Bottom-Dump Pneumatic Flow Control With Buffered Proppant Pods
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Solution Overview
Problem
Current methods for handling proppant delivery in hydraulic fracturing operations face inefficiencies, particularly in transitioning between pneumatic and mechanical conveying systems, and in managing varying delivery rates, which can lead to overloading and uneven flow, requiring additional equipment and expertise.
Innovation Solution
A material handling system comprising a chassis with a mechanical conveyor system and a pneumatic conveyor system, including multiple pods connected in parallel, with sensors for flow control, allowing for automatic regulation of proppant flow from a storage container to an off-system destination, enabling efficient pneumatic conveying and preventing overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple pods are connected in parallel to convey proppant from storage container to pneumatic conveying line, then the pneumatic conveying rate is maximized, but the system complexity increases
Solution Approach 1:
The system divides the proppant flow path into multiple parallel pods (first pod, second pod, etc.), each capable of conveying proppant independently to the pneumatic conveying line. This segmentation allows the system to maximize conveying rate through parallel operation while managing complexity by using identical, modular pod units that can be added or removed based on capacity requirements.
2Reliability
If automatic flow control with sensors is implemented, then overloading is prevented and flow uniformity is improved, but the device complexity increases
Solution Approach 1:
Each pod is equipped with level sensors (first level sensor, second level sensor, etc.) that provide feedback on proppant levels within the pod. This feedback enables automatic control of the flow control gates, opening them when proppant reaches a certain level and closing them when the pod is emptied, thereby preventing overloading and ensuring uniform flow without requiring complex external control systems.
Solution Approach 2:
The pods are designed to self-regulate their own filling and emptying cycles through the integrated level sensors and flow control gates. Each pod automatically knows when to receive proppant from the storage container and when to discharge it to the pneumatic conveying line, eliminating the need for centralized complex control mechanisms.
3Adaptability or versatility
If pods are used as buffer between mechanical conveyor and pneumatic conveying line, then the transition between disparate conveying rates is facilitated, but the device complexity increases
Solution Approach 1:
The pods act as intermediate buffer chambers that receive proppant from the mechanical conveyor system in advance and hold it ready for pneumatic conveying. This preliminary action allows the mechanical conveyor to operate at its own rate while the pods accumulate material, then release it to the pneumatic system at the required rate, bridging the disparity between the two conveying mechanisms without requiring complex rate-matching controls.
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 maximizes pneumatic conveying rates while preventing overloading, facilitates seamless transition between delivery methods, and provides a buffer for disparate conveying rates, ensuring continuous and efficient operation with reduced need for additional equipment and expertise.
Implementation Method 1
a pneumatic conveying system configured to convey the proppant to an off-system destination (e.g., a silo or the like)
Implementation Method 2
Each pod has a full level sensor configured to sense when the pod is full or close to full, and an empty level sensor configured to sense when the pod is empty or close to empty
Implementation Method 3
providing a flow control gate for each pod that controls a flow of proppant from each pod to the pneumatic conveying line
Data Source
AI summary
A material handling system includes a chassis, a conveyor system supported by the chassis, a pneumatic conveying system supported by the chassis and a storage container supported by the chassis. The conveyor system is configured to convey a granular material from a material unloading station to an inlet of the storage container. Multiple pods are beneath the storage container. Each pod is connected to the storage container by a corresponding pod fill line. A pneumatic conveying line is beneath the pods. The pneumatic conveying line is connected to each of the pods. Each pod has a full level sensor configured to sense when the pod is full or close to full, and an empty level sensor configured to sense when the pod is empty or close to empty.