Classifications

• • E—FIXED CONSTRUCTIONS
  • E21—EARTH OR ROCK DRILLING; MINING
  • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
  • E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
  • E21B21/06—Arrangements for treating drilling fluids outside the borehole
  • E21B21/063—Arrangements for treating drilling fluids outside the borehole by separating components
  • E21B21/065—Separating solids from drilling fluids
  • E21B21/066—Separating solids from drilling fluids with further treatment of the solids, e.g. for disposal
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
  • H05H1/00—Generating plasma; Handling plasma
  • H05H1/24—Generating plasma
  • H05H1/26—Plasma torches
  • H05H1/32—Plasma torches using an arc
  • H05H1/34—Details, e.g. electrodes, nozzles
• • E—FIXED CONSTRUCTIONS
  • E21—EARTH OR ROCK DRILLING; MINING
  • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
  • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
  • E21B43/34—Arrangements for separating materials produced by the well
  • E21B43/35—Arrangements for separating materials produced by the well specially adapted for separating solids
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
  • H05H1/00—Generating plasma; Handling plasma
  • H05H1/24—Generating plasma
  • H05H1/26—Plasma torches
  • H05H1/32—Plasma torches using an arc
  • H05H1/34—Details, e.g. electrodes, nozzles
  • H05H1/3431—Coaxial cylindrical electrodes
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
  • H05H1/00—Generating plasma; Handling plasma
  • H05H1/24—Generating plasma
  • H05H1/26—Plasma torches
  • H05H1/32—Plasma torches using an arc
  • H05H1/42—Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder or liquid
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
  • H05H1/00—Generating plasma; Handling plasma
  • H05H1/24—Generating plasma
  • H05H1/26—Plasma torches
  • H05H1/32—Plasma torches using an arc
  • H05H1/44—Plasma torches using an arc using more than one torch
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
  • H05H1/00—Generating plasma; Handling plasma
  • H05H1/24—Generating plasma
  • H05H1/4697—Generating plasma using glow discharges

Definitions

• the present invention relates generally to field of oil and gas production and, more particularly, to a system, method and apparatus for treating mining byproducts.
• Hydrocarbon production starts with mining. Either surface mining with large cranes and trucks used for oil sands mining or drilling a well to mine the hydrocarbons in a subsurface formation. In either case, byproducts from mining, drilling, completing and/or producing hydrocarbons range from drill cuttings to frack flowback water to produced water and huge volumes of tailings in the case of oil sands surface mining (collectively referred to as "mining byproducts").
• Solvents and/or valuable drilling fluids are used in the mining or drilling process to, among other things, provide hydrostatic pressure, cool and clean the drill bit, carry out drill cuttings (e.g., rock, soil, sand, etc.), and suspend the drill cuttings when the drill is not active.
• the cost of most drilling fluids is directly proportional to the cost of crude oil.
• oil based muds (“OBM”) are predominantly diesel, and synthetic based muds (“SBM”) are synthetic oils similar to Shell Rotella ® .
• formate drilling fluids manufactured by Cabot Corporation are extremely expensive but are environmentally safe, do not contain solids and can be used within high temperature and high pressure formations.
• synthetic based drilling fluids are commonly employed for offshore drilling because the drill cuttings can be discharged overboard as long as the Fluid Retention On Cuttings (“ROC”) is less than what is required by regulations.
• ROC Fluid Retention On Cuttings
• the mixture of mining fluids and mining byproducts that exit the mine or well also contain hydrocarbons.
• This mixture is typically processed by a solids control system (e.g., shale shakers, mud gas separators, desanders, desilters, degassers, cleaners, etc.) to substantially separate the mining fluids and hydrocarbons from the mining byproducts.
• a solids control system e.g., shale shakers, mud gas separators, desanders, desilters, degassers, cleaners, etc.
• Air dryers and friction dryers such as Schlumberger's (M-I Swaco) Hammermill are commonly employed, but neither have been successful at recovering base fluids. Why? Both dryer types comminute the cuttings into very fine powders which makes it difficult to separate the base fluid from the fine cuttings. Likewise, air dryers can produce an explosive mixture since drilling fluids contain fuels (diesel, synthetic oil, etc). Although Schlumberger markets a Zero Discharge thermal desorption TPS system, the system still only achieves a removal of Total Percent Hydrocarbons (TPH) of less than 0.5%. Finally, the U.S. Department Of Energy's Drilling Waste Management Information System discloses many different thermal technologies for treating drilling waste.
• the Canadian oil sands has its own problems ranging from very large tailings ponds to a lack of upgrading capacity for the bitumen recovered from the oil sands.
• the steam assisted gravity drainage (SAGD) process utilizes copious amounts of energy to produce steam. Two problems associated with producing steam are first the source of water and removing its contaminants that may be deposited upon boiler tube walls and second recovering the latent heat within the steam when injected downhole.
• the problem is indirect heat transfer. Heat is transferred via radiation, convection and conduction. Indeed, SAGD evaporators and boilers transfer heat via radiation, convection and conduction. Although the flame in the boiler transfers heat via radiation and convection to boiler tubes, heat transfer through boiler tubes is solely via thermal conduction. And the impediment to reducing production costs at SAGD facilities is heat transfer via thermal conduction through boiler tubes. [0013] When the heat transfer surface of the boiler tubes becomes coated with contaminants, for example silica, then heat transfer is reduced and the boiler and/or evaporator must be shut down for maintenance. At SAGD facilities this is a common problem, especially with silica, and is now being viewed as non-sustainable. The silica is produced with the oil sand. Hence, sand contamination via volatile silica compound evaporation, as well as volatile organic compounds (“VOCs”) is an inherit problem in current EOR operations utilizing traditional water treatment methods with boilers and once through steam generation equipment.
• VOCs volatile organic compounds
• the present invention provides a system, method and apparatus for recovering mining fluids from mining byproducts. Moreover, the present invention can couple the recovery of valuable mining fluids with the production of clean water using a steam plasma. Furthermore, the present invention can melt the mining byproducts, such as sand, clays, cuttings and salts, to produce an inert material. As a result, the present invention may reduce or eliminate the legacy cradle to grave liability for operators. [0016] In addition, one embodiment of the present invention can crack abundantly available natural gas to hydrogen and carbon, and then use the hydrogen as a plasma gas in a counter current fashion for melting cuttings and recovering fluids would allow for ZERO or reduced diesel and/or natural gas engine emissions.
• the hydrogen can be compressed and stored onsite for the completion phase or used during drilling operations to reduce diesel emissions by leaning out the diesel engine using hydrogen.
• the present invention couples oil and gas water treatment with the recovery of valuable resources such as, hydrocarbons, drilling fluids, synthetic gas (“syngas”), hydrogen and clean water. All of which can be accomplished in a closed loop system.
• the present invention provides a system, method and apparatus for upgrading or partial upgrading heavy oil to lighter oil in situ and/or at the wellhead.
• the present invention also provides a system, method and apparatus for recycling all of the water used in oil and gas production in a very effective manner while reducing or eliminating environmental impacts such as air emissions, for example burning of fossil fuels to recover fossil fuels.
• the present invention provides a plasma system that includes an oil/water separator, an input of a pump connected to the oil/water separator, a first three- way valve connected to the input of the pump, a glow discharge cell having a input connected to an output of the pump and a bottom inlet/outlet connected to the first three- way valve, and a plasma arc torch.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a second three-way valve is connected to a top outlet of the glow discharge cell the first tangential inlet/outlet of the plasma arc torch, a compressor is connected between the second three-way valve and the first tangential inlet/outlet of the plasma arc torch.
• a third three-way valve is connected to the second tangential inlet/outlet of the plasma arc torch.
• a fourth three-way valve is connected to the third three-way valve.
• a cyclone separator has a tangential inlet connected to the third three-way valve, an underflow connected to the fourth three-way valve and an overflow connected to the compressor.
• a fifth three-way valve is connected to the fourth three-way valve.
• a pump is connected to the first three-way valve and the fifth three-way valve.
• the present invention provides an electrolysis system that includes an oil/water separator, an input of a pump connected to the oil/water separator, a first three-way valve connected to the input of the pump, and a glow discharge cell having a input connected to an output of the pump, a bottom inlet/outlet connected to the first three-way valve, a top gas outlet connected to a top of a hollow electrode.
• the present invention provides a plasma system that includes an oil/water separator and a plasma arc torch having a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a pump has an input connected to the oil/water separator, and an output connected to the second tangential inlet/outlet of the plasma arc torch.
• a three-way valve is connected to the input
• the present invention provides a plasma system that includes an oil/water separator and a first and second plasma arc torch.
• Each plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a pump has an input connected to the oil/water separator, and an output connected to the second tangential inlet/outlet of the first plasma arc torch.
• a four-way valve is connected to the input of the pump and the hollow electrode nozzle of the first plasma arc torch.
• a compressor is connected between the first tangential inlet/outlet of the first plasma arc torch and the first tangential inlet/outlet of the second plasma arc torch.
• An eductor is connected to the hollow electrode nozzle of the second plasma arc torch and the four-way valve.
• a three-way valve is connected to the second tangential inlet/outlet of the second plasma arc torch and an input to the compressor.
• the present invention provides a plasma system that includes a plasma arc torch having a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a first three- way valve is connected to the hollow electrode nozzle of the plasma arc torch and the first tangential inlet/outlet of the plasma arc torch.
• a second three-way valve is connected the first tangential inlet/outlet of the plasma arc torch.
• a third three-way valve is connected to the second three-way valve.
• a glow discharge cell has a input connected to second tangential inlet/outlet of the plasma arc torch and an output of a hollow electrode connected to the third three-way valve.
• a fourth three-way valve is connected to a gas outlet of the glow discharge cell and the second three-way valve.
• a thermal oxidizer is connected to the first three-way valve, the fourth three-way valve, the third three-way valve and an input of the hollow electrode of the glow discharge cell.
• the present invention provides a plasma system that includes a first and second plasma arc torch.
• Each plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a floatation cell is connected between the second tangential inlet/outlet of the first plasma arc torch and the first tangential inlet/outlet of the second plasma arc torch.
• a three-way valve is connected to a f oats/skim outlet of the flotation cell and the hollow electrode nozzle of the second plasma arc torch.
• a booster pump is connected to the three-way valve.
• a volute inlet valve is connected to the booster pump.
• a graphite electrode plug valve is connected to the hollow electrode nozzle of the first plasma arc torch.
• a pump volute is connected to the graphite electrode plug valve and the volute inlet valve.
• An electrode feeder is connected to the pump volute.
• the present invention provides a plasma system that includes a first and second plasma arc torch.
• Each plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a thickener is connected between the second tangential inlet/outlet of the first plasma arc torch and the first tangential inlet/outlet of the second plasma arc torch.
• a three-way valve is connected to a bottom of the thickener, the hollow electrode nozzle of the first plasma arc torch and the hollow electrode nozzle of the second plasma arc torch.
• the present invention provides a plasma system that includes a pump, a first three-way valve connected to the input of the pump, a glow discharge cell having a input connected to an output of the pump and a bottom inlet/outlet connected to the first three- way valve and a plasma arc torch.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• a second three-way valve is connected to a top outlet of the glow discharge cell the first tangential inlet/outlet of the plasma arc torch.
• a compressor is connected between the second three-way valve and the first tangential inlet/outlet of the plasma arc torch.
• a booster pump is connected to a volute inlet valve.
• a graphite electrode plug valve is connected to the hollow electrode nozzle of the plasma arc torch.
• a pump volute is connected to the graphite electrode plug valve and the volute inlet valve.
• An electrode feeder is connected to the pump volute.
• the present invention provides a plasma treatment system that includes a plasma arc torch and a screw feed unit.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• the screw feed unit has an inlet and an outlet, the outlet aligned with the centerline and proximate to the hollow electrode nozzle.
• the present invention provides a plasma treatment system that includes a plasma arc torch, a screw feeder, a filter screen, a tee and a high temperature vessel.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• the screw feeder has an inlet and an outlet, the outlet aligned with the centerline of the hollow electrode nozzle.
• the filter screen is attached to the outlet of the screw feeder, aligned with the centerline of the hollow electrode nozzle and extending proximate to the hollow electrode nozzle.
• the tee is attached to the outlet of the screw feeder and enclosing a portion of the filter screen proximate to the screw feeder.
• the high temperature vessel is connected to the plasma arc torch and the tee such that the hollow electrode nozzle is attached to or extends into the high temperature vessel and the filter screen extends into the high temperature vessel.
• the present invention provides a method for treating a material using a plasma arc torch and a screw feed unit.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• the screw feed unit has an inlet and an outlet, the outlet aligned with the centerline and proximate to the hollow electrode nozzle.
• a steam is supplied to the first tangential inlet/outlet and an electrical arc is created between the first electrode and the hollow electrode nozzle.
• the material e.g., a mining byproduct containing a mining fluid, etc.
• the material is provided to the inlet of the screw feed unit and the material is treated by moving the material through the outlet of the screw feed unit towards a steam plasma exiting the hollow electrode nozzle using the screw feed unit.
• the treatment produces a fluid (e.g., a recovered mining fluid such as a recovered drilling fluid, etc.) and an inert vitrified slag (e.g., an inert vitrified mining byproduct slag such as an inert vitrified drill cuttings, etc.).
• a fluid e.g., a recovered mining fluid such as a recovered drilling fluid, etc.
• an inert vitrified slag e.g., an inert vitrified mining byproduct slag such as an inert vitrified drill cuttings, etc.
• FIGURE 1 is a diagram of a plasma arc torch in accordance with one embodiment of the present invention
• FIGURE 2 is a cross-sectional view comparing and contrasting a solid oxide cell to a liquid electrolyte cell in accordance with one embodiment of the present invention
• FIGURE 3 is a graph showing an operating curve a glow discharge cell in accordance with one embodiment of the present invention.
• FIGURE 4 is a cross-sectional view of a glow discharge cell in accordance with one embodiment of the present invention.
• FIGURE 5 is a cross-sectional view of a glow discharge cell in accordance with another embodiment of the present invention.
• FIGURE 6 is a cross-sectional view of a Solid Oxide Plasma Arc Torch System in accordance with another embodiment of the present invention.
• FIGURE 7 is a cross-sectional view of a Solid Oxide Plasma Arc Torch System in accordance with another embodiment of the present invention.
• FIGURE 8 is a cross-sectional view of a Solid Oxide Transferred Arc Plasma Torch in accordance with another embodiment of the present invention.
• FIGURE 9 is a cross-sectional view of a Solid Oxide Non-Transferred Arc Plasma
• FIGURE 10 is a table showing the results of the tailings pond water and solids analysis treated with one embodiment of the present invention.
• FIGURE 11 is a cross-sectional view of a Multi-Mode Plasma Arc Torch in accordance with another embodiment of the present invention.
• FIGURE 12 is illustrates a second electrode for use with the Multi-Mode Plasma Arc Torch in accordance with another embodiment of the present invention.
• FIGURES 13A-13F are cross-sectional views of various shapes for the hollow electrode nozzle in accordance with another embodiment of the present invention.
• FIGURE 14 is a cross-sectional view of an anode nozzle flange mounted assembly for the Multi-Mode Plasma Arc Torch in accordance with another embodiment of the present invention.
• FIGURE 15 is a cross-sectional view of dual first electrode configuration in accordance with another embodiment of the present invention.
• FIGURE 16 illustrates a first electrode positions to operate a Multi-Mode Plasma
• FIGURE 17 is a block diagram of a system for operating the Multi-Mode Plasma Arc Torch in five different modes in accordance with another embodiment of the present invention
• FIGURE 18 is a diagram of a Multi-Mode Plasma Arc Torch with various attachment devices in accordance with another embodiment of the present invention.
• FIGURE 19 is a diagram of a Multi-Mode Plasma Arc Torch with various attachment devices in accordance with another embodiment of the present invention.
• FIGURE 20 is a system, method and apparatus for continuously feeding electrodes within a cyclone reactor in accordance with another embodiment of the present invention.
• FIGURE 21 A discloses top injection of microwaves into a cyclone reactor while FIGURE 2 IB discloses side injection of microwaves into the cyclone in accordance with another embodiment of the present invention
• FIGURE 22 discloses a system, method and apparatus for co-injecting microwaves and filter cake directly into the whirling plasma in accordance with another embodiment of the present invention
• FIGURE 23 discloses the co-injected microwaves and filter cake may be fed directly in the plasma which then flows into the cyclone separator and allows for pretreating the filter coke prior to injection into cyclone separator in accordance with another embodiment of the present invention
• FIGURE 24 discloses a system, method and apparatus for injecting the plasma from the Arc Whirl ® Torch 100 directly into the eye of a cyclone separator in accordance with another embodiment of the present invention
• FIGURE 25 discloses feed material such as filter cake or petroleum cake may be injected into the cyclone separator via a tangential entry in accordance with another embodiment of the present invention
• FIGURE 26 discloses a system, method and apparatus for continuous operation of the Plasma ArcWhirl ® torch in accordance with another embodiment of the present invention
• FIGURE 27 discloses a means for adding additional EMR and heat to the gas stream exiting V3 by heating the anode nozzle with an induction coil in accordance with another embodiment of the present invention
• FIGURE 28 discloses two ArcWhirls in series to form a unique system for operating two identical multi-mode plasma torches in different modes in accordance with another embodiment of the present invention
• FIGURE 29 discloses another configuration using two ArcWhirls ® piped in series that can be operated in different modes based upon the application and desired end products in accordance with another embodiment of the present invention
• FIGURE 30 discloses a means for combusting and/or quenching the products produced from the multi-mode Plasma ArcWhirl ® Torch in accordance with another embodiment of the present invention
• FIGURE 31 discloses a means for countercurrent flowing material to be treated via an auger and stinger electrode aligned along the longitudinal axis of the multi-mode ArcWhirl ® Torch in accordance with another embodiment of the present invention
• FIGURE 32A discloses a unique configuration similar to the ArcWhirl ® Torch of FIGURE 1 utilizing the electrode and piston configuration as shown in FIGURE 14 that can be operated as a blowback torch in accordance with another embodiment of the present invention
• FIGURE 32B discloses a system that can be powered with two separate power supplies by replacing the spring with a hydraulic/pneumatic port and electrically isolating the electrode piston from the electrode rod in accordance with another embodiment of the present invention
• FIGURE 33B allows for operation with alternating current ("AC") by electrically connecting the three electrodes, electrode rod, electrode piston and electrode nozzle to LI, L2 and L3 respectively of a three wire power cable to an AC source located on the surface in accordance with another embodiment of the present invention;
• AC alternating current
• FIGURE 35 discloses a liquid resistor using the multi-mode ArcWhirl ® Torch 100 as a resistor within a series circuit in accordance with another embodiment of the present invention
• FIGURE 36 discloses a unique system, method and apparatus for enhanced oil recovery in accordance with another embodiment of the present invention.
• FIGURE 37 discloses a three phase AC Plasma ArcWhirl ® downhole tool that may also be used for downhole steam generation for EOR or for plasma drilling in accordance with another embodiment of the present invention
• FIGURE 38 discloses a novel material treating system that uses Variable Plasma Resistors(VPR) wired in parallel with a large ArcWhirl ® Torch in accordance with another embodiment of the present invention
• FIGURE 39 discloses a system, method and apparatus for retrofitting and converting a carbon arc gouging torch into an ArcWhirl ® Torch in accordance with another embodiment of the present invention
• FIGURE 40 discloses a unique system, method and apparatus for using the Coanda Effect to wrap plasma around a graphite electrode in accordance with another embodiment of the present invention
• FIGURE 41 discloses another system, method and apparatus for using the Coanda
• FIGURE 42 discloses a counter current steam plasma system in accordance with one embodiment of the present invention.
• FIGURE 43 is a block diagram of a closed loop mining waste steam plasma system in accordance with another embodiment of the present invention.
• FIGURE 44 is a block diagram of a closed loop mining waste steam plasma system in accordance with another embodiment of the present invention.
• FIGURES 45-49 are diagrams of various steam plasma treatment systems using various types of screw feeders in accordance with the present invention.
• FIGURE 50 is a flow chart of a method for treating a material in accordance with various embodiments of the present invention.
• FIGURE 51 is a cross-sectional view of a Solid Oxide Glow Discharge Cell and Plasma Arc Torch Enhanced Oil Recovery System in accordance with another embodiment of the present invention.
• FIGURE 52 is a cross-sectional view of a Solid Oxide Glow Discharge Cell Enhanced Oil Recovery System in accordance with another embodiment of the present invention.
• FIGURE 53 is a cross-sectional view of an ArcWhirl ® Glow Discharge Cell Enhanced Oil Recovery System in accordance with another embodiment of the present invention
• FIGURE 54 is a cross-sectional view of an Arc Whirl Glow Discharge Cell and ArcWhirl ® Plasma Torch Enhanced Oil Recovery System in accordance with another embodiment of the present invention
• FIGURE 55 is a cross-sectional view of an ArcWhirl ® Plasma Torch and Solid Oxide Glow Discharge Cell Enhanced Oil Recovery System in accordance with another embodiment of the present invention.
• FIGURE 56 is a cross-sectional view of Dual ArcWhirl ® Plasma Torches and a Flotation Cell System in accordance with another embodiment of the present invention.
• FIGURE 57 is a cross-sectional view of Dual ArcWhirl ® Plasma Torches and a Thickener System in accordance with another embodiment of the present invention.
• FIGURE 58 is a cross-sectional view of a SOGD ArcWhirl ® Upgrader in accordance with another embodiment of the present invention.
• FIGURE 1 a plasma arc torch 100 in accordance with one embodiment of the present invention is shown.
• the plasma arc torch 100 is a modified version of the ARCWHIRL ® device disclosed in U.S. Patent No. 7,422,695 (which is hereby incorporated by reference in its entirety) that produces unexpected results. More specifically, by attaching a discharge volute 102 to the bottom of the vessel 104, closing off the vortex finder, replacing the bottom electrode with a hollow electrode nozzle 106, an electrical arc can be maintained while discharging plasma 108 through the hollow electrode nozzle 106 regardless of how much gas (e.g., air), fluid (e.g., water) or steam 110 is injected into plasma arc torch 100.
• gas e.g., air
• fluid e.g., water
• plasma arc torch 100 includes a cylindrical vessel 104 having a first end 116 and a second end 118.
• a tangential inlet 120 is connected to or proximate to the first end 116 and a tangential outlet 136 (discharge volute) is connected to or proximate to the second end 118.
• An electrode housing 122 is connected to the first end 116 of the cylindrical vessel 104 such that a first electrode 112 is aligned with the longitudinal axis 124 of the cylindrical vessel 104, extends into the cylindrical vessel 104, and can be moved along the longitudinal axis 124.
• a linear actuator 114 is connected to the first electrode 112 to adjust the position of the first electrode 112 within the cylindrical vessel 104 along the longitudinal axis of the cylindrical vessel 124 as indicated by arrows 126.
• the hollow electrode nozzle 106 is connected to the second end 118 of the cylindrical vessel 104 such that the centerline of the hollow electrode nozzle 106 is aligned with the longitudinal axis 124 of the cylindrical vessel 104.
• the shape of the hollow portion 128 of the hollow electrode nozzle 106 can be cylindrical or conical. Moreover, the hollow electrode nozzle 106 can extend to the second end 118 of the cylindrical vessel 104 or extend into the cylindrical vessel 104 as shown. As shown in FIGURE 1, the tangential inlet 120 is volute attached to the first end 116 of the cylindrical vessel 104, the tangential outlet 136 is a volute attached to the second end 118 of the cylindrical vessel 104, the electrode housing 122 is connected to the inlet volute 120, and the hollow electrode nozzle 106 (cylindrical configuration) is connected to the discharge volute 102. Note that the plasma arc torch 100 is not shown to scale.
• a power supply 130 is electrically connected to the plasma arc torch 100 such that the first electrode 112 serves as the cathode and the hollow electrode nozzle 106 serves as the anode.
• the voltage, power and type of the power supply 130 is dependant upon the size, configuration and function of the plasma arc torch 100.
• a gas (e.g., air), fluid (e.g., water) or steam 110 is introduced into the tangential inlet 120 to form a vortex 132 within the cylindrical vessel 104 and exit through the tangential outlet 136 as discharge 134.
• the vortex 132 confines the plasma 108 within in the vessel 104 by the inertia (inertial confinement as opposed to magnetic confinement) caused by the angular momentum of the vortex, whirling, cyclonic or swirling flow of the gas (e.g., air), fluid (e.g., water) or steam 110 around the interior of the cylindrical vessel 104.
• the linear actuator 114 moves the first electrode 112 into contact with the hollow electrode nozzle 106 and then draws the first electrode 112 back to create an electrical arc which forms the plasma 108 that is discharged through the hollow electrode nozzle 106.
• the linear actuator 114 can adjust the position of the first electrode 112 to change the plasma 108 discharge or account for extended use of the first electrode 112.
• an inductively coupled induction coil can be added to the various components of the Steam Plasma Unit as described herein.
• FIGURE 2 a cross-sectional view comparing and contrasting a solid oxide cell 200 to a liquid electrolyte cell 250 in accordance with one embodiment of the present invention is shown.
• An experiment was conducted using the Liquid Electrolyte Cell 250.
• a carbon cathode 202 was connected a linear actuator 204 in order to raise and lower the cathode 202 into a carbon anode crucible 206.
• OCV open circuit voltage
• the 8" diameter anode crucible 206 was filled with sand and the electrolyte was added to the crucible. Power was turned on and the cathode 202 was lowered into the sand and electrolyte. Unexpectedly, a glow discharge was formed immediately, but this time it appeared to spread out laterally from the cathode 202. A large amount of steam was produced such that it could not be seen how far the glow discharge had extended through the sand.
• FIGURE 3 A graph showing an operating curve for a glow discharge cell in accordance with the present invention is shown in FIGURE 3 based on various tests. The data is completely different from what is currently published with respect to glow discharge graphs and curves developed from currently known electro-plasma, plasma electrolysis or glow discharge reactors. Glow discharge cells can evaporate or concentrate liquids while generating steam.
• FIGURE 4 a cross-sectional view of a glow discharge cell 400 in accordance with one embodiment of the present invention is shown.
• the glow discharge cell 400 includes an electrically conductive cylindrical vessel 402 having a first end 404 and a second end 406, and at least one inlet 408 and one outlet 410.
• a hollow electrode 412 is aligned with a longitudinal axis of the cylindrical vessel 402 and extends at least from the first end 404 to the second end 406 of the cylindrical vessel 402.
• the hollow electrode 412 also has an inlet 414 and an outlet 416.
• a first insulator 418 seals the first end 404 of the cylindrical vessel 402 around the hollow electrode 412 and maintains a substantially equidistant gap 420 between the cylindrical vessel 402 and the hollow electrode 412.
• a second insulator 422 seals the second end 406 of the cylindrical vessel 402 around the hollow electrode 412 and maintains the substantially equidistant gap 420 between the cylindrical vessel 402 and the hollow electrode 412.
• a non- conductive granular material 424 is disposed within the gap 420, wherein the non- conductive granular material 424 (a) allows an electrically conductive fluid to flow between the cylindrical vessel 402 and the hollow electrode 412, and (b) prevents electrical arcing between the cylindrical vessel 402 and the hollow electrode 412 during a electric glow discharge.
• the electric glow discharge is created whenever: (a) the glow discharge cell 400 is connected to an electrical power source such that the cylindrical vessel 402 is an anode and the hollow electrode 412 is a cathode, and (b) the electrically conductive fluid is introduced into the gap 420.
• the vessel 402 can be made of stainless steel and the hollow electrode can be made of carbon.
• the non-conductive granular material 424 can be marbles, ceramic beads, molecular sieve media, sand, limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nut shell or wood chips.
• the electrical power supply can operate in a range from 50 to 500 volts DC, or a range of 200 to 400 volts DC.
• the cathode 412 can reach a temperature of at least 500°C, at least 1000°C, or at least 2000°C during the electric glow discharge.
• the electrically conductive fluid comprises water, produced water, wastewater, tailings pond water, or other suitable fluid.
• the electrically conductive fluid can be created by adding an electrolyte, such as baking soda, Nahcolite, lime, sodium chloride, ammonium sulfate, sodium sulfate or carbonic acid, to a fluid.
• FIGURE 5 a cross-sectional view of a glow discharge cell 500 in accordance with another embodiment of the present invention is shown.
• the glow discharge cell 500 includes an electrically conductive cylindrical vessel 402 having a first end 404 and a closed second end 502, an inlet proximate 408 to the first end 404, and an outlet 410 centered in the closed second end 502.
• a hollow electrode 504 is aligned with a longitudinal axis of the cylindrical vessel and extends at least from the first end 404 into the cylindrical vessel 402.
• the hollow electrode 504 has an inlet 414 and an outlet 416.
• a first insulator 418 seals the first end 404 of the cylindrical vessel 402 around the hollow electrode 504 and maintains a substantially equidistant gap 420 between the cylindrical vessel 402 and the hollow electrode 504.
• a non-conductive granular material 424 is disposed within the gap 420, wherein the non-conductive granular material 424 (a) allows an electrically conductive fluid to flow between the cylindrical vessel 402 and the hollow electrode 504, and (b) prevents electrical arcing between the cylindrical vessel 402 and the hollow electrode 504 during a electric glow discharge.
• the electric glow discharge is created whenever: (a) the glow discharge cell 500 is connected to an electrical power source such that the cylindrical vessel 402 is an anode and the hollow electrode 504 is a cathode, and (b) the electrically conductive fluid is introduced into the gap 420.
• FIGURE 6 a cross-sectional view of a Solid Oxide Plasma Arc Torch System 600 in accordance with another embodiment of the present invention is shown.
• a plasma arc torch 100 is connected to the cell 500 via an eductor 602.
• the cell 500 was filled with a baking soda and water solution.
• a pump was connected to the first volute 31 of the plasma arc torch 100 via a 3 -way valve 604 and the eductor 602.
• the eductor 602 pulled a vacuum on the cell 500.
• the plasma exiting from the plasma arc torch 100 dramatically increased in size. Hence, a non-condensable gas B was produced within the cell 500.
• the 3 -way valve 604 was adjusted to allow air and water F to flow into the first volute 31 of plasma arc torch 100.
• the additional mass flow increased the plasma G exiting from the plasma arc torch 100.
• Several pieces of stainless steel round bar were placed at the tip of the plasma G and melted to demonstrate the systems capabilities.
• wood was carbonized by placing it within the plasma stream G. Thereafter the plasma G exiting from the plasma torch 100 was directed into cyclone separator 610.
• the water and gases I exiting from the plasma arc torch 100 via second volute 34 flowed into a hydrocyclone 608 via a valve 606.
• Titanium Ti mg/kg 4
• This method can be used for concentrating black liquor from pulp, paper and fiber mills for subsequent recaustizing.
• FIGURE 7 a cross-sectional view of a Solid Oxide Plasma Arc Torch System 700 in accordance with another embodiment of the present invention is shown.
• a plasma arc torch 100 is connected to the cell 500 via an eductor 602.
• the cell 500 was filled with a baking soda and water solution.
• Pump 23 recirculates the baking soda and water solution from the outlet 416 of the hollow electrode 504 to the inlet 408 of the cell 500.
• a pump 22 was connected to the first volute 31 of the plasma arc torch 100 via a 3 -way valve 604 and the eductor 602.
• An air compressor 21 was used to introduce air into the 3 -way valve 604 along with water F from the pump 22.
• the pump 22 was turned on and water F flowed into the first volute 31 of the plasma arc torch 100 and through a full view site glass 33 and exited the torch 30 via a second volute 34.
• the plasma arc torch 100 was started by pushing a carbon cathode rod (-NEG) 32 to touch and dead short to a positive carbon anode (+POS) 35. A very small plasma G exited out of the anode 35.
• the High Temperature Plasma Electrolysis Reactor (Cell) 500 was started in order to produce a plasma gas B. Once again at the onset of boiling voltage climbed to OCV (370 VDC) and a gas began flowing to the plasma arc torch 100.
• the eductor 602 pulled a vacuum on the cell 500.
• the plasma G exiting from the plasma arc torch 100 dramatically increased in size.
• a non-condensable gas B was produced within the cell 500.
• the color of the arc within the plasma arc torch 100 when viewed through the sightglass 33 changed colors due to the gases produced from the HiTemperTM cell 500.
• the 3 -way valve 604 was adjusted to allow air from compressor 21 and water from pump 22 to flow into the plasma arc torch 100.
• the additional mass flow increased the plasma G exiting from the plasma arc torch 100.
• Several pieces of stainless steel round bar were placed at the tip of the plasma G and melted to demonstrate the systems capabilities.
• wood was carbonized by placing it within the plasma stream G.
• the water and gases exiting from the plasma arc torch 100 via volute 34 flowed into a hydrocyclone 608. This allowed for rapid mixing and scrubbing of gases with the water in order to reduce the discharge of any hazardous contaminants.
• the cyclone separator 610 was removed to conduct another test. To determine the capabilities of the Solid Oxide Plasma Arc Torch System as shown in FIGURE 6, the pump 22 was turned off and the system was operated only on air provided by compressor 21 and gases B produced from the solid oxide cell 500. Next, 3-way valve 606 was slowly closed in order to force all of the gases through the arc to form a large plasma G exiting from the hollow carbon anode 35. [0054] Next, the 3-way valve 604 was slowly closed to shut the flow of air to the plasma arc torch 100. What happened was completely unexpected. The intensity of the light from the sightglass 33 increased dramatically and a brilliant plasma was discharged from the plasma arc torch 100.
• Solid Oxide Plasma Arc Torch System When viewed with a welding shield the arc was blown out of the plasma arc torch 100 and wrapped back around to the anode 35.
• the Solid Oxide Plasma Arc Torch System will produce a gas and a plasma suitable for welding, melting, cutting, spraying and chemical reactions such as pyrolysis, gasification and water gas shift reaction.
• the pond water has a very low pH. It cannot be discharged without neutralization.
• the phosphogypsum contains a slight amount of radon. Thus, it cannot be used or recycled to other industries.
• the excess water in combination with ammonia contamination produced during the production of P 2 O 5 fertilizers such as diammonium phosphate (“DAP”) and monammonium phosphate (“MAP”) must be treated prior to discharge.
• the excess pond water contains about 2% phosphate a valuable commodity.
• a sample of pond water was obtained from a Houston phosphate fertilizer company. The pond water was charged to the solid oxide cell 500.
• the Solid Oxide Plasma Arc Torch System was configured as shown in FIGURE 6.
• the 3 -way valve 606 was adjusted to flow only air into the plasma arc torch 100 while pulling a vacuum on cell 500 via eductor 602.
• the hollow anode 35 was blocked in order to maximize the flow of gases I to hydrocyclone 608 that had a closed bottom with a small collection vessel.
• the hydrocyclone 608 was immersed in a tank in order to cool and recover condensable gases.
• FIGURE 10 Tailings Pond Water Results.
• the goal of the test was to demonstrate that the Solid Oxide Glow Discharge Cell could concentrate up the tailings pond water.
• the percent P 2 O 5 was concentrated up by a factor of 4 for a final concentration of 8.72% in the bottom of the HiTemperTM cell 500.
• the beginning sample as shown in the picture is a colorless, slightly cloudy liquid.
• the bottoms or concentrate recovered from the HiTemper cell 500 was a dark green liquid with sediment. The sediment was filtered and are reported as SOLIDS (Retained on Whatmann #40 filter paper).
• the percent SO 4 recovered as a solid increased from 3.35% to 13.6% for a cycles of concentration of 4.
• the solid oxide or solid electrolyte 424 used in the cell 500 were floral marbles (Sodium Oxide). Floral marbles are made of sodium glass. Not being bound by theory it is believed that the marbles were partially dissolved by the phosphoric acid in combination with the high temperature glow discharge. Chromate and Molydemun cycled up and remained in solution due to forming a sacrificial anode from the stainless steel vessel 402. Note: Due to the short height of the cell carryover occurred due to pulling a vacuum on the cell 500 with eductor 602. In the first run (row 1 HiTemper) of FIGURE 10 very little fluorine went overhead. That had been a concern from the beginning that fluorine would go over head. Likewise about 38% of the ammonia went overhead. It was believed that all of the ammonia would flash and go overhead.
• a method has been disclosed for concentrating P2O5 from tailings pond for subsequent recovery as a valuable commodity acid and fertilizer.
• the black liquor can be recaustisized by simply using CaO or limestone as the solid oxide electrolyte 424 within the cell 500.
• the marbles 424 can be treated with the plasma arc torch 100. Referring back to FIGURE 6, the marbles 424 coated with the concentrated black liquor or the concentrated black liquor only is injected between the plasma arc torch 100 and the cyclone separator 610. This will convert the black liquor into a green liquor or maybe a white liquor.
• the marbles 424 may be flowed into the plasma arc torch nozzle 31 and quenched in the whirling lime water and discharged via volute 34 into hydrocyclone 608 for separation and recovery of both white liquor and the marbles 424.
• the lime will react with the NaO to form caustic and an insoluble calcium carbonate precipitate.
• FIGURE 4 several oilfield wastewaters were evaporated in the cell 400.
• a vapor compressor (not shown) can be connected to upper outlet 410.
• the discharge of the vapor compressor would be connected to 416.
• alloys such as Kanthal® manufactured by the Kanthal corporation may survive the intense effects of the cell as a tubular cathode 412, thus allowing for a novel steam generator with a superheater by flowing the discharge of the vapor compressor through the tubular cathode 412.
• Such an apparatus, method and process would be widely used throughout the upstream oil and gas industry in order to treat oilfield produced water and frac flowback.
• EXAMPLE 5 TREATING TUBES, BARS, RODS, PIPE OR WIRE.
• EXAMPLE 6 - SOLID OXIDE PLASMA ARC TORCH [0070]
• a plasma torch system that could operate on the aforementioned waters could potentially dramatically affect the wastewater infrastructure and future costs of maintaining collection systems, lift stations and wastewater treatment facilities.
• metals industry requires a tremendous amount of energy and exotic gases for heating, melting, welding, cutting and machining.
• the Solid Oxide Plasma Torch is constructed by coupling the plasma arc torch 100 to the cell 500.
• the plasma arc torch volute 31 and electrode 32 are detached from the eductor 602 and sightglass 33.
• the plasma arc torch volute 31 and electrode assembly 32 are attached to the cell 500 vessel 402.
• the sightglass 33 is replaced with a concentric type reducer 33. It is understood that the electrode 32 is electrically isolated from the volute 31 and vessel 402.
• the electrode 32 is connected to a linear actuator (not shown) in order to strike the arc.
• PS2's -negative lead would be attached to the lead of switch 60 that goes to the electrode 32.
• a series of switches are not shown for this operation, it will be understood that in lieu of manually switching the negative lead from PS2 an electrical switch similar to 60 could be used for automation purposes.
• the +positive lead would simply go to the workpiece as shown.
• a smaller electrode 32 would be used such that it could slide into and through the hollow cathode 504 in order to touch the workpiece and strike an arc.
• the electrically conductive nozzle 802 would be replaced with a non-conducting shield nozzle. This setup allows for precision cutting using just wastewater and no other gases.
• the Solid Oxide Non-Transferred Arc Plasma Torch 800 is used primarily for melting, gasifying and heating materials while using a contaminated fluid as the plasma gas.
• Switch 60 is adjusted such that PS2 +lead feeds electrode 32.
• electrode 32 is now operated as the anode. It must be electrically isolated from vessel 402.
• gas begins to flow by opening valve 16 the volute 31 imparts a spin or whirl flow to the gas.
• the anode 32 is lowered to touch the centered cathode 504.
• An arc is formed between the cathode 32 and anode 504.
• the anode may be hollow and a wire may be fed through the anode 504 for plasma spraying, welding or initiating the arc.
• the entire torch is regeneratively cooled with its own gases thus enhancing efficiency.
• a waste fluid is used as the plasma gas which reduces disposal and treatment costs.
• the plasma may be used for gasifying coal, biomass or producing copious amounts of syngas by steam reforming natural gas with the hydrogen and steam plasma.
• FIGURE 8 and 9 have clearly demonstrated a novel Solid Oxide Plasma Arc Torch that couples the efficiencies of high temperature electrolysis with the capabilities of both transferred and non-transferred arc plasma torches.
• the multi-mode plasma arc torch 1100 is a plasma arc torch 100 of FIGURE 1 that is modified to include some of the attributes of the glow discharge cell 500 of FIGURE 5.
• the multi-mode plasma arc torch 1100 includes a cylindrical vessel 104 having a first end 116 and a second end 118.
• a tangential inlet 120 is connected to or proximate to the second end 118 and a tangential outlet 136 is connected to or proximate to the first end 116.
• An electrode housing 122 is connected to the first end 116 of the cylindrical vessel 104 such that a first electrode 112 is aligned with the longitudinal axis 124 of the cylindrical vessel 104, extends into the cylindrical vessel 104, and can be moved along the longitudinal axis 124.
• a linear actuator 114 is connected to the first electrode 112 to adjust the position of the first electrode 112 within the cylindrical vessel 104 along the longitudinal axis of the cylindrical vessel 124 as indicated by arrows 126.
• the hollow electrode nozzle 106 is connected to the second end 118 of the cylindrical vessel 104 such that the centerline of the hollow electrode nozzle 106 is aligned with the longitudinal axis 124 of the cylindrical vessel 104.
• the tangential inlet 120 is volute attached to the second end 118 of the cylindrical vessel 104
• the tangential outlet 136 is a volute attached to the first end 116 of the cylindrical vessel 104
• the electrode housing 122 is connected to the outlet volute 102
• the hollow electrode nozzle 106 (cylindrical configuration) is connected to the inlet volute 120.
• the multi-mode plasma arc torch 1100 is not shown to scale.
• a substantially equidistant gap 420 is maintained between the cylindrical vessel 402 and the hollow electrode nozzle 106.
• a non-conductive granular material 424 is disposed within the gap 420, wherein an optional non-conductive granular material 424 allows an electrically conductive fluid to flow between the cylindrical vessel 402 and the hollow electrode nozzle 106.
• the non-conductive granular material 424 is not used. Note that using the non-conductive granular material 424 improves the efficiency of the device by increasing the contact surface area for the fluid, but is not required.
• the non-conductive granular material 424 can prevent electrical arcing between the cylindrical vessel 402 and the hollow electrode nozzle 106 during a electric glow discharge.
• the shape of the hollow portion 128 of the hollow electrode nozzle 106 can be varied as needed to provide the desired operational results as shown in FIGURES 13A-F and 16. Other shapes can be used.
• a power supply 130 is electrically connected to the multi-mode plasma arc torch 1100 such that the first electrode 112 serves as the cathode and the hollow electrode nozzle 106 serves as the anode.
• the voltage, power and type of the power supply 130 are dependent upon the size, configuration and function of the multi-mode plasma arc torch 1100.
• a second electrode 1102 and second linear actuator 1110 can be added as an (+) anode, such as a graphite electrode, along the longitudinal axis 124 to dead short to the first electrode 112 (-) cathode.
• This configuration allows for continuous feed of electrodes 112 and 1102 for continuous duty operation and/or to increase the life of the anode nozzle 106.
• the second electrode 1102 can be moved in either direction along the longitudinal axis 124 using the second linear actuator 1110 as shown by arrow 126b.
• the second electrode 1102 allows for operating in a plasma arc mode by dead shorting the first electrode 112 and the second electrode 1102 together and then separating them to draw the arc.
• FIGURE 13A shows a straight hollow electrode nozzle 106a.
• FIGURE 13B shows a straight hollow electrode nozzle flange 106b.
• FIGURE 13C shows a tapered hollow electrode nozzle 106c.
• FIGURE 13D shows a tapered hollow electrode nozzle flange 106d.
• FIGURE 13E shows a hollow electrode nozzle counterbore flange 106e.
• FIGURE 13F shows a hollow electrode nozzle counterbore exterior tapered flange 106f.
• FIGURE 12 shows a hollow electrode nozzle counterbore 106.
• Other shapes can be used as will be appreciated by those skilled in the art.
• FIGURE 14 shows a method for securing the (+) hollow electrode nozzle 106 to the volute of plasma arc torch 100 or 1100 using flanges 1402a, 1402b as a coupling means. It will be understood that any type of coupler that will hold and secure the (+) hollow electrode nozzle 106 will suffice for use in the present invention. Likewise, using couplers or flanges on both sides of the (+) hollow electrode nozzle 106 allows for it to be flipped and used as a protruding or reducer type coupling nozzle.
• FIGURE 15 a diagram of a dual first electrode 1500 in accordance with another embodiment of the present invention is shown.
• the dual first electrode 1500 is a combination of the first electrode 112 and a larger diameter, but shorter, third electrode 1502 that is either electrically connected to the first electrode 112 or the power supply 130 (same polarity as the first electrode 112).
• the third electrode 1502 can be moved up and down independently from the first electrode 112 as indicated by arrows 126c.
• the third electrode 1502 can be physically connected to the first electrode 112.
• the third electrode 1502 provides additional electrode surface area to enhance the process.
• a fluid, slurry, liquid/gas mixture or other pumpable material 1104 is introduced into the tangential inlet 120 to a desired fluid level 1106, which can vary based on the desired operational results, within the cylindrical vessel 104. Note that the actual level will typically fluctuate during operation.
• the linear actuator 114 moves the first electrode 112 into contact with the hollow electrode nozzle 106 or the second electrode 1102 and then either leaves the first electrode 112 there (dead short resistive heating mode 1600) or draws the first electrode 112 back a specified distance yet remains below the desired fluid level 1106.
• the linear actuator 114 can adjust the position of the first electrode 112 to operate the multi-mode plasma arc torch 1100 in a dead short resistive mode 1600, a submerged arc mode 1602, an electrolysis mode 1604 or a glow discharge mode 1606.
• gases or steam 1108 will rise and exit through tangential outlet 136.
• the fluid 1104 can be recirculated by allowing the fluid 1104 to flow through the hollow electrode nozzle 106 and reenter the cylindrical vessel 104 via tangential inlet 120.
• the fifth operating mode is the plasma arc mode as described and shown in FIGURE 1.
• FIGURE 17 a diagram of a system 1700 to operate the plasma arc torch 100 or 1100 in five operating modes in accordance with the present invention is show.
• the system 1700 includes a plasma arc torch 100 or 1100, 3 three- way valves 1702a, 1702b, 1702c and a pump and/or compressor 1704.
• the first three- way valve 1702a is connected to the inlet/outlet (depends on the operating mode) located at the first end 116 of the plasma arc torch 100 or 1100, and has a first valve inlet/outlet (depends on the operating mode) 1708a.
• the second three-way valve 1702b is connected to the inlet/outlet (depends on the operating mode) located at the second end 118 of the plasma arc torch 100 or 1100, and has a second valve inlet/outlet (depends on the operating mode) 1708b.
• the third three-way valve 1702c is connected to the exterior end of the hollow electrode nozzle 106, and has a third valve inlet/outlet (depends on the operating mode) 1708c.
• Each of the three-way valves 1702a, 1702b, 1702c are connected to the discharge 1706 of the pump and/or compressor 1704.
• the fluid, slurry, liquid/gas mixture or other pumpable/compressable material 1104 enters the suction 1710 of the pump and/or compressor 1704.
• the three-way valves 1702 are adjusted to operate the plasma arc torch 100 or 1100 in the five modes, while adjusting the first electrode 112 with the linear actuator 114.
• Operating Mode 1 Plasma Arc a. Compressed and/or pressurized fluid 1104 from a pump/compressor 1704 is fiowed into three-way valve 1702a and then into plasma arc torch 100 or 1100.
• Three-way valve 1702b is fully open to allow fluid to flow out of plasma arc torch 100 or 1100 and to outlet 1708b.
• Three-way valve 1702c is fully open to flow to outlet 1708c.
• Very small plasma may be discharged through outlet 1708c.
• Three-way valve 1702b may be throttled to increase/decrease plasma flow through (+) hollow electrode nozzle 106 and outlet 1708c.
• Three-way valve 1702b may be shut to flow all fluid into (+) hollow electrode nozzle 106 and outlet 1708c.
• Compressed and/or pressurized fluid 1104 from a pump/compressor 1704 is fiowed into three-way valve 1702b and then into plasma arc torch 100 or 1100
• Three-way valve 1702a is fully open to flow out of plasma arc torch 100 or 1100 and to outlet 1708a.
• Three-way valve 1702b is throttled to allow fluid to flow into plasma arc torch 100 or 1100 very slowly.
• Three-way valve 1702c is shut.
• Power supply 130 is turned ON.
• Resistive mode begins.
• Valves remain aligned as in Operating Mode 2 above.
• the (-) first electrode 112 is slowly within drawn from (+) hollow electrode nozzle 106.
• Three-way valve 1702c may be opened to allow pressurized fluid from pump/compressor 1704 to flow through (+) hollow electrode nozzle 106 and into plasma arc torch 100 or 1100.
• Valves remain aligned as in Operating Mode 2 above.
• the (-) first electrode 112 is slowly within drawn further from (+) hollow electrode nozzle 106 using linear actuator 114.
• Valves remain aligned as in Operating Mode 2 above.
• the (-) first electrode 112 is slowly within drawn further from (+) hollow electrode nozzle 106 using linear actuator 114.
• Three-way valve 1702b and three-way valve 1702c may be adjusted to allow pressurized flow to enter plasma arc torch 100 or 1100 either through three-way valve 1702b or three-way valve 1702c, and/or three- way valve 1702b and three-way valve 1702c aligned for fluid flow recirculation using pump/compressor 1704.
• Vapors exit from plasma arc torch 100 or 1100 and out of outlet 1708a.
• the plasma arc torch 100 or 1100 can be adapted for use in many applications by attaching various devices 1802 to the exterior of the hollow electrode nozzle 106 or the three-way valve 1702c.
• a partial list of attachments 1802 include a cyclone separator 1802a (inlet, vortex collector, overflow or underflow), volute 1802b, pump/compressor 1802c, filter screen 1802d, ejector/eductor 1802e, cross 1802f, screw feeder 1802g, valve 1802h, tee 1802i, electrode & linear actuator 1802j, wave guide 1802k or RF coil 18021 that may be attached alone or in any combination thereof to the (+) anode nozzle 106.
• Other devices 1802 may include, but is not limited to a vessel, flange, cover, hatch, electrode stinger, injector, screw press, auger, ram feeder, mixer, extruder, T-fired boiler, coker drum, gasifier, pipe, conduit, tubing, submerged melting furnace, rotary kiln, rocket nozzle, thermal oxidizer, cyclone combustor, precombustion chamber, ice screw-in cylinder, turbine combustor, pulse detonation engine, combustion exhaust pipe/stack, thermal oxidizer, flare, water tank, raw sewage pipe, wastewater influent/effluent piping/conduit, anaerobic digester influent/effluent piping, sludge press/centrifuge inlet/outlet piping, potable water piping point of use or point of entry, water storage tank, CNC cutting/welding table, direct contact water heater, wet gas chlorine line/pipe, O&G wellhead, O&G produced water piping, ship ballast water line, engine
• FIGURE 19 demonstrates how some of the devices 1802 may be connected to the plasma arc torch 100.
• System 1900 is a plasma arc torch 100 or 1100 having a cyclone separator 1802a attached to the exterior of the hollow anode nozzle 106 and a volute 1802b attached to the cyclone separator 1802a.
• System 1902 is a plasma arc torch 100 or 1100 having a filter screen 1802d attached to the exterior of the hollow anode nozzle 106.
• System 1904 is a plasma arc torch 100 or 1100 having an ejector/eductor 1802e attached to the exterior of the hollow anode nozzle 106.
• System 1906 is a plasma arc torch 100 or 1100 having a tee 1802i attached to the exterior of the hollow anode nozzle 106 and a screw feeder 1802g attached to the tee 1802L
• System 1908 is a plasma arc torch 100 or 1100 having a tee 1802i attached to the exterior of the hollow anode nozzle 106, and an auger 1914 and a cyclone separator 1802a attached to the tee 1802L
• System 1910 is a plasma arc torch 100 or 1100 having a tee 1802i attached to the exterior of the hollow anode nozzle 106 and an anode electrode with linear actuator 1802j attached to the tee 1802L
• the anode electrode 1102 with linear actuator 1802j in combination with the anode nozzle 106 form a stopper valve that allows the flow in/out of the (+) anode nozzle to be controlled.
• FIGURE 17 three-way valves 1702a and 11702b were connected to the tangential inlet 118 and tangential outlet 136 of the plasma arc torch 100 disclosed in FIGURE 1.
• the plasma 108 of FIGURE 1 was discharged from the plasma arc torch 100 and was measured with an optical pyrometer. With the gases produced from the cell 500 as shown in FIGURES 6 and 7, the plasma 108 temperature was measured at +3,000°C (+5,400°F). With only air, the plasma 108 was measured at +2,100°C (+3,800°F).
• the system was operated with a ceramic tee 1802i attached to the plasma arc torch 100.
• a filter screen 1802d was attached to the plasma arc torch 100. Wood pellets produced with a pelletizer were placed in the filter screen 1802d prior to attaching to the plasma arc torch 100. The steam plasma fully carbonized the wood pellets.
• the plasma arc torch 100 with an attached filter screen 1802d is particularly useful for remote and/or stand alone water treatment and black water (raw sewage) applications.
• the plasma arc torch 100 or 1100 is started by dead- shorting the cathode 112 to the anode nozzle 106 with power supply 130 in the off position.
• the vessel 104 is partially filled by jogging the pump 1704.
• the power supply 130 is turned on allowing the system to operate in a resistive heating mode.
• the benefit to this system is preventing the formation of gases such as chlorine if sodium chloride is present within the water and/or wastewater.
• the fluid, water and/or wastewater is heat treated which is commonly referred to as pasteurization.
• the cathode 112 is simply withdrawn from the anode nozzle 106.
• a submerged arc will be formed instantly. This will produce non-condensible gases such as hydrogen and oxygen by splitting water.
• non-condensible gases such as hydrogen and oxygen by splitting water.
• gases such as but not limited to methane, butane, propane, air, oxygen, nitrogen, argon, hydrogen, carbon dioxide, argon, biogas and/or ozone or any combination thereof can be added between the pump and inlet 1702a or 1702b with an injector (not shown).
• hydrogen peroxide will convert to oxygen and water when irradiated with UV light.
• the plasma arc torch 100 or 1100 will convert hydrogen peroxide to free radicals and oxygen for operation as an advanced oxidation system.
• the present invention's submerged arc mode is ideally suited for submerged combustion. It is well known that submerged combustion is very efficient for heating fluids. Likewise, it is well known and understood that gases and condensates are produced along with heavy oil from oil and gas wells. In addition, the oil sands froth flotation process produces tailings and wastewater with residual solvent and bitumen. The remaining fossil fuels left in produced water and/or froth flotation processes can be advantageously used in the present invention. Since the plasma arc torch 100 or 1100 is a cyclone separator then the lighter hydrocarbons will report to the plasma center.
• a second electrode 1102 can be added to the plasma arc torch 100 or 1100 as shown in system 1910 (FIGURE 19).
• Air and/or an air/fuel mixture can be flowed into the tee 1802i and converted into a rotating plasma arc flame.
• the fluid to be heated will enter into one volute while exiting the other volute in combination with hot combusted gases.
• the air/fuel may be added to the fluid entering into the plasma arc torch 100 or 1100.
• Three-way valve 1702b would be shut.
• a volute 1802b or cyclone separator 1802a may be used in lieu of the tee 1802L If a cyclone separator 1802a is used, then the plasma arc torch 100 or 1100 can be operated as a torch while shooting a plasma into the vortex of the whirlpool of water within the cyclone separator 1802a.
• the benefit of the second (+) electrode 1102 is to ensure that the arc remains centered and is not blown out.
• the discharge from the tee 1802i, volute 1802b or cyclone separator 1802a would be flowed into a tank (not shown) or stand pipe thus allowing complete mixture and transfer of heat from the non-condensible gas bubbles to the water/fluid.
• the electrode 112 In order to transition to an electrolysis mode the electrode 112 is withdrawn a predetermined distance from the anode nozzle 106 or anode electrode 1102. This distance is easily determined by recording the amps and volts of the power supply as shown by the GRAPH in FIGURE 3.
• the liquid level 1106 is held constant by flowing liquid into the plasma arc torch 100 or 1100 by jogging the pump 1704 or using a variable speed drive pump to maintain a constant liquid level.
• a grounding clamp can be secured to the vessel 104 in order to maintain an equidistant gap 420 between the vessel 104 and cathode 112, provided the vessel is constructed of an electrically conducted material.
• the equidistant gap 420 can be maintained between the anode nozzle 106 and cathode 112 and electrically isolating the vessel 104 for safety purposes. Glass and/or ceramic lined vessels and piping are common throughout many industries.
• the submerged plasma arc combustor 1910 would be configured as shown in FIGURE 19 with a tee 1802i and electrode 1802j and an air ejector would siphon the hydrogen generated from the plasma arc torch 100 or 1100.
• Another benefit for using the plasma arc torch 100 or 1100 in a combustion mode is that the Ultraviolet ("UV") Light produced from the plasma arc and the electrodes will dechlorinate the water thus eliminating adding a reducing agent to the water.
• UV Ultraviolet
• a simple but effective raw sewage system can be constructed by attaching the plasma arc torch 100 or 1100 to a common filter vessel in which the filter screen would be coupled directly to the plasma arc torch 100 or 1100.
• the plasma arc torch 100 or 1100 is coupled to the filter screen 1802d in system 1902.
• the filter screen 1802d is then inserted into a common filter vessel up to the filter screen 1802d flange.
• the plasma arc torch 100 or 1100 is operated in an electrolysis mode allowing the raw sewage to flow through the anode nozzle and into the filter screen. Solids would be trapped in the filter screen.
• the filter screen can be cleaned by several methods. First the screen can simply be backwashed.
• the screen can be cleaned by simply placing the plasma arc torch 100 or 1100 in a plasma arc mode and either steam reforming the solids or incinerating the solids using an air plasma.
• a third mode can be used which allows for a combination of back washing and glow discharge.
• the liquid level 1106 is decreased by throttling three-way valve 1702b until the plasma arc torch 100 or 1100 goes into glow discharge. This is easily determined by watching volts and amps. When in glow discharge the power supply voltage will be at or near open circuit voltage. However, to rapidly transition from electrolysis to glow discharge the cathode electrode is extracted until the power supply is at OCV. This can be determined by viewing the glow discharge thru a sight glass or watching the voltage meter.
• This novel feature also allows for fail safe operation. If the pump 1704 is turned off or fluid flow is stopped then all of the water will be blown down through the anode nozzle 106 of the plasma arc torch 100 or 1100. Electrical flow will stop and thus the system will not produce any gases such as hydrogen.
• variable speed drive pump in combination with three-way valve 1702c may be used to control the liquid level to maintain and operate in a glow discharge mode.
• Another fail safe feature such as a spring, can be added to the linear actuator such that the system fails with the cathode fully withdrawn.
• the mode of operation can be reversed from glow discharge to electrolysis to arc and then to resistive heating.
• the plasma arc torch 100 or 1100 will immediately go into glow discharge mode. Continually lowering the cathode 112 will shift the system to electrolysis then to arc then to resistive heating.
• water/liquid flow may be reversed and blowdown three-way valve 1702c is fully opened to allow the plasma to discharge from the plasma arc torch 100 or 1100.
• Adding an anode electrode 1102 will aid in maintaining an arc.
• the water/liquid can be flowed through the plasma arc torch 100 or 1100 in a plasma arc mode.
• outlet 136 is used as the inlet and inlet 120 is used as the outlet.
• This configuration will work for any fluid whether it is more dense or less dense than water and/or the liquid flowing through the system. If the material density is greater than the liquid the granular material will flow through 120. If the material is less dense then the liquid then it will flow through the nozzle.
• remote applications that are in dire need of a solution are potable water treatment and black water (raw sewage) treatment.
• remote water and wastewater applications can be found on offshore drilling rigs, offshore production platforms, ships, cabins, base camps, military posts/camps, small villages in desert and/or arid environments and many developing countries that do not have centralized water and wastewater treatment facilities.
• Another remote application is electricity produced from wind and solar farms.
• oil and gas wells that are not placed in production such as stranded gas can be considered a remote application.
• a natural disaster such as a hurricane or tsunami basic services such as garbage/trash collection
• water treatment and wastewater treatment facilities may be destroyed, thus there is a dire need for water disinfection as well as raw sewage treatment in addition to handling the buildup of trash.
• the inventor of the present invention has tested this configuration with an ESAB EPW 360 power supply.
• the EPW 360 is a "Chopper" type DC power supply operating at a frequency of 18,000 Hertz.
• the above described configuration held voltage at an extremely steady state.
• the discharge 134 was throttled with a valve. Whether the valve was open, shut or throttled the voltage remained rock steady.
• the EPW 360 current control potentiometer was turned down to less than 30 amps and the electrodes were positioned to hold 80 volts. This equates to a power rating of about 2,400 watts.
• the plasma arc torch 100 of the present invention clearly demonstrated a turn down rate of 54 without any additional electronic controls, such as a secondary high frequency power supply. That is virtually unheard of within the plasma torch world.
• Pyrogensis markets a 25 kw torch operated in the range of 8- 25kW (A 3: 1 turn down ratio).
• the present invention's plasma arc torch 100 does not require any cooling water.
• the Pyrogensis torch requires cooling with deionized water.
• Deionized (“DI”) water is used because the DI water is flowed first into one electrode then into the shield or another part of the torch. Consequently, DI water is used to avoid conducting electricity from the cathode to the anode via the cooling media.
• heat rejection is another impediment for using an indirectly cooled plasma torch.
• An indirectly cooled plasma torch may reject upwards of 30% of the total input power into the cooling fluid.
• the plasma arc torch 100 as disclosed in FIGURES 1, 6, 7 is a liquid/gas separator and extreme steam superheater forming an ionized steam/hydrogen plasma when coupled to the glow discharge cell 500 and/or any steam source.
• the plasma arc torch 100 can easily be controlled by manipulating valves 604 and 606.
• the plasma arc torch 100 as shown in FIGURE 1 is similar to a blow-back torch.
• the (-) negative electrode 112 will dead short and shut flow through the (+) anode nozzle 106 by adjusting the linear actuator 114.
• control valve 604 to the discharge 134, this allows for the plasma arc torch 100 to be operated in a resistive heating mode.
• Electrode Feeder A feeds in-line and countercurrent to the first electrode along the longitudinal axis of Arc Whirl ® 100.
• electrodes may be fed perpendicular to one another as shown by Electrode Feeder B.
• Electrode Feeder B It will be understood that only one multi-mode torch 100 may be necessary for processing feed material which has been pretreated such as quenched filter cake from a heavy oil, bitumen or petroleum coke gasifier. Likewise, petroleum coke from a delayed coker can easily be plasma steam reformed with the system, method and apparatus of the present invention.
• a preferred method for pretreating high moisture filter cake from an oil sands gasifier is with Electromagnetic Radiation (EMR).
• EMR Electromagnetic Radiation
• the preferred EMR is within the Radio Frequency spectrum and more specifically within the microwave range.
• the ideal frequencies range from 915 MHz to 2.45 GHz.
• FIGURE 22 An ideal reactor for enhancing plasma and/or coupling to plasma and material to be treated is disclosed in FIGURE 22.
• FIGURE 21 A discloses top injection of microwaves into a cyclone reactor while FIGURE 21B discloses side injection of microwaves into the cyclone.
• FIGURE 20 discloses a multi-entry or multi-exit cyclone that incorporates 4 inlets/outlets to stabilize the rotating WHIRL of fluid.
• FIGURES 21A and 21B an ideal whirl generator, commonly referred to as a vortex generator or cyclone separator, is disclosed in FIGURES 21A and 21B.
• the multiple inlets/outlets allow for stabilizing the whirl without forming a pressure gradient typical on single entry cyclones.
• many cyclones utilize an involute for enhancing separation of matter.
• the involute feed housing is prone to erosion at the wall fluid curve interface.
• the present invention uses the velocity of fluid jets impinging on one another to prevent wall erosion while also eliminating a pressure gradient.
• a single entry cyclone separator produces a pressure gradient with a whipping tail of less dense fluid exiting and whipping 180 out from the inlet of the cyclone separator.
• the pressure gradient may not affect the operation of the cyclone.
• the arc may be extinguished or in a worse case scenario the arc may be pushed away from the anode nozzle and transferred to the wall or vessel. This could result in melting the reactor vessel.
• a ceramic electrical insulator is used as shown in FIGURES 20 and 21.
• the plasma injected into the cyclone can be enhanced and coupled to with RF energy.
• the ceramic be permeable or transparent to EMR within microwave frequency range from 915 Mhz to 2450 Mhz (2.45 GHz). It will be understood that the microwaves may be injected directly into the eye of the whirling fluid or through the side of the ceramic that is transparent to microwaves.
• the shell of the vessel should be made of microwave blocking or opaque material.
• FIGURE 22 discloses a system, method and apparatus for co-injecting microwaves and filter cake directly into the whirling plasma.
• the microwaves will pretreat the material prior to entering into the eye of the whirling fluid.
• a waveguide directs the microwaves perpendicular to the travel of the filter cake.
• a screw feeder pushes the material directly into the eye of the plasma.
• the co-injected microwaves and filter cake may be fed directly in the plasma which then flows into the cyclone separator and allows for pretreating the filter coke prior to injection into cyclone separator 100.
• FIGURE 24 discloses a system, method and apparatus for injecting the plasma from the Arc Whirl ® Torch 100 directly into the eye of a cyclone separator.
• Feed material such as filter cake
• a quench fluid may be used for quenching the reaction between plasma and the feed material.
• feed material such as filter cake or petroleum cake may be injected into the cyclone separator via a tangential entry.
• feed material may be pretreated with microwaves prior to injection into the plasma.
• FIGURE 26 discloses a system, method and apparatus for continuous operation of the Plasma Arc Whirl ® torch. By installing a second anode electrode and linear actuator the arc can be transferred from the first electrode of 100 to anode nozzle and then to the anode electrode. This allows for an extremely high turn down rate.
• FIGURE 1 and FIGURE 11 were electrically connected to an ESAB ESP150 plasma arc power supply ("PS").
• PS plasma arc power supply
• the ESP 150 PS was modified to operate in a load bank mode similar to a dead short.
• the ArcWhirl ® Torch of FIGURE 1 operated with voltage spikes which is typical of non-transferred arc torches due to the arc dancing around the anode nozzle. The minimum amps required to sustain an arc was 50 amps.
• the pet coke was placed inside an induction coil powered by an Ambrel 50/30 EKOHEAT ® Induction Power Supply.
• the EKOHEAT ® PS is rated at:
• the RF within the above frequency range did not couple to the pet coke.
• the pet coke was transparent to EMR within the 15-45 kHz frequency range.
• This microwave pretreatment process step prior to injection into a plasma torch gives rise to an entirely new system, method and apparatus for calcining, oxidizing and steam reforming. Quite simply by coupling microwaves to pet coke and allowing any leakage of microwaves to irradiate the plasma arc allows for a highly efficient and nearly leak free Hyrbrid Microwave Plasma Torch.
• any form of pet coke including coal may be used as a susceptor to ignite and sustain plasma.
• steam plasma to the pretreated red hot pet coke allows for a system for producing copious amounts of hydrogen and/or syngas.
• Multi-Mode ArcWhirl ® Torch is switched to the plasma arc mode.
• Another multi-mode ArcWhirl ® Torch operated in a glow discharge mode would be placed upstream to produce steam/H 2 for the Arc Whirl operated in a plasma arc mode.
• FIGURE 6 This configuration is disclosed in FIGURE 6 wherein Arc Whirl ® 100 and Cyclone 610 are replaced with any one of the configurations disclosed in FIGURES 20 thru 27.
• the attachment devices selected from FIGURE 18 would be the microwave waveguide, screw feeder (auger) and cyclone as retrofits to FIGURE 6 in order to carry out the present invention.
• FIGURE 27 discloses a means for adding additional EMR and heat to the gas stream exiting V3 by heating the anode nozzle with an induction coil. This allows for preserving the anode nozzle and simply using RF energy to heat the graphite nozzle.
• FIGURE 28 discloses two ArcWhirls ® in series to form a unique system for operating two identical multi-mode plasma torches in different modes.
• FIGURE 29 discloses another configuration using two ArcWhirls ® piped in series that can be operated in different modes based upon the application and desired end products.
• FIGURE 30 discloses a means for combusting and/or quenching the products produced from the multi-mode Plasma Arc Whirl ® Torch.
• Arc Whirl ® Torch 100 By attaching the Arc Whirl ® Torch 100 to a peripheral jet eductor/ejector, products may be quenched when a quench fluid is flowed into the second compressor and/or pump.
• the syngas can be thermally oxidized or combusted by flowing air into the peripheral jet eductor/ejector via the second compressor. An extremely hot flame will exit the peripheral jet eductor at a very high velocity that can be used for thrust, heating and rotational energy.
• FIGURE 31 discloses a means for countercurrent flowing material to be treated via an auger and stinger electrode aligned along the longitudinal axis of the multi- mode Arc Whirl ® Torch.
• the additional stinger electrode allows for high turn down rates.
• the peripheral jet eductor/ejector allows for rapid quenching or thermal oxidation based upon the desired solution.
• microwaves can be introduced into the stinger tube to pretreat material, for example pet coke, prior to injection into the steam plasma or just steam if operated in a Glow Discharge Cell (“GDC”) GDC mode.
• GDC Glow Discharge Cell
• FIGURE 32A discloses a unique configuration similar to the Arc Whirl Torch 100 of FIGURE 1 utilizing the electrode and piston configuration as shown in FIGURE 15 that can be operated as a blowback torch. Blowback plasma torches are well known and well understood. By including a spring behind the piston, this keeps the electrode piston in contact with the electrode nozzle for operating in a dead short.
• the electrode rod may be controlled separately with a linear actuator. When it is necessary to operate in another mode, the valve on the tangential exit is throttled, thus forcing the electrode piston to move away from the electrode nozzle. If for example, air or steam is flowed into the torch, then a plasma arc will be formed between the electrode rod, electrode nozzle and electrode plasma.
• blowback torches and all other plasma torches are a lack of throttling the plasma gas.
• the gas is regulated prior to entry into the torch.
• the present invention's blowback torch regulates the gas on the discharge tangential exit. Consequently, this allows for high turn down rates.
• the electrode piston allows for operating in any mode previously described - resistance heating, plasma arc, glow discharge, electrolysis and submerged arc.
• the system can be powered with two separate power supplies.
• this allows the same system to be operated in separate multi-modes.
• the electrode nozzle and electrode piston can be operated in a glow discharge mode by utilizing an electrolyte while the two electrode rods can be operated in a plasma arc mode to convert the steam/FL mixture into a steam/FL plasma.
• This configuration does not require a solid oxide between the equidistant gap.
• FIGURE 34 discloses a novel and unobvious liquid resistor using the multi- mode Arc Whirl ® Torch 100 as a resistor within a series circuit. Liquid resistors are well known and well understood. Likewise, resistive wire type resistors are well known and well understood.
• Wire Resistors typically produce waste heat. Likewise, liquid resistors produce steam and/or hot water as waste heat. Power supplies incorporating resistors normally are not designed to make use of the waste heat. However, the present invention has clearly shown that the multi-mode torch can make steam/H2 from an electrolyte.
• Arc Whirl ® Torch 100 is operated in a glow discharge mode it operates in a very predictable manner. For example, an ESAB ESP 150 has been operated with Arc Whirl ® Torch 100 and the device shown in FIGURES 4 and 5. When operated as a Glow Discharge Cell ("GDC") the only necessary control parameter is a pump or a linear actuator or combination of both.
• GDC Glow Discharge Cell
• liquid level determines current flow (amps).
• electrode depth for the Arc Whirl ® Configuration as shown in FIGURE 12 would determine current flow and voltage. Controlling liquid level and electrode depth would give precise control for varying resistance, by varying voltage and current.
• the use of the present invention as a variable resistor with the ability to recover heat by using the steam/H2 mixture as the plasma gas in a separate Arc Whirl ® Torch 100 or for general heating purposes.
• EXAMPLE 14 VARIABLE PLASMA RESISTOR FOR HEAT, HYDROGEN AND 380 VDC BUILDINGS
• VPR Variable Plasma Resistor
• FIGURE 36 discloses a unique system, method and apparatus for enhanced oil recovery.
• the GDC of FIGURE 4 and 5 discloses a surface method for generating steam for enhanced oil recovery ("EOR").
• EOR enhanced oil recovery
• the device is well suited for surface production of steam using DC power.
• DC electrical leads from the power supply to the Arc Whirl ® Torch are limited in length due to voltage drop.
• the downhole heating tool may be small enough in diameter to insert within the well bore.
• widely available downhole power cable available from GE, Boret and Schlumberger can be used to provide AC power to the integrated Rectifier Variable Resistor Plasma Heater.
• hydrogen, steam and C0 2 can be produced for maintaining pressure within the formation by producing a non-condensible gas.
• FIGURE 36 can be used to produce a true plasma arc downhole.
• steam would be produced on the surface with a separate GDC and then the steam would be flowed downhole into the Plasma Arc Whirl ® Tool for plasma drilling.
• This allows for eliminating the entire mud system commonly found on drilling rigs by melting the formation and producing a slag that results in 90% volume reduction from original hole volume.
• the inventor of the present invention melted drill cuttings and achieved a 90% volume reduction. Consequently, the molten slag would form a ceramic type casing.
• the ideal Arc Whirl ® design may be the blowback piston or pneumatic/hydraulic piston as shown in FIGURES 32 and 33.
• FIGURE 37 discloses a three phase AC Plasma Arc Whirl ® downhole tool that may also be used for downhole steam generation for EOR or for plasma drilling.
• the ArcWhirl ® shown in FIGURE 33B can operate with three phase AC power.
• FIGURE 11 can be configured to be operated with three phase AC power.
• FIGURE 38 discloses a novel material treating system that uses Variable Plasma Resistors (VPR) wired in parallel with a large ArcWhirl ® Torch.
• VPR Variable Plasma Resistors
• the bulk of the DC current would flow into the carbon electrode 112 and carbon electrode nozzle(not shown) while VPR-1 through VPR-4 are wired in parallel with the carbon electrode 112 and nozzle butoperated individually to produce steam, hydrogen, disinfected water, ozone, air plasma, oxygen plasma and hot water that may be discharged into the large Arc Whirl ® Torch are discharged through their respective outlets.
• FIGURE 39 discloses a system, method and apparatus for retrofitting and converting a carbon arc gouging torch into an Arc Whirl ® Torch.
• the carbon arc gouging torch with the Plasma Arc Whirl ® Retrofit kit can now be operated in multi-modes for carbon arc gouging, plasma gouging, plasma welding, plasma marking, plasma spraying, plasma coating and plasma cutting applications.
• a carbon arc gouging torch such as an Arcair ® N7500 System is coupled to the Arc Whirl ® First End 116 via the Arcair® torch head nozzle. Consequently, the Arcair ® Gouging Torch then becomes both the electrode housing 122 and the linear actuator 114 for the Arc Whirl ® 100.
• the Plasma Arc Whirl ® conversion kit now allows for a standard off-the-shelf carbon arc gouging torch to be operated as a non-transferred plasma arc torch, plasma welder, plasma sprayer, plasma cutter and plasma marker.
• a standard off-the-shelf carbon arc gouging torch to be operated as a non-transferred plasma arc torch, plasma welder, plasma sprayer, plasma cutter and plasma marker.
• the system can be operated with a steam/hydrogen plasma. This opens the door for reducing the costs for cutting risers off castings, plasma steam/hydrogen cutting thick plate steel and aluminum, steam plasma preheating ladles, steam plasma heat treating and steam plasma reforming.
• the Plasma Arc Whirl ® Gouging and Welding Torch can be operated as an inert Steam/Hydrogen Plasma Welder.
• the carbon electrode would be replaced with a tungsten electrode.
• the plasma arc would be constricted with the steam/hydrogen gas.
• the Plasma Arc Whirl ® torch differs from all other plasma torches by using the discharge valve to throttle the gas going through the nozzle. This allows for an extremely high turn down rate while also allowing for welding or cutting based upon the velocity of the plasma gas exiting from the nozzle. Quite simply, to weld the throttling valve would be fully open thus allowing for a low velocity plasma jet exiting from the nozzle. To plasma cut, the throttle would be shut thus forcing all of the gas through the nozzle to produce an extremely high velocity plasma jet for severing and blowing slag out of the way.
• FIGURE 40 discloses a unique system, method and apparatus for using the Coanda Effect to wrap plasma around a graphite electrode.
• the Coanda Effect is the tendency of a fluid jet to be attracted to a nearby surface.
• the principle was named after Romanian aerodynamics pioneer Henri Coanda, who was the first to recognize the practical application of the phenomenon in aircraft development.
• Dual ArcWhirls ® Torches 100 couple the arc to a graphite electrode thus allowing for 24/7 operation with an extremely steady voltage.
• the plasma wraps around the graphite electrode and enters into the coanda plasma gap 39108. Material to be treated is fed directly into the plasma gap 39108.
• FIGURE 41 discloses another system, method and apparatus for using the Coanda Effect to transfer an electrical arc to a graphite electrode thus sustaining and confining the plasma.
• two Arc Whirl ® torches are shown it will be understood that only one torch is necessary to operate as a Coanda Effect Plasma System.
• the ArcWhirl ® Torch arc attaches itself to the central graphite electrode while the plasma wraps around the electrode. Thus, this allows for feeding a large central electrode and smaller electrodes within the torch for continuous duty operation.
• FIGURE 42 an embodiment of the Steam Plasma Unit of FIGURE 1 is disclosed as a counter current plasma system 4200 showing a graph with a temperature vs. phase graph.
• a plasma torch 100 is attached to a feed unit 4202.
• the plasma torch 100 may be selected from a DC arc torch, AC arc torch, microwave torch, inductively coupled plasma torch and/or any combination thereof.
• the feed unit 4202 may be selected from a screw press, hydraulic press, an auger with a well screen, a concrete pump with a sintered metal screen and/or any means for conveying solid material while separating fluids from the solids.
• the feed unit 4202 includes filter screen 1802d attached to the output of a screw feeder 1802g where a portion of the filter screen 1802d is enclosed within a tee 1802L
• the longitudinal axis 124 of the plasma torch 100 is preferably aligned with a longitudinal axis of the feed unit 4202.
• Mining byproducts e.g., drill cuttings, etc.
• mining fluids e.g., drilling fluids, etc.
• Steam 4208 is flowed into the tangential inlet 120 of the Plasma ArcWhirl ® torch 100 where the steam 4208 is converted to a steam plasma 4210 and exits through the nozzle 106. It is well known that there are 4 states of matter - solid, liquid, gas and plasma.
• the graph 4200 discloses the phases the steam plasma 4210 goes through as it contacts the byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g., drilling fluids, etc.) (collectively 4204) that are flowed counter current to the steam plasma 4210.
• the steam 4208 traverses around, through and forms a Plasma Arc ("PA").
• the ionized gas exiting from the nozzle 106 is a Steam Plasma ("SP") 4210.
• SP Steam Plasma
• a valve may be attached to the tangential exit 136 of the ArcWhirl ® Torch 100. This allows for throttling and controlling the amount of Steam Plasma 4210 exiting from the nozzle 106. Consequently, this allows for a 100: 1 turn down rate of the system.
• the tangential exit 136 allows for backflowing mining byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g., drilling fluids, etc.) (collectively 4204) all the way into the ArcWhirl ® Torch 100.
• This feature sets the Plasma ArcWhirl ® Torch apart from all other plasma torches currently being marketed and sold today.
• the ArcWhirl ® Torch can also be operated as a steam/water quench reactor.
• the Steam Plasma 4210 traverses through the filter screen 1802d and directly contacts the mining byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g., drilling fluids, etc.) (collectively 4204), the Steam Plasma 4210 gives up some of its heat and its temperature is reduced to form Super Heated Steam ("SS").
• SS Super Heated Steam
• the Super Heated Steam flows counter current to the mining byproducts (e.g., drill cuttings, etc.) containing mining fluids (e.g., drilling fluids, etc.) (collectively 4204) through the filter screen 1892d into tee 1802i, the Super Heated Steam continues to give up heat and is converted to Wet Steam ("WS").
• Hot Water By pulling a vacuum on the discharge exit 4212 of the tee 1802i, the Hot Water washes the mining fluids (e.g., drilling fluids, etc.) from the mining byproducts (e.g., drill cuttings, etc.) without cracking the base fluids to light ends. This is very important for the recovery and reuse of the base fluids.
• mining fluids e.g., drilling fluids, etc.
• mining byproducts e.g., drill cuttings, etc.
• the steam plasma 4210 continues to process or "incinerate" the mining byproducts (e.g., drill cuttings, etc.) such that the processed byproducts (e.g., drill cuttings, etc.) 4216 are inert and substantially reduced in volume and either fall through the filter screen 1802d or exit the end of the filter screen 1802d.
• FIGURE 43 a block diagram of a Closed Loop Drilling Fluids Recovery System, Method and Apparatus 4300 is shown in accordance with one embodiment of the present invention.
• Mining fluids, Hydrocarbons and Mining Byproducts 4302 from a drilling rig mud system and/or shaker room 4304 report to a shale shaker 4306.
• Mining Fluids 4308 are returned to the drilling rig mud system 4304 while cuttings (mining byproducts with residual mining fluids and hydrocarbons) 4204 fall from the shaker 4306 and into a mud/cuttings pump/conveyor system 4310.
• the pump/conveyor system 4310 may be a cement/concrete pump, centrifugal pump, progressive cavity pump, screw conveyor, auger, eductor, ejector, ram feeder, pneumatic conveyor and/or any conveyance means for transporting the cuttings (mining byproducts with residual mining fluids and hydrocarbons) 4204 from the shaker 4306 to the counter current plasma system 4200.
• water 4312 or recovered mining fluids and/or water 4314 can be added to the cuttings (mining byproducts with residual mining fluids and hydrocarbons) 4204 to form a slurry 4316 to flow the materials through the counter current plasma system 4200 more easily.
• the counter current plasma system 4200 produces recovered mining fluid and hot water 4214, which reports back to the drilling rig mud system 4304 and/or is used as a motive fluid 4314 in the mud/cuttings pump/conveyor 4310 for producing a slurry 4316 for transport back to the plasma system 4200.
• the recovered mining fluid and hot water 4214 may also undergo further processing and/or separation 4316 in which case the recovered mining fluid 4318 can be stored or sent back to the drilling rig mud system 4304.
• the plasma system 4200 heats and melts the mining byproducts or cuttings producing a molten slag 4216 that is quenched in a water quench system 4320.
• Ideal fluids for the water quench system 4320 are frack flowback 4322a from a well that has been hydraulically fractured and/or produced water 4322b from a producing well, but other sources can be used. This allows for recovering and recycling water in lieu of injection into a disposal well. Gases (e.g., inert gases, hydrogen, syngas, etc.) from a gas source 4324 may also be injected into the plasma system 4200. [00188] An inert vitrified slag 4326 is removed from the water quench unit or vessel (quencher) 4320 that may be used in construction and metallurgical applications, such as roads on the farm, ranch or property where the well is drilled.
• the slag 4326 may be suitable for grinding and use as a cement additive for cementing the well.
• another alternative use for the slag 4326 may be as a proppant or proppant ingredient.
• the slag 4326 is a fully fired ceramic material.
• frack flowback 4322a and/or produced water 4322b contains insoluble salts/chlorides.
• the quench water can be concentrated and thus only concentrated brine 4328 will need to be disposed of via an injection well. This will reduce transportation costs.
• the water quench unit or vessel (quencher) 4320 can be rated for pressure. Thus, a mixture of steam and/or hot water 4208 can be produced within the quench vessel 4320. This allows for flowing hot water, steam and/or a combination of both to the plasma system 4200 and/or to the cooler/condenser 4330. It will be understood that the cooler/condenser 4330 may use any fluid available as the heat exchange fluid. Clean water 4332 exits from the cooler/condenser 4330 for reuse and recycle as drill water and/or frac water.
• FIGURE 44 is another embodiment of the present invention's plasma system 4400 disclosing a High Temperature Vessel 4402 for holding vitrified molten solids 4216.
• the operation of the counter current plasma torch 100, filter screen 1802d, screw feeder 1802g and a tee 1802i were described in reference to FIGURE 42.
• the mining fluids and hot water 4214 flow out of the outlet of the tee 1802i into a primary separation system 4404, which separates the recovered mining fluids from the water.
• the extracted mining fluids 4318 can be further separated into a recovered mining fluids (product) 4318 and gases (e.g., hydrogen) 4406 using a degasser 4408.
• the recovered mining fluids (product) 4318 can be fed back to the mud system or stored.
• the gases 4406 can then be used to upgrade the fuels sources for diesel engine, gas turbines, boiler, thermal oxidizers, etc.
• the water from the primary separation system 4404 is feed to a pump or compressor 4410 to be used as the motive fluid for eductor 4412.
• the high temperature vessel 4402 collects the vitrified solids 4216 dropping from the filter screen 1802d and allows steam and gases to be extracted to three-way gas recirculation valve 4414.
• the eductor 4412 is used to quench and recover heat from the vitrified solids 4216.
• the resulting vitrified solids slurry 4416 is flowed into the glow discharge system 500 of FIGURE 5.
• the glow discharge system 500 produces steam and hydrogen 4418, which are used as the motive gas for thermo-compressor 4420 connected to the tangential inlet 120 of the counter current plasma torch 100.
• FIGURE 45 is another embodiment of the present invention 4500.
• Hollow shaft screw presses 4502 are well known and well understood. Although a screen for separating solids from liquids is not shown, it will be understood that one can be installed in the system 4500.
• a stinger electrode 4504 is installed for continuous 24/7 operation of the Arc Whirl ® torch 100.
• This configuration allows for feeding the first electrode 112 and the stinger electrode 4504 towards one another. Likewise, this configuration allows for transferring the arc from the nozzle 106 to the stinger electrode 4504 and thus centering the arc between the electrodes. Thus, it is extremely difficult to "BLOW" out the arc because the arc is confined between the electrodes.
• Drill cuttings or other mining byproducts are introduced into the feeder inlet 4506 and pressed towards the plasma generated by the arc in the Arc Whirl ® torch 100. As previously disclosed the drill cuttings may be backflowed directly into the Arc Whirl ® torch 100.
• FIGURE 46 shows an embodiment 4600 of the present invention wherein a Salsnes Filter 4602 by Trojan UV (see U.S. Patent No. 6,942,786 which is incorporated herein in its entirety) is attached to the Arc Whirl ® torch 100.
• a glow discharge system 400 of FIGURE 4 is attached between an outlet of the Salsnes Filter 4602 and the tangential inlet 120 of the Arc Whirl ® torch 100.
• FIGURE 47 shows an embodiment 4700 of the present invention wherein a Salsnes Filter 4602 by Trojan UV (see U.S. Patent No. 6,942,786) is attached to the Arc Whirl ® torch 100.
• a glow discharge system 500 of FIGURE 5 has an inlet attached a pump 4702 connected to an outlet of the Salsnes Filter 4602 and an outlet attached to a compressor 4704, which is connected to an eductor 4706.
• a mixer 4708 is also attached between an outlet (filtered wastewater) of the Salsnes Filter 4602 and the glow discharge system 500 to mix oxidant with the filtered wastewater to produce the effluent.
• the exhaust from the Salsnes Filter 4706 is vented and flowed to the eductor 4706 to be injected into the tangential inlet 120 of the Arc Whirl ® torch 100.
• the exhaust from the tangential outlet 136 of the Arc Whirl ® torch 100 is flowed to the effluent.
• FIGURE 48 shows an embodiment 4800 of the present invention in which a Screen Washing Monster Auger 4802 (see U.S. Patent No. 7,081,171 which is incorporated herein in its entirety) is attached to a tee 1802i connected to the Arc Whirl ® torch 100.
• a glow discharge system 400 of FIGURE 4 is attached between an outlet of the Screen Washing Monster Auger 4802 and the tangential inlet 120 of the Arc Whirl ® torch 100.
• the Screen Washing Monster Auger 4802 separates material to be processed into fluids and solids. The fluids are fed and mixed with rock salt or sea water to form an electrolyte that is then fed into the glow discharge system 400.
• the glow discharge system 400 produces bleach and steam.
• the steam is input into the tangential inlet 120 of the Arc Whirl ® torch 100.
• the solids are pushed up into the tee 1802i where the plasma from the Arc Whirl ® torch 100 reacts with and vitrifies the solids.
• FIGURE 49 shows an embodiment 4900 of the present invention in which a Screen Washing Monster Auger 4902 (see U.S. Patent No. 7,081,171) is attached to a curved tee 1802i connected to the Arc Whirl ® torch 100.
• a glow discharge system 400 of FIGURE 4 is attached between an outlet of the Screen Washing Monster Auger 4802 and the tangential inlet 120 of the ArcWhirl ® torch 100.
• the Screen Washing Monster Auger 4802 separates material to be processed into fluids and solids. The fluids are fed into the glow discharge system 400.
• the glow discharge system 400 produces effluent and steam. The steam is input into the tangential inlet 120 of the ArcWhirl ® torch 100.
• the plasma 108 from the ArcWhirl ® torch 100 reacts with and vitrifies the solids producing syngas.
• a stinger electrode 4904 is installed for continuous 24/7 operation of the Arc Whirl ® torch 100. This configuration allows for feeding the first electrode 112 and the stinger electrode 4904 towards one another. Likewise, this configuration allows for transferring the arc from the nozzle 106 to the stinger electrode 4904 and thus centering the arc between the electrodes. Thus, it is extremely difficult to "BLOW" out the arc because the arc is confined between the electrodes.
• the present invention provides a method 5000 for treating a material.
• a plasma arc torch and a screw feed unit are provided in block 5002, which can be any of the embodiments shown in FIGURES 1, 11 and 42-49, any combinations thereof, or modifications recognized by those skilled in the art.
• the plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel, the hollow electrode nozzle having a first end disposed within the cylindrical vessel and a second end disposed outside the cylindrical vessel.
• the screw feed unit has an inlet and an outlet, the outlet aligned with the centerline and proximate to the hollow electrode nozzle.
• a steam is supplied to the first tangential inlet/outlet in block 5004.
• An electrical arc is created between the first electrode and the hollow electrode nozzle in block 5006.
• the material e.g., a mining byproduct containing a mining fluid, etc.
• the material is provided to the inlet of the screw feed unit in block 5008.
• the material is treated by moving the material through the outlet of the screw feed unit towards a steam plasma exiting the hollow electrode nozzle using the screw feed unit in block 5010.
• the treatment produces a fluid (e.g., a recovered mining fluid such as a recovered drilling fluid, etc.) and an inert vitrified slag (e.g., an inert vitrified mining byproduct slag such as an inert vitrified drill cuttings, etc.).
• a fluid e.g., a recovered mining fluid such as a recovered drilling fluid, etc.
• an inert vitrified slag e.g., an inert vitrified mining byproduct slag such as an inert vitrified drill cuttings, etc.
• steps may include, but are not limited to: (a) injecting a gas into the steam before the steam is supplied into the first tangential inlet/outlet; (b) pumping or conveying the material to inlet of the screw feed unit; (c) quenching the vitrified material with water, frac flowback or produced water; (d) quenching the vitrified material produces the steam that is fed into the first tangential inlet/outlet; (e) separating the fluid into a recovered fluid and water; and/or (f) producing the steam using a glow discharge system. Additional steps are apparent to those skilled in the art in light of FIGURES 42- 49.
• An impediment to reducing production costs at SAGD facilities is heat transfer via thermal conduction through boiler tubes.
• the problem is indirect heat transfer. Heat is transferred via radiation, convection and conduction. Indeed, SAGD evaporators and boilers transfer heat via radiation, convection and conduction. Although the flame in the boiler transfers heat via radiation and convection to boiler tubes, heat transfer through boiler tubes is solely via thermal conduction.
• the present invention provides a glow discharge electrode evaporator and/or boiler that can operate with produced water directly from an oil/water separator. Moreover, the present invention provides an electrode evaporator and/or boiler coupled to a plasma superheater for producing very high quality steam (approximately 100%) and hydrogen.
• SAGD facilities refer to saturated or wet steam as steam that is less than 100% quality. For example, 85% quality steam in their words is steam that is 85% vapor and 15% moisture and/or water. On the other hand, 100% steam is just vapor with no moisture/water. The term, superheated steam, is rarely used or heard of in SAGD operations. Likewise another term commonly used in SAGD operations is Steam to Oil Ratio ("SOR"). SOR is the most relied upon number for calculating and predicting profitable operations based upon the price of crude oil. Simply put, the cost to produce steam is based upon water treatment and current fuel prices. And utilizing natural gas to produce bitumen from oil sands is no longer feasible for many reasons.
• SOR Steam to Oil Ratio
• Upgrading is another major obstacle with production of heavy oil. Heavy oil requires upgrading to decrease the viscosity in order to produce a marketable "CRUDE OIL" that can be refined in modern day refineries. Upgraders are very expensive to construct, maintain and operate. The upgrading spread similar to the term “CRACK SPREAD” is the value of the incoming raw product, for example bitumen, to the value of the upgraded bitumen - synthetic crude oil. It is the Upgrading Spread that allows for heavy oil producers to undertake a massive construction project such as an Upgrader.
• FIGURE 51 SOGD Plasma EOR
• GDC Glow Discharge Cell
• the Cell 500 may be configured as shown in FIGURES 4, 5 or 52.
• a very good granular media 424 for Enhanced Oil Recover is petroleum coke, commonly referred to as "petcoke”. The petcoke may be used in a green or calcined state.
• Petroleum coke is produced through the thermal decomposition of heavy petroleum process streams and residues.
• the three most common feedstocks used in coking operations are: (1) reduced crude (vacuum residue); (2) thermal tar; and (3) decant oil (catalytically cracked clarified oil) (Onder and Bagdoyan, 1993). These feedstocks are heated to thermal cracking temperatures and pressures (485 to 505°C at 400 kPa) that create petroleum liquid and gas product streams.
• the material remaining from this process is a solid concentrated carbon material, petroleum coke (Ellis and Paul, 2000b; EC, 2003).
• U.S. Patent No. 8,087,460 discloses a process for RESISTIVE heating oil shale in situ using petroleum coke as a resistor between two electrodes and/or electrical conductors.
• the specification states in part, "As an alternative, international patent publication WO 2005/010320 teaches the use of electrically conductive fractures to heat the oil shale.
• a heating element is constructed by forming wellbores and then hydraulically fracturing the oil shale formation around the wellbores.
• the fractures are filled with an electrically conductive material which forms the heating element.
• Calcined petroleum coke is an exemplary suitable conductant material.
• the fractures are created in a vertical orientation extending from horizontal wellbores.
• Electricity may be conducted through the conductive fractures from the heel to the toe of each well.
• the electrical circuit may be completed by an additional horizontal well that intersects one or more of the vertical fractures near the toe to supply the opposite electrical polarity.
• the WO 2005/010320 process creates an "in situ toaster" that artificially matures oil shale through the application of electric heat. Thermal conduction heats the oil shale to conversion temperatures in excess of 300° C, causing artificial maturation.”
• the present invention can use green or calcined petroleum coke as the GRANULAR MEDIA 424.
• a gas mixture B consisting mainly of steam with small amounts of hydrogen and other non-condensible gases (“NCGs"), is generated within the Cell 500. Liquids are blown down from Cell 500 through a 3-way valve 5106. Liquids C can be recirculated to the suction side of the GDC Pump 5104 and/or liquids D can be flowed into the suction of a blowdown pump 5108.
• the NCGs produced within the Cell 500 are based upon the ions within the produced water in addition to electrolytes added to the water. For example, if sodium carbonate and/or bicarbonate are present, then the NCGs produced may be hydrogen and carbon dioxide. In addition, volatile material within the green petcoke 424 will produce additional gases. Likewise, the high temperature glow discharge will steam reform the petcoke near the cathode, thus enhancing the production of syngas.
• electrolytes such as sulfuric acid
• the Cell 500 may be operated as an evaporator with the vapor compressor 5110 by flowing the gases E via a 3-way valve 5112 to the compressor 5110.
• the Cell 500 may be operated as a boiler using a high pressure feedwater GDC pump and opening the 3-way valve 5112 to flow as gas B bypassing the vapor compressor 5110 21.
• the Cell 500 can be operated as a hybrid evaporator boiler using both the vapor compressor and the pump.
• the gases E and/or B are then flowed into the Plasma Arc Whirl Torch 100.
• the vapors are superheated and then converted to a steam/NCGs plasma G then discharged into the injection well 5114 for EOR.
• An eductor 5116 hereinafter to mean and include but not limited to a thermocompressor, ejector, injector, mixer, and desuperheater may be attached to the plasma G discharge.
• the eductor 5116 may be attached such that either fluids X or G are the motive fluid.
• the operation and use of eductors are well known and well understood thus need no further explanation.
• the plasma arc torch of the present invention can be throttled with a valve. This is completely unheard of within the plasma cutting industry.
• a valve 5122 on the discharge volute of the Arc Whirl ® Torch 100, the amount of fluid flowing through the anode nozzle 106 as shown in FIGURE 1 can be adjusted from 0 to 100%.
• the Arc Whirl ® Plasma Torch as disclosed in FIGURE 1 has an infinite turndown ratio. With the proper power supply it can be operated in a resistive heating mode by simply dead shorting the cathode 112 to the anode nozzle 106 thus shutting flow through the hollow portion 128 of the anode nozzle 106.
• the Arc Whirl ® Torch can be operated in a resistive heating mode.
• any fluid closely approaching and/or touching the anode 106 and/or cathode 112 will be heated with EMR emitted from the resistive element as well as via conduction and convection by heating gases and/or fluids near the resistive element.
• Resistive heating is also commonly referred to as Joule Heating.
• the Plasma Arc Whirl ® Torch as disclosed in FIGURE 1 is a liquid/gas separator and extreme steam superheater that can be controlled with the linear actuator and the 3 -way valve 606 attached to the Tangential Exit.
• the linear actuator 114 moves as shown by arrow 126 the cathode electrode 112 towards the anode nozzle 106, it is dead-shorted to the anode nozzle 106. Thus, no fluid will flow through the nozzle 106.
• the combination of the cathode electrode 112 and anode nozzle 106 form a valve. When dead shorted the valve is in the closed position.
• the valve opens.
• the power supply is turned ON.
• the dead short causes resistive heating of the electrodes.
• the cathode electrode 112 is moved away from the anode nozzle 106 and an arc is formed between the cathode 112 and anode 106. If fluid is discharged 134 from the Tangential Outlet 118, then a very small plasma 108 will be discharged from the anode nozzle 106.
• a 3-way valve 5122 is connected to the Tangential Outlet 118 of the Arc Whirl ® Torch 100.
• the plasma 108 was discharged from the Arc Whirl ® Torch 100 and measured with an optical pyrometer. With the gases produced from the Cell 500, the plasma 108 was measured at +3,000°C (+5,400°F). With only air, the plasma 108 was measured at +2,100°C (+3,800°F).
• the system as shown in 700 was operated with a ceramic eductor 5116.
• the ceramic eductor 5166 was actually a ceramic TEE provided by Bausch Ceramics. However, the velocity of the plasma G was sufficient to pull a vacuum through the perpendicular entrance of the TEE, thus it operated as an eductor. To date the ceramic TEE has not cracked and has survived both rapid heating and cooling without any signs of deterioration.
• the present invention provides a high quality steam (approximately 100%) for EOR. If the operator desires to reduce the temperature of the steam plasma 108 shown in FIGURE 1 and shown as G in FIGURE 51, the power supply amps and/or volts can be adjusted in addition to opening 3-way valve 5122 to discharge as a gas I to cyclone separator 5124 or a gas H and drawn back into the plasma G with an injection eductor 5116. However, if maximum steam quality, for example an extreme steam plasma G is required, then the 3-way valve 5122 will be shut. In order to reduce the temperature of the steam injected into the well and increase mass flow, then blowdown liquid stream D may be mixed with the plasma steam/NCGs plasma G.
• the blowdown pump 5108 ensures that the liquid G is pressurized and can be used as the motive fluid X for the eductor 5116.
• An ideal injection eductor 5116 for this application is a peripheral jet eductor, for example the PeriJet ® Eductor manufactured by Derbyshire Machine, Philadelphia, PA. It will be understood that plasma G may be used as the motive fluid for the eductor 5166 by using a single jet eductor. If blowdown G from the Cell 500 must be discharged into the disposal well 5126, then the 3-way valve 520 would be opened for injection into the disposal well.
• a 3-way valve 5120 may be opened to allow fluid underflow K from the cyclone separator 5124 to flow into the eductor 5116. Overflow I from the cyclone separator 5124 would flow into the gas E entering into the compressor 5110.
• the Plasma Arc Whirl ® Torch 100 has nearly an infinite turndown. For example, by adjusting 3-way valve 5122, the amount of fluids going through the Anode Nozzle 106 as shown in FIGURE 1 and converted to plasma G can be from 0% to 100% of total flow into the Arc Whirl Torch 100. Referring to FIGURES 1 and 51, the Arc Whirl Torch 100 may be started and operated in accordance with the following steps:
• 3-way valve 5122 is fully opened to allow discharge through the second volute.
• the Cathode Electrode is dead shorted to the Anode acting as a valve to prevent flow entering into the Anode Nozzle.
• Amps can be adjusted with the power supply's potentiometer.
• the 3-way valve 5122, the cathode position and distance from the anode, and the potentiometer can be adjusted to infinitely control the volume and temperature of the Steam/NCGs Plasma G discharged from the Arc Whirl ® Torch.
• renewable energy may be in the form of solar, wind, hydro and/or biomass.
• Biomass would be converted to Plasma BioCharTM and syngas would be provided lean combustion (see U.S. Patent No. 8,074,439).
• any waste material such as Municipal Solid Waste could be converted to a fuel and energy for use in the present invention.
• Coke produced from upgrading bitumen would be an ideal fuel for lean combustion with the present invention.
• Coke is an ideal granular media 424 for use in the GDC Cell.
• granular petcoke can be directly injected into the Plasma G with the eductor 5116 and thus steam reformed as traveling down the Injection Well 5114.
• the coke could be plasma steam reformed.
• oxygen By adding oxygen to the syngas it would be combusted and produce high temperature steam and carbon dioxide ("C0 2 "). Once again, the steam and C0 2 would be flowed into the injection well 5114 for EOR.
• a very good configuration for adding coke and oxygen to the coupling plasma steam reforming with oxy combustion is the Plasma Whirl ® Reactor disclosed in U.S. Patent No. 7,622,693. By placing three or more torches on a reactor, the plasma will be confined and allow for complete gasification and oxy combustion of the coke. The oxygen may be reduced in order to produce only syngas.
• Oil and water from the production well is fed to an oil & water separator 5200 where the oil is separated from the oily water.
• the oily water is fed into the inlet 408 of the Glow Discharge Cell 400 using pump 5201.
• Petcoke is used as a fuel for many industries. Many oil companies are advocating it as means for sequestering carbon.
• Petcoke as the granular media 424 in the Glow Discharge Cell 400 a portion of the Petcoke will be steam reformed and converted to a non-condensible gas.
• an oxidant selected but not limited to air, oxygen, hydrogen peroxide, ozone may be added to the oily water via the recirculation line 5202 or directly into the inlet 408 of the vessel 402 by means known in the art.
• the oxidant will react with the syngas formed from steam reforming the petcoke 424. Consequently, makeup petcoke will have to be added to the replace the granular petcoke 424. This eliminates the need for removal of the granular media petcoke 424 from the vessel.
• the metals within the petcoke such as nickel and vanadium may be coated to the cathode tubular 412 and/or may be discharged via outlet 410 and blown down via 3-way valve 5204 for recovery as valuable metals.
• the gas exiting from 410 is looped around and flowed 5206 directly into the cathode tubular 412.
• the cathode tubular 412 will glow at temperatures exceeding 1000°C and upwards of the melting point of many metals.
• the typical temperature of the gases exiting the GDC 400 is based upon the pressure within the GDC 400.
• the temperature is at or slightly above 100°C.
• FIGURE 53 - ArcWhirl ® GD Cell for EOR - the ArcWhirl ® 100 has been tested and operated as a glow discharge electrolysis cell without granular media.
• Oil and water from the production well is fed to an oil & water separator 5200 where the oil is separated from the oily water.
• the oily water is fed into the inlet 408 of the Glow Discharge Cell 400 using pump 5201.
• the Plasma ArcWhirl ® Torch can easily be configured and operated in 4 different modes for EOR: (1) Resistive Heating; (2) Arc; (3) Electrolysis, and/or (4) Glow Discharge.
• the Plasma ArcWhirl® can be configured and operated in any of the aforementioned modes simply requires valving and/or a manifold (not shown) for changing the outlet 134 as shown in FIGURE 1 to be the inlet 120 as shown in FIGURE 12. Now by cycling valve 5302 from shut to open, the ArcWhirl ® GDC will be demonstrated for operating in all 4 modes. Likewise, but not shown a valve would be attached to outlet 118.
• the Arc Whirl ® GDC is started by dead-shorting the cathode to the anode with power supply in the off position. Next, the vessel is partially filled by jogging the pump. And the power supply is turned on allowing the system to operate in a resistive heating mode. The benefit to this system is preventing the formation of gases such as chlorine if sodium chloride is present within the oily water. Saturated gases will exit outlet 118 as a discharge 5304 to another Arc Whirl ® Torch or GDC for superheating or to a boiler and/or to the injection well. [00232] If the system is to be operated in an Arc Mode, the cathode is simply withdrawn from the anode.
• a submerged arc will be formed instantly. This will produced noncondensible gases such as hydrogen and oxygen by splitting water.
• gases such as but not limited to methane, butane, propane, air, oxygen, nitrogen, argon, hydrogen, carbon dioxide, argon, biogas and/or ozone or any combination thereof can be added between the pump and inlet 120 with an injector (not shown).
• an injector not shown
• hydrogen peroxide will convert to oxygen and water when irradiated with UV light.
• the ArcWhirl ® will convert hydrogen peroxide to free radicals and oxygen.
• gases and condensates are produced along with heavy oil.
• the present invention has clearly demonstrated a system, method and apparatus for operating a plasma torch in an Arc mode as well as transitioning from a resistive heating mode an arc mode.
• the electrode In order to transition to an electrolysis mode the electrode is withdrawn a predetermined distance from the anode. This distance is easily determined by recording the amps and volts of the power supply as shown by the GRAPH in FIGURE 3.
• the liquid level is held constant by flowing liquid into the ArcWhirl ® GDC by jogging the pump or using a variable speed drive pump to maintain a constant liquid level.
• a grounding clamp can be secured to the vessel in order to maintain an equidistant gap between the vessel and cathode, provided the vessel is constructed of an electrically conducted material. However, the equidistant gap can be maintained between the anode and cathode and electrically isolating the vessel for safety purposes. Glass and/or ceramic lined vessels and piping are common throughout many industries.
• the mode of operation can be reversed from Glow Discharge to Electrolysis to Arc and then to Resistive Heating.
• the ArcWhirl ® GDC will immediately go into glow discharge mode. Continually lowering the cathode will shift the system to electrolysis then to arc then to resistive heating.
• water/liquid flow is reversed and blowdown valve 5302 is opened to allow the plasma to discharge from the ArcWhirl ® GDC.
• the water/liquid can be flowed through the ArcWhirl ® GDC 100.
• outlet 118 is obstructed or a downstream valve is shut, then all of the liquid/water will be flowed through the anode nozzle.
• the mode of operation, resistive heating, arc, electrolysis or glow discharge will be determined based upon the electrical conductivity of the water/liquid.
• Dual ArcWhirls® for EOR - a second Arc Whirl ® Plasma Torch 100 can be placed in series and/or parallel with the Arc Whirl GDC 500 for operation as a complete system 5400. It will be understood that both units are piped series such that either one is the GDC while the other is the Plasma Torch and/or both are operated in parallel as Glow Discharge Cells or Plasma Torches. Manifolds, valves and headers are very common that allow for operation of filters, pumps and equipment in parallel and/or series.
• the Dual ArcWhirl ® System 5400 is extremely useful for EOR, especially SAGD applications because standard High Pressure and Low Pressure Steam Separators can be modified and converted to the ArcWhirl ® GDC 500 and the ArcWhirl ® Plasma Torch 100.
• the Vapor Compressor between the GDC 500 and Torch 100, the gases from exit 5402 can be compressed to injection well pressure requirements.
• the Torch 100 is controlled by means of a discharge valve 5404 connected to a compressor recirculation line.
• discharge through nozzle 5406 from the GDC 500 unit can be flowed via a 4-way manifold 5408 to the pump recirculation, or as blowdown to an injection well or to the eductor for mixing with the Plasma 5410 and discharge into the injection well. Mixing with the plasma thus allows for a ZERO DISCHARGE SYSTEM and not just a ZERO LIQUID DISCHARGE system.
• FIGURE 55 by coupling the present invention with the current inventor's Plasma Thermal Oxidizer, U.S. Patent No. 8,074,439 the costs for treating frac flowback and/or produced water can be reduced by using Petcoke and/or activated carbon as the granular media 424 in the GDC 400.
• a MIX (mixture) of Gas, Fluid (produced water, frac flowback) and/or Fuel and/or any combination thereof is flowed into the inlet of the Arc Whirl ® 100.
• the MIX is exposed to Wave Energy.
• the plasma 108 is discharged from the anode nozzle and into the Thermal Oxidizer of U.S. Patent No. 8,074,439.
• the mixture is discharged B from the Arc Whirl ® 100 and is flowed into the Glow Discharge Cell 400.
• a good granular media 424 is selected from a carbon containing material such as activated carbon, nutshell, woodchips, biochar and/or petcoke.
• the GDC 400 granular media will trap and filter organics and solids within the mixture.
• the mixture exits as a Gas through a Gas OUTLET and/or as liquid via a Liquid OUTLET.
• the Gas can be flowed via a 3- way valve to a mixing valve and/or to the compressor of the Thermal Oxidizer.
• the compressed GAS flows through a 3-way throttle valve for feed into the plasma 108 or recycled back into the Arc Whirl ® 100.
• the gas entering into the Mixing Valve may flow back into the INLET of the ArcWhirl ® 100.
• an oxidant is combined with a hot plasma for lean combustion in the thermal oxidizer, Plasma Rocket of FIGURE 7, the pump or for converting hot gases to rotational energy.
• FIGURE 56 - Dual Arc Whirl ® Flotation - the present invention is ideally suited for adapting to a flotation cell.
• Flotation cells such as a Dissolved Air Flotation ("DAF"), Induced Gas Flotation (“IGF”) and/or Froth Flotation Cell are common amongst many industries. DAFs are common in the wastewater treatment industry. IGFs are common in refineries, O&G Production Platforms and O&G gathering facilities/pads.
• Froth Flotation Cells are common in the metals and minerals industries. Likewise, Froth Flotation Cells are used extensively within the Oil Sands surface mining industry.
• the present invention dramatically improves the performance of a flotation cell by adding a First Arc Whirl ® for production of UV Light, oxidants such as Ozone and also for operation as a submerged thermal oxidizer.
• oxidants such as Ozone
• an oxidant such as air or oxygen
• This will help push hydrophobic contaminants such as hydrocarbons to the arc.
• the rotating gaseous mixture of hydrocarbons and oxidants around the arc will form a plasma and will be combusted within the Whirlpool formed by the rotating water.
• ArcWhirl ® The mixture comprising water, solids and hot combustion gases is then discharged directly into the Flotation Cell.
• Floats and Skims are collected in a Collection Header and discharged into a 3-way valve.
• the floats/skims may then be recycled back to the ArcWhirl ® UV/OZONE Oxidizer or to a second ArcWhirl ® Submerged Thermal Oxidizer.
• the plasma 108 from the second ArcWhirl ® may be discharged into the thermal oxidizer of U.S. Patent No. 8,074,439.
• the floats/skims can be boosted in pressure with a booster pump and discharged into a Graphite Electrode Plug Valve.
• the Plug Valve assembly is unique to the ArcWhirl ® Plasma Torch in that it allows for continuous feeding of electrodes.
• the electrode feeder consists of a feeder housing in which a traction feeder grips a second electrode.
• traction feeder operates similar to any track type conveyor belt system. By pushing the tracks together to compress against the electrode the tracks move the electrode in and out based upon the direction of the tracks.
• graphite electrodes are screwed together similar to drill pipe found throughout the oil and gas industry.
• a coiled tubing rig can be used that includes a traction drive system that is common throughout the Coiled Tubing Drilling Industry.
• the metal tubing would be used as a sacrificial anode. This allows for the introduction of micronized iron. When ozone and/or hydrogen peroxide are combined with micronized iron, in particular ferric oxide, a reaction known occurs which forms a very powerful oxidant known as the hydroxy 1 radical. This reaction is commonly referred to as Fenton's Reagent.
• the electrode can be electrically connected to the anode lead cable via common DC brushes used on DC motors and/or generators.
• the anode lead is coupled to the housing via a power feed thru.
• a motor for driving the traction drive system can be an air or pneumatically operated motor.
• the traction drive electrode feeder of the present invention can also be used for the cathode. However, it will be understood that the traction feeder must be electrically isolated form the feeder housing and should be electrically isolated from the electrode.
• the ArcWhirl ® Submerged Thermal Oxidizer may also include the traction drive electrode feeder of the present invention.
• the purpose of the second ArcWhirl ® is to ensure that contaminants are removed below permit discharge levels or to within limits for recycling and reuse of the water.
• the second ArcWhirl ® polishes the water prior to reuse.
• the present invention provides a unique system, method and apparatus for solving the water recycling and tailings drying problem.
• the oil sands tailings pond problem is well known and is a legacy problem that if not solved will make surface mining unsustainable for several reasons.
• the present invention produces unexpected results in that petcoke can be fed into the ArcWhirl ® with the oxidant. Since the density of petcoke will allow reporting to the plasma vortex, then this allows for submerged combustion. Likewise, another ideal and near perfect feed point for the petcoke is through the anode nozzle or through a hollow cathode. Why is this a great petcoke feed location? Simply put, the petcoke is calcined by the extreme temperature of the carbon arc and then it becomes electrically conductive. Thus, the petcoke becomes the consumable electrode within the ArcWhirl ® .
• FIGURE 56 A feed mechanism for the petcoke is shown in FIGURE 56.
• the petcoke is slurried fed by injection into the suction of the Booster Pump via recirculation through an eductor.
• the petcoke slurry is then fed directly into the anode nozzle.
• FIGURE 58 - SOGD ArcWhirl ® Upgrader - petcoke is produced by upgrading heavy oil.
• using petcoke to enhance upgrading by gasifying and/or steam reforming the petcoke by using it as the granular media 424 for the GDC 500 helps eliminate the problem of petcoke disposal. In addition, it provides the needed hydrogen for upgrading.
• both the GDC 500 and the ArcWhirl ® Plasma Torch Upgrader 100 operate with DC power, the system, method and apparatus as disclosed in FIGURE 19 is ideal for renewable energy regions.
• the EOR system of FIGURE 51 can be operated on Solar and Wind power for recovering the oil, while the Upgrader as disclosed in FIGURE 58 can upgrade the heavy oil at the well head or on the pad.
• a heavy oil booster pump would supply heavy oil to the Graphite Electrode Plug Valve assembly. Steam and Hydrogen produced in the GDC 500, using petcoke as the granular material 424, would be compressed then flowed in the ArcWhirl ® Upgrader 100. An oxidant such as oxygen may be used to partially combust the heavy oil to reduce electrical power to the ArcWhirl ® 100.
• the high pressure and very hot Upgraded Oil would flow into a cyclone flash separator. The gas oil would be separated from the heavy fractions and condensed as a synthetic oil.
• FIGURE 58 The present invention as disclosed in FIGURE 58 was operated with woodchips and an auger feeder in lieu of a booster pump.
• a mixture of steam and hydrogen produced by the GDC 500 was flowed into the Arc Whirl ® 100 forming a steam plasma in excess of 3,000°C (5,400°F).
• FT Fischer Tropschs
• Heavy oil contains copious amounts of sulfur.
• the GDC 500 will produce caustic soda for scrubbing H 2 S and sulfur species produced in the Arc Whirl ® Upgrader.
• the ideal electrolyte is weak sulfuric acid. Not being bound by theory, it is believed that the H 2 S will be converted to sulfur trioxide by operating several Arc Whirl ® GDC 100 systems as shown in FIGURE 14 as Hot Gas Cleanup systems in a glow discharge, electrolysis or arc mode.
• Sulfuric acid is a good electrolyte for the glow discharge cell of the present invention because electrical conductivity does not decrease with increasing concentration. It is the only electrolyte that provides that benefit for use in the present invention. Consequently, the present invention also includes a system, method and apparatus for disposal of large sulfur piles from heavy oil upgrading by manufacturing sulfuric acid.
• Wood has been carbonized with the Plasma Arc Whirl ® Torch 100 using a plasma gas generated from the Glow Discharge Cell 500 configured as shown in FIGURE 7.
• the gases exiting from the Plasma Arc Whirl ® Torch 100 using baking soda within the Glow Discharge Cell 500 as the plasma gas produced a plasma G temperature of 2,900°C (5,250°F) as measured with an optical pyrometer.
• sawdust was flowed directly into the steam/hydrogen plasma G and were formed producing syngas with a composition shown in the following SYNGAS TABLE:
• syngas produced from the present invention is now ready for lean combustion with the Plasma Arc Whirl ® Turbine as disclosed in US Patent No. 8,074,439.
• the syngas can be converted to liquid biofuels using a Fischer Tropschs catalyst or any suitable process and/or catalyst that will convert syngas to liquid fuels.
• the syngas may be mixed with the Oil and upgraded to meet pipeline quality oil standards.
• Syngas and/or a hot gas and char are produced from the Plasma ArcWhirl ® Torch's plasma plume G.
• the hot syngas and/or hot gas is used to rotate a turbine that is connected to a compressor, pump, generator and/or mixer.
• the Plasma ArcWhirl ® Turbine '439 may be operated in a lean combustion mode to simply drive a turbocharger for providing compression via the vapor compressor 5110 as disclosed in FIGURE 51.
• the System 700 as shown in FIGURE 7 rated at 35 kw was operated at only 9 kw-hr for plasma steam reforming woodchips for conversion to Plasma BioCharTM.
• the Carbon in the wood is sequestered as a usable form of BioCharTM for water treatment.
• the off-gas temperature was measured at over 900°C and dumped directly into a recirculating water bath. The total process demonstrated that for every 1 kw of out of the wall power, 2 kw of energy could be recovered within the water as hot water.
• Biochar produced from the present invention was visually analyzed and determined to be a suitable BioCharTM for water treatment purposes. Consequently, as previously disclosed the Plasma BioCharTM could be used as the media for the glow discharge cell 400 or 500 as shown in FIGURES 4-9 and 51-58 of the present invention. BioCharTM makes and excellent water filtration aid and can be used in conjunction with the petcoke.

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• 2014
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