Flexible Bellows Filter Housing for Proppant Dust Control
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Solution Overview
Problem
Current methods for reducing silica dust emission during hydraulic fracturing, such as using loose-fitting fabric filter bags and metal manifolds with vacuum systems, are ineffective in preventing airborne silica particles from escaping, posing inhalation hazards and obstructing visibility for workers.
Innovation Solution
A filtering and containment system comprising custom-fit proppant reduction covers, vent socks, trailer skirts, stinger covers, and pod covers with integrated vacuum adapters and waterproof materials to control air pressure and capture dust, allowing for clear visibility and efficient dust reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If loose-fitting fabric filter bags are used to reduce dust emission, then some dust capture is achieved, but the bags are easily blown off the vent hatch allowing large amounts of dust to escape
Solution Approach 1:
The patent uses a flexible bellows-shaped filter housing that can expand and contract with pressure changes while maintaining a secure seal on the vent hatch. This flexible structure reliably captures dust particles while adapting to pressure fluctuations, preventing the filter from being blown off unlike rigid or loose-fitting alternatives
Solution Approach 2:
The filter housing incorporates a bellows shape with specific local expansions and contractions that create effective dust capture zones. The housing includes a collection chamber at the bottom and filter elements positioned strategically to intercept dust particles while allowing controlled air flow through the vent hatch
2Object-affected harmful factors
If loose-fitting fabric filter bags are used, then dust reduction is attempted, but workers cannot look down into the vent hatch to monitor proppant levels
Solution Approach 1:
The bellows-shaped filter housing includes transparent or translucent panels that allow workers to visually monitor proppant levels inside the vent hatch while the flexible structure maintains effective dust capture. The transparency provides visibility without compromising the filter's ability to reduce dust emission
Solution Approach 2:
The filter housing extends vertically in a bellows configuration, creating a three-dimensional structure that provides both dust capture capability and viewing access. The vertical expansion and contraction of the bellows allows monitoring of proppant levels while maintaining effective filter coverage
3Object-affected harmful factors
If metal manifolds with vacuum systems are used to reduce dust, then some dust capture is achieved, but large amounts of proppant are collected which can then be re-incorporated into the fracking process
Solution Approach 1:
The bellows filter housing creates a contained environment that captures dust particles through filtration while allowing proppant to pass through and be discharged. The flexible filter elements trap fine dust particles while permitting larger proppant particles to flow through to the discharge point, preventing proppant loss
Solution Approach 2:
The filter housing includes a collection chamber specifically designed to capture dust particles while maintaining a separate discharge path for proppant. The local differentiation between the filter capture zone and the discharge zone ensures that dust is retained while proppant flows freely to be discharged, preventing re-incorporation into the fracking process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively minimizes airborne silica dust emissions during proppant handling and transfer, enhancing worker safety and operational efficiency by maintaining internal pressure and preventing dust escape while allowing air release and visibility monitoring.
Implementation Method 1
A filter assembly is provided that covers and filter a first aperture of the chamber to reduce an emission of airborne proppant
Implementation Method 2
A vacuum adapter mates with a second port of the chamber to supply a negative pressure to the chamber during the filling process
Data Source
AI summary
Apparatus and method for reducing airborne proppant adjacent a fracking material handling system. In some embodiments, a proppant storage chamber is configured to store a volume of proppant. A blow-in adapter mates with a first port of the chamber to facilitate a flow of proppant into the chamber at an inlet pressure. A filter assembly covers and filter a first aperture of the chamber to reduce an emission of airborne proppant during the transfer of the proppant into the proppant storage chamber. A vacuum adapter mates with a second port of the chamber to supply a negative pressure to the chamber during the filling process to maintain an internal pressure within the chamber below a predetermined pressure threshold.