# US 8,784,545 B2 · Shale-gas separating and cleanout system

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- Number: US 8,784,545 B2
- Document ID: US8784545B2
- Status: Granted
- Kind: B2
- Application number: 14/049,726
- Filed: 2013-10-09
- Published: 2014-02-06
- Granted: 2014-07-22
- Earliest claimed: 2011-04-12
- Assignees: Mathena, Inc.
- Applicants: Mathena, Inc.
- Inventors: Harold Dean Mathena
- Web page: https://patentgrep.com/patent/US8784545B2

## CPC

- C10G 1/045: {Separation of insoluble materials}
- C10G 1/00: Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal (mechanical winning of oil from oil-shales, oil-sand, or the like B03B)
- E21B 43/35: {specially adapted for separating solids (down-hole drilling fluid separation systems E21B21/002; separating solids from drilling fluids E21B21/065)}
- B01D 45/12: by centrifugal forces (centrifuges B04B; cyclones B04C)
- E21B 21/065: {Separating solids from drilling fluids}
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)

## Abstract

This invention relates to the separation of shale, gas and fluid at a shale-gas well. The shale debris and water from a shale-gas well is tangentially communicated to a vessel where the cyclonic effect within the vessel facilitates the separation of the gas from the shale debris. The separated shale debris and fluid falls to a jet assembly whereby it encounters a jet communicating a fluid therethrough. A venturi provides a motive force to the shale debris and fluid sufficient to propel it into a collection bin. The shale-gas separator incorporates a fluid bypass overflow line to prevent a buildup of fluid within the vessel. The shale-gas separator also incorporates an internal aerated cushion system (IACS) pipe for further motivating the shale debris and into the jet assembly, to ensure the walls of the vessel are clean, and to provide an air cushion restricting gas migration to the jet assembly.

## Claims

### Claim 1

A shale-gas separator, comprising:
a vessel into which a shale-gas-liquid mixture is adapted to be communicated;
a first port adapted to communicate from the vessel a gas;
a second port adapted to communicate from the vessel a shale debris and fluid separated from the shale-gas-liquid mixture; and
a first jet adapted to provide a motive force to the shale debris and fluid separated from the shale-gas-liquid mixture.

### Claim 2 (depends on 1)

The shale-gas separator of claim 1, further comprising a pipe disposed within the vessel, the pipe comprising a longitudinal portion and one or more nozzles positioned therealong.

### Claim 3 (depends on 2)

The shale-gas separator of claim 2, wherein the pipe is an internal aerated cushion system (1ACS) pipe adapted to provide a fluid cushion within the vessel.

### Claim 4 (depends on 3)

The shale-gas separator of claim 3, wherein the vessel comprises:
a top through which the first port is disposed; and
a conically-shaped bottom through which the second port is disposed;
wherein the IACS pipe is centrally disposed in the conically-shaped bottom.

### Claim 5 (depends on 1)

The shale-gas separator of claim 1, further comprising a jet assembly in fluid communication with the second port to receive the shale debris and fluid separated from the shale-gas-liquid mixture;
wherein the first jet extends into the jet assembly and is adapted to jet a fluid into the jet assembly to provide the motive force to the shale debris and fluid separated from the shale-gas-liquid mixture.

### Claim 6 (depends on 5)

The shale-gas separator of claim 5, wherein the jet assembly comprises at least one of a venturi and a cleanout plug.

### Claim 7 (depends on 1)

The shale-gas separator of claim 1, further comprising a flare stack feedline in fluid communication with the first port.

### Claim 8 (depends on 1)

The shale-gas separator of claim 1, further comprising a dust eliminator, the dust eliminator comprising:
a housing, the housing comprising an inlet, an outlet in fluid communication with the vessel, and a sidewall extending between the inlet and the outlet;
a second fluid jet disposed through the sidewall and adapted to propel a fluid into the housing; and
at least one baffle positioned within the housing, wherein the at least one baffle is adapted to deflect the propelled fluid towards the outlet of the housing.

### Claim 9 (depends on 8)

The shale-gas separator of claim 8, wherein the dust eliminator comprises a plurality of baffles positioned within the housing, the at least one baffle being part of the plurality of baffles.

### Claim 10 (depends on 9)

The shale-gas separator of claim 9, wherein each of the baffles is a spiraling baffle.

### Claim 11 (depends on 9)

The shale-gas separator of claim 9, wherein the plurality of baffles comprises at least three baffles, one of which is obliquely positioned near each of the inlet and the second fluid jet, and the others of which are alternately positioned between the second fluid jet and the outlet.

### Claim 12 (depends on 1)

The shale-gas separator of claim 1, further comprising an overflow line disposed in the vessel to communicate away from the vessel any excess fluid buildup within the vessel, the overflow line comprising an intake port.

### Claim 13 (depends on 12)

The shale-gas separator of claim 12, wherein the vessel comprises a top through which the first port is disposed, and a conically-shaped bottom through which the second port is disposed; and
wherein the intake port of the overflow line is oriented towards the conically-shaped bottom.

### Claim 14 (depends on 13)

The shale-gas separator of claim 13, further comprising an intake pipe connected to the vessel and via which the shale-gas-liquid mixture is adapted to be communicated into the vessel;
wherein the intake port of the overflow line is vertically positioned between the second port and the intake pipe.

### Claim 15 (depends on 14)

The shale-gas separator of claim 14, further comprising an internal aerated cushion system (1ACS) pipe adapted to provide a fluid cushion within the vessel, the IACS pipe being centrally disposed within the conically-shaped bottom;
wherein the IACS pipe is vertically positioned between the second port and the intake port of the overflow line and thus the intake port of the overflow line is vertically positioned between the IACS pipe and the intake pipe.

### Claim 16

A shale-gas separator, comprising:
a vessel into which a shale-gas-liquid mixture is adapted to be communicated, the vessel comprising a top and a bottom,
a first port disposed through the top and adapted to communicate from the vessel a gas;
a second port disposed through the bottom and adapted to communicate from the vessel a shale debris and fluid separated from the shale-gas mixture; and
an internal aerated cushion system (IACS) pipe disposed within the vessel and adapted to provide a fluid cushion within the vessel, the IACS pipe extending towards the second port in the bottom, the IACS pipe comprising at least one discharge nozzle.

### Claim 17 (depends on 16)

The shale-gas separator of claim 16, further comprising:
a jet assembly in fluid communication with the second port in the bottom to receive the shale debris and fluid separated from the shale-gas-liquid mixture; and
a first jet extending into the jet assembly and adapted to provide a motive force to the shale debris and fluid separated from the shale-gas-liquid mixture.

### Claim 18 (depends on 17)

The shale-gas separator of claim 17, wherein the jet assembly comprises at least one of a venturi and a cleanout plug.

### Claim 19 (depends on 16)

The shale-gas separator of claim 16, wherein the bottom of the vessel is conically shaped and the IACS pipe is centrally disposed therein.

### Claim 20 (depends on 16)

The shale-gas separator of claim 16, further comprising a flare stack feedline in fluid communication with the first port.

### Claim 21 (depends on 16)

The shale-gas separator of claim 16, further comprising a dust eliminator, the dust eliminator comprising:
a housing, the housing comprising an inlet, an outlet in fluid communication with the vessel, and a sidewall extending between the inlet and the outlet;
a second fluid jet disposed through the sidewall and adapted to propel a fluid into the housing; and
at least one baffle positioned within the housing, wherein the at least one baffle is adapted to deflect the propelled fluid towards the outlet of the housing.

### Claim 22 (depends on 21)

The shale-gas separator of claim 21, wherein the dust eliminator comprises a plurality of baffles positioned within the housing, the at least one baffle being part of the plurality of baffles.

### Claim 23 (depends on 22)

The shale-gas separator of claim 22, wherein each of the baffles is a spiraling baffle.

### Claim 24 (depends on 22)

The shale-gas separator of claim 22, wherein the plurality of baffles comprises at least three baffles, one of which is obliquely positioned near each of the inlet and the second fluid jet, and the others of which are alternately positioned between the second fluid jet and the outlet.

### Claim 25 (depends on 16)

The shale-gas separator of claim 16, further comprising an overflow line disposed in the vessel to communicate away from the vessel any excess fluid buildup within the vessel, the overflow line comprising an intake port oriented towards the bottom of the vessel.

### Claim 26 (depends on 25)

The shale-gas separator of claim 25, further comprising an intake pipe connected to the vessel and via which the shale-gas-liquid mixture is adapted to be communicated into the vessel;
wherein the intake port of the overflow line is vertically positioned between the second port and the intake pipe.

### Claim 27 (depends on 26)

The shale-gas separator of claim 26, wherein the IACS pipe is vertically positioned between the second port and the intake port of the overflow line and thus the intake port of the overflow line is vertically positioned between the IACS pipe and the intake pipe.

### Claim 28

A shale-gas separator, comprising:
a vessel into which a shale-gas-liquid mixture is adapted to be communicated, the vessel comprising a top and a bottom,
an intake pipe connected to the vessel and via which the shale-gas-liquid mixture is adapted to be communicated into the vessel;
a first port disposed through the top and adapted to communicate from the vessel a gas;
a second port disposed through the bottom and adapted to communicate from the vessel a shale debris and fluid separated from the shale-gas mixture;
a flare stack feedline in fluid communication with the first port;
an overflow line disposed in the vessel to communicate away from the vessel any excess fluid buildup within the vessel, the overflow line comprising an intake port oriented towards the bottom of the vessel, the intake port of the overflow line being vertically positioned between the second port and the intake pipe;
an internal aerated cushion system (IACS) pipe disposed within the vessel and adapted to provide a fluid cushion within the vessel, the IACS pipe extending towards the second port in the bottom, the IACS pipe comprising at least one discharge nozzle, the IACS pipe being vertically positioned between the second port and the intake port of the overflow line, the intake port of the overflow line being vertically positioned between the IACS pipe and the intake pipe;
a jet assembly in fluid communication with the second port in the bottom to receive the shale debris and fluid separated from the shale-gas-liquid mixture; and
a jet extending into the jet assembly and adapted to provide a motive force to the shale debris and fluid separated from the shale-gas-liquid mixture.