Electric Conveyor Proppant Metering for Hydraulic Fracturing
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Solution Overview
Problem
Existing proppant supply systems for hydraulic fracturing face challenges such as inconsistent slurry concentration, excessive dust generation, and large footprint, due to reliance on independent metering systems and hydraulically driven conveyors, which limit efficiency and safety.
Innovation Solution
A proppant supply system utilizing an electrically driven, enclosed conveyor to control proppant discharge rate into a blender based on conveyor speed, eliminating the need for independent metering systems and incorporating multiple conveyors for redundancy, while minimizing dust generation through enclosed designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an independent metering system is used to control proppant discharge rate, then proppant delivery rate can be controlled, but device complexity increases and consistent slurry concentration cannot be maintained
Solution Approach 1:
The patent combines the metering function with the conveyor system by making the conveyor itself the metering device. The conveyor's speed and capacity are used to control and measure proppant discharge rate, eliminating the need for a separate independent metering system. This integration simplifies the overall device complexity while maintaining precise control over proppant delivery to achieve consistent slurry concentration.
Solution Approach 2:
The conveyor system is designed to perform multiple functions: it conveys proppant from storage to the blender, meters the discharge rate through its controlled speed, and provides mechanical transport. By making the conveyor multi-functional, the patent eliminates the need for dedicated separate metering equipment, reducing device complexity while maintaining measurement precision.
2Object-generated harmful factors
If an enclosed conveyor design is used, then dust generation is reduced, but device complexity increases
Solution Approach 1:
The patent employs an enclosed conveyor design where flexible or rigid enclosures (shells) are used to contain the conveyor belt and proppant movement. This enclosure prevents proppant from exposing to the environment and generating dust, while the enclosed structure itself manages the complexity by integrating the containment function into the existing conveyor framework rather than adding separate complex dust control systems.
3Reliability
If multiple conveyors are used for redundancy, then system reliability improves, but device complexity and footprint increase
Solution Approach 1:
The patent divides the proppant delivery system into multiple independent conveyor units that can operate separately. Each conveyor is a segmented, modular unit that can be independently controlled and maintained. This segmentation provides redundancy - if one conveyor fails, others can continue operation - while keeping each individual unit relatively simple and manageable, thus balancing reliability improvement with controlled complexity.
4Manufacturing precision
If hydraulically driven conveyors are used, then proppant discharge rate can be controlled, but manufacturing precision and consistency are compromised
Solution Approach 1:
The patent replaces hydraulic drive systems with electrically driven conveyors. Electrical motors provide more precise and consistent speed control through standard electrical controls (VFDs, encoders) compared to hydraulic systems. This substitution maintains the ability to control discharge rate while improving manufacturing precision and consistency, as electrical control systems are generally easier to manufacture and calibrate more accurately than hydraulic systems.
Data Source
AI summary
A proppant supply system can include a fluid supply system including a blender configured to receive and mix liquid and proppant to form a proppant slurry. and an electrically driven conveyor configured and arranged for direct and metered delivery of proppant to the blender. The proppant supply system can include a proppant source configured to discharge proppant to the conveyor. and a control system for controlling a speed of the conveyor, to control a rate at which proppant is delivered to the blender.