Conveyor Belt Proppant Metering for Hydraulic Fracturing Blenders
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Solution Overview
Problem
Hydraulic fracturing blender augers are prone to jamming, inaccurate in metering proppant flow rates, and inefficient in power consumption, with existing solutions like nuclear densitometers being costly and difficult to maintain.
Innovation Solution
A proppant metering and loading apparatus using a continuous loop conveyor belt with a measurement device, such as a weigh scale or optical scanner, to accurately measure and control proppant flow into a hydraulic fracturing blender, replacing augers and reducing power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If augers are used to transfer proppant, then proppant can be moved from source to blending device, but the augers are prone to jamming and unreliable operation
Solution Approach 1:
The patent replaces the auger mechanical system with a belt conveyor system that has no moving parts in contact with the proppant. The belt conveyor moves proppant through a trough using friction and gravity, eliminating the screw mechanism that causes jamming. This substitution resolves the reliability issue by removing the crevices and moving components that trap and compact proppant.
Solution Approach 2:
The patent extracts the measurement function from the proppant transfer system by placing a scale beneath the discharge point. This separates the transfer function (performed by the simple belt conveyor) from the measurement function (performed by the scale), allowing accurate metering without complex modifications to the conveyor mechanism itself.
2Measurement precision
If augers are used to meter proppant, then proppant flow rate can be controlled, but the flow rate measurement is inaccurate and problematic
Solution Approach 1:
The patent replaces complex mechanical flow rate measurement methods with a simple gravitational discharge system combined with a scale. The proppant flows freely under gravity from the discharge chute, and the scale directly measures the weight over time, providing accurate flow rate measurement without complex mechanical sensors or calculations.
Solution Approach 2:
The proppant itself serves as the measurement medium by accumulating on the scale. The system uses the natural weight of the discharged proppant to provide direct measurement, eliminating the need for separate flow sensors, RPM sensors, or complex calculation systems that would be required with auger-based metering.
3Productivity
If augers are used to transfer proppant, then proppant delivery is achieved, but power consumption is inefficient
Solution Approach 1:
The patent replaces the high-power auger system with a low-power belt conveyor that uses friction and gravity to move proppant. The belt system requires significantly less power because it doesn't need to overcome the friction of rotating screws against the proppant mass, nor does it need to force proppant through tight crevices. The gravity-assisted discharge further reduces power requirements.
Solution Approach 2:
The patent designs the conveyor system to utilize gravity by positioning the discharge point at a lower elevation than the loading point. This gravitational potential energy conversion reduces the mechanical work required by the conveyor motor, improving overall energy efficiency while maintaining productive proppant delivery.
4Measurement precision
If nuclear densitometers are used to measure slurry density, then proppant amount can be calculated, but the equipment is costly, difficult to maintain, and requires radioactive materials
Solution Approach 1:
The patent replaces expensive, complex nuclear densitometers with simple, inexpensive scales that have no radioactive materials and require minimal maintenance. The scale is a basic weighing device that can be easily calibrated and replaced if needed, eliminating all the complexity and safety concerns associated with nuclear measurement equipment.
Solution Approach 2:
The patent replaces the complex nuclear physics-based measurement system with a simple mechanical/electrical weighing system. The scale directly measures the weight of proppant discharged, providing all necessary measurement data without requiring density calculations, radioactive sources, or complex signal processing equipment.
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 conveyor belt system provides accurate and reliable proppant flow measurement and control, reducing jamming and power consumption, and eliminating the need for costly densitometers, while ensuring efficient and precise slurry production.
Implementation Method 1
a continuous loop conveyor belt...configured to receive proppant from a source location... and deliver the proppant to a blender device
Implementation Method 2
a measurement device (e.g. weigh scale, optical scanner, or radiometric device) operatively coupled to the continuous loop conveyor belt and configured to provide an indication of amount (e.g. weight) of the proppant
Data Source
AI summary
A proppant metering and loading apparatus for a hydraulic fracturing blender unit is provided. A continuous loop conveyor belt receives proppant from a source location on the blender, such as a hopper, and delivers the proppant to a blender device of the blender. A measurement device (e.g. weigh scale) measures and provides an indication of amount (e.g. weight, volume and/or density) of the proppant delivered to the blender device by the conveyor belt.