Cuttings injection system and method

A modular processing and injection system for the injection of drill cuttings, in an earth formation comprising:

• a) a drill cutting collection and conveying system connected to a drilling rig's solids control shale shaker system;
• b) a slurry system connected to said collecting and conveying system;
• c) a means for producing a cuttings slurry within said slurry system and circulating said slurry throughout said processing and injection system;
• d) a milling means for reducing particle size of said drill cuttings entrained within said slurry;
• e) an injection pump means attached to said processing system, for injecting said drill cuttings slurry into an earth formation;
• f) a drive means for driving said injection pump means;
• g) a speed and torque regulation system connected to said drive means;
• and
• h) a computer means for electrically controlling said speed and torque regulation, processing, and injection systems.

A modular processing and injection system for the injection of drill cuttings, in an earth formation comprising:

• a) a drill cutting collection and conveying system connected to a drilling rig's solids control shale shaker system;
• b) a slurry system connected to said collecting and conveying system;
• c) a means for producing a cuttings slurry within said slurry system and circulating said slurry throughout said processing and injection system;
• d) a milling means for reducing particle size of said drill cuttings entrained within said slurry;
• e) a means of impinging said drill cuttings entrained within said slurry for further reducing said particle size;
• f) an injection pump means attached to said processing system, for reinjecting said drill cuttings slurry into an earth formation;
• g) a drive means for driving said injection pump means;
• h) a speed and torque regulation system connected to said drive means;
• and
• i) a computer means for electrically controlling said speed and torque regulation, processing, and injection systems.

A method of processing and injecting drill cuttings into an earth formation comprising the steps of:

• a) premixing chemical gels in a drill cuttings slurry for controlling yield strength and fluid loss over long periods;
• b) providing an automated means for introducing said gels into said slurry;
• and
• c) programming said automated means to introduce said gels into said slurry at a predetermined rate based on formation requirements when injecting drill cuttings into a well while drilling said well.

An oil and gas well, drill cuttings, processing and injection system comprising:

• a) a conveying means for collecting and delivering cuttings via fluid recovery shale shakers to said processing and injection system;
• b) at least one slurry tank connected to said conveying means;
• c) a means located within said slurry tank for mixing a fluid with said cuttings to produce a slurry;
• d) a means for circulating said slurry;
• e) a system shale shaker fludically connected to said means for circulating said slurry;
• f) a means for grinding cuttings particles entrained in said slurry and discharging said slurry into slurry tank;
• g) a holding tank fluidically connected to said system shale shaker, said means for circulating and said second slurry tank;
• h) a pump means for circulating said slurry from said system shale shaker fludically connected to said holding tank and said second slurry tank;
• i) an injection pump means fludically connected to said first and second slurry tanks and said holding tank for injecting processed cuttings in said slurry into an earth formation;
• j) an electrical drive means for driving said injection pump means;
• k) a means for controlling speed and torque of said electrical drive means;
• and
• l) a fragmentation means comprising a plurality of nozzles attached to an inflow line from said injection pump discharge, said nozzles being further directed towards a metal surface plate located inside said holding tank for fragmenting entrained particles in said slurry.

A method of processing and injecting drill cuttings into an earth formation adjacent a well casing while drilling comprising the steps of:

• a) collecting drill cuttings from shale shakers associated with a drilling mud recovery system;
• b) processing said drill cuttings by passing said cuttings through an injection module comprising;
• i) a conveying means for delivering said drill cuttings to said injection module;
• ii) a first slurry tank connected to said conveying means;
• iii) a second slurry tank connected to said first slurry tank;
• iv) a means located within said first and second slurry tanks for mixing a fluid with said cuttings to produce a slurry;
• v) a means for circulating said slurry between said first and second slurry tanks;
• vi) a system shaker screen connected to said means for circulating said slurry;
• vii) a means for high speed grinding and discharging entrained cuttings into said first and second slurry tanks;
• viii) a holding tank fluidically connected to said shaker screen, said means for circulating and said second slurry tank;
• ix) a means for circulating said slurry from said shaker screen connected to said holding tank and said second slurry tank;
• x) an injection pump means fludically connected to said first and second slurry tanks and said holding tank for injecting said slurry into an earth formation;
• xi) an electrical drive means for driving said injection pump means;
• xii) a means for controlling speed of said electrical drive means;
• and
• xiii) a fragmentation means located inside said holding tank for fragmenting entrained particles in said slurry;
• c) controlling quality of said slurry by fragmenting entrained particles in said slurry;
• d) injecting said drill cuttings into an earth formation;
• e) controlling speed, and torque of said injection pump, electrically;
• and
• f) impinging said entrained particles, at high pressure, against a set of plates.

A method for processing drill cuttings for injection into an earth formation comprising the steps of:

• a) collecting said drill cuttings;
• b) producing a slurry by adding fluid to said drill cuttings;
• c) sizing by milling said drill cutting slurry;
• d) homogenizing by mixing and circulating said slurry until all solid particles are entrained in solution;
• and
• e) fragmenting said entrained solid particles by impinging said solid particles at high pressure, against a surface.

A method of injecting oil and gas well drill cuttings into an earth formation comprising;

• a) providing a drill cuttings injection pump;
• b) providing an electrical means for driving said injection pump;
• and
• c) providing a means for electrically controlling speed and horsepower input to said injection pump;
• and
• d) programming said means for electrically controlling speed and horsepower to compensate for variable conditions encountered while injecting drill cuttings in a well while drilling said well based on real time data input from a well logging system.