Separator System And Method
Patent No. US12173567 (titled "Separator System And Method") was filed by Cp Energy Services Inc on Sep 30, 2022.
What is this patent about?
’567 is related to the field of separation technology, specifically addressing the removal of hazardous materials like gas and sand from well-born fluids during drilling operations. Traditional separators often suffer from long rig-up times, permit requirements, and potential failures due to electronic components, creating inefficiencies and safety concerns in the oil and gas industry.
The underlying idea behind ’567 is to create a self-cleaning, multi-stage separation system that efficiently removes sand and gas from drilling fluids. This is achieved through a combination of vertical circulation, strategically placed baffles, and a series of interconnected recirculation chambers, all powered by a reliable hydraulic system.
The claims of ’567 focus on a separator system featuring a main unit with multiple recirculation chambers, each having angled sides and a suction port for continuous sand circulation to a vertical circulation separator. The claims also cover the method of separating material by receiving it into a hopper, trapping escaped material in the recirculation chambers, and continuously recirculating residual sand from the suction port back to the vertical circulation separator and then to the hopper.
In practice, the material enters a vertical circulation separator where gases are vented and solids are extracted. The remaining fluid and solids are then directed to a hopper, where an auger removes the bulk of the sand. Any sand that escapes the auger is captured by a series of recirculation chambers. These chambers are designed with angled sides and suction ports to continuously recirculate the trapped sand back to the vertical circulation separator, ensuring thorough removal.
A key differentiation from prior approaches lies in the continuous recirculation and the hydraulic-only operation . The recirculation system prevents clogging and ensures that even fine particles are eventually removed. The hydraulic drive eliminates the risk of electrical failures and explosions, while also providing adjustable transfer rates. This combination results in a faster rig-up time, reduced personnel requirements, and a more reliable and safer separation process.
How does this patent fit in bigger picture?
Technical landscape at the time
In the late 2010s when ’567 was filed, well-drilling operations typically involved separating hazardous materials from well-born fluids using multi-stage separation systems. At a time when such systems commonly relied on mechanical separators and gravity settling, hardware or software constraints made continuous circulation and automated material handling non-trivial.
Novelty and Inventive Step
The examiner approved the application because a prior art search did not find any references that disclosed or suggested the claimed separator system. The patentable aspects of the system include a main unit with recirculation chambers arranged to separate materials like water and sand, internal angled sides in the chambers, a suction port for continuous circulation to a vertical circulation separator, internal baffles to force sand down to the suction port, a tank within the main unit, and a hopper to receive material, with the recirculation chambers trapping material escaping the hopper. The examiner also considered the method claims, which involve receiving hazardous material, water, and sand, trapping material escaping the hopper in recirculation chambers with angled sides and a suction port, and continuously recirculating residual sand from the suction port to a vertical circulation separator and then to the hopper, to be patentable over the prior art.
Claims
This patent contains 13 claims, with independent claims 1 and 10. Independent claim 1 is directed to a separator system with recirculation chambers and a vertical circulation separator, while independent claim 10 is directed to a method of separating material using a separator system. The dependent claims elaborate on the features and functionalities of the separator system and method described in the independent claims.
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Date
Description
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US12173567
- Application Number
- US17937083
- Filing Date
- Sep 30, 2022
- Status
- Granted
- Expiry Date
- Feb 7, 2039
- External Links
- Slate, USPTO, Google Patents