US20130168291A1

US20130168291A1 - Method, Apparatus and System for Hydrocarbon Recovery

Info

Publication number: US20130168291A1
Application number: US13/729,900
Authority: US
Inventors: Brian Recatto; Andy Dufrene
Original assignee: Omni Energy Services Corp
Current assignee: Omni Energy Services Corp
Priority date: 2011-12-28
Filing date: 2012-12-28
Publication date: 2013-07-04

Abstract

The present invention relates to a system, method and apparatus for the extraction of hydrocarbons from contaminated solids. The method for separating hydrocarbons from solids comprising exposing the solid to a heat source of sufficient temperature to release substantially all of the hydrocarbon and water from the solids as volatile vapors, condensing at least a portion of the hydrocarbon vapor, and condensing the water vapor. The apparatus for extracting hydrocarbons from solids comprises a heat source capable of reaching temperatures sufficient to vaporize substantially all of the hydrocarbons in the contaminated solids and at least one separation tank in fluid communication with an outlet of said heat source for condensing at least part of the hydrocarbons. The present invention also relates the system for applying said method to said apparatus to extract and recover hydrocarbons from contaminated solids.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to the provisional U.S. patent application No. 61/580,757 entitled “Hydrocarbon Recovery,” filed Dec. 28, 2011.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM

Not Applicable.

DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and include exemplary embodiments of the Method, Apparatus, and System for Hydrocarbon recovery, which may be embodied in various forms. It is to be understood that in some instances, various aspects may be shown exaggerated or enlarged to facilitate an understanding of certain features. Therefore the drawings may not be to scale.

FIG. 1 depicts a flow diagram illustrating one embodiment of a process for Hydrocarbon Recovery.

FIG. 2( a) is an enlarged fragmentary view depicting one half of a process for hydrocarbon recovery, including the heating and solid removal portions.

FIG. 2( b) is an enlarged fragmentary view depicting the other half of a process for hydrocarbon recovery, including the condensing portions of the process.

FIG. 3 is a fragmentary view depicting an alternate embodiment for a process for condensing the hydrocarbon and water vapors resulting from the process depicted in FIG. 2( a).

DESCRIPTION

The instant invention concerns the removal of hydrocarbons from solid materials, such as from drill cuttings in drilling mud, which contain hydrocarbons. During rotary drilling operations, a volume of subterraneous material encountered is removed to provide the well bore. This material is generally referred to as drill cuttings. The cuttings are usually mixed with the drilling fluid used and any water or hydrocarbons encountered subterraneously during drilling operations.
In a typical drilling operation, the cuttings are separated from the drilling fluid by way of a shale shaker. The recovered drilling fluid is usually recirculated for further use in the drilling operation. The cuttings removed by the shale shaker are not only coated with but contain a mixture of water, hydrocarbons, and constituents of the drilling fluid. In some cases, the drilling fluid itself may contain hydrocarbons which contribute to the contamination of the drill cuttings.
The disposal of the drill cuttings and drilling mud is a complex environmental problem. Drill cuttings contain not only the residual drilling mud product that would contaminate the surrounding environment, but may also contain oil and other waste that is particularly hazardous to the environment, especially when drilling in a marine environment.
In addition to shakers, various methods for removing hydrocarbons and contaminants from drill cuttings and drilling fluids have been employed. However, the high costs and plant construction complexity, significant energy waste, limited safety, especially when operating offshore, and low efficiency have rendered such previous methods disadvantageous for extraction of hydrocarbons.
Accordingly, there exists a continuing need for methods and systems for extracting hydrocarbons from drill cuttings.
The methods of treating solids described herein may, in one embodiment, comprise delivering a contaminated energetic material to a heat source or heat chamber; subjecting the contaminated energetic material to a temperature sufficient to vaporize substantially all of the diesel fuel present in the contaminated energetic material; and condensing a portion of the diesel fuel from the contaminated energetic material. As used herein, the phrase “contaminated energetic material” refers to a material comprising hydrocarbon fuel and contaminants. As used herein, the term “heat source” refers to any known source capable of producing the required heat. Examples of heat sources which can be used include, but are not limited to, evaporators, rotary heaters, or any machines capable of deriving heat from the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. In a related example, the contaminated energetic material contains drill cuttings; and the step of subjecting the contaminated energetic material to a temperature sufficient enough to vaporize substantially all of the diesel fuel present is carried out by a calciner. In a related example, the heat source is a rotary heater. In a further related example, the heat source is a calciner. In a further example, the heat source is provided by fuel burners. In a further related example, the heat source is provided by electric heating. In a further related example, the heat source is provided by steam heating.
The methods of treating solids described herein may, for example, comprise delivering a first material to a first zone; heating the first material in the first zone thereby producing a second material in vapor form and a third material having a lower water and hydrocarbon content than the first material; delivering the second material to a second zone; and condensing at least a portion of the second material in the second zone thereby separating a fuel from the second material such that a fuel containing liquid and a fourth material are produced. In a related example, the heating of the first material in the first zone is accomplished by a heat source; a condenser in fluid communication with the heat source condenses at least a portion of the fuel in the second material. As used herein, the term “condenser” may refer to any device capable of condensing a vapor into liquid form. For example, the condensing may occur through direct condensing by a direct condenser including, but not limited to, scrubbers with spray nozzles, packed or frayed columns, or dispersion of the vapor within a column of cooler liquid. The condensing may also occur through indirect condensing by an indirect condenser including, but not limited to, a heat exchanger or heat trap.
In a further related example, fuel is condensed wherein the fuel is selected from gasoline, diesel, kerosene, jet fuel, and fuel oil.
In a still further related example, the heating of the first material in the first zone is accomplished by a rotary heater; a condenser in fluid communication with the rotary heater condenses at least a portion of the fuel; the largest component of the second material is water vapor; the solids content of the third material is higher than the solids content of the first material; and the fuel released from the second material contains hydrocarbons. In a further related example, the condenser is a scrubber condenser, in a related example, the condensing occurs by subjecting the vapors to cooler temperatures in a tank. In a related example, the heat source is a rotary heater. In a further related example, the heat source is a calciner. In a further example, the heat source is provided by fuel burners. In a further related example, the heat source is provided by electric heating. In a further related example, the heat source is provided by steam heating.
A solids treatment apparatus described herein may for example, comprise a first zone comprising one or more vessels, a first zone feed stream, a first zone first outlet stream, a first zone second outlet stream, and a heat source; a second zone comprising one or more vessels, a second zone first outlet stream, a second zone second outlet stream, and a condenser; wherein the first zone feed stream comprises a hydrocarbon fraction, a water fraction, and a solids fraction; and wherein the hydrocarbon fraction comprises a first hydrocarbon component having an atmospheric boiling point of between 250° F. and 1000° F. As used herein, the term “stream” encompasses the movement of both fluid and non-fluid material. In a related example, the first zone feed stream comprises drill cuttings; the first zone heat source is an indirect heat source arranged and configured to heat the accepted contents of the first zone feed stream; the first zone first output stream is in fluid communication with a first condenser; the first condenser circulates a liquid hydrocarbon scrubber stream; and the second one second outlet stream is in fluid communication with a second condenser. In a related example, the first zone feed stream comprises drill cuttings. The heat source may be any known source capable of producing the required heat. Examples of heat sources which can be used include, but are not limited to, evaporators, rotary heaters, calciners, or any machines capable of deriving heat from the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. In one embodiment, the heat source is an evaporator. In another embodiment, the heat source is a rotary heater. In another embodiment the heat source is a calciner. In a related example, the heat source comprises a rotary calciner. In another embodiment, the heat source is an indirect heat source arranged and configured to heat the accepted contents of the first zone feed stream. In another related example, the first condenser is a scrubber condenser. In another related example, the second condenser is a scrubber condenser. In another related example, the second zone first outlet is connected to a storage vessel. In another related example, the second zone second outlet stream is in fluid communication with a second condenser.
In another related example, the first zone feed stream comprises drill cuttings; the first zone first outlet stream is in fluid communication with a first condenser; the second one second outlet stream is in fluid communication with a second condenser; the first condenser circulates a liquid hydrocarbon scrubber condenser stream; the first zone further comprises a calciner; the first zone second outlet stream has a solids content that is higher in the solids content of the first zone feed stream; the second zone is arranged and configured to accept contents of the first zone first outlet stream; the second zone first outlet stream comprises condensed hydrocarbons; and the second one second outlet stream has a water vapor content that is higher than the water vapor content of the first zone first outlet stream. In a related example, the first zone second outlet stream is connected to a solids residue vessel. In a further related example, the solids residue vessel is connected to a vent. In a further related example, the solids residue vessel is connected to a solids residue scrubber, and material three discussed above is exposed to the solids residue scrubber. In a related example, the first condenser has a third outlet which is used to expel excess sludge particulates from the second material.
In another related example, the first condenser operates as an indirect condenser. In a further related example, the first condenser is a heat trap; wherein ambient temperatures cooler than the temperature of the vapors cool and condense the vapors. In another example, the condenser is any device capable of condensing the vapors.

DETAILED DESCRIPTION

The subject matter described herein is described with specificity to meet statutory requirements. However, the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Although the terms “step” and/or “block” or “module” etc. might be used herein to connote different components of methods or systems employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of heating the first zone feed stream, condensing the hydrocarbons, and condensing the water vapor. One skilled in the relevant art will recognize, however, that said heating and condensing may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
Referring to FIG. 2( a), incoming materials 8 are supplied by roll off box, rail, truck or other form of transportation to incoming materials handling area 10. In one embodiment, incoming materials are wet solids contaminated with hydrocarbons such as oilfield waste, drilling mud, drill cuttings, contaminated soil or sludge. Incoming materials 8 are then moved from incoming materials handling area 10 to receiving pit 20 by receiving pit supply line 15. In an alternate embodiment, incoming materials 8 are loaded directly into receiving pit 20. Material from receiving pit 20 is then supplied by feed pit supply line 25 to feed pit 30. Feed pit 30 provides material to heat source 50 by way of a conveyance system. Various embodiments of the feed conveyance system will include any of the following, alone, or in combination: conveyers including but not limited to screw, belt or spiral conveyors or pumps including but not limited to centrifugal, diaphragm, positive displacement and screw pumps. In an embodiment of the invention, the conveyor system includes a feed line 35, concrete pump 40, and heat source feed line 45. In one embodiment, feed line 35 is a horizontal auger.
The heat source 50 may take many forms including a rotary drum and rotary or other indirect-heated dryers. The supply of heat to the heat source 50 may include but is not limited to the combustion of hydrocarbons such as natural gas, liquid petroleum gas, petroleum liquids, hot combustion gases from other sources (flares, engines, or heaters), steam, or electricity. The operating temperatures of heat source 50 may be selected based on a reference compound either theoretically or actually selected for removal, in one embodiment the operating temperatures may be greater than or equal to the boiling point of the first reference compound. In one embodiment, the heat source 50 is a calciner that uses the indirect heat of the calcining process to drive of all of the volatile components supplied by heat source feed line 45. In one embodiment, the calciner is set up to evaporate diesel hydrocarbons and has three temperature zone ranges: calciner zone one at 700° F. to 800° F., calciner zone two at 800° F. to 1000° F. and calciner zone three at 1000° F. Catchier zone one raises the temperature of the feed material to vaporize most of the water content, calciner zone two begins the vaporization of the hydrocarbon material, and calciner zone three removes any hydrocarbon compounds with a higher boiling point. These volatile components leave heat source 50 by vapor line 53. Solid residue from heat source 50 is removed by a conveyance system to solids residue vessel 80. This conveyance system is of a type capable of moving dry hot solids, including but not limited to screw, belt, or spiral conveyors. In one embodiment, this conveyance system includes a hood 55 to direct the solid residues, a horizontal auger 60 and inclined auger 70 which ultimately transport the solid residues from heat source 50 to solids residue vessel 80. In an alternate embodiment horizontal auger 60 is a trough auger and incline auger 70 is a tube auger.
Incline auger 70 conveys solid residue to solids residue vessel 80. Solids residue vessel 80 can be any vessel capable of housing solid residues conveyed from heat source 50. In one embodiment, a solids residue vessel vent 83 is attached to solids residue vessel 80. In one embodiment, solids residue vessel vent 83 is a fan driven vent that maintains a negative pressure to aid in air flow within solids residue vessel 80. In another embodiment, solids residue vessel vent 83 is a vent with a water scrubber. Solid residues are transported from solids residue vessel 80 to disposal 90 by solids residue conveyor 85. Solids residue conveyor 85 can include, but is not limited to, any of the following, alone, or in combination: roil off box, fork lift, truck or other form of transportation or conveyance for dry materials. From disposal 90, the solid residue can be transported to a landfill or combined with additional drill cuttings to solidify the drill cuttings for disposal. In one embodiment, the hydrocarbon content in the solid residue is in the range of 1500 to 5000 parts per million (ppm).
Referring now to FIG. 2( b) of the drawings, vapor from the heat source 50 is in fluid communication with the diesel condenser 120 via vapor line 53. Vapors exiting the heat source 50 via vapor line 53 may be condensed indirectly via a heat exchanger or directly by contact with a cool liquid. Condensation through direct contact may be accomplished by one of several methods including scrubbers with spray nozzles, packed or trayed columns, or dispersion of the vapor within a column of cooler liquid. In one embodiment, condensation occurs through direct contact of the heat source vapors with a circulating hydrocarbon stream. In one embodiment, diesel condenser 120 condenses the hydrocarbon vapor directly by contact with a cooled liquid diesel stream. Diesel condenser 120 also collects diesel and drains to sludge settling and separation box 140 by line to sludge settling 125. Sludge settling and separation tank 140 separates diesel from sludge removing the sludge through sludge removal line to landfill 146 and supplies diesel to diesel storage tank 160 through sludge separator line to diesel storage 142. Diesel condenser 120 is supplied with cooled liquid diesel for the condensing of diesel vapors from diesel storage tank 160 by diesel condenser spray feed line 165. Diesel condenser 120 also directly supplies diesel to diesel storage tank 160 through condensed diesel line to diesel storage 128. A stream of un-condensed gas and vapors containing water vapor leaves diesel condenser 120 through water vapor exhaust line 123 and travels to water condenser system 180. Remaining water and condensable matter delivered through water vapor exhaust line 123 are condensed in water condenser system 180. Sludge and debris from the condensing process are removed from water condenser system 180 by way of sludge removal line from water condenser system 184 and condensed water line to water storage 186 carries the remaining condensed water from water condenser system 180 to water storage tank 200. Water storage tank 200 vents to the atmosphere through vent to atmosphere 204 and drains through water washout for disposal 206. Vent to atmosphere 204 contains a fan which creates a negative flow or suction which aids in pulling the volatile vapors released from heat source 50 through the system. Water from water storage tank 200 is recirculated by water supply line 210 and water condenser bypass line 212. A portion of the water traveling through water supply line 210 is routed to water condenser system 180 by way of water condenser liquid water feed line 214.
Referring now to an alternate embodiment in FIG. 3, vapor from the heat source 50 is in fluid communication with the diesel trap tank 220 via vapor line 53. Vapors exiting the heat source 50 via vapor line 53 may be condensed indirectly via a heat exchanger or directly by contact with a cool liquid. The vapors are indirectly condensed by exposure to ambient temperatures sufficient to condense substantially all of the diesel vapor in diesel trap tank 220. The condensed diesel vapors are then transported to sludge settling and separation tank 240 through line to sludge settling 225. In one embodiment, a pump is used to transport the condensed vapors from diesel trap tank 220 to sludge settling and separation tank 240. Sludge settling and separation tank 240 separates diesel from sludge removing the sludge through sludge removal line to landfill 246 and supplies diesel to diesel storage tank 260 through sludge separator line to diesel storage 242. Condensed diesel exits diesel storage tank 260 through diesel removal to sales 265. Excess sludge in diesel storage tank 260 is removed through sludge removal line from diesel storage to landfill 263.
A stream of un-condensed gas and vapors containing water vapor leaves diesel trap tank 220 through water vapor exhaust line 223 and travels to Water condenser system 280. Condensed liquids from diesel trap tank 220 are intermittently sprayed into water vapor exhaust line 223 to aid in the condensing process. Remaining water and condensable matter delivered through water vapor exhaust line 223 are condensed in water condenser system 280. Sludge and debris from the condensing process are removed from water condenser system 280 by way of sludge removal line from water condenser system 284 and condensed water line to water storage 286 carries the remaining condensed water from water condenser system 280 to water storage tank 300. Water storage tank 300 vents to the atmosphere through vent to atmosphere 304 and drains through water washout for disposal 306. Vent to atmosphere 304 contains a fan which creates a negative flow or suction which aids in pulling the volatile vapors released from heat source 50 through the system. Water from water storage tank 300 is recirculated by water supply line 310 and water condenser bypass line 312. A portion of the water traveling through water supply line 310 is routed to water condenser system 280 by way of water condenser liquid water feed line 314.
In one embodiment, contaminated solids are fed into the feed pit 30 at a rate of one ton per hour. The contaminated solids have a hydrocarbon concentration of 15% by weight, water concentration of 20% by weight, and solids content of 65%. In this example, the hydrocarbon is primarily diesel. The materials are pumped through feed line 35 to heat source 50 by concrete pump 40 so that the hydrocarbons can be vaporized and removed through evaporation. In one embodiment, heat source 50 is a rotary catchier which is separated into three heat zones that heat the material through the ambient temperatures it provides. Upon entering the rotary catchier of heat source 50, the solid materials reach calciner zone one and are subjected to an externally measured temperature range of 850° F. to 950° F. The temperatures of catchier zone one are sufficient to vaporize substantially all of the water in the contaminated solids. Continuing through the catchier, the materials arrive to catchier zone two and are subjected to an externally measured temperature range of 1000° F. to 1100° F., vaporizing most of the hydrocarbons in the contaminated solids. The remaining material continues down the calciner to calciner zone three where an externally measured temperature of 950° F. to 1000° F. is maintained to vaporize the final small amount of the hydrocarbon that, remains. The solid residues exit the calciner and are transported to solids residue vessel 80 via a conveyance system. Through this calcining process, all of the water is vaporized. Furthermore, substantially all of the hydrocarbon is vaporized. The hydrocarbon content is reduced from 15% by weight in the contaminated material to a range of 1500 to 4500 parts per million (PPM) in the solid residue. This marks a total removal of hydrocarbons in the range of 99.9965% to 99.9985%. From solids residue vessel 80, the cleansed solid residues are conveyed to disposal 90.
In order to adequately pull the volatile vapors from the calciner through the condensing zones, the entire operation is maintained at a negative pressure measured in a range of −02 to −0.6 inches of water column. The volatile vapors are transported from the heat source 50 calciner to diesel condenser 120 through vapor line 53. In one embodiment, diesel condenser 120 is a scrubber condenser which condenses the diesel vapors by spraying them with a stream of cooled vapors that are recirculated from a diesel storage tank 160. In an alternate embodiment, diesel is condensed indirectly via a heat exchanger instead of directly through contact with cool liquid diesel. From the diesel condenser, the condensed diesel is transported to the diesel storage tank. The condensed diesel is collected, stored, and eventually sold for reuse. The uncondensed water vapors exit diesel condenser and are transported to water condenser system via water vapor exhaust line 123. The water vapor system is a scrubber condenser which directly condenses the water vapors by spraying cooled liquid water into the vapors. The condensed water is transported to water storage tank 200. At least a portion of the cool condensed water in water storage tank 200 is recirculated into water condenser system to be sprayed by the scrubber condenser. Through this process a portion of the water is condensed and recovered while the balance of the water is vented to the atmosphere as saturated gas. In one embodiment, cooled liquids are sprayed into water exhaust line in order to aid in the condensing of the water vapor.
For the purpose of understanding the Method, System and Apparatus for Hydrocarbon Recovery, references are made in the text to exemplary embodiments of the Method, System and Apparatus for Hydrocarbon Recovery, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, designs, and equipment may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized should be or are in any single embodiment. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the method may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles disclosure. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.
Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change to the basic function to which it is related.

8—Incoming materials
10—Incoming materials handling area
15—Receiving pit supply line
20—Receiving pit
25—Feed pit supply line
30—Feed pit
35—Feed line
40—Concrete pump
45—Heat source teed line
50—Heat source
53—Vapor line
55—Hood
60—Horizontal auger
70—Incline auger
80—Solids residue vessel
83—Solids residue vessel vent
85—Solids residue conveyor
90—Disposal
120—Diesel condenser
123—Water vapor exhaust line
125—Line to sludge settling
128—Condensed diesel line to diesel storage
140—Sludge settling and separation tank
142—Sludge separator line to diesel storage
146—Sludge removal line to landfill
160—Diesel storage tank
165—Diesel condenser spray feed line
180—Water condenser system
184—Sludge removal line from water condenser system
186—Condensed water line to Water storage
200—Water storage tank
204—Vent to atmosphere
206—Water washout for disposal
210—Water supply line
212—Water condenser bypass line
214—Water condenser liquid water feed line
220—Diesel trap tank—-Need new term for this
223—Water vapor exhaust line
225—Line to sludge settling (needs to be pumped now, not gravity)
227—Spray line
240—Sludge settling and separation tank
242—Sludge separator line to diesel storage
246—Sludge removal line to landfill
260—Diesel storage tank
263—Sludge removal line from diesel storage to landfill
265—Diesel removal to sales;
280—Water condenser system
284—Sludge removal line from water condenser system
286—Condensed water line to water storage
300—Water storage tank
304—Vent to atmosphere
306—Water washout for disposal
310—Water supply line
312—Water condenser bypass line
314—Water condenser liquid water feed line

Claims

1. A method for treating solids, comprising:

a. delivering a contaminated energetic material to a heat source, said contaminated energetic material comprising a hydrocarbon filet and water;

b. utilizing said heat source to heat said contaminated energetic material to a temperature sufficient to vaporize substantially all of said hydrocarbon fuel and water present comprising said contaminated energetic material, producing a vaporized hydrocarbon fuel and vaporized water;

c. condensing at least a portion of said vaporized hydrocarbon fuel from said contaminated energetic material, producing a condensed hydrocarbon fuel;

d. collecting said condensed hydrocarbon fuel; and

e. introducing said vaporized water to a condenser.

2. The method for treating solids of claim 1, wherein the solid residue of said contaminated energetic material is collected after said contaminated energetic material is vaporized.

3. The method for treating solids of claim 1, wherein said heat source is a rotary heater.

4. The method for treating solids of claim 1, wherein said heat source is a rotary calciner.

5. The method for treating solids of claim 1, wherein the method further comprises condensing at least a portion of said vaporized water.

6. The method for treating solids of claim 1, wherein at least one condensing step is carried out by at least one direct condenser.

7. The method for treating solids of claim 1, wherein at least one condensing step is carried out by at least one scrubber condenser.

8. The method for treating solids of claim 1, wherein at least one condensing step is carried out by at least cue indirect condenser.

9. The method for treating solids of claim 1:

a. wherein the contaminated energetic material comprises drill cuttings and said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil;

b. wherein said heat source is a rotary calciner; and,

c. wherein at least one scrubber condenser is used to carry out at least one condensing step.

10. The method of treating solids of claim 1, further comprising condensing said hydrocarbon fuel and wherein the fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

11. The method of treating solids of claim 1 further comprising:

a. delivering said contaminated energetic material to a heat source;

b. heating said contaminated energetic material to a temperature sufficient to vaporize substantially all of the hydrocarbon fuel and water present in the contaminated, energetic material;

c. wherein said heat source is a rotary heater;

d. introducing the vaporized hydrocarbon fuel and water to a first condenser;

e. condensing at least a portion of said vaporized hydrocarbon fuel in said first condenser;

f. introducing said vaporized water from said first condenser to a second condenser in fluid communication with said first condenser;

g. condensing at least a portion of said vaporized water in said second condenser;

h. collecting the solid residues remaining after the heating of said contaminated energetic material; and

i. wherein said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

12. A method for treating solids comprising:

a. delivering a first material comprising a hydrocarbon fuel and water to a first zone;

b. heating said first material in said first zone thereby producing a second material in vapor form and a third material having a lower hydrocarbon and water content than said first material;

c. delivering said second material to a second zone; and

d. condensing at least a portion of said second material in said second zone thereby producing a hydrocarbon fuel in liquid form and a fourth material having a lower hydrocarbon content than said second material.

13. The method for treating solids of claim 12:

a. wherein the heating of said first material in said first zone is accomplished by a rotary heater;

b. wherein said second material comprises a hydrocarbon fuel;

c. wherein a first condenser in said second zone is in fluid communication with said rotary heater and said first condenser condenses at least a portion, of said hydrocarbon fuel;

d. wherein said fourth material comprises water vapor; and

e. wherein a second condenser in said second zone is in fluid communication with said first condenser and said second condenser condenses at least a portion of said water vapor present in the fourth material.

14. The method of treating solids of claim 12:

a. wherein the hydrocarbon content of said first material is between approximately 7 wt. % and approximately 26 wt. %;

b. wherein the solids content of said third material is higher than the solids content of said first material;

c. wherein the largest component of said fourth material is water vapor; and

d. wherein said hydrocarbon fuel released from said second material comprises hydrocarbons.

15. The method of treating solids of claim 12 further comprising delivering the third material to a storage vessel.

16. The method for treating solids of claim 12, wherein at least one of said first and second condenser is a scrubber condenser.

17. The method of treating solids of claim 12, wherein at least one condenser is an indirect condenser.

18. The method of treating solids of claim 12, wherein said indirect condenser is a heat exchanger.

19. The method for treating solids of claim 12, wherein said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

20. The method for treating solids of claim 12 further comprising:

a. delivering said first material to a first heat zone, wherein the heating of said first material in said first zone is accomplished by a rotary heater; wherein said first material is a contaminated energetic material; wherein said first material comprises between approximately 7 wt. % and approximately 26 wt. % hydrocarbon by weight;

b. heating said first material in said first zone, producing a second material in vapor form and a third material having a lower hydrocarbon and water content than said first material, wherein the solids content of said third material is higher than the solids content of said first material;

c. delivering said second material to a second zone, wherein said second material comprises a hydrocarbon component and a water vapor component;

d. introducing said second material to a first condenser, said first condenser in fluid communication with said rotary beater;

condensing at least a portion of said hydrocarbon component in the second material in said second zone, thereby producing a hydrocarbon in liquid form and a fourth material having a lower hydrocarbon content than said second material, wherein the largest component of said fourth material is water vapor;

e. introducing said fourth material to a second condenser, said second condenser in fluid communication with said first condenser; and

f. condensing at least a portion of said water vapor in said fourth material.

21. An apparatus for extracting hydrocarbons from a material comprising said hydrocarbons which comprises:

a. a heat zone for subjecting said material to a temperature sufficient to vaporize substantially all of the hydrocarbons in said material;

b. a first condenser zone for condensing at least a portion of said hydrocarbons; and

c. a second condenser zone for condensing water vapors that have been vaporized from said material.

22. The apparatus as in claim 21, wherein said first and second condensers are scrubber condensers.

23. The apparatus of claim 21, wherein at least a portion of said hydrocarbons are condensed via a heat exchanger.

24. A system of extracting hydrocarbons from a material comprising hydrocarbons which comprises:

a. delivery of a first material to a first zone, wherein said first zone comprises a heat chamber and said heat chamber comprises at least two outlets;

b. subjecting said first material to a heat chamber in said first zone, thereby forming a second material, which is a vapor comprising a higher concentration of a fuel and water than said first material, and a third material, comprising a lower concentration of a hydrocarbon than does said first material;

c. transporting said second material from said heat chamber, through one of said at least two outlets, to a first condenser in a second zone, wherein said outlet is in fluid connection with said first condenser in said second zone and the vapor of said second material is exposed to a sprayer of cooled condensed vapors, causing the vapor in said second material to condense and separate into a fuel and a fourth material, said fourth material comprising water vapor;

d. transporting said fourth material from said first condenser to a second condenser, said second condenser in fluid communication with said first condenser, wherein said fourth material is exposed to a sprayer of cooled condensed vapors causing said water vapor in said fourth material to condense into liquid water; and

e. transporting said third material from said heat chamber in said first zone to a dust trap.

25. A solids treatment apparatus comprising:

a. a first zone comprising one or more vessels, a first zone feed stream, a first zone first outlet stream, a first zone second outlet stream, and a heat chamber; and

b. a second zone comprising one or more vessels, a first condenser, a second zone first outlet stream, a second zone second outlet stream, and a second condenser; wherein said first zone feed stream comprises a hydrocarbon fraction, a water fraction, and a solids fraction and said hydrocarbon fraction comprises a first hydrocarbon component with an atmospheric boiling point of between approximately 250° F. and approximately 1000° F.

26. A solids treatment apparatus comprising:

a. a first zone comprising one or more vessels, a receiving pit for the intake of materials, a feed pit, and a heat source, wherein said feed pit is in fluid connection with said heat source, wherein a flow pump is used to convey said materials from said feed pit to said heat source, wherein said heat source has a first zone first outlet stream and a first zone second outlet stream; wherein said first zone first outlet stream is in fluid connection with a vessel in a second zone; and wherein said first zone second outlet stream is in connection with a vessel in a fourth zone;

b. a second zone comprising one or more vessels, a first condenser, a second zone storage vessel, and a sludge removal vessel; wherein said first condenser is in fluid communication with said heat source via said first zone first outlet stream; wherein said condenser has a second zone first outlet stream which is in fluid connection with said sludge removal vessel; wherein said condenser has a second zone second outlet stream in fluid connection with a vessel in a third zone;

c. a third zone comprising one or more vessels, a second condenser, a second storage vessel, and a sludge removal line; wherein said second condenser has a third zone first outlet stream in fluid communication with said second storage vessel; wherein said second condenser has a third one second outlet stream; wherein said second storage vessel has a second condenser feed line in fluid connection with said second condenser; wherein said second condenser feed line has a bypass line in fluid connection with second storage vessel; and

d. a fourth zone comprising one or more vessels, a solids residue vessel, and a disposal; wherein said solids residue vessel receives solids residue from said heat source through first zone second output stream.

27. The solids treatment apparatus of claim 26:

a. wherein said first condenser has a second zone third outlet stream which is in fluid connection with said storage vessel;

b. wherein said second zone storage vessel has a first condenser feed line in fluid connection with said first condenser; and

c. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

28. The solids treatment apparatus of claim 26:

a. wherein said first condenser has a second zone third outlet stream which is in fluid connection with said storage, vessel;

b. wherein said second zone storage vessel has a first condenser feed line in fluid connection with said first condenser;

c. wherein cooled liquids are recirculated from said second zone storage vessel to said first condenser through said first condenser feed line; and

d. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

29. The solids treatment apparatus as in claim 26:

a. wherein said first condenser has a second zone third outlet stream which is in fluid communication with said second zone second outlet stream; and

b. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

30. The solids treatment apparatus of claim 26, wherein said heat source is a rotary heater.

31. The solids treatment apparatus of claim 26, wherein said heat source is a calciner.