Bucket Conveyor Bulk Material Transfer System
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Solution Overview
Problem
Pneumatic conveying of bulk materials in well operations is time-consuming, leads to high detention costs, generates dust and noise, and requires extensive dust control equipment, limiting accessibility and increasing operational costs.
Innovation Solution
A bucket conveyor system that uses pre-filled or on-location filled containers to directly transfer bulk materials into a storage/delivery system, eliminating the need for pneumatic transfer and reducing dust and noise generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pneumatic conveying is used to transfer bulk material from tank truck to storage/delivery system, then material transfer can be achieved, but the process is time-consuming and leads to high detention costs
Solution Approach 1:
The invention extracts and eliminates the pneumatic conveying system from the material transfer process. Instead of using pneumatic conveyance, the system uses direct mechanical transfer methods (such as gravity feed chutes or mechanical conveyors) to move bulk material directly from the tank truck to the storage/delivery system, thereby removing the time-consuming pneumatic process while maintaining transfer capability
Solution Approach 2:
The invention replaces the pneumatic conveying system (which uses compressed air) with a mechanical transfer system. This substitution eliminates the need for complex pneumatic infrastructure and reduces transfer time by using more direct mechanical means such as gravity-fed chutes or mechanical conveyors that can move material more quickly and efficiently
2Productivity
If pneumatic conveying is used to deliver bulk material, then material can be transported, but large amounts of dust and noise are generated
Solution Approach 1:
The invention extracts and removes the pneumatic conveying mechanism that generates dust and noise. By eliminating the high-velocity air flow through which material is conveyed, the source of dust generation and noise is removed entirely, while material transport is achieved through alternative dust-controlled mechanical means
Solution Approach 2:
The invention employs enclosed conveying channels or hoppers with sealed surfaces that prevent dust from escaping into the environment. These enclosed structures contain the bulk material during transfer, preventing dust generation while allowing continuous material flow from the tank truck to storage
3Object-affected harmful factors
If dust control equipment is added to control dust during conveying, then dust can be captured, but additional cost and equipment complexity are introduced
Solution Approach 1:
The invention extracts and eliminates the need for separate dust control equipment by removing the pneumatic conveying system that generates dust in the first place. By using enclosed mechanical transfer methods, dust control becomes inherent to the transfer mechanism rather than requiring additional captured and disposed of dust
Solution Approach 2:
The invention converts the potential harm of dust generation into a benefit by designing the mechanical transfer system with enclosed channels and sealed surfaces. The same structural elements that enable material transfer also serve as dust containment barriers, turning what would be a harmful byproduct into an opportunity for integrated dust control without additional equipment
4Productivity
If multiple transfer points are used between storage/delivery systems and blender, then material can be delivered, but dust release and ventilation requirements increase
Solution Approach 1:
The invention merges multiple separate transfer points into a single integrated enclosed conveying system. By combining the transfer operations into one continuous enclosed pathway from storage/delivery system to blender, the number of potential dust release points is reduced, and the entire transfer process is contained within a single sealed infrastructure that requires minimal ventilation
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 bucket conveyor system reduces detention costs, minimizes dust and noise, and decreases equipment footprint by enabling quicker and more efficient bulk material transfer, while also lowering the need for dust control equipment.
Implementation Method 1
A bucket conveyor system may then deliver the bulk material from the fill hopper into an internal storage volume of the storage/delivery system
Data Source
AI summary
In accordance with embodiments of the present disclosure, systems and methods for using containers of bulk material along with a bucket conveyor system, instead of a pneumatic transfer process, to move the bulk material from a transportation unit to a storage/delivery system are provided. A transportation unit may deliver one or more containers full of bulk material toward a fill hopper of the bucket conveyor system. The containers may be positioned proximate the fill hopper to release the bulk material directly into the fill hopper. The bucket conveyor may deliver the bulk material from the fill hopper into the storage/delivery system. Since the containers are maneuverable into a position to output bulk material directly into the fill hopper and without pneumatic transfer, the bucket conveyor system may enable a cleaner and more efficient bulk material transfer at the site.