Underground cuboid sulfur storage systems

Patent metadata

Field	Value
Publication number	US-12352002-B2
Application number	US-202318323991-A
Country	US
Kind code	B2
Filing date	May 25, 2023
Priority date	May 25, 2023
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

An underground storage unit for storing bulk sulfur includes a base layer comprising leachate collection pipes arranged to form a grid of cells, and high strength sulfur positioned at each cell, an intermediate layer comprising high strength sulfur side walls extending from a perimeter of the base layer, and bulk sulfur positioned on top of the base layer, a top layer positioned at an extent of the side walls and comprising a first sub-layer formed from high strength sulfur, a second sub-layer formed from a rigid moisture resistant material, and a third sub-layer formed from top soil, and one or more hatches positioned at the top layer that provide access to the bulk sulfur of the intermediate layer.

First claim

The invention claimed is:

1. An underground storage unit for storing bulk sulfur comprising:
a base layer having a length and a width defining a substantially rectangular shape configured to flex, the base layer comprising leachate collection pipes arranged to form a grid of cells, and high strength sulfur positioned at each cell;
an intermediate layer having a substantially cuboid shape aligned with the cells of the base layer, the intermediate layer comprising high strength sulfur side walls extending from a perimeter of the base layer, and bulk sulfur positioned on top of the base layer;
a top layer positioned at an extent of the side walls and comprising a first sub-layer formed from high strength sulfur, a second sub-layer formed from a rigid moisture resistant material, and a third sub-layer formed from top soil; and
one or more hatches positioned at the top layer that provide access to the bulk sulfur of the intermediate layer.

2. The underground storage unit of claim 1 , wherein the high strength sulfur side walls, the cells of the grid, and the first sub-layer are each formed from Pre-case Sulfur Concrete (PSC), Sulfur Extended Asphalt (SEA), or Sulfur-Asphalt-Sand (SAS).

3. The underground storage unit of claim 1 , wherein the second sub-layer and the one or more hatches are formed from spoolable Reinforced Thermoplastic Pipes (RTP) or Flexible Composite Pipes (FCP).

4. The underground storage unit of claim 1 , wherein the cells of the grid of the base layer are flexibly coupled to adjacent cells such that the base layer flexes in response to subsidence below or surrounding the underground storage unit.

5. The underground storage unit of claim 1 , wherein the side walls are angled away from the base layer.

6. The underground storage unit of claim 5 , further comprising a perimeter wall formed from high strength sulfur that encircles the top layer.

7. The underground storage unit of claim 6 , further comprising a sulfur detection system that includes a plurality of detection sensors configured to sense sulfur and moisture in sensing wells extending beneath the perimeter wall.

8. The underground storage unit of claim 7 , wherein the bulk sulfur comprises a plurality of sulfur cuboids aligned with the grid of cells, and the plurality of detection sensors are positioned at or near the sulfur cuboids within the intermediate layer.

9. An underground sulfur storage system comprising:
a project storage site located proximal to an oil and gas field comprising two or more underground storage units, each underground storage unit comprising:
a base layer having a substantially rectangular shape configured to flex, the base layer comprising leachate collection pipes arranged to form a grid of cells, wherein each cell is sealed with high strength sulfur;
an intermediate layer comprising high strength sulfur side walls extending from and tilted away from a perimeter of the base layer, and sulfur cuboids positioned on top of the base layer and aligned with the cells of the base layer;
a top layer spanning an extent of the side walls and comprising a first sub-layer formed from high strength sulfur, a second sub-layer formed from a rigid moisture resistant material, and a third sub-layer formed from top soil; and
one or more hatches positioned at the top layer to provide access to the sulfur cuboids of the intermediate layer.

10. The system of claim 9 , wherein the sulfur cuboids are formed at the project storage site by compacting bulk sulfur produced from sour hydrocarbon at the oil and gas field.

11. The system of claim 9 , wherein the second sub-layer and the hatches are formed from spoolable Reinforced Thermoplastic Pipes (RTP) or Flexible Composite Pipes (FCP).

12. The system of claim 9 , wherein the second sub-layer is formed from polyvinyl chloride (PVC).

13. The system of claim 9 , wherein the cells are sealed with Sulfur Extended Asphalt (SEA) formed at a concrete and asphalt facility located at the project storage site.

14. The system of claim 13 , wherein the high strength sulfur side walls and first sub-layer are formed from Pre-cast Sulfur Concrete (PSC) at the concrete and asphalt facility and the concrete and asphalt facility forms PSC and SEA from bulk Sulfur produced from sour hydrocarbon at the oil and gas field.

15. The system of claim 9 , further comprising a perimeter wall formed from PSC that encircles the top layer and a portion of the side walls.

16. The system of claim 15 , further comprising a sulfur detection system including a plurality of detection sensors configured to sense sulfur and moisture in sensing wells beneath the perimeter wall and between sulfur cuboids of the intermediate layer.

17. A method of building the underground sulfur storage system of claim 9 comprising:
laying high strength sulfur to form a base layer of a first storage unit of the project storage site, the base layer comprising a leachate collection system including a plurality of leachate collection pipes arranged to form a grid of cells, each cell being sealed with high strength sulfur;
laying high strength sulfur to form side walls extending from and tilted away from a perimeter of the base layer of the first storage unit;
storing bulk sulfur on top of the base layer and between the side walls of the first storage unit; and
laying high strength sulfur spanning extents of the side walls to form a top layer and seal the first storage unit.

18. The method of claim 17 , the method further comprising:
compacting bulk sulfur into sulfur cuboids at the project storage site;
storing the sulfur cuboids in the intermediate layer to align with the grid of cells of the base layer;
laying polyvinyl chloride (PVC) on top of the high strength sulfur of the top layer to resist acid and moisture; and
accessing the sulfur cuboids on top of the base layer through a hatch positioned at the top layer.

19. The method of claim 17 , further comprising flexing the base layer between a normal mode and a flexible mode in response to subsidence below or near the first storage unit.

20. The method of claim 19 , wherein the project storage site further includes a second storage unit, the method further comprising:
assessing sulfur produced at the oil and gas field to determine a volumetric estimation of the sulfur of the first and second storage units;
analyzing land proximal to the oil and gas field to determine a location and size of a project storage site based on the volumetric estimation;
treating, via sulfur recovery unit, oil and gas produced by the oil and gas field to extract the sulfur as bulk sulfur;
processing, via a concrete and asphalt facility, bulk sulfur to form high strength sulfur; and
transporting high strength sulfur and bulk sulfur to the project storage site.

Assignees

• Saudi Arabian Oil Co

Inventors

• Hall-Thompson Bryan
• Alhuthali Humaid Ahmed

Classifications

• E02D29/045 Primary

  Underground structures, e.g. tunnels or galleries, built in the open air or by methods involving disturbance of the ground surface all along the location line; Methods of making them · CPC title