초록 ▼

Methods for creating a proppant of a specific size from a slurry extracted from a fractured hydrocarbon well is provided, including the steps of separating water from the slurry, resulting in a solid stream and a liquid stream; mixing the slurry stream with particulate, resulting in a feed material;

Methods for creating a proppant of a specific size from a slurry extracted from a fractured hydrocarbon well is provided, including the steps of separating water from the slurry, resulting in a solid stream and a liquid stream; mixing the slurry stream with particulate, resulting in a feed material; fusing proppant material in the feed material; quenching the fused proppant material; breaking the fused proppant material; sizing the broken material for the specific size; and mixing broken material that is not of the specific size with the feed material. A system for performing the method is also described.

대표청구항 ▼

1. A method for creating a proppant of a specific size from a slurry extracted from a fractured hydrocarbon well, the method comprising: separating water from the slurry, resulting in a solid stream and a liquid stream;mixing the solid stream with particulate, resulting in a feed material;fusing pro

1. A method for creating a proppant of a specific size from a slurry extracted from a fractured hydrocarbon well, the method comprising: separating water from the slurry, resulting in a solid stream and a liquid stream;mixing the solid stream with particulate, resulting in a feed material;fusing proppant material in the feed material;quenching the fused proppant material;breaking the fused proppant material;sizing the broken material for the specific size; andmixing broken material that is not of the specific size with the feed material. 2. A method as in claim 1 wherein said mixing comprises: injecting the feed material into a kiln; andinjecting particulate into the kiln, wherein the injection of the particulate changes the viscosity of a slagging material wherein the slagging material comprises the slurry stream and the injected particulate. 3. A method as in claim 2 wherein the injecting of the particulate is increased when the slagging material is too viscous for even flow in the kiln. 4. A method as in claim 2 wherein the injecting of the particulate is decreased when the slagging material is so viscous that the flow rate through the kiln is too fast for fusing of proppant material. 5. A method as in claim 1 wherein said quenching comprises spraying the fused proppant material with the liquid stream. 6. A method as in claim 1 wherein said breaking comprises: crushing the quenched proppant material; andgrinding the crushed proppant material. 7. A method as in claim 1 wherein said sizing comprises screening. 8. A method as in claim 1 wherein said sizing comprising weight-separating. 9. A method as in claim 1 further comprising: measuring the rate of flow of the fused material outputting a kiln; andadjusting the heating in the kiln based on the measuring. 10. A method as in claim 1 further comprising separating the slurry from a flow of produced fluid from a hydrocarbon well, wherein the produced fluid includes water and slurry, wherein said separating the slurry results in at least two streams, wherein one of the at least two streams comprises a substantially liquid stream of water and another of the at least two streams comprises the slurry. 11. A method as in claim 10 further comprises imparting an electromagnetic pulse to the substantially liquid stream of water. 12. A method as in claim 11 wherein proppant is mixed with the substantially liquid stream of water before the imparting. 13. A method as in claim 11 wherein proppant is mixed with the substantially liquid stream of water after the imparting. 14. A system for creating a proppant of a specific size from a slurry extracted from a fractured hydrocarbon well, the system comprising: means for separating water from the slurry, resulting in a wet solid stream and a liquid stream;means for mixing the wet solid stream with particulate, resulting in a feed material;means for fusing the feed material resulting in fused proppant material;means for quenching the fused proppant material;means for breaking the fused proppant material;means for sizing the broken material for the specific size; andmeans for mixing broken material that is not of the specific size with the feed material. 15. A system as in claim 14 wherein said means for mixing the wet solids stream with particulate comprises: means for injecting the solid stream into a kiln; andmeans for injecting particulate into the kiln, wherein the injection of the particulate changes the viscosity of a slagging material and wherein the slagging material comprises the wet solid stream and the injected particulate. 16. A system as in claim 14 wherein said means for quenching comprises means for spraying the fused proppant material with the liquid stream. 17. A system as in claim 14 wherein said means for breaking comprises: means for crushing the quenched proppant material; andmeans for grinding the crushed proppant material. 18. A system as in claim 14 wherein said means for sizing comprises at least one screen. 19. A system as in claim 14, wherein said means for heating comprises a kiln. 20. A system as in claim 19 further comprising: means for measuring the rate of flow of the fused material outputting the kiln; and means for adjusting the heating in the kiln based on the measuring. 21. A system as in claim 14 further comprising means for separating the slurry from a flow of produced fluid from a hydrocarbon well, wherein the produced fluid includes water and a slurry, wherein the separating of the slurry results in at least two streams, wherein one of the at least two streams comprises a substantially liquid stream of water and another of the at least two streams comprises the wet solids stream. 22. A system as in claim 21 further comprises means for imparting an electromagnetic pulse to the substantially liquid stream of water. 23. A system as in claim 22 further comprising means for mixing proppant with the substantially liquid stream of water before the means for imparting. 24. A system as in claim 22 further comprising means for mixing proppant with the substantially liquid stream of water after the imparting. 25. A system as in claim 14 wherein said means for mixing broken material that is not of the specific size comprises the means for fusing.