TECHNICAL FIELD

The disclosure relates generally to a separator system and method, and more specifically, to a separator system and method for removing hazardous materials, including eliminating harmful gases and sand.

BACKGROUND

Separators may remove sand, gas, and other hazardous materials during a drill out process but may not eliminate all hazardous materials. Conventional separators can provide significantly long rig-up times that exceed two hours and can require third-party trucking and additional personnel. Further, conventional separators can require permits and cannot be hauled at any time. Electronic systems can fail separator systems and can even cause explosions.

SUMMARY

Embodiments of the present disclosure may provide a separator system and method that may include a main unit. The main unit may provide a plurality of chambers that may be arranged to separate a material that may include a hazardous material, and the hazardous material may be removed from the separator system. The separator system and method may provide a tank that may be partitioned within the main unit. The separator system and method may further provide a vertical circulation separator that may be connected to the main unit. A scrubber may be arranged between the vertical circulation separator and a flare system. The separator system may be a four-way separator and may provide an auger hopper that may be arranged to receive the hazardous material. The plurality of chambers may be provided to trap a residual material that may escape the auger hopper. The flare system may receive gas from the scrubber and may provide one or more roll-off boxes that may be stored under an auger to capture the hazardous material. The separator system and method may provide a diesel engine including at least one hydraulic pump, wherein the diesel engine may power a recirculation pump, a transfer pump, and the auger. The scrubber may be arranged between the flare system and the main unit.

Other embodiments of the present disclosure may provide a four-way separator that may include a main unit including three chambers arranged to remove harmful gas and sand from a hazardous material. The four-way separator may provide a tank that may be partitioned within the main unit, a vertical circulation separator that may be connected to the main unit, and a scrubber that may be arranged between the vertical circulation separator and a flare system. The four-way separator may completely eliminate sand from the hazardous material. The tank may measure an amount of a return fluid and may transfer the return fluid to another tank, a pit, or a fracturing tank. The tank may provide a sight glass that may measure the return fluid and may view the return fluid inside of the tank. The four-way separator may provide an auger hopper that may be arranged to receive the hazardous material, and the three chambers may trap a residual material that may escape the auger hopper. The main unit may prevent the hazardous material from clogging the four-way separator through continuous circulation. The four-way separator may further reduce a rig-up time.

Embodiments of the present disclosure may provide a method of separating a material in a separator system that may include sending the material to a vertical circulation separator. The material may include a hazardous material, and the hazardous material may include a gas and a well-born fluid. The method may further include the step of continuously circulating the material to prevent the separator system from clogging. The method may also include the step of constantly moving the material by utilizing a water jet system to keep the material including a particulate matter in motion. The method may include creating a Venturi effect that may pull a fluid and a sand out of the material and into the separator system. The method may include feeding the gas to a scrubber and a flare system and trapping a residual sand that escapes an auger hopper into a plurality of chambers. The plurality of chambers may provide three chambers. The method may include capturing the residual sand that may be removed from the auger hopper into roll-off boxes stored underneath the auger hopper.

Other technical features may be readily apparent to one skilled in the art from the following drawings, descriptions and claims.

