed water storage, combustion gas temperature and pressure, run time, processing volumes and the like are collected and managed.

[0030] Furthermore, there has also been a need for systems that effectively manage concentrated salt solutions, either by drying salts so there is substantially zero liquid concentrate discharge or a system that can concentrate a salt solution to just under its maximum saturation point so the salts stay in solutions and can be disposed of by deep well injection.

[0031] Further still, there has also been a need for systems that can be readily retrofit to existing oilfield equipment with minimal capital cost, operating cost, footprint, or operational impact.

[0032] Examples of past systems include US 8,066,844 which describes a concentrator designed to operate utilizing waste "heat" from land fill gas in which the system is under negative pressure. Applying vacuum pressure on the system is taught due to lack of positive push pressure from the land fill gas heat source. The prior art discusses an alternative use of "heat" only from an engine exhaust system as a preheating method, but does not contemplate the use of the positive pressure resource within engine exhaust. In operation, the effect of the negative pressure applied to the exit of the prior art system would at least in part neutralize the effect of positive engine exhaust pressure. Additionally, as a result of the focus of US '844 on land fill gas waste heat utilization with no or little associated positive pressure, there is no teaching of using the positive pressure within engine exhaust gas to at least partially atomize, shear or break droplets as a means for interfacial surface area generation.
Importantly, in the US '844 system, negative pressure at the exit of the system allows a venturi effect upstream of the suction as a means of creating raw water interfacial surface area generation. In other embodiments the US '844 system describes using a blower upstream of the vaporizer section of the system to provide required push pressure needed for the venturi water mixing system.
Regarding the latter, a drawback to this system is that new energy input is required, at a cost, in order to shear and mix water with a heat source. Substantial drawbacks to various US '844 systems are the described requirement for cleaning and maintenance of scale and salt deposits due to many wet/dry surfaces within the system. These drawbacks are also associated with a cyclonic demister whose inlet is tangential rather than concentric in that within the cyclone there are substantial dry surfaces that buildup scale, salts, etc. and require much maintenance and cleaning.

[0033] Examples of past systems also include those described in US Patent 7,722,739, US Patent 5,259,931, US Patent Publication 2009/0199972, US Patent Publication 2009/0294074, US Patent 5,770,019, US Patent 5,573,895, US Patent 7,513,972, US Patent 2,101,112, and US Patent 6,200,428.

[0034] Applicant's Canadian patent 2,751,895 (and related co-pending applications based on PCT/CA2010/001440) also describes improved raw water vaporization systems and are incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTION

[0035] According to a first aspect, there is provided a raw water vaporization system (RVVVS) comprising:
a vaporization chamber having:
raw water and gas inlets configured inject water and gas to within the vaporization chamber to effect raw water vaporization; and an outlet at the bottom of the vaporization chamber;
a concentrator tank positioned in a plane below the vaporization chamber such that material exiting the vaporization chamber via the vaporization chamber outlet impinges with liquid in the concentrator tank; and a raw water channel configured to inject raw water from the concentrator tank into the vaporization chamber via at least one of the raw water inlets.

[0036] The gas inlet may be configured to direct gas flow through the vaporization chamber and directly into liquid contained in the concentrator tank.

[0037] The concentrator tank may have gas outlets arranged in the top surface of the concentrator so that gas entering the concentrator tank from the vaporization outlet must change direction to exit the concentrator tank gas outlets.

[0038] The concentrator tank may be tapered at the bottom.

[0039] The concentrator tank may comprise a recirculation loop for recirculating the liquid within the concentrator tank.

[0040] The concentrator tank may comprise an agitator.

[0041] A vaporization chamber gas inlet may be configured to manipulate the gas flow, direction and/or speed enabling control of the gas at the outflow orifice in relation to the inlet orifice of the adaptor, resulting in the improved or optimal use the gas heat, pressure, vector and/or velocity. For example, by constricting the gas flow the speed of the gas flow may be increased.

[0042] A said vaporization chamber gas inlet may be an air knife.

[0043] The gas may be one or more of hot gas; an exhaust gas; and a combustion gas.

[0044] The gas source may be one or more of: an engine exhaust; an ICE
exhaust; a turbine engine exhaust; and a combustion gas from a flame.

[0045] At least a portion of the RVVVS may be coated with PTFE.

[0046] The gas inlet may be configured to introduce hot gas into the top of the vaporization chamber.

[0047] The air knife may be configured to induce a hot gas speed within the chamber of:
between 40m/s and 150m/s when water inlet pressure is 2-100psi or when fine to very course droplet sizes are introduced into the gas velocity; or between 1m/s and 60m/s when water inlet pressure is 10-500p5i or when fog droplets to course droplet sizes are introduced into the gas velocity.

[0048] The apparatus may comprise a gas conduit configured to deliver gas to the gas inlet wherein the gas conduit comprises a gas piping configuration, including a "Y" or "Tee"
shaped pipe, and the gas conduit includes:
a release valve, the release valve configured when open to allow gas from the gas source to be vented into the atmosphere either directly or through an adjacent muffler and when released allows the valve to close or partially close and to direct at least a portion of gas towards the air knife adaptor; and a control valve configured when open to allow gas to be directed through the air knife and when closed to prevent gas being directed through the air knife.

[0049] The RVVVS may be configures such that when the release valve is open air is drawn counterflow from the air knife or gas inlet.

[0050] The RVVVS may comprise a demister configured to receive gas and entrained liquid from the headspace within the concentrator tank and separate the gas from the entrained liquid.

[0051] The RVVVS may comprise a rotational-flow inducer to induce rotational motion to the gas and entrained liquid to separate the gas and entrained liquid using centrifugal forces.

[0052] The RVVVS may comprise multiple vaporization chambers feeding into a single concentrator tank.

[0053] A pump bringing new raw water into the concentrator tank may be configured to operate a flow corresponding to the rate of vaporization in the vaporization chamber to thereby allow the RVVVS to operate in a continuous mode. A controller may be configured to control the pump rate of the pump pumping fresh raw water into the system to maintain a continuous rate of operation.

[0054] The RVVVS may comprise a barium precipitating reagent injector configured to inject a reagent (e.g. a soluble sulfate such as Na2SO4) into the raw water to precipitate dissolved barium salts.

[0055] According to a further aspect of the present disclosure, there is provided a raw water vaporization system (RVVVS) comprising:
a vaporization chamber having:
raw water and gas inlets configured inject water and gas to within the vaporization chamber to effect raw water vaporization and an outlet to allow gas and liquid out of the vaporization chamber; and multiple demisters, each demister configured to receive a portion of the gas from the vaporization chamber and to remove high density material entrained in the received portion of the gas.

[0056] The high density material entrained in the gas may comprise liquid water. The high density material entrained in the gas may comprise solids.

[0057] The outlet of the vaporisation chamber may be connected to each of the multiple demisters by a channel.

[0058] The outlet of the vaporisation chamber may be connected to each of the multiple demisters by a channel, the channel being formed by the headspace of a concentrator tank.

[0059] The outlet of the vaporisation chamber may be connected directly to each of the multiple demisters.

[0060] Each demister may comprise a circularly symmetric body with a rotational-flow inducer at one end of the demister body; a gas outlet at the other end of the demister body; and a second outlet (e.g. for high density materials such as liquid water and/or entrained solid particulates) at the bottom of the demister.

[0061] The liquid outlet may comprise a channel which connects the demister with a position below the liquid level of a concentrator tank.

[0062] According to a further aspect of the present disclosure, there is provided a method of vaporising raw water comprising:
injecting raw water and gas such that they mix together in a mixing zone to effect raw water vaporization, wherein the mixing occurs directly above an open concentrator tank positioned such that high density materials from the mixing zone will be directed to impinge with liquid in the concentrator tank;
and wherein the raw water for injection into the mixing zone is pumped from the concentrator tank.

[0063] According to a further aspect of the present disclosure, there is provided a method of vaporising raw water comprising:

injecting raw water and gas such that they mix together in a mixing zone to effect raw water vaporization;
directing gas flow from the mixing zone to multiple demisters, each demister configured to receive a portion of the gas from the mixing zone; and removing high density material entrained in the received portion of the gas using the demisters.

[0064] It will be appreciated that vaporization may encompass one or more of:
vaporization, evaporation and boiling.

[0065] In various embodiments, the gas inlet has a round, oval, square, irregular, rectangular, duckbill or helical configuration and may constrict exhaust flow or expand exhaust flow.

[0066] The gas inlet may comprise a diverter within or adjacent the outflow orifice. The diverter can be manually or automatically adjustable based on gas pressures or PLC control increase or decrease exhaust gas velocity within the outflow orifice.

[0067] The gas inlet may comprise openings to enable introduction of additional gas to the air knife upstream of the outflow orifice.

[0068] A diversion valve may be operatively connected to the engine exhaust connector for diverting exhaust under pressure to or from the engine exhaust source to the exhaust conduit and/or the air knife.

[0069] In one embodiment, the exhaust connector is adapted for any one of or a combination of constricting, expanding, diverting and focusing engine exhaust within the shearing chamber as a means to utilize the engine exhaust pressure and velocity to effect raw water shearing.

[0070] In other embodiments, the axis of the demisters may be inclined away from the vertical (e.g. by between 5 and 30 ).

[0071] The vaporization chamber may be a shearing chamber where water droplets are sheared to a smaller size through interaction with the moving gas flow.

[0072] In one embodiment, the RVVVS includes a controller operatively connected to i) a water pump operatively connected to a raw water conduit, the water pump for pumping raw water to the raw water influx system and ii) at least one thermocouple operatively connected downstream of the shearing chamber for measuring a first temperature of gases exiting the RVVVS and wherein the controller increases flow of raw water to the shearing chamber if the first temperature is above a first threshold and decreases the flow of raw water to the shearing chamber if the first temperature is below a second threshold. In one embodiment, the first threshold is 100 C and the second threshold is 50 C. In other embodiments the first threshold is between 90 C and 120 C and the second threshold is between 65 C and 100 C. In some embodiments the first threshold is between 90 C and 120 C and the second threshold is between 65 C and 90 C.

[0073] In one embodiment, the shearing chamber is adapted to receive engine exhaust from an associated engine at substantially the same pressure and temperature of the engine exhaust exiting the associated engine.

[0074] In one embodiment, at least one surface within a combination, 2-in-1 shearing chamber and demister imparts a centrifugal force to the exhaust gas and water vapor to enable entrained water droplets to impinge and coalesce on inner surfaces of the 2-in-1 vessel to effect demisting of exhaust gas and water vapor prior to release to the atmosphere.

[0075] In another aspect, the invention provides a centrifugal demisting apparatus having: a frustoconical drum having a first smaller outer diameter at an inlet end and a larger outer diameter at an outlet end, the frustoconcial drum having an inner surface for imparting centrifugal forces on a mixture of exhaust gas, water vapor and entrained water droplets as the mixture transits from the inlet end to the outlet end under pressure to effect impact of entrained water droplets on the inner surfaces and removal of the entrained water droplets from the mixture.

[0076] In a further aspect, the invention provides a centrifugal demisting apparatus having: a chamber having an inlet end and an outlet end and having at least one inner surface within the chamber, at least one surface for imparting centrifugal forces on a mixture of exhaust gas, water vapor and entrained water droplets as the mixture transits from the inlet end to the outlet end to effect impact of entrained water droplets on the inner surfaces and removal of the entrained water droplets from the mixture, the inlet and the outlets being concentrically aligned.

[0077] In yet another aspect, the invention provides a raw water vaporization system (RVVVS) kit. The kit may comprise: an adaptor for connecting an engine exhaust source from an associated engine, the adaptor having an exhaust conduit having an engine exhaust connector for connecting the conduit to engine exhaust piping; an air knife at an outflow end having an outflow orifice adapted for connection to a shearing chamber; the shearing chamber having a raw water influx system for operative connection to an engine exhaust pressure and temperature source to enable rapid interaction between input raw water and engine exhaust for i) increasing interfacial surface area between the input raw water and the engine exhaust gas and ii) rapid heat transfer between the input raw water and the engine exhaust to effect vaporization of water from the raw water and the concentration of raw water contaminants when a engine exhaust source is conveying pressurized engine exhaust into the shearing chamber;
wherein the adaptor and shearing chamber are independent apparatus operatively connectable to one another.

[0078] In various embodiments more than one water nozzle or water injection device may be used. In these embodiments various water injection systems may be under various pressures and injected at the same or various angles in relation to the flow of either the exhaust gas or the other water sources. Various water sources may be raw water, raw water concentrate and/or clean water, any of which may be preheated.

[0079] In one embodiment, the invention includes the step of monitoring the back pressure on the engine and controlling at least one diversion valve operatively connected between the shearing chamber and the engine exhaust source to maintain the back pressure below a threshold. In various embodiments depending on the size of the ICE, the backpressure threshold may be a maximum of 10"WC, 14"WC, 27"WC or 40"WC. Any valve configured to the exhaust delivery system may vent exhaust to atmosphere, to another vaporizer or to a muffler.

[0080] In other embodiments, the invention includes a counter-weighted valve adjustable or configurable to vent excess exhaust pressure that would exceed an engine specific upper threshold, from the ICE exhaust delivery system to allow maximum delivered exhaust flow and pressure to a vaporization chamber. The counter weighted valve may be decoupled from a main valve controlled by a PLC or may be a separate valve adding redundant safety to the ICE exhaust delivery system. The counter-weighted valve(s) may vent exhaust to atmosphere, to another vaporizer or to a muffler.

[0081] In one embodiment, the method includes the step of measuring the temperature and/or pressure of any combustion gas prior to the shearing chamber and based on the combustion gas temperature and/or pressure adjusting the flow rate of water, the combustion gas volume, gas velocity and/or gas pressure delivered to a shearing chamber or an array of shearing chambers configured to one or more combustion gas sources.

[0082] In various embodiments, the method includes the step of measuring the temperature of the exhaust gas after exiting the shearing chamber and based on the temperature of the exhaust gas after exiting the shearing chamber adjusting the flow rate of the water or exhaust gas volume, gas velocity and/or gas pressure to the shearing chamber to maintain the temperature of the exhaust gas after exiting the shearing chamber with a range of temperature.

[0083] In other embodiments, the flow rate of raw water or combustion gas volume, gas velocity and/or gas pressure into the shearing chamber is controlled to maintain the temperature of exhaust gas exiting the shearing chamber between 50 and 100 C. In other embodiments the first threshold is between 65 C and 90 C and the second threshold is between 90 C and 120 C.

[0084] In another embodiment, the engine exhaust is introduced to the shearing chamber under pressure and flow conditions substantially equivalent to the pressure and flow of exhaust gas exiting the associated engine or combustion gas source.

[0085] In another embodiment, a combustion gas exhaust is introduced to the shearing chamber under pressure and flow conditions greater than the pressure and flow conditions of the exhaust gas exiting the combustion gas source.

[0086] In another aspect, the invention provides a method for distributed management of raw water and combustion gas as a means of maximizing resource utilization comprising the steps of: a) establishing at least one physical or virtual hub to receive raw water or other resource or waste inputs from members, member sites or member sub-sites within a network of raw water generators, resource consumers or waste collectors; b) analyzing location data of the members, member sites or member sub-sites within the network for utilization availability; and c) distributing or redistributing the raw water, condensed clean water, brine concentrate and/or salts to the members, member sites or member sub-sites in a prioritized manner as a means to enable maximum benefit, efficiencies, resource consumption reductions and/or use to those within the network.

[0087] In one embodiment, at least one central hub can communicate utilization data to members within a network, group or sub-group.

[0088] In another aspect, the invention provides a method of controlling a raw water vaporization system (RVVVS) having an engine exhaust source operatively connected to a shearing chamber used to effect vaporization of raw water, the method comprising the steps of:
a) monitoring backpressure on the engine exhaust and b) increasing or decreasing raw water flow to the shearing chamber to maintain the backpressure on the engine exhaust below a threshold.

[0089] In other aspects, the invention provides a method of controlling a raw water vaporization system (RVVVS) having an combustion gas source operatively connected to a shearing chamber, the method comprising the steps of: a) monitoring at least one combustion gas pressure upstream or downstream of a shearing chamber or demisting device, b) monitoring at least one temperature upstream or downstream of a shearing chamber or demisting device and c) adjusting raw water inlet pressure against at least one water distribution nozzle to enable distribution of a desired average raw water droplet size as the raw water is distributed within the shearing chamber to maintain the at least one temperature within a temperature range. In various embodiments the desired temperature exiting a demisting device is above 65 C and less than 120 C, preferably between 90-110 C. Other embodiments the desired temperature exiting a demisting device may be less than 90 C.

[0090] In another aspect, the invention provides a method of assembling a raw water vaporization system (RVVVS) at a remote site having an engine and engine exhaust piping, the method comprising the steps of: a) configuring an adaptor as defined above to the exhaust source b) attaching a vaporization chamber as defined below the adaptor; and c) attaching a raw water supply to the vaporization chamber.

[0091] The chamber and directed outflow orifice of the hot gas conduit may be substantially circularly symmetric.

[0092] The deflector plate may be configured to allow at least a portion of the raw water flow to drain from the vaporization chamber away from the vessel and/or into a demisting device.

[0093] The deflector plate may be configured to be at the base of the vaporization chamber and the hot gas outflow orifice is configured to introduce hot gas into the top of the chamber.

[0094] The chamber may be a cylinder. The chamber may be 18-24" high and 24"
in diameter)

[0095] The outflow orifice may be formed from a hollow cone.

[0096] The raw water/gas mixture within the chamber may be in the form of a toroid.

[0097] The RVVVS may comprise a rotational-flow inducer positioned below the deflector to induce an axially rotational motion to raw water draining from the chamber.
The rotational-flow inducer may comprise a stator with angled blades. The rotational-flow inducer may comprise an actively or passively driven rotor.

[0098] According to a further aspect, there is provided a raw water vaporization system (RVVVS) comprising:
a shearing chamber;
a raw water nozzle configured to introduce raw water into the chamber;
a hot gas conduit having an air knife at an outflow end of the hot gas conduit, the air knife configured to direct at least a portion of the engine exhaust within the exhaust conduit into the raw water flow inside the shearing chamber to effect raw water shearing.

[0099] The air knife may be configured to induce a combustion gas speed within the chamber of between 2-20m/s, 10-30m/s, 20-40m/s and other ranges 30-100m/s.

[0100] The air knife may comprise a hollow cone or a full cone

[0101] The air knife may be comprised of a cylindrical or frustoconical shape.

[0102] The RVVVS may comprise a control system configured to control the air knife to maintain gas flow velocity from the air knife within a threshold range.

[0103] An ICE may have a power in the range of one or more of: 600-850bhp;

1000bhp; 1000-1500bhp; 1500-2300bhp; and 2300-2500bhp (or larger).

[0104] The air knife may be considered to be a pressurized air channel containing a series of holes or continuous slots through which pressurized air exits in a laminar flow pattern.
The air knife may be straight or curved. The air knife may extend along an axis (e.g. straight or curved axis) and have a restricted lateral dimension. The exit velocity of the pressurized air from the air knife may be one or more of: between 40-50m/s; between 50-70m/s;
between 70-100m/s; and greater than 100m/s; between 2-20m/s, between 10-30m/s, between 20-40m/s and between 30-100m/s. Other ranges may also be used.

[0105] The air knife may have openings to enable introduction of additional gas to the air knife upstream of the outflow orifice. The additional gas may comprise ambient air (e.g. to increase the water carrying capacity of the gas) or hot gas from an additional hot gas source.

[0106] The raw water nozzle may be configured to introduce raw water into the shearing chamber with one or more of: dry fog (<10 pm Volume Mean Diameter ¨ VMD); fine mist (10-100 pm VMD); a fine droplet size (100-200pm VMD); a medium droplet size (200-350pm VMD);
a coarse droplet size (350-600pm VMD); a very coarse droplet size (600-900pm VMD); an extremely coarse droplet size (900-2000pm VMD); and an ultra coarse droplet size (>2000pm VMD). In each case, the raw water flow, angle, direction and force should considered in combination with width and velocity of the gas stream its being injected into.
It is desirable the chosen design is sufficient to permit raw water to penetrate the gas flow stream to at least 20%
of the width/length of the gas flow stream, but preferably 30-100% penetration is preferred. In other words, it is desirable that the impact force between the gas and water streams is sufficient for the water to penetrate the gas stream to enable mixing and, hence, shearing. This improves system efficiency but also enables proper sizing of the chamber, washing of the chamber and the minimization or elimination of any dry spots.

[0107] Generally, the higher the raw water pump pressure acting as shearing force on a water nozzle (for a given water flow rate), the smaller the average droplet size. The smaller the average droplet size, the greater the surface area of the droplet in relation to the mass of the droplet. The greater the surface area in relation to droplet mass, the faster thermal energy can transfer from gas into the droplet enabling vaporization of a portion of the droplet. In an example embodiment if there is sufficient waste pressure in engine exhaust to perform the shearing of the raw water so the thermal transfer of combustion gas heat is enabled within a short timeframe and geometric space, then there would be no need to provide input energy to a raw water pump or provide energy input to a blower. In this case the push pressure of the engine mitigates or subsidizes the need for energy inputs. In other example embodiments where there is little or no pressure within a combustion gas source, the overall system can be designed to minimize supplementary energy inputs by balancing how input energy is used for raw water shearing and demisting of water entrainment. For example, an operator may choose to pressurize the raw water with a raw water pump to enable sufficient shearing of raw water thus minimizing the need for gas pressure to do the shearing. In this way input energy required for a blower is minimized and relegated primarily to drive a demisting cyclone. In other embodiments where there is at least partial pressure from a combustion gas source, such as downstream from a muffler, the system can be balanced to minimize energy input needed for blower pressure by at least partially utilizing waste pressure within the combustion gas.

[0108] As such, in some embodiments, the shear chamber may be considered to be a vaporization chamber in which a hot gas flow impinges on a raw water flow in order to reduce the size of the raw water droplets. A vaporization chamber may be considered to be a substantially enclosed vessel (with inlets and outlets for liquid and gas) in which heat is transferred from a hot gas to raw water to effect vaporization through vaporization and/or boiling.

[0109] After interaction between the raw water from the nozzle and the hot gas, the droplet size may be smaller than the droplets ejected from the nozzle.

[0110] The pressure applied to the raw water nozzle may be 30p5i or greater (or 40p5i or greater) for medium to course droplets. Dry fog may be induced by 100-500 psi pump pressure. The pressure may be 10-30 psi for medium to course droplets or under 20 psi for course to ultra-course droplets. As can be understood, various nozzle shapes and pressures can result in varying droplets sizes and the described sizes are not intended to be limiting, but used as examples.

[0111] The shearing chamber may be cylindrically shaped.

[0112] The width (e.g. diameter) of the chamber is typically less than 36 inches (e.g.
around 2-4 feet). The height of the chamber may be between 12-36 inches (e.g.
between 1.5 and 2 feet). Larger systems can vary in size and proportion, although it is desirable to limit the chambers inner surface area as much as possible to promote washing and limit dry surfaces within the shearing chamber.

[0113] The shearing chamber may comprise a raw water influx system operatively positioned adjacent the gas connector to enable rapid interaction between input raw water and gas for washing the interior surfaces of the vaporization chamber.

[0114] The cross-sectional width of the air knife stream may be configured to permit raw water being sprayed or delivered to it, under various pressure and with various average droplet sizes, to penetrate from 20%-100% of the entire width of the gas stream, or cross the gas stream. This may reduce or minimize the volume of space within the vaporization chamber needed for thermal transfer and so facilitates the washing effect within the vaporization chamber.

[0115] Regarding monitoring pressure of gases being delivered to the shearing chamber, when using an ICE, the controller helps ensure no overpressure or temperature is applied to the engine while increasing or maximizing heat and pressure used for optimal water vaporization and system washing. The pressure control system may be used to control the valves in the exhaust diversion system to ensure a desired pressure range is maintained.

[0116] The control system may comprise a processor and memory. The memory may store computer program code. The processor may comprise, for example, a central processing unit, a microprocessor, an application-specific integrated circuit or ASIC or a multicore processor. The memory may comprise, for example, flash memory, a hard-drive, volatile memory. The computer program may be stored on a non-transitory medium such as a CD.

[0117] The system may comprise a release valve upstream from the shearing or vaporization chamber to vent air into the atmosphere (e.g. directly or via a muffler). The release valve may be configured to open to various degrees in response to pressure signal from backpressure at any point in the exhaust circuit. This may be facilitated by enabling any one or all of the following to act upon the valve to open (or partially open) it:
= a counter-weighed stand alone, integrated or decoupled valve for non-automated venting control = a direct air line from anywhere in the exhaust circuit, = pressure transmitter signalling a PLC (programmable logic controller) to activate an electric, pneumatic, hydraulic, or other means.

[0118] The release valve may comprise a counterweighted vent. The counter-weighed vent valve may be decoupled for passive pressure control. The amount of counterweight or other bias may be tailored to the hot gas source and, in particular, to the tolerance the hot gas source has to overpressure. It will be appreciated that the release valve may open to allow gas to allow a portion of gas to vent without passing through the vaporization chamber whilst a 'control valve' also stays open allowing another portion of gas to travel through the vaporization chamber. If the pressure is even higher, the control valve may be closed to divert all exhaust gasses away from the vaporization chamber and into the atmosphere, either directly or through a muffler.

[0119] This configuration may help increase or maximise the use of the exhaust pressure and heat by venting as little as possible away from the air knife.
For example, the weighted release valve can have weights associated with a balanced internal valve designed to only vent the minimal portion of over pressure gas. Gas delivery can be further optimized to the air knife when assisted with direct air pressure signal to an electric device that is configured to open the release valve incrementally due to predesignated pressures within the exhaust circuit in order to maintain a maximum pressure within the exhaust circuit. For example if the engine in use is a 2500bph with a maximum allowable engine back pressure of 14"WC, then by a signal from PLC (programmable logic controller) or direct air pressure from an airline connected to the exhaust pipe closer to the engine and the other end to a small actuator, the actuator can be configured to assist the release valve with incremental opening to allow staged and controlled venting. This may help reduce or minimize the amount of exhaust being vented away from the air knife when the exhaust circuit pressure begins to climb, primarily due to engine load increases. The release valve, for placement inside an exhaust pipe system (e.g. to vent to a muffler) or at the exit of an exhaust pipe (e.g. to vent to atmosphere), may have the following traits or attributes:
(1) ensure low friction on a valve rod or other rotatable fixture that can withstand:
high heat, rapid heating and cooling without warping from thermal shock, combustion gas particulate matter;
(2) ensure the placement of the valve within the exhaust pipe and on the bearing rod or similar fixture is optimized to allow a counter weight to open it with pressure and (3) configured with a counterweight or other biasing mechanism (e.g. spring), the bias being adjustable to enable a maximum pressure delivery to the air knife without creating excessive backpressure to the gas source (e.g. chosen engine type per manufacture specification).

[0120] These various exhaust delivery systems can be used with an air knife with a fixed cross-sectional orifice or with an air knife configured to actively or passively adjust the gas velocity at the outflow orifice. In other various embodiments or combinations they can be configured to allow a fixed gas volume through an air knife (by venting excess away from the air knife), a fixed pressure within the exhaust system (resulting in variable gas flow through the air knife) or modulated actively or passively to enable other desired combinations.

[0121] The RVVVS may have a concentric design, and a round water nozzle (hollow or full cone). The water nozzle(s) may self-clean via pneumatic connection or periodic pulsing with air. In addition, portions or the system may be coated with PTFE or other non-stick coatings to help reduce scaling (formation of solid precipitate or other solids on the surfaces of the system).

[0122] Regarding controlling or adjusting the air knife, the air knife can be controlled actively or passively. Active control may use a control system with an actuator configured to adjust the air knife based on one or more of user input or sensed variables such as temperature or pressure. Passive control may be implemented by the air knife being spring loaded (or manually set in increments) to manage itself based on backpressure. That is, the back pressure itself may act on the spring to open or close off (or otherwise modify) the cross-sectional opening of the air knife exit orifice. This modulating of cross-sectional orifice in response to gas flow fluctuations and pressure, permits the velocity of the gas being delivered to the vaporization chamber to remain within a narrower band resulting in more predictable gas/water mixing behaviour.

[0123] A hollow cone is a geometric shape formed between two complete cones arranged coaxially with a displacement along the axis. It may describe the shape of fluid flow (liquid or gas) in which the fluid flows from a point within an angle range around a particular cone axis. It may also describe a gas conduit formed by placing a solid cone obstruction within a channel.

[0124] Regarding the stators described herein, the stator may comprise angled vanes with one or multiple angles surfaces, various channelled configurations or helical configurations to induce rotational motion of gas when pushed or pulled past the stator surfaces.

[0125] Regarding the pressure of the gas being supplied to the vaporization chamber, the gas may be introduced to the shearing chamber under pressure and flow conditions substantially equivalent to the pressure and flow of gas exiting the associated gas source. The pressure may be supplied by the gas source itself (e.g. an engine). In other embodiments, the pressure supplied by the gas source may be supplemented by active elements such as a blower for induction or suction. This may be advantageous in embodiments where the hot gas source does not provide pressure (e.g. flares or flames).

[0126] In some embodiments there may be no air knife and so gas velocity may be low.
In such cases, the water may be mechanically sheared to reduce the droplet size. Mechanical shearing may be effected using higher water pump pressure or by impinging the water flow on a solid surface or through a mesh. In this case where water is atomized and sheared by the water pump, the gas may be cooled by vaporization causing cyclonic demisting takes place.

[0127] Some embodiments may use a blower to induce gas flow through the vaporization chamber primarily to reduce the pressure within the demisting chamber to induce cyclonic separation.
BRIEF DESCRIPTION OF THE DRAWINGS

[0128] Various objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention. Similar reference numerals indicate similar components.
Figures 1A and 1B are perspective and plan views respectively of multiple RVVVS's configured to a compressor facility in accordance with one embodiment of the invention.
Figure 1C is a perspective of a RVVVS system configured to a gas production facility in accordance with various embodiments of the invention.
Figure 2 is a schematic view of the sub-components of a RVVVS in accordance with one embodiment of the invention.
Figures 3A-3C are schematic vertical cross sectional views of a raw water vaporization system in accordance with one embodiment of the invention.
Figures 3D is a front perspective view of the raw water vaporization system of Figure 3A.
Figures 3E-3F are front and end views of the of the raw water vaporization system of Figure 3A.
Figures 3G-3I are vertical cut-through views of the of a raw water vaporization system of Figure 3A.
Figures 3J-3M are a series of horizontal cut-through views of the of a raw water vaporization system of Figure 3A.
Figures 4A-4F are schematic diagrams of various hot gas delivery systems and various exhaust/water contact configurations in accordance with various embodiments of the invention.
Figure 5 is a schematic vertical cross sectional view of a raw water vaporization system in accordance with one embodiment of the invention.
Figures 6A and 6B are schematic vertical cross sectional views of various flushing configurations of a demister.

Figures 7A-7B are schematic horizontal cross sectional views of a raw water vaporization system showing different demister cyclone configurations.
DETAILED DESCRIPTION OF THE INVENTION
Rationale and Introduction

[0129] The subject invention seeks to improve the efficiency of the vaporization of waste water utilizing "waste" heat and pressure from a heat source such as an engine (e.g. an engine/generator combo unit or exhaust from steam generators, turbines, boilers, flares, flame exhaust and the like) so as to effect a reduction of the volume of raw water and the concentration of contaminants within the raw water and/or the exhaust gasses.
The invention also provides a low-maintenance solution for water vaporization by reducing the effects of scaling. In addition, the invention may provide a more compact system in which the need for insulation to maintain fluid temperature is reduced or minimized.

[0130] In various embodiments, the invention also seeks to perform one or more of the following:
a. reduce the need for maintenance through the design and operation of a system that minimizes scale, particulate, salt and other build-up;
b. reduce ongoing operating expense and manpower due to minimized need for operator oversight;
c. reduce or minimize new energy input over and above the primary heat source from an ICE, combustion gas, flare gas or other similar source;
d. reduce the release of volatiles and pollutants to the atmosphere;
e. minimize pressure drop related to water vaporization and/or entrainment separation;
f. maximize beneficial use of any available waste pressure and/or heat;
g. effectively use low grade waste heat to vaporize raw water;
h. effectively use low grade waste heat not typically suitable for another industrial purpose or optimally accessible for use close to its source;
i. reduce or minimize the creation and control of soapy foams associated with some raw waters;
j. enable effective recovery of condensates from raw water;
k. enable recovery of re-condensed water for reuse;
I. reduce the capital cost of raw water vaporization equipment;

m. provide a light weight and compact system for remote or satellite installations close to a heat source;
n. provide a light weight and compact system that can be made with plastics allowing rapid mass production and the ability to custom manufacture and configure various embodiments;
o. provide a modular system that can be built into either one unit or a cluster of units operating separately or in conjunction with one another;
p. provide a monitoring and reporting system for remote management of many distributed systems, functions, products and resources within a larger grid;
q. reduce ground level footprint when installed or retrofit to existing oilfield equipment;
r. reduce or minimize the number of moving parts within a raw water vaporization system; and s. reduce a ground level footprint of vaporization equipment when installed or retrofit to existing oilfield equipment.

[0131] In another aspect of the invention, the invention provides methods, systems and apparatus for distributed management of raw water and internal combustion engine (ICE) gas emissions generated during industrial operations, including but not limited to oilfield drilling, completions and production operations with a mobile processing unit.

[0132] In another aspect of the invention, the invention provides systems and methods that at least partially utilize positive pressure waste within distributed internal combustion engine (ICE) exhaust sources as a substantially free energy for demisting input pressure and/or shearing force to increase or partially increase interfacial surface area between raw water and an engine exhaust gas for rapid mass and thermal transfer of engine exhaust gas heat into the raw water in order to vaporize a proportion of the aqueous phase of the raw water and concentrate contaminants within a residual raw water concentrate. The water vapor generated by the vaporization process may be demisted, discharged directly to the atmosphere or alternatively condensed by a condenser and captured for use.

[0133] The invention may also simultaneously facilitate rapid transfer of at least a portion of ICE combustion gas particulates and ICE combustion gas chemicals into the raw water as it concentrates.

[0134] The invention may also use an exhaust diversion system as means to provide exhaust heat and pressure to a region of a dual fluid interaction zone and continued pressure force for demisting within the system in a manner that does not affect the operation of an associated ICE.

[0135] The invention may provide an economically viable and environmentally synergistic means of distributed raw water and emissions management to reduce and/or recycle large volumes of industrial raw water and emissions within localized regions.
That is, the invention provides systems and methods to enable effective and efficient processing of raw water that is often remote and stranded from waste management infrastructure.
In one aspect, the invention provides distributed management of raw water and emissions that is enhanced by networking data from remote raw water management processing units as a means to ensure that each satellite system in the network can be utilized to its full capacity either by actors within an organization operating within a geographic region/grid or by many organizations operating within a geographic region utilizing each other's raw water processing system(s), salts, brine fluids and/or condensed clean water vapor. An algorithm may be used as a means to communicate data points to those within the network such as individual system run time, raw water processing rates, available, accumulating or unused capacity, timing and/or availability of upcoming spare capacity, etc.

[0136] As described herein, part of the novelty of the present invention is its simplicity.

[0137] Various aspects of the invention will now be described with reference to the figures. For the purposes of illustration, components depicted in the figures are not necessarily drawn to scale. Instead, emphasis is placed on highlighting the various contributions of the components to the functionality of various aspects of the invention. A number of possible alternative features are introduced during the course of this description. It is to be understood that, according to the knowledge and judgment of persons skilled in the art, such alternative features may be substituted in various combinations to arrive at different embodiments of the present invention.
Drilling Rigs, Gas Compression and Steam Generation Facilities

[0138] As is known, drilling rigs have high power requirements and are typically located away from the electricity grid. Hence, drilling rigs usually require that electrical power is generated on these often remote, stranded sites. A typical drilling rig may have one or more engines/generators used to generate power for various equipment and rig operations including the rig draw works, mud pumping, numerous auxiliary equipment as well as power for the personnel camps.

[0139] At gas compression facilities, high power engines and compressors are used to effect gas compression of produced gases. A typical gas compression facility may have one or more engines/compressors that are operated to compress produced gases to high pressure gas delivery pipelines.

[0140] At steam generation facilities, high power boilers are used to generate high pressure steam. Waste heat from such boilers is usually passed through various heat exchange systems to recover heat that may be usable in the steam generation and other processes prior to venting to the atmosphere. Such waste heat that is vented to the atmosphere is generally low temperature and low pressure heat generally without a further industrial benefit and not easily accessible. That is, the waste heat may have low exergy (or a low amount of useful energy), wherein exergy is a measure of how much of the heat can be converted to work.
The exergy content of heat depends on the temperature at which heat is available and the temperature level at which the reject heat can be disposed (usually the temperature of the surroundings).

[0141] Figures 1A, 1B and 10 show further details of a typical gas production and compression facility that may be retrofitted to include the RVVVS's as described herein. Typical equipment at such a facility may include gas lines 4, flare stack 4a, produced water tanks 4b where production water (raw water) is stored, production gas storage tanks 4c and facility control building 4d. In accordance with the invention, one or more RVVVS's 10 (see Figures 10, 3A) are configured to engines 12 within compressor buildings 1 and one of the production water tanks 4e may be purposed to store concentrated brine as described herein.
Overview

[0142] The invention is primarily described with reference to gas compression, drilling rig, incinerator, gas turbine and steam generation operations although it is understood that the invention can be applied to other industries where the disposal of raw water is required or where engine exhaust, combustion gas and other heat source emissions are available.

[0143] Figure 2 is a schematic overview of a Raw Water Vaporization System (RVVVS) including the inter-related components that enable efficient water vaporization in a system with reduced maintenance requirements in accordance with one embodiment of the invention.
As shown, the RVVVS is configured to an engine 12 associated with a muffler 2.
In normal operation, the engine 12 produces power for various purposes, examples of which are provided above. The muffler 2 receives hot exhaust gases from the engine, muffles noise and vents exhaust gases to the atmosphere. While Figure 2 is shown as being configured to an engine 12 and muffler 2, it is understood that the engine 12 could be another combustion gas source such as a flare 4a, in which case, the muffler system may not be present. The combustion gas source may also be a gas turbine.

[0144] In accordance with one embodiment of the invention, a RVVVS 10 is operatively connected to the engine exhaust either upstream or downstream of the muffler or both, so as to divert engine exhaust to vaporization chamber 11.

[0145] More specifically, in operation, raw water is pumped from a bulk raw water storage tank 105 to a concentrator tank 107. The bulk raw water storage tank may be a larger tank (See 4b, Figure 1A) designed to hold raw water that has been collected from one or more sources (e.g. multiple gas production lines connected to one or more wells).
Bulk raw water storage tank 4b may hold volumes of water typically in the range of about 50 m3 to 100 m3. As shown in Figure 2, pump P1 pumps raw water to the smaller concentrator tank 107 (typically 1-2 m3) that is used to hold water being cycled through vaporization chamber 11.
In various other embodiments tanks 105 and 107 may be the same tank. An optional filter 120 may be included to screen larger particulates from entering the pump P1 and concentrator tank 107.

[0146] In various embodiments, a VOC or H25 remover 126 may be added to remove Volatile Organic Compounds (VOC's), H25, or other compounds from the water prior to discharge into Concentrator Tank 107. One option would be to use traditional stripping towers or such as packed bed tower. In another embodiment an air-sparged hydrocyclone may be included to remove these readily evaporated compounds (e.g. light hydrocarbons such as benzene) from the liquid prior to the raw water being introduced into the concentrator tank or vaporization chamber.

[0147] Examples of air-sparged hydrocyclones can be found in US 4,279,743 (1981), US 5,131,980 (1992) and US 5,560,818 (1996). In 2012 US 8,153,069 was issued directed to placing cyclones in series and adding a step of ultrasonics for so called "cold boiling". In the present technology, a number of hydrocyclones in series may help effectively remove light hydrocarbons. Having removed the hydrocarbons in a gaseous state, a condenser, a chiller and/or compressor may be used to return the gas to a liquid state for storage and transport. Air-sparged hydrocyclones alone does not necessarily create an economically compelling reason for removal of VOC's from production water. However, then used in combination with the various elements of the present invention, such as a wastewater volume reduction method using free and waste energy, the removal of VOC's becomes economical providing an environmental benefit.

[0148] Pump P2 pumps raw water in a continuous cycle from concentrate tank 107 to vaporization chamber 11 where the raw water undergoes at least partial vaporization and un-vaporized water is returned to the concentrator tank 107. In this case, the concentrator tank 107 is integrated directly below chamber 11. In other embodiments not shown, vaporization chamber 11 may not be directly above tank 107 but instead be to the side, or offset from above center. In still further embodiments, more than one vaporization chambers 11 may be configured to a single concentrator tank 107 wherein the vaporized water is returned to concentrator tank 107 from more than one vaporizer. In all various configurations, the dense materials within the chamber (e.g. liquids such as water and contaminates, and solids such as scale) can fall directly from the vaporization chamber into the concentrator tank. This may help reduce maintenance costs because, for example, if scale (e.g. solid CaCO3 deposits) builds up, they can slough off and fall directly into the concentrator tank where they may re-dissolve and/or settle. That is, positioning the tank 107 on a plane below the vaporization chamber may help prevent scale being stuck in elements or on surfaces of the apparatus where they require cleaning or regular maintenance.

[0149] The vaporization cycle in a primary embodiment is completed as follows:
a) Pump P2 pumps raw water from the concentrator tank 107 into the vaporization chamber 11.
b) The raw water is ejected through nozzles against an exhaust gas flow from the engine 12 within a vaporization chamber 11. This results in at least a portion of the raw water being sheared and vaporized as a result of the exhaust gas/raw water impact.
c) Unevaporated raw water is returned directly to the concentrator tank 107 in a more concentrated state than when initially introduced into the vaporization chamber via pump P2. The concentrator tank 107 may typically operate in a semi-batch mode where pumps raw water into the concentrate tank from bulk raw water tank 105 until a high level is reached in tank 107 and replenishes raw water within the concentrator tank 107 when a low level is reached. In an alternative embodiment, P1 may be controlled to pump water from a storage source at the same rate at which water is being vaporized. In this latter case, the RVVVS is a continuous, non-batch operating system.

d) Gas, possibly with entrained water, is then directed through at least one demister 12b, which in this embodiment is illustrated as a cyclonic demister, to separate any entrained water from the gas. The separated water is returned to the concentrator tank.
e) Demisted vapor is discharged to atmosphere.
f) Demisted vapor may pass through an optional condenser 113 in the event that water recovery is desired.
g) When the concentrator tank has sufficient raw water, P2 will continuously pump raw water from the concentrator tank 107 through the vaporization chamber 11 until either the raw water level within the concentrate tank reaches a low level or the concentration of brine within the concentrator tank 107 reaches a density threshold level.
h) If the low level is reached in tank 107, P1 will turn on and pump raw water into the concentrator tank 107 until the high level is reached.
i) If the brine concentration reaches a high density threshold level, P3 will activate to pump concentrated brine solution to bulk concentrate storage tank 109 that stores larger volumes of concentrated raw water prior to final disposal or reuse. Additional optional filter 122 may be present to assist in the removal of fine particulates, such as salt precipitates, from the concentrated solution. P1 may also turn on to pump new raw water into the concentrator tank 107 while P3 and vaporization in chamber 11 continue to deplete the volumes in tank 107.
j) Either way, when concentrator tank 107 is pumped out to a low level, P1 reactivates to pump raw water into concentrator tank 107 to ensure sufficient water is in the concentrator tank and to maintain adequate water volume through P2 to vaporization chamber 11.

[0150] As shown, in one embodiment when using pressure is desired, engine exhaust is diverted to the vaporization chamber 11 by valve systems V1 and/or V2. V1 is shown configured upstream of muffler 2 and V2 is downstream of muffler. In the preferred embodiment, V1 valve system is used to divert exhaust gas as the primary diversion system. In this embodiment, V1 is activated such that a portion (0-100%) of exhaust gas is diverted to the vaporization chamber.
Importantly, V1 may be controlled to divert only a portion of exhaust gas that does not adversely affect backpressure on engine 12. That is, in the event that measured backpressure on the engine exceeds a threshold value, the V1 system will divert more exhaust through the muffler 2 until the backpressure is below the threshold.

[0151] As exhaust is diverted through the vaporization chamber 11, engine noise may be muffled due to the flow of raw water through the vaporization chamber, the impact of engine sound waves with the turbulent water within the vaporization chamber further suppresses sound waves. In addition, removal of heat from the gas to the liquid water may help cause the volume of the gas to decrease as it passes through the vaporization chamber. As such, the pressure, water and gas diversion within vessel 11 is effective to maintain noise levels from the engine at or below noise levels of exhaust being exhausted entirely through the muffler.

[0152] In one embodiment, the system is provided with V2 to redirect gas passing through the muffler to the vaporization chamber 11. However, as can be appreciated, as V2 is downstream of the muffler, the pressure, temperature of exhaust gas exiting the muffler is lower than at V1 and, hence, is less effective as a shearing, evaporating and demisting energy than exhaust gas diverted through V1 within a specific engines backpressure limits.
In various embodiments as will be described herein, a fan or blower may be configured to the inlet or outlet of RVVVS 10 to at least partially assist engine pressure. Of course the more pressure required by an assistive blower, the greater the consumption of new input energy. From an energy input cost perspective and capital cost perspective higher supplemental energy input is less desirable when there is waste ICE pressure that can be utilized.

[0153] The valve systems will preferably be provided with fail safe systems such that in the event of inadvertent or unexpected changes in pressure, V1 or V2 will automatically open or partially open to divert some or all exhaust gases to atmosphere through the muffler so as to maintain the desired performance of the engine and its associated equipment.

[0154] In the embodiment shown in Figure 2, the gas conduit comprises a "Y" or "Tee"
shaped pipe, and the gas conduit includes:
a release valve V2, the release valve configured when open to allow gas from the gas source to be vented into the atmosphere either directly or through an adjacent muffler and when released allows the valve to close or partially close and to direct at least a portion of gas towards the vaporization chamber; and a control valve V1 configured when open to allow gas to be directed to the vaporization chamber and when closed to prevent gas being directed to the vaporization chamber.

[0155]
In some embodiments, the "Y" or "Tee" shaped pipe may be configured such that, when air is diverted away from the vaporization chamber (e.g. through the muffler), a negative pressure is applied to the channel leading to the vaporization chamber to draw air in counter-flow from the gas inlet. That is, in this configuration rather than hot gas being provided to the vaporization chamber, atmospheric air is drawn back through the system.
This may allow the system to be cooled more quickly due to this airflow.

[0156]
It will be appreciated that the valves (e.g. V1 and V2) and/or pumps (e.g. one or more of pumps P1-P5) may be controlled by a controller 111. The controller may comprise a processor, memory and computer program code. The computer program code may be stored on a non-transitory medium such as a CD or DVD. The computer program may receive inputs from sensors configured to monitor the temperature of inlet and outlet gas, inlet and outlet water, density of water, etc.

[0157]
Further details and embodiments of the vaporization chamber, concentrator tank and demister are described below.
Raw Water Vaporization System

[0158]
Figure 3A-3M shows more detailed perspective and cross-sectional views of a raw water vaporization system 10. To clarify how materials in different states are separated, in figures 3A-3C, the motion of liquid is shown by line arrows with solid arrow heads, whereas the motion of gas is shown by block arrows, E>.

[0159]
As shown in Figure 3A, in this case, the raw water vaporization system (RVVVS) comprises:
a vaporization chamber 11 having:
raw water 222 and gas 226 inlets configured inject water and gas to within the vaporization chamber to effect raw water vaporization and an outlet 231 at the bottom of the vaporization chamber 11;
a concentrator tank 107 positioned in a plane below the vaporization chamber 1, (in the illustrated embodiment it is directly below) such that material exiting the vaporization chamber via the vaporization chamber outlet impinges with liquid in the concentrator tank 107;

a raw water channel 104 configured to inject raw water from the concentrator tank 107 into the vaporization chamber 11 via at least one of the illustrated raw water inlets 222.
Vaporization and Capture of Raw Water

[0160] In this case, as shown in Figure 3B, the gas inlet 226 is configured to direct gas flow through the vaporization chamber 11 and directly into liquid contained in the concentrator tank 107. This is achieved in this embodiment by providing a direct line of sight between the gas inlet 226 and the surface of the liquid contained in the concentrator tank 107. This may help redirect unevaporated water directly into the water body contained in the concentrator tank 107, assisting in the demisting process by coalescing through gravity and droplet adsorption. In one embodiment this is considered a coalescing or pre-demisting step that helps remove entrained droplets from the gas stream prior to the gas stream exiting the tank 107 into demister 12a.

[0161] In this case, water is injected into the vaporization chamber through nozzles 222a-d. In this case, the nozzles are arranged to be directed radially inwards to the axis of flow of the gas ejected by the gas inlet 226. In this case, there are two levels of nozzles (222a and 222b form part of a first level and 222c and 222d form part of a second level), each comprising 8 radially and inwardly directed nozzles. The water flow may be sheared by passing though the nozzles then sheared further through interaction of the liquid flow from the nozzles 222a-d with the gas flow velocity from the gas inlet 226.

[0162] In the interaction zone 11a within the vaporization chamber the hot gas is configured to vaporize (e.g. boil and/or evaporate) liquid from the water flow. Any un-vaporized water is forced downwards towards the liquid contained in the concentrator tank by gravity (by virtue of the concentrator tanks position below the vaporization chamber) and by the motion imparted to the water droplets by the gas flow. Contained in this gas flow is among other things, water droplets and dry particles of various sizes.

[0163] As shown in Figure 3a, in one embodiment the area of the outlet is a significant portion of the area of the vaporization chamber. For example, the ratio of the outlet area to vaporization chamber may be greater than 1:10 (or greater than 1:5; or greater than 1:2). This ensures that material is not impeded from exiting the vaporisation chamber.
The outlet 231 in this case is tapered to direct fluid flow towards the surface of the liquid in the concentrator tank.
However this taper is configured such that the angle of the taper with respect to horizontal is greater than 30 (e.g. greater than 45 ). This helps prevent scale or other solids remaining within the vaporization chamber. That is, the vaporization chamber is a simple open structure with upright side walls and a tapered or completely open bottom to easily allow materials to be ejected from the inside of the vaporisation chamber.

[0164] Another function of the tapered outlet 231 is as a coalescing cone.
The coalescing cone is a narrowed portion of the vaporization chamber downstream of the vaporization zone. By reducing the cross-sectional area of the gas and liquid droplet flow, the coalescing cone re-entrains both water and gypsum formed during the water shearing and vaporization process upstream. This helps lower the PPM count in the condensed water from the exit. It will be appreciated that other coalescers may be used. For example, rather then a cone the coalescer may comprise a diffuser plate with multiple holes in it to diffuse and coalesce the water and particulate from the gas flow. The holes may operate in a similar way to the cone by restricting the cross-sectional area of the gas and liquid droplet flow.

[0165] Other means of coalescing may be employed along with, or in place of, the tapered outlet 231 such as a forced change of gas flow direction by a chimney.
For example, one of the design targets of the present invention is to minimize or reduce the pressure drop through the entire RVVVS which minimizes or reduces electrical or other power consumption to run the system effectively. By employing a change of direction of the gas flow downstream the vaporization chamber and sacrificing perhaps 0.25-3"WC (pressure), water droplets and particles with a similar mass of salt of >100um can be adsorbed into the water in the concentrator tank. For example, a chimney, cone or other such means of gas flow delivery, flowing generally downwards toward the top face of the water in the concentrator tank, would be designed to that the outlet of the chimney would be 1-24" above the surface of the water.
Depending on that distance and acceptable system pressure, the system may be configured to effectively demist, coalesce and adsorb droplets ranging from 20um to larger then 100um. One of the limits on the pressure and distance design would be to ensure the pressure is sufficient to break the surface tension of the water in the concentration chamber thereby re-entraining new droplets.

[0166] In one preferred embodiment, structured packing or other such device of known art (not shown) may be used at or near outlet 231 as a means of coalesce. In FIG 2, the coalescing means in one embodiment may be positioned between Chamber 11 and Tank 107.
Larger droplets are easier to separate from the combustion gas stream using mechanical means. Larger droplets in a RVVVS can advantageously be at least partially separated utilizing gravity and/or vector or centrifugal force via change of direction, thereby reducing the requirements of new energy to power demisting function within the overall RVVVS. With regard to particles that form in the vaporization, such as salt, calcium based particles, gypsum or the like, the use of this coalescing step has been shown to substantially reduce dry particles <50um in the gas stream. When sizing a demisting device for geometry and pressure drop, it is advantageous to have a pre-coalescing step reducing or minimizing the need to have a high pressure drop device targeted at particles <20um, <10um, <2.5um, and <1um.

[0167] A drawback of prior art systems is that the final demisting step (for example a Chevron mist pad), at the tail end of the gas circuit, is typically designed to separate out of the gas stream the smallest particles and droplets, typically down to <20um, <10um, <2.5um, and <1um. This design practice leads to higher pressure drop and substantial cleaning and maintenance, resulting in system downtime. The demisting process in all cases will then have a wet and dry boundary between the inlet and outlet of any demisting system which needs periodic cleaning and downtime. The economic value of a RVVVS is diminished when maintenance requirements are high and when power consumption is higher than necessary.
The process and steps herein described as a multi-step gas entrainment separation help provide the advantages of lower pressure drop, less maintenance and less system downtime than any prior art system.

[0168] This multi-step entrainment removal process can effectively limit the design of the final demisting step to separate particles and droplets ranging between 20-100um, as an example, because particles <20um are adsorbed within the structured packing step and the droplets above >100um are adsorbed by the change in direction step. As described herein the middle droplet size range can vary depending on how each sub-step is engineered. For clarity the steps for one embodiment are as follows: Step 1, employ a means to adsorb small particles (e.g. <100um, <50um, <20um, <10um, <2.5um, etc.) and coalesce small droplets into larger droplets; Step 2 employ a means to utilize gravity or force to separate larger droplets (eg, >50um, >100um, >200um, etc.); Step 3 employ a final demisting step for the remaining entrained droplets and/or particles.

[0169] As a result of the techniques described herein, a preferred embodiment of the present invention has a total overall pressure drop of 0-10"WC, 0-7"WC, 0-5'WC
and <3"WC.
An RVVVS with a total system pressure drop of <5-7"WC makes available the ability to utilize the pressure from ICE exhaust without the need for additional power to move the gas through the system via use of the fan or blower.

[0170] In this case, the concentrator tank is not configured to be filled up to the bottom of the vaporization chamber. Therefore, there is always a headspace 107a (or ullage) at the top of the concentrator tank 107a as shown in Figure 3B. This headspace 107a provides a channel which receives the gas and liquid from the vaporization chamber. The gas may comprise vaporized raw water and gas from the heat source (e.g. engine). The liquid will comprise un-vaporized water. In addition, any solids generated by the vaporization process (e.g. scale or particulates) will also fall through this headspace from the vaporization chamber 11.

[0171] In this case, the concentrator tank has gas outlets 107b arranged in the top surface of the concentrator so that gas entering the concentrator tank headspace 107a from the vaporization outlet must change direction to exit the concentrator tank gas outlets. This may help aid separation in two ways: firstly gas is more mobile and so the can change direction more easily than the liquid which is directed into the liquid already in the concentrator tank; and secondly, liquid is more dense than gas so the liquid will inherently gravitate towards the surface of the liquid in the concentrator tank 107. In this way the concentrator tank can directly receive concentrated raw water from the vaporization chamber 11.

[0172] Another possible advantage of positioning the concentrator tank directly below the vaporization chamber is that the heat of the vaporization chamber is transmitted to the contents of the vaporization chamber. Heat transmission may include directly receiving heat from the warmed un-vaporized droplets of concentrated raw water as well as receiving heat from the warm gas flow across the liquid surface in the concentrator tank.
This helps allow water injected into the vaporization chamber from the concentrator tank to be injected at a higher temperature which may allow for more efficient vaporization.
Concentrator Tank

[0173] The concentrator tank in this case is a storage tank configured to provide raw water to the vaporization chamber where the water is at least partially vaporized then the remaining liquid is returned to the concentrator tank. Therefore, in the absence of additional flows, the water is recycled between the concentrator tank and the vaporization chamber such that amount of liquid water is diminished (i.e. by being turned into a gas) and such that the concentration of contaminants within the liquid water is increased.

[0174] In this case, the concentrator tank is configured to pump raw water out of the concentrator tank and into a storage container using pump P3 when the liquid within concentrator tank 107 has reached a threshold concentration of contaminants, or density.
Removing concentrated water lowers the level liquid within the concentrator tank. This allows the surface of the liquid stored in the concentrator tank to fall below the level of an angled baffle 195 for removing floating contaminants 197 (e.g. hydrocarbons). Of course, the vaporization of water within the vaporization chamber will also cause the level of liquid within the concentrator tank 107 to lower.

[0175] In this case, the concentrator tank is configured to receive new raw water (i.e.
which has not been passed through the vaporization chamber) from a bulk water tank (e.g. 105 in Figure 2) when the level of water in the concentrator tank 107 falls below a threshold level.
The addition of new raw water raises the level of liquid and directs the floating contaminants 197 along the bottom of the angled baffle and into a condensate tank (not shown), where it can be pumped into a bulk condensate recovery tank.

[0176] That is, in operation, the level of raw water in the concentrator tank 107 cycles between the high and low levels. The baffle 195 is configured to funnel any floating components 197 above the water line into a narrow vertical channel as the water in the concentrator tank 107 rises. This has the effect of increasing the vertical height of the floating components 197 such that they overflow into the overflow or condensate chamber 192 (see figure 2) when the water level in the main chamber 191 reaches its maximum height. This allows these floating components 197 to be removed from the raw water so that they are not recycled through the vaporization unit and to be stored as they may be a valuable byproduct of the process including recoverable hydrocarbons. The overflow chamber 192 may be configured with level switches which activate a further pump P4 to control the level of fluids in the overflow tank.

[0177] The concentrator tank in this case has a recirculation loop (P5) for recirculating the liquid within the concentrator tank. This helps control the level of stratification and/or flocculation of density or temperature within the concentrator tank 107 which may occur due to the concentration of contaminants affecting the density of the liquid and/or that may cause aggregation of particles that may trap unevaporated water. It will be appreciated that, in other embodiments, the concentrator tank may comprise an agitator. In another preferred embodiment not shown, P5 is not required and wherein P3 is used as a tank 107 circulation pump when it is not diverting brine to tank 109. To accomplish this, a tee joint in the flow line and a couple solenoids can be automated to facilitate redirecting the fluid flow. In this embodiment P3 draws water from the bottom of tank 107.

[0178] In this case, the concentrator tank 107 is tapered at the bottom and the recirculation loop 107c is configured to remove liquid from the tapered bottom. This may help ensure that scale does not build up at the bottom (i.e. where the liquid is likely to be densest and have the highest concentration of contaminates). The taper may be conical (as depicted in Figure 3A) or rounded. It will be appreciated that a rounded bottom tank may have a smaller height to volume ratio than a conically shaped tank, and so may be more compact. In a preferred embodiment P3 is inline 107c and P5 does not exist. When the water density in tank 107 reaches an upper threshold, P3 would divert all or a portion of the flow to a brine storage tank 109.
Demister

[0179] Although much of the un-vaporized water will directly impinge on the surface of the liquid in the concentrator tank, small droplets may be retained in the gas flow and be directed towards the concentrator tank gas outlets 107b which are in this case are positioned at the top of the concentrator tank. This first water separation step removes the need to use cyclone separation pressure from having to spin all water volume traveling through a vaporization chamber. This energy savings allows any cyclonic separation system to only consume energy relating a much smaller volume of entrained liquid resulting in higher separation efficiency, lower cyclone water loading and lower pressure drop across a cyclone demisting system. In one embodiment, to recapture the water droplets which remain entrained in the gas flow, each of the concentrator-tank gas outlets 107b lead into a cyclone demister 12a, 12b. Demister 12b is shown separately in Figure 30.

[0180] The demister 12b in this case comprises a circularly symmetric body 283 (e.g.
cylindrical or frustoconical) with a rotational-flow inducer 280 (e.g. a stator or an actively or passively driven rotor) at one end of the demister body; a gas outlet 281 at the other end of the demister body; and a outlet 282 at the bottom of the demister 12b. Gas and entrained solid or liquid material entering the demister through the rotational-flow inducer 280 is induced into rotational motion within the demister body 283. This imparts a centrifugal force on the entrained solids and/or liquid droplets which impinge on the inner surface of the demister body 283 and fall to the bottom where they can exit through the outlet 282. The second outlet in this case comprises a channel which connects the demister 12b with a position below the liquid level of the concentrator tank 107. In this way, gas cannot enter into the demister from the headspace 107a of the concentrator tank 107 via the demister liquid outlet 282.

[0181] In this arrangement, the gas passes upwardly through the demister 12b. This means that there are two competing forces being applied to the liquid and/or solids: gravity which tends to draw the high-density materials downwards; and the air flow which tends to draw the high density materials upwards. To ensure that some high-density materials are not retained within the demister at a point where gravity and air flow forces are balanced, embodiments may be configured to provide a time-varying airflow pattern (e.g. with passive or active elements), or to design the curvature of the demister body wall to help preclude dead-spot positions (where forces are balanced).

[0182] Gas exiting the demisters, in this case, is then aggregated in a gas manifold 285 and allowed removed from the device via a flue 286. In various embodiments one or more optional blowers 287 at the outlet of the gas manifold provide a negative pressure within the gas manifold which encourages air flow through the vaporization chamber 11, the headspace 107a within the concentrator tank 107 and the demisters 12a, 12b. This in turn may reduce the amount of back pressure exerted on the engine and so allow greater throughput without exceeding engine tolerances. In various embodiments blowers 287 are not required as the engine pressure is enough to force exhaust gasses through the engine RVVVS 10 without exceeding backpressure limitations of the engine, including pressure needed to provide a comfortable safety margin. In another embodiment when the RVVVS is configured to a flare stack void of substantial pressure, optional blower 287 may be employed to facilitate all of the pressure required to suck gas though the RVVVS.

[0183] In this case, the RVVVS comprises multiple demisters arranged in a circle around the vaporization chamber. Using multiple cyclone demisters with a smaller radius allows a greater proportion of the high-density material to be removed because smaller radius cyclone demisters allow a greater centrifugal force to be applied for the same gas speed. Put another way, multiple smaller cyclone provide greater separation efficiency for less pressure drop when compared to a larger, single cyclone demister. When seeking to re-condense the vaporized water for further industrial use, it becomes important to separate gypsum, droplets and particles of the smallest size possible in order to achieve the lower TDS in the condensed vapor stream.
For example, for a given inlet gas flow of 30000FM at 3000, a single frustoconical cyclone separator with an inlet diameter of 24" may experience a pressure drop of 3.5"WC and separate salt particles of 20um and greater. Where as using 4 smaller 12" diameter cyclones may have the pressure drop of less than 1" and the capacity to separate salt particles down to 12um. This may be the difference between re-condensed water having 6,000ppm salt (considered brine) or 300ppm salt (considered drinking water).

[0184] In other various embodiments a cyclonic demister may not be used in favor of another style, for example impingement bases demisters. In other embodiments, geometry with narrow outlets, direction change and pressure may be used to fully or partially demist the gas.
Raw Water Shearing and Vaporization

[0185] It will be appreciated that the embodiment of Figure 2, 3A-30 represents one way of effecting evaporation according to the present invention. There may be a range of variants and optional features which may be included while remaining within the scope of the invention.
By way of example, the demisting system may be positioned above and in the center of the concentrator tank 107. In another embodiment the air knife and vaporization chamber may be positioned to the side, adjacent to and/or above or inline with the high water level of tank 107. In the latter example, the un-vaporized water flowing from at least one vaporizer 11 to at least one tank 107 would do so in a downward flowing directions. In other various embodiments, at least one vaporization chamber 11 would be positioned beside tank 107 in which case the un-vaporized water would have to flow from the vaporization chamber into tank 107 via water level head pressure.

[0186] In the embodiment shown in Figure 3, the exhaust gas inlet into the vaporization chamber is an orifice with a slightly narrowed tapering bore with respect to the full bore with of the gas conduit. This has the effect of controlling and/or increasing the velocity of the gas at the point of entering the vaporization chamber. This higher relative velocity may help shear the water flow to create a larger number of smaller-sized droplets, sub-micron droplets, mist and fog. This increases the surface area to volume ratio of the water droplet which increases the rate of vaporization due to enabling rapid thermal transfer of the heat in the gas into the water.

[0187] As shown in Figures 4A-4F, raw water shearing and vaporization may be at least partially achieved as a result of the push pressure of the exhaust gas (or blower motor, or a combination of engine exhaust gas with partial assistance of a blower) in combination with the shearing forces imparted on the raw water from the exiting nozzles, or other water discharge device or system delivering raw water to vaporization zone 24a (where the liquid raw water interacts the hot gas to effect vaporization) under any range of engine or blower pressure from very little pressure to high pressure, and the subsequent impact and/or mixing with the exhaust gas stream.

[0188] In one embodiment, within the zone 24a, raw water is pumped through a nozzle or nozzle system, or other water discharge device or system (herein sometimes referred to as a nozzle or nozzles) that will create an initial amount of raw water surface area and/or initially atomize at least a portion of the water into droplets at the moment of exit through the nozzles or discharge device. In this embodiment, as a result of the positioning of the nozzles relative to the exhaust stream, the water droplets are immediately impacted by high temperature and/or rapidly flowing exhaust gases which will further impart shearing forces on the water droplets.

[0189] Depending on the particular parameters of the system at a given time including raw water flow rate, nozzle design, exhaust gas temperature, exhaust gas pressure and flow rate, and position of the nozzles, a desirable rate of vaporization of raw water will occur resulting in the creation of water vapor and concentrated raw water contaminants.

[0190] As shown in Figures 4A-4F, the interaction of raw water with the exhaust can occur in a number of ways to impart shearing forces and/or turbulence as a means of interfacial surface area generation and therefore desirable thermal and mass transfer.
Further, these Figures also illustrate various separate and combined examples of optional exhaust delivery devices or systems herein sometimes referred to as air knives, the air knives configured directly to deliver exhaust gas 14a from an exhaust system 14 to a vaporization chamber 11. Various optional air knives may be configured and utilized as a means to manipulate the exhaust gas pressure, velocity, delivery orientation and/or speed prior to the delivery of the exhaust gas 14a into interaction zone 24a.

[0191] An air knife may be considered to be a component of a pressurized air channel containing a series of one or more holes or slots through which pressurized air exits in a laminar flow pattern. That is, the holes and/or slots may be sized and positioned such that the individual air flows combine to produce a laminar flow pattern. The air knife may be straight or curved. The air knife may extend along an axis (e.g. straight or curved axis) and have a restricted lateral dimension. The exit velocity of the pressurized air from the air knife may be one or more of:
between 20-60m/s; 40-60m/s; between 40-80m/s; between 50-100m/s; and greater than 100m/s.

[0192] For example, in Figure 4A, exhaust piping 26 conveys exhaust gases 14a to interaction zone 24a where raw water 22b is sprayed countercurrent to the exhaust gas flow.
The entry point of exhaust piping 26 to zone 24a may be tapered to expand the transition zone which may be used to create areas of lower pressure.

[0193] Figure 4B shows a straight piping embodiment together with potential positions and angles of the raw water spray 22b, including concurrent flow, countercurrent flow, angled flow and right-angled flow that may occur within piping 26 and/or zone 24a.

[0194] Figure 40 shows an embodiment with an exhaust diverter 26a that may be used as a means to create a radial flow pattern with a low pressure or void space in the center while maintaining the exhaust pressure at a level as it enters zone 24a by maintaining the cross sectional area of the piping at a given value at the point of entry. In another embodiment 26a enables compression and diversion of exhaust gasses to increase gas flow speed as it enters zone 24a when compared to gas flow speed prior to diverter 26a. A system may be employed to adjust the position of the diverter 26a to maintain a consistent gas velocity as shown by the double-headed arrow.

[0195] Figure 4D shows a decoupled exhaust delivery system as an embodiment where ambient air 26b may be introduced to a first gas stream 14a to decrease exhaust gas temperature prior to entering zone 24a. This embodiment may also or alternatively allow any water/moisture within the gas or from zone 24a or water distribution system to drain through the decoupled or partially decoupled area. The decoupled area may be configured as a means to drain raw water and/or raw water concentrate from a vaporization chamber or an air knife, depending on the configuration. Figure 4E shows an embodiment with an exhaust diverter/compressor 26a where the compressor constricts or reduces the cross-sectional area of the piping 26 to increase the pressure and therefore speed of the exhaust gas 14a as it enters zone 24a. As illustrated in 4E the exhaust diverter/compressor is placed in the center of a pipe as a means to divert and/or compress exhaust gas flow, however it should be understood that in various other configurations the cross sectional area may be reduced by overall pipe diameter reduction or any other means of compressing or diverting a gas flow to create a desired gas entry pressure and speed as the gas enters zone 24a.

[0196] Figure 4F shows a plan (I), side (II) and front (III) view of a "duck-bill" exhaust nozzle as an example of a means of constricting or expanding the cross-sectional area of the piping 26 to increase or decrease exhaust gas pressure and therefore speed as it enters zone 24a. In this example, the nozzles may be placed at 90 degrees to the flow of the exhaust gas as one example of the possible positioning. In another embodiment the nozzle may be a flat fan nozzle to enable the delivery of raw water across the gas delivery shape as it enters zone 24a

[0197] In various embodiments, any configuration illustrated in Figures 4A-4F or described herein may be configured with louvers as a means of further controlling, managing or manipulating gas flow characteristics as the gas flow 14a enters zone 24a.
More specifically, the latter may be configured to allow a throttling of gas pressure as a means to control gas flow speed or pressure as a means for enabling a consistent exhaust gas 14a speed and/or speed range as its being delivered to and entering zone 24a. This configuration may be desirable to maintain a consistent range of interaction of raw water and delivered exhaust gasses at times when the engine load various in a manner that creates fluctuations of engine exhaust gas flow, pressure, speed and/or temperature. By way of example if Figure 4B is configured with louvers, not shown, they may remain fully open when the engine is under 80% load.
However if the engine load were to decrease to, for example 50%, and thus decrease the total exhaust gas 14a flow rate and/or temperature, the louvers would choke the cross sectional area in which the exhaust gas enters zone 24a. This choking or reduction of cross sectional surface area under reduced gas flow conditions thereby enables a consistent range of gas flow speed range as it enters zone 24a.

[0198] As another means of providing a consistent range of desirable exhaust gas speed to zone 24a, in various embodiments, the exhaust diversion device 14b may be weighed such that upward fluctuations of gas pressure from increased engine load would be vented to atmosphere. In the latter example, 14b may be configured to divert all of the exhaust gas 14a to zone 24a when the pressure between an air knife illustrated in 4A-4F and engine 12 is less than 10"WC or other desired threshold, however if this pressure increases above the 10"WC due to increased exhaust gas flow form increased engine load exceeded the excess exhaust flow would be permitted to vent to atmosphere.

[0199] Nozzles or other means of distributing raw water within exhaust gas 14a may include full cone nozzles, flat fan nozzles, hollow cone nozzles, atomizing nozzles, open piping, gravity waterfall system or other known systems. The pressure of raw water distribution may vary from gravity distribution to high pressure. When choosing a water pressure droplet size and raw water distribution characteristic and how they interact with the pressure and temperature of exhaust gas must be considered. For example the higher the pump pressure at a nozzle head of a hollow cone nozzle, the smaller the average droplet size and droplet mass of raw water droplets exiting the nozzle and therefore the greater the surface area of the average droplet related to its mass (or volume).

[0200] Since interfacial surface area is desirable as a means of thermal transfer of heat energy into the water and mass transfer from a liquid to gaseous state, the smaller the average droplet size the faster the thermal transfer takes place. Continuing, the average droplet size of the raw water exiting the water nozzle create the starting average droplet size for which the pressure within the exhaust gas flow must act against as shearing force. Combined, the pressure of the pump and the pressure of the exhaust gas act on the raw water to shear it as a means of rapid thermal transfer. Further, a suitable water pump can be chosen to accommodate the scale of system based on system specific needs, but generally based on engine exhaust specifications.
In one embodiment, a pump pressure of 10-100psi is suitable. Pump type is preferably a centrifugal pump due to their ability to pump waste water and slurries plus desired draining characteristics, however other pumps such as positive displacement, diaphragm, screw or other known pump types may be used.
Back Pressure and Engine Parameters

[0201] Depending on the engine, the back pressure on the engine is controlled to ensure compliance with the engine specifications. For example, a typical drilling rig engine/generator such as a CaterpillarTM 400 ekW 500 kVA gen set may require that the back pressure is below 40 inches WC. In various embodiments the RVVVS can be operated with about 5-20in WC, typically 8-12in WC back pressure. Importantly, in one embodiment, a pressure sensor or switch monitoring system backpressure at or near the base of on engine exhaust system near the engine block itself may be employed and configured with a control system and an engine exhaust diversion system to allow the exhaust 14a to flow to atmosphere in the event the total system backpressure exceeds a minimum threshold. In one embodiment, this threshold may be 5-40 in WC, or in other embodiments may be 5-20 in WC.
When configured to a combustion gas source with no available "free" pressure, pressure within the system may be 0-20 in WC or below 5 in WC. In some embodiments configured with a blower or fan, certain flow zones within a system may be under slightly negative pressure. It may be preferable to design the entire system to have as low of a pressure drop as possible in order to consume less power if using a blower and to use minimal engine pressure as possible if configured to an engine.

[0202] Exhaust temperatures for operating 250-1500 kW engine/generators will typically be in the range of 350-500 C but may range from 200-700 C. Exhaust gas flow rates for these example sizes may be in the range of 3400-8500 cfm (cubic feet per minute) and heat content rejection to exhaust gas may typically be in the range of 25,000-60,000 Btu/min. As a result, the total amount of heat available for vaporization can be determined based on known engine parameters and operation which can be used for effective control of the RVVVS
as will be explained in greater detail below.

[0203] Generally, the energy transformation chain within the system is as follows:
a. The engine/generator transforms the chemical energy of the engine fuel to mechanical energy and heat.
b. A portion of the heat and pressure losses from the engine/generator are in the form of exhaust gas and are diverted to the RVVVS 10 and/or a vaporization chamber 11.
c. The kinetic energy of the exhaust may be increased between the engine and zone 24a by compressing, controlling or manipulating the gas against the engine pistons pushing the combusted exhaust gas from the engine block into an exhaust system and/or adding kinetic energy through multiple gas streams.
d. The kinetic energy of the exhaust gas contributes to the atomization and/or surface area generation of raw water coming into contact with the exhaust gas through shearing forces which increases the interfacial surface area of water and gas as a means for increasing thermal and mass transfer between the exhaust and raw water droplets.
e. The heat of the exhaust gas effects at least partial vaporization of raw water droplets.
Downward Flow Demister

[0204] Figure 5 shows an alternative embodiment of the present invention.
Like the embodiment of Figure 3A, this embodiment of a raw water vaporization system (RVVVS) comprises:
a vaporization chamber 511 having:
raw water 522 and gas 526 inlets configured inject water and gas to within the vaporization chamber to effect raw water vaporization and an outlet 531 at the bottom of the vaporization chamber 511;

205 PCT/CA2018/050142 a concentrator tank 507 positioned directly below the vaporization chamber 511 such that material exiting the vaporization chamber via the vaporization chamber outlet impinges with liquid in the concentrator tank;
a raw water channel 504 configured to inject raw water from the concentrator tank 507 into the vaporization chamber 511 via at least one of the raw water inlets 522.
[0205] In this case however, the demisters 512a, 512b are inverted with respect to the orientation of the embodiment of Figure 3A. That is, the airflow is configured to be directed through one or more air channels upwards before entering the demister at the top.

[0206] Like the demister shown in Figure 30, each demister 512a, 512b in this case comprises a circularly symmetric body (e.g. cylindrical or frustoconical) with a rotational-flow inducer (e.g. a stator or an actively or passively driven rotor) at one end of the demister body; a gas outlet at the other end of the demister body; and a liquid outlet at the bottom of the demister 12b. However, the rotational-flow inducer in this case is located at the top of the demister and the gas outlet is located at the bottom of the demister.

[0207] Gas and entrained solid or liquid material entering the demister through the rotational-flow inducer is induced into rotational motion within the demister body. This imparts a centrifugal force on the entrained solids and/or liquid droplets which impinge on the inner surface of the demister body and fall to the bottom where they can exit through the liquid outlet.

[0208] In this case, each demister has a separate gas outlet. However, in other embodiments, the gas outlets may be connected to a manifold for aggregating the gas for ejecting into the atmosphere. It will be appreciated that aggregating gas flows into a single outlet may allow the plume from the system to be projected to higher altitudes which may be preferable.

[0209] Another option for improving the projection of the gas from the exhaust is diverting a portion of hot combustion gas 14a from the exhaust piping 26 directly into the manifold 285 or into the flue 286. That is, in other embodiments a portion of combustion gas 14a may be diverted from upstream of the vaporization chamber 11 and/or AK 226 and directed into RVVVS exhaust header or gas manifold 285 or exhaust circuit (e.g. flue 286) to increase the exit temperature. This helps facilitate the creation of a larger dispersion cloud and less visible vapor plume.

[0210] The liquid outlet in this case comprises a channel which connects the demister 512b with a position below the liquid level of the concentrator tank 507. In this way, gas cannot enter into the demister from the headspace of the concentrator tank 507 via the demister liquid outlet.
Demister Flushing

[0211] The function of the demister is to separate entrained water from the gas flow before the gas is ejected into the atmosphere. Within the demister precipitate or scale may form which may require maintenance, depending on may other various parameters of the overall system. For example, one could ensure the cyclone separators remain dry and separate out only gypsum particles which would drain via 282 FIG 30. Alternatively, the cyclones could be run wet wherein un-vaporized liquid is discharged from the cyclone via 282 FIG
30. The water flow in the vaporizer from P2, the water pressure of the nozzles 222x, the velocity of gas 14a and share of air knife 26, the shape of the optional coalescing cone preceding opening 231 and the ratio of head space 107a are all factors.

[0212] To mitigate the build of scale, the demister may be periodically washed with water. This will help dissolve scale or precipitate which has built up within the demister. Figures 6A and 6B illustrate two options for flushing a demister. It will be appreciated that other flushing mechanisms may also be used.

[0213] In Figure 6A, the feed water is pumped from raw water tank 105 via P1 into the top of the demister 612a. This water flows downwardly through the demister and can exit either through the rotational-flow inducer and/or through the liquid outlet at the bottom of the demister.
In both cases the flushing water will return to the main body of the concentrator tank below.

[0214] Figure 6B shows an alternative flushing arrangement where raw water flow from 105 is pumped upwardly via P1 from the bottom of the demister 612b. Once the water is introduced into the demister gravity causes the water to flow downwardly through the demister where it can exit either through the rotational-flow inducer and/or through the liquid outlet at the bottom of the demister. In both cases the flushing water will return to the main body of the concentrator tank below, in both cases the cleaning and salt/scale dissolving action is conducted by feed water from tank 105 having the lowest TDS and the best ability to re-dissolve salts and remove buildup. Coating the cyclones with PTFE also contributed to the best overall clean cyclones due to its non-stick properties.

[0215] In cases where the water is flushed in a direction opposite to the normal flow of gas through the demister, the flushing generally cannot be done at the same time as the demister is operating. Therefore, in these cases flushing would typically be a periodic function (e.g. once every 1/2 day).

[0216] On the other hand, in cases where the water is flushed with the normal flow of the gas through the demister, the flushing may take place more frequently (e.g. once every 1/2 hour).
Demister Rotational Configurations

[0217] As noted above, it may be advantageous if the present RVVVS can be efficiently use the energy from the heat source to reduce the need for additional energy input. Because the available pressure from an engine heat source is limited, it is important to reduce or minimize the resistance to air flow through the device. Therefore, it may be important to ensure that where a number of cyclone demisters are used in conjunction with each other that the rotation of each cyclone is coordinated with the other cyclone demisters.

[0218] Figure 7A and Figure 7B are horizontal cross-sections through the demisters to show the two main configurations which may be used where the demisters are arranged in a circle. In Figure 7A, all of the demisters are configured to induce the same direction of rotation to the gas. This may allow a larger rotation to be set up where the gas outside the demisters at the outside of the circle is induced to rotate in one direction, whereas the gas outside the demisters at the inside of the circle is induced to rotate in the opposite direction. Another advantage of the arrangement of Figure 7A is that all of the demisters may be identical which may reduce manufacturing and maintenance and repair costs.

[0219] In Figure 7B, neighbouring demisters are configured to induce rotational motion of the opposite orientation. That is each right-handed cyclonic demister will have neighbours which are induce left-handed rotation (and vice versa). In this case, the gas flow between neighbouring demisters do not form a turbulent boundary because the gas flow (shown in dotted arrows) from each is travelling in the same direction.

[0220] It will be appreciated that which of these modes will provide the least resistance to airflow may depend on the number of cyclone demisters, the spacing between the demisters, the angular velocity induced by each demister, the diameter of each demister, and so on. The optimal configuration may be determined using airflow modelling.

Condenser

[0221] In some embodiments, it may be desirable to condense the water vapor generated by the vaporization system within a condenser 113 to provide clean water 111 (Figure 1G).

[0222] The condenser 113 may comprise a condensing chamber through which the water vapor passes, wherein the chamber comprises a heat exchange elements for cooling the water vapor. The heat exchange elements may be cooled by flowing raw water through channels within the heat exchange elements. This has the advantage that as the water vapor is cooled and condensed the raw water within the heat exchange elements is heated. This means that when the heated raw water is introduced into the vaporization chamber 10a, vaporization may be more effective.
Barium Removal

[0223] When concentrating water from producing wells, Barium Chloride may form and is know to be soluble and is therefore toxic. In a vaporization and concentration system such as the present invention, it may be desirable to remove Barium from the concentrate by making it insoluble and therefore benign to the environment. One such known method is to introduce a reagent such as sodium sulfate into a solution containing barium chloride, ideally under heat and vigorous mixing to facilitate a reaction. Since the air knife, water injection, vaporization chamber, combustion gas heat and gas velocity shearing pressure collectively create the ideal environment wherein violent and hot mixing occur, one need only add the proper reagent to precipitate out a non-soluble and environmentally benign barium sulfate.

[0224] In one embodiment the reagent sodium sulfate is added to the water flow in the P1 flow circuit between the optional VOC removal step 126 and concentrator tank 107. In another embodiment sodium sulfate is added into the water flow circuit of P2 and injected directly into the vaporization chamber. In both cases mixing occurs wherein a sulfide ion from the sodium sulfate reacts with a barium ion from the barium chloride to form barium sulfate, which is highly insoluble. The reagent may be stored in a vessel that is fluidly connected to either of P1 or P2 flow circuits. The insoluble and benign barium sulfate may be removed by filtration and disposed of in any non-hazardous landfill.

[0225] The cost of removing barium from produced water is thereby substantially subsidized by the RVVVS vaporization process. In other words, if one were to remove barium sulfide from produced water by a similar method without a RVVVS 10, there would be cost associated with heating and mixing the solution.
Modes of Operation

[0226] Generally, the vaporization process will vaporize the water (e.g.
by evaporation, boiling or partial boiling) within the raw water but will not evaporate contaminants within the raw water if the temperature within exhaust/water contact system is maintained below the evaporative temperatures of any contaminants.

[0227] Accordingly, raw water falling to the concentrator tank 107 will generally be enriched with contaminants relative to raw water entering the vaporization chamber 10. As contaminants within unvaporized raw water will have different densities, they will have a tendency to settle towards the bottom of the concentrator tank and/or create stratification of contaminants within the concentrator tank. To enable stratification to occur, raw water being transferred to the vaporization chamber 10 will generally be drawn from upper regions of the concentrator tank but a distance below the surface (Figure 2). Raw water from a bulk raw water tank 105 or source will be introduced to the concentrator tank at a generally mid-height location and concentrated contaminants will be withdrawn from a lower location of the concentrator tank.

[0228] The system may be operated to vaporize raw water continuously, semi-continuously or in batch depending on particular configurations and operation.

[0229] In a continuous or semi-continuous mode of operation, raw water from a bulk raw water tank or source may be continuously or periodically added to the concentrator tank such that the water level within the tank remains at a particular level. In this case, as contaminants are concentrated and settle within the concentrator tank, periodically, the concentrated raw water may be removed through a drain system.

[0230] In a batch mode of operation, a single volume of raw water may be added to the tank and the system is operated until a desired concentration/volume of concentrated raw water is achieved within the tank whereupon the tank may be emptied before starting a new batch.
Fluids and Contaminants

[0231] The system is highly effective in handling a variety of waste fluids that may be collected at drill rig site or other stranded well site, such as a producing well, including viscous drilling fluids that may contain a variety of viscosifying agents. Generally, it has been observed that the effect of passing viscous fluids like polymer water through the vaporization zone 24a causes at least partial a breakdown of the hydrocarbon chains of the viscosifying agents which then effectively reduces the viscosity of the raw water due to heat and/or shearing effects within the system as previously described herein.

[0232] As is commonly known raw water produced in conjunction with oil or gas production wells contains volatiles and other organics such as BTEX and F1-F2 chain hydrocarbons (06-016). It has been observed that the vaporization chamber system as described herein provides a means of allowing the absorption of engine exhaust gas combustion chemicals from into the raw water concentrate. It has been observed that a majority of BTEX (80%+) and a portion F1-F2 hydrocarbons contained within produced water evaporate to atmosphere within 1-5 days, typically within 2 days, when the produced water has been drawn from below surface and permitted access to standard atmospheric conditions, including atmospheric pressure. When considering a method of produced water vaporization, it is desirable to limit overall atmospheric discharge or volatile and toxic chemicals. The present invention synergistically removes at least a portion of these at least a portion of these chemicals from exhaust gas 14a that would otherwise be discharged to atmosphere. When considering the entire mass balance of these chemicals in produced water, typical water transport and injection methods that discharge exhaust gasses and waste exhaust gasses from engine sources used for vaporization and how they are added and subtracted from an environmental discharge perspective, it becomes apparent that utilization of engine exhaust gasses in as described herein as a means to reduce total volumes of produced water become an attractive environmentally subtractive alternative to current management of both produced water and exhaust gasses.

[0233] Brine water, whether produced water or created as a drilling fluid, is another water that is costly to dispose of and harsh on processing and handling equipment due to it high saline content. Due to the system keeping relatively low temperatures, typically under 100 C, on all wetted surfaces the current invention becomes an attractive and cost effective means of management when compared to alternatives.

[0234] Although the present invention has been described and illustrated with respect to preferred embodiments and preferred uses thereof, it is not to be so limited since modifications and changes can be made therein which are within the full, intended scope of the invention as understood by those skilled in the art.

Claims

1. A raw water vaporization system (RVWS) comprising:
a vaporization chamber having:
raw water and gas inlets configured to inject water and gas to within the vaporization chamber to effect raw water vaporization and an outlet at the bottom of the vaporization chamber;
a concentrator tank positioned in a plane below the vaporization chamber such that material exiting the vaporization chamber via the vaporization chamber outlet impinges with liquid in the concentrator tank; and a raw water channel configured to inject raw water from the concentrator tank into the vaporization chamber via at least one of the raw water inlets.

2. The RWVS of claim 1 wherein the gas inlet is configured to direct gas flow through the vaporization chamber and directly into liquid contained in the concentrator tank.

3. The RWVS of any one of claims 1-2 wherein the concentrator tank has gas outlets arranged in the top surface of the concentrator so that gas entering the concentrator tank from the vaporization outlet must change direction to exit the concentrator tank gas outlets.

4. The RWVS of any one of claims 1-3 wherein the concentrator tank is tapered at the bottom.

5. The RWVS of any one of claims 1-4 wherein the concentrator tank comprises a recirculation loop for recirculating the liquid within the concentrator tank.

6. The RWVS of any one of claims 1-5 wherein the concentrator tank comprises an agitator.

7. The RWVS of any one of claims 1-6 where a said vaporization chamber gas inlet is configured to constrict gas flow enabling an increase in gas velocity at the outflow orifice in relation to the velocity of the inlet orifice of the adaptor.

8. The RWVS of any one of claims 1-7 where a said vaporization chamber gas inlet is an air knife.

9. The RWVS of any one of claims 1-8 wherein the gas is one or more of hot gas; an exhaust gas; and a combustion gas.

10. The RWVS of any one of claims 1-9 wherein the gas source is one or more of: an engine exhaust; an ICE exhaust; a turbine engine exhaust; and a combustion gas from a flame.

11. The RWVS of any one of claims 1-10 wherein at least a portion of the RWVS is coated with PTFE.

12. The RWVS of any one of claims 1-11 wherein the gas inlet is configured to introduce hot gas into the top of the vaporization chamber.

13. The RWVS of any one of claims 1-12 wherein the air knife is configured to induce a hot gas speed within the chamber of:
between 40m/s and 150m/s when water inlet pressure is 2-100psi or when fine to very course droplet sizes are introduced into the gas velocity; or between 1 m/s and 60m/s when water inlet pressure is 10-500psi or when fog droplets to course droplet sizes are introduced into the gas velocity.

14. The RWVS of any one of claims 1-13 wherein the apparatus comprises a gas conduit configured to deliver gas to the gas inlet wherein the gas conduit comprises a gas piping configuration, including a "Y" or "Tee" shaped pipe, and the gas conduit includes:
a release valve, the release valve configured when open to allow gas from the gas source to be vented into the atmosphere either directly or through an adjacent muffler and when released allows the valve to close or partially close and to direct at least a portion of gas towards the air knife adaptor; and a control valve configured when open to allow gas to be directed through the air knife and when closed to prevent gas being directed through the air knife.

15. The RWVS of claim 14 wherein the RWVS is configures such that when the release valve is open air is drawn counterflow from the air knife.

16. The RWVS of any one of claims 1-15 wherein the RWVS comprises a demister configured to receive gas and entrained liquid from the headspace within the concentrator tank and separate the gas from the entrained liquid.

17. The RWVS of claim 16 wherein the demister comprises a rotational-flow inducer to induce rotational motion to the gas and entrained liquid to separate the gas and entrained liquid using centrifugal forces.

18. The RWVS of any one of claims 1-17 wherein the RWVS comprises multiple vaporization chambers feeding into a single concentrator tank.

19. The RWVS of any one of claims 1-18 wherein pump bringing new raw water into the concentrator tank is configured to operate at a flow corresponding to the rate of vaporization in the vaporization chamber to thereby allow the RWVS to operate in a continuous mode.

20. The RWVS of any one of claims 1-19 wherein the RWVS comprises a barium-precipitating-reagent injector configured to inject a reagent into the raw water to precipitate dissolved barium salts.

21. A raw water vaporization system (RWVS) comprising:
a vaporization chamber having:
raw water and gas inlets configured inject water and gas to within the vaporization chamber to effect raw water vaporization; and an outlet to allow gas and liquid out of the vaporization chamber; and multiple demisters, each demister configured to receive a portion of the gas from the vaporization chamber and to remove high density material entrained in the received portion of the gas.

22. The RWVS of claim 21 wherein the high density material entrained in the gas comprises liquid water.

23. The RWVS of any one of claims 21-22 wherein the outlet of the vaporisation chamber is connected to each of the multiple demisters by a channel.

24. The RWVS of any one of claims 21-23 wherein the outlet of the vaporisation chamber is connected to each of the multiple demisters by a channel, the channel being formed by the headspace of a concentrator tank.

25. The RWVS of any one of claims 21-24 wherein the outlet of the vaporisation chamber is connected directly to each of the multiple demisters.

26. The RWVS of any one of claims 21-25 wherein each demister comprises a circularly symmetric body with a rotational-flow inducer at one end of the demister body;
a gas outlet at the other end of the demister body; and a second outlet at the bottom of the demister.

27. The RWVS of claim 26 wherein the liquid outlet comprises a channel which connects the demister with a position below the liquid level of a concentrator tank.

28. A method of vaporising raw water comprising:

injecting raw water and gas such that they mix together in a mixing zone to effect raw water vaporization, wherein the mixing occurs directly above an open concentrator tank positioned such that high density materials from the mixing zone will be directed to impinge with liquid in the concentrator tank;
and wherein the raw water for injection into the mixing zone is pumped from the concentrator tank.

29. A method of vaporising raw water comprising:
injecting raw water and gas such that they mix together in a mixing zone to effect raw water vaporization;
directing gas flow from the mixing zone to multiple demisters, each demister configured to receive a portion of the gas from the mixing zone; and removing high density material entrained in the received portion of the gas using the demisters.