Multi-Component Granular Blending System for Hydraulic Fracturing
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Solution Overview
Problem
The oil and natural gas mining industries face challenges in efficiently delivering, storing, and blending large quantities of multi-component granular compositions, particularly at remote well sites, due to limited storage space and the need for precise mixing of proppants for hydraulic fracturing operations, which leads to inefficiencies and increased costs.
Innovation Solution
A coordinated system for on-site storage and blending of multi-component granular compositions, including a blender, storage containers with monitoring devices, central and ingredient feeders, feeder regulators, and a management system that dynamically monitors and adjusts the flow of materials to maintain predetermined blend mixture levels, ensuring efficient storage and blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If materials are stored in tractor trailer rigs that delivered them to the well site, then storage space is utilized, but driver and truck idle time increases and costs increase
Solution Approach 1:
The system divides the storage function from the delivery function by implementing separate on-site storage containers (silos) from the delivery trucks. This segmentation allows trucks to deliver materials and leave, while storage continues independently at the well site, eliminating the need for trucks to remain parked and reducing driver idle time while maintaining adequate storage capacity.
Solution Approach 2:
The patent introduces on-site storage containers as an intermediary between the delivery trucks and the blending operation. These containers serve as a buffer that decouples the delivery schedule from the consumption schedule, allowing trucks to deliver and depart while the stored materials continue to supply the blender, thereby reducing truck idle time while maintaining storage availability.
2Productivity
If large quantities of granular material are stored close to the well site, then storage efficiency improves, but available storage space is limited due to terrain and inaccessibility
Solution Approach 1:
The system employs nested storage containers where smaller storage units are placed within larger containment structures. The silos are designed with nested configurations that maximize the use of vertical space and utilize the internal volume of outer containers, thereby achieving high storage efficiency within the limited space available at remote well sites with difficult terrain.
Solution Approach 2:
The patent transitions from horizontal storage expansion to vertical storage utilization by implementing tall, narrow silo structures. This dimensional change allows the system to achieve large storage capacity without requiring additional horizontal footprint, effectively overcoming the space constraints imposed by difficult terrain and inaccessibility at well sites.
3Manufacturing precision
If precise blending of multi-component granular compositions is achieved, then proppant quality improves, but system complexity and monitoring requirements increase
Solution Approach 1:
The system implements feedback control through monitoring devices that continuously track the flow rates and composition of materials being blended. These devices provide real-time data to the control system, which automatically adjusts feeder operations to maintain precise blend ratios. This feedback mechanism achieves high manufacturing precision while managing system complexity through automated control rather than manual intervention.
Solution Approach 2:
The blending system is designed with automated monitoring and control capabilities that enable it to self-regulate the blending process. The system automatically detects composition variations and adjusts material flows without external intervention, achieving precise blending while reducing the operational complexity burden on personnel through self-managing control functions.
Data Source
AI summary
Embodiments of the present invention include a method and system for blending multi-component granular compositions such as proppant used in hydraulic fracturing in well drilling. The system includes the control and management of an on-site storage system for each of the components, regulating the delivery of specified quantities of each component to a well site, and coordinating the flow of materials into and out of the blender.