Method, Apparatus and System for Hydrocarbon Recovery

1 . A method for treating solids, comprising:

a. delivering a contaminated energetic material to a heat source, said contaminated energetic material comprising a hydrocarbon filet and water;

b. utilizing said heat source to heat said contaminated energetic material to a temperature sufficient to vaporize substantially all of said hydrocarbon fuel and water present comprising said contaminated energetic material, producing a vaporized hydrocarbon fuel and vaporized water;

c. condensing at least a portion of said vaporized hydrocarbon fuel from said contaminated energetic material, producing a condensed hydrocarbon fuel;

d. collecting said condensed hydrocarbon fuel; and

e. introducing said vaporized water to a condenser.

2 . The method for treating solids of claim 1 , wherein the solid residue of said contaminated energetic material is collected after said contaminated energetic material is vaporized.

3 . The method for treating solids of claim 1 , wherein said heat source is a rotary heater.

4 . The method for treating solids of claim 1 , wherein said heat source is a rotary calciner.

5 . The method for treating solids of claim 1 , wherein the method further comprises condensing at least a portion of said vaporized water.

6 . The method for treating solids of claim 1 , wherein at least one condensing step is carried out by at least one direct condenser.

7 . The method for treating solids of claim 1 , wherein at least one condensing step is carried out by at least one scrubber condenser.

8 . The method for treating solids of claim 1 , wherein at least one condensing step is carried out by at least cue indirect condenser.

9 . The method for treating solids of claim 1 :

a. wherein the contaminated energetic material comprises drill cuttings and said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil;

b. wherein said heat source is a rotary calciner; and,

c. wherein at least one scrubber condenser is used to carry out at least one condensing step.

10 . The method of treating solids of claim 1 , further comprising condensing said hydrocarbon fuel and wherein the fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

11 . The method of treating solids of claim 1 further comprising:

a. delivering said contaminated energetic material to a heat source;

b. heating said contaminated energetic material to a temperature sufficient to vaporize substantially all of the hydrocarbon fuel and water present in the contaminated, energetic material;

c. wherein said heat source is a rotary heater;

d. introducing the vaporized hydrocarbon fuel and water to a first condenser;

e. condensing at least a portion of said vaporized hydrocarbon fuel in said first condenser;

f. introducing said vaporized water from said first condenser to a second condenser in fluid communication with said first condenser;

g. condensing at least a portion of said vaporized water in said second condenser;

h. collecting the solid residues remaining after the heating of said contaminated energetic material; and

i. wherein said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

12 . A method for treating solids comprising:

a. delivering a first material comprising a hydrocarbon fuel and water to a first zone;

b. heating said first material in said first zone thereby producing a second material in vapor form and a third material having a lower hydrocarbon and water content than said first material;

c. delivering said second material to a second zone; and

d. condensing at least a portion of said second material in said second zone thereby producing a hydrocarbon fuel in liquid form and a fourth material having a lower hydrocarbon content than said second material.

13 . The method for treating solids of claim 12 :

a. wherein the heating of said first material in said first zone is accomplished by a rotary heater;

b. wherein said second material comprises a hydrocarbon fuel;

c. wherein a first condenser in said second zone is in fluid communication with said rotary heater and said first condenser condenses at least a portion, of said hydrocarbon fuel;

d. wherein said fourth material comprises water vapor; and

e. wherein a second condenser in said second zone is in fluid communication with said first condenser and said second condenser condenses at least a portion of said water vapor present in the fourth material.

14 . The method of treating solids of claim 12 :

a. wherein the hydrocarbon content of said first material is between approximately 7 wt. % and approximately 26 wt. %;

b. wherein the solids content of said third material is higher than the solids content of said first material;

c. wherein the largest component of said fourth material is water vapor; and

d. wherein said hydrocarbon fuel released from said second material comprises hydrocarbons.

15 . The method of treating solids of claim 12 further comprising delivering the third material to a storage vessel.

16 . The method for treating solids of claim 12 , wherein at least one of said first and second condenser is a scrubber condenser.

17 . The method of treating solids of claim 12 , wherein at least one condenser is an indirect condenser.

18 . The method of treating solids of claim 12 , wherein said indirect condenser is a heat exchanger.

19 . The method for treating solids of claim 12 , wherein said hydrocarbon fuel is selected from the group consisting of gasoline, diesel, kerosene, jet fuel, and fuel oil.

20 . The method for treating solids of claim 12 further comprising:

a. delivering said first material to a first heat zone, wherein the heating of said first material in said first zone is accomplished by a rotary heater; wherein said first material is a contaminated energetic material; wherein said first material comprises between approximately 7 wt. % and approximately 26 wt. % hydrocarbon by weight;

b. heating said first material in said first zone, producing a second material in vapor form and a third material having a lower hydrocarbon and water content than said first material, wherein the solids content of said third material is higher than the solids content of said first material;

c. delivering said second material to a second zone, wherein said second material comprises a hydrocarbon component and a water vapor component;

d. introducing said second material to a first condenser, said first condenser in fluid communication with said rotary beater;

condensing at least a portion of said hydrocarbon component in the second material in said second zone, thereby producing a hydrocarbon in liquid form and a fourth material having a lower hydrocarbon content than said second material, wherein the largest component of said fourth material is water vapor;

e. introducing said fourth material to a second condenser, said second condenser in fluid communication with said first condenser; and

f. condensing at least a portion of said water vapor in said fourth material.

21 . An apparatus for extracting hydrocarbons from a material comprising said hydrocarbons which comprises:

a. a heat zone for subjecting said material to a temperature sufficient to vaporize substantially all of the hydrocarbons in said material;

b. a first condenser zone for condensing at least a portion of said hydrocarbons; and

c. a second condenser zone for condensing water vapors that have been vaporized from said material.

22 . The apparatus as in claim 21 , wherein said first and second condensers are scrubber condensers.

23 . The apparatus of claim 21 , wherein at least a portion of said hydrocarbons are condensed via a heat exchanger.

24 . A system of extracting hydrocarbons from a material comprising hydrocarbons which comprises:

a. delivery of a first material to a first zone, wherein said first zone comprises a heat chamber and said heat chamber comprises at least two outlets;

b. subjecting said first material to a heat chamber in said first zone, thereby forming a second material, which is a vapor comprising a higher concentration of a fuel and water than said first material, and a third material, comprising a lower concentration of a hydrocarbon than does said first material;

c. transporting said second material from said heat chamber, through one of said at least two outlets, to a first condenser in a second zone, wherein said outlet is in fluid connection with said first condenser in said second zone and the vapor of said second material is exposed to a sprayer of cooled condensed vapors, causing the vapor in said second material to condense and separate into a fuel and a fourth material, said fourth material comprising water vapor;

d. transporting said fourth material from said first condenser to a second condenser, said second condenser in fluid communication with said first condenser, wherein said fourth material is exposed to a sprayer of cooled condensed vapors causing said water vapor in said fourth material to condense into liquid water; and

e. transporting said third material from said heat chamber in said first zone to a dust trap.

25 . A solids treatment apparatus comprising:

a. a first zone comprising one or more vessels, a first zone feed stream, a first zone first outlet stream, a first zone second outlet stream, and a heat chamber; and

b. a second zone comprising one or more vessels, a first condenser, a second zone first outlet stream, a second zone second outlet stream, and a second condenser; wherein said first zone feed stream comprises a hydrocarbon fraction, a water fraction, and a solids fraction and said hydrocarbon fraction comprises a first hydrocarbon component with an atmospheric boiling point of between approximately 250° F. and approximately 1000° F.

26 . A solids treatment apparatus comprising:

a. a first zone comprising one or more vessels, a receiving pit for the intake of materials, a feed pit, and a heat source, wherein said feed pit is in fluid connection with said heat source, wherein a flow pump is used to convey said materials from said feed pit to said heat source, wherein said heat source has a first zone first outlet stream and a first zone second outlet stream; wherein said first zone first outlet stream is in fluid connection with a vessel in a second zone; and wherein said first zone second outlet stream is in connection with a vessel in a fourth zone;

b. a second zone comprising one or more vessels, a first condenser, a second zone storage vessel, and a sludge removal vessel; wherein said first condenser is in fluid communication with said heat source via said first zone first outlet stream; wherein said condenser has a second zone first outlet stream which is in fluid connection with said sludge removal vessel; wherein said condenser has a second zone second outlet stream in fluid connection with a vessel in a third zone;

c. a third zone comprising one or more vessels, a second condenser, a second storage vessel, and a sludge removal line; wherein said second condenser has a third zone first outlet stream in fluid communication with said second storage vessel; wherein said second condenser has a third one second outlet stream; wherein said second storage vessel has a second condenser feed line in fluid connection with said second condenser; wherein said second condenser feed line has a bypass line in fluid connection with second storage vessel; and

d. a fourth zone comprising one or more vessels, a solids residue vessel, and a disposal; wherein said solids residue vessel receives solids residue from said heat source through first zone second output stream.

27 . The solids treatment apparatus of claim 26 :

a. wherein said first condenser has a second zone third outlet stream which is in fluid connection with said storage vessel;

b. wherein said second zone storage vessel has a first condenser feed line in fluid connection with said first condenser; and

c. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

28 . The solids treatment apparatus of claim 26 :

a. wherein said first condenser has a second zone third outlet stream which is in fluid connection with said storage, vessel;

b. wherein said second zone storage vessel has a first condenser feed line in fluid connection with said first condenser;

c. wherein cooled liquids are recirculated from said second zone storage vessel to said first condenser through said first condenser feed line; and

d. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

29 . The solids treatment apparatus as in claim 26 :

a. wherein said first condenser has a second zone third outlet stream which is in fluid communication with said second zone second outlet stream; and

b. wherein said sludge removal vessel is in fluid communication with said second zone storage vessel.

30 . The solids treatment apparatus of claim 26 , wherein said heat source is a rotary heater.

31 . The solids treatment apparatus of claim 26 , wherein said heat source is a calciner.