Dual Proppant Delivery System for Rapid Offloading
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Solution Overview
Problem
Pneumatic conveying of bulk materials in well operations is time-consuming, costly, and generates excessive dust and noise, with limited space and equipment accessibility issues at well sites, leading to inefficiencies and high detention costs.
Innovation Solution
A system utilizing multiple pre-filled or on-site filled containers for bulk material transfer directly into a blender receptacle via gravity feed, eliminating the need for pneumatic transfer and reducing dust and noise generation, while allowing for efficient and rapid offloading of tank trucks.
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 is achieved, but the process is time-consuming and leads to high detention costs
Solution Approach 1:
The patent extracts the bulk material directly from the tank truck into the blender hopper, eliminating the intermediate storage/delivery system and pneumatic conveying equipment. This direct extraction approach removes the time-consuming pneumatic transfer step while maintaining continuous material supply to the blender.
Solution Approach 2:
The patent introduces a bridge conveyor as an intermediary device that directly connects the tank truck outlet to the blender hopper. This mediator enables direct material transfer without pneumatic conveying, reducing transfer time and eliminating the need for intermediate storage systems.
2Productivity
If pneumatic conveying is used to deliver bulk material, then material is moved, but large amounts of dust and noise are generated
Solution Approach 1:
The patent replaces the pneumatic conveying system (which uses compressed air and generates dust and noise) with a mechanical bridge conveyor system. The conveyor provides controlled, enclosed material transport that eliminates turbulent air flow, thereby preventing dust generation and reducing noise while maintaining delivery capability.
3Quantity of substance
If tank trucks are positioned for pneumatic filling, then bulk material can be loaded, but limited space and accessibility issues arise at well sites
Solution Approach 1:
The bridge conveyor acts as a fixed intermediary structure that remains stationary at the well site. Tank trucks can be positioned anywhere near the blender, and the conveyor bridge provides a fixed transfer path, eliminating the need for trucks to access specific pneumatic filling positions. This improves accessibility while maintaining full loading capacity.
4Productivity
If traditional material handling systems with multiple transfer points are used, then material can be moved from storage to blender, but dust release and ventilation requirements increase
Solution Approach 1:
The patent merges the material transfer function directly into the blender hopper by extending the bridge conveyor to deliver material directly into the hopper. This eliminates separate transfer points and intermediate handling stages, creating a continuous enclosed transfer path that prevents dust release throughout the entire material handling process.
Solution Approach 2:
The patent extracts the material transfer operation from the traditional multi-point handling system and consolidates it into a single direct conveyor path. By removing intermediate transfer points, the system eliminates multiple opportunities for dust release and reduces ventilation requirements while maintaining full material handling capability.
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
This approach reduces detention costs, minimizes dust and noise pollution, and enhances operational efficiency by enabling quicker bulk material delivery and handling, with reduced equipment footprint and setup time.
Implementation Method 1
The bulk material is transferred from the tank truck pneumatically. More specifically, the bulk material is blown pneumatically from the tank truck into an on-location storage/delivery system
Implementation Method 2
during the pneumatic conveying process, the bulk material is moved from the tank truck to the storage/delivery system in a turbulent manner, leading to large amounts of dust and noise generation
Implementation Method 3
The air used for conveying the material must be vented from the storage tank and typically carries an undesirable amount of dust with it
Data Source
AI summary
In accordance with presently disclosed embodiments, systems and methods for using containers, instead of pneumatic transfer, to move bulk material from a transportation unit to a blender receptacle (e.g., hopper or mixer of a blender) are provided. A transportation unit may deliver multiple containers of bulk material to the well site, where multiple conveyors may deliver the containers to a location proximate the blender receptacle. Openings at the bottom of the containers are arranged adjacent one another so that the load of two containers may be delivered to the tight space occupied by the blender receptacle. Since the transportation unit is able to unload the containers of bulk material without pneumatic transfer, the containers may enable a cleaner and more efficient bulk material transfer at the site.