Corrugated Storage Container Funnel Design for Proppant
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Solution Overview
Problem
Conventional storage containers are not optimized for efficiently transporting and storing large quantities of proppant, such as silica sand, which is required in hydraulic fracturing operations, leading to difficulties in handling and maintaining the material at fracturing sites, and requiring significant capital investment in storage facilities.
Innovation Solution
A corrugated bulk storage container with a unique design featuring an upper box section and a lower funnel section, optimized for maximum interior volume, capable of storing between 50,000 and 51,000 pounds of proppant, with angled side plates and radiused corner sections to facilitate smooth discharge and reduce friction, and fabricated from materials like stainless steel or plastic with non-stick coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional storage containers are used for proppant, then storage capacity is limited, but capital investment in storage facilities increases
Solution Approach 1:
The container is divided into an upper box section for storage and a lower funnel section for discharge, allowing the storage system to be modular and transportable while maintaining large capacity. This segmentation enables deployment at fracturing sites without requiring permanent facility infrastructure.
Solution Approach 2:
The container utilizes vertical space efficiently with a height of 127 inches, transitioning from horizontal expansion to vertical utilization. This dimensional approach maximizes storage capacity within transportable dimensions, reducing the need for extensive facility infrastructure.
2Volume of stationary object
If conventional container structures are used, then manufacturing is simpler, but interior volume and storage capacity are reduced
Solution Approach 1:
The funnel section incorporates radiused corner sections with specific radii (8 inches at top, 2 inches at bottom) to optimize material flow and maximize interior volume. The curved surfaces eliminate dead zones and improve discharge efficiency while maintaining manufacturability through standard forming processes.
Solution Approach 2:
The side plates are angled at greater than 31 degrees (optimally 37 degrees) to maximize interior volume while ensuring proper material flow. This parameter optimization balances storage capacity with discharge performance without requiring complex structural modifications.
3Ease of operation
If standard funnel angles are used, then discharge is adequate, but friction and material flow are impeded
Solution Approach 1:
Radiused corner sections with 8-inch top radii and 2-inch bottom radii create smooth transitions that eliminate sharp corners where material can bridge or stall. This curvature reduces friction and promotes continuous material flow to the outlet.
Solution Approach 2:
The side plate angle is optimized to greater than 31 degrees (preferably 37 degrees) to achieve the optimal balance between storage volume and discharge flow. This angle reduces frictional forces while maintaining structural integrity and maximizing interior capacity.
4Productivity
If conventional handling equipment is used, then handling capability is limited, but operational efficiency decreases
Solution Approach 1:
The container design with its optimized funnel geometry and outlet configuration enables self-discharge of proppant through gravity flow. This self-service capability reduces the need for additional handling equipment and manual intervention, improving operational efficiency while maintaining ease of operation.
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 container effectively transports and stores large volumes of proppant, enhancing operational efficiency and reducing capital investment by maximizing storage capacity while ensuring smooth handling and discharge, even with 'wet' or 'dirty' proppant, and can be used in various bulk material applications beyond hydraulic fracturing.
Implementation Method 1
angled side plates and radiused corner sections to facilitate smooth discharge and reduce friction
Data Source
AI summary
A corrugated storage container is provided that includes a box section with a top wall and corrugated side walls and end walls, a tapered funnel section extending downwardly from the box section and a frame supporting the box section and the funnel section. The frame includes vertical posts that are integrally joined with the box section and a base section formed at the lower end of the vertical posts and supporting the funnel section. The configuration of the corrugated storage container provides approximately 600 cubic feet of enclosed interior volume capable of storing between 50,000 and 51,000 pounds of bulk material.