Separator system and method

What is this patent about?

’022 is related to the field of industrial fluid separation, specifically for removing sand and hazardous gases from well-bore fluids during drill-out operations. In oil and gas extraction, return materials often contain a volatile mix of liquids, particulates, and gases that must be processed quickly to maintain flow and safety. Conventional separators frequently suffer from long setup times, reliance on complex electronics that are prone to failure in harsh environments, and a tendency for sand to settle and clog the internal plumbing, requiring frequent maintenance and specialized transport permits.

The underlying idea behind ’022 is to maintain a state of constant fluid motion through a purely hydraulic architecture to prevent particulate settling and eliminate electrical ignition risks. By utilizing a continuous circulation loop driven by water jets and a Venturi-assisted extraction mechanism, the system ensures that sand remains suspended in the fluid until it can be mechanically removed. This approach replaces static settling tanks with active recirculation hoppers that use gravity and fluid velocity to funnel solids toward extraction points, ensuring the system remains clear even during high-volume returns.

The claims of ’022 focus on a multi-stage separation architecture comprising a vertical gas buster, an auger-driven sand extractor, and a main unit containing a series of specialized recirculation chambers. These chambers are characterized by internal angled sides with suction ports located at the bottom crux, creating a geometry that forces material into the circulation path. The independent claims also specify the integration of a partitioned strap tank for fluid measurement and a scrubber positioned between the vertical separator and a flare system to manage hazardous gas discharge.

In practice, the system functions as a four-way separator that processes material through a vertical circulation unit where internal baffles break up the fluid to release trapped gases. While gas is routed through a scrubber to a flare, the liquid and sand are pulled into an auger hopper via a Venturi effect created by the recirculation pump. The auger extracts the bulk of the sand, while any residual particulates that overflow are caught in the three recirculation chambers and fed back into the primary extraction loop, ensuring nearly total removal of solids.

This design differentiates itself from the prior art by being exclusively driven by hydraulics, which allows for precise speed control of the auger and pumps without the explosion risks associated with electronic controllers. The physical footprint is optimized to meet standard transport dimensions, eliminating the need for special hauling permits and reducing rig-up time to under two hours. By combining active water jets with the specific hopper geometry, the invention prevents the common industry problem of sand accumulation in the corners of the separation tanks.