Modular Gravity-Fed Material Delivery System for High-Volume Blending
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Solution Overview
Problem
Current proppant delivery systems to oil and gas well sites are inefficient, with pneumatic and conveyor systems delivering at rates less than 10,000 pounds per minute, requiring large footprints, high power consumption, and prone to breakdowns, and causing silica dust ejection and material loss.
Innovation Solution
A modular material delivery system comprising a primary base module, surge modules, and material containers that allow for direct gravity-fed delivery to a blender hopper, featuring a surge hopper with a discharge gate and container actuators for efficient and controlled material distribution, capable of delivering over 30,000 pounds per minute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pneumatic or conveyor systems are used to deliver proppant, then material can be transported to the blender hopper, but the delivery rate is limited to less than 10,000 pounds per minute
Solution Approach 1:
The system is divided into modular components including a primary base module, secondary base module, surge module, and container module that can be independently assembled and configured. This segmentation allows for scalable capacity while maintaining simple individual component designs, resolving the contradiction between high delivery rate and system complexity.
Solution Approach 2:
The system transitions from horizontal conveyor systems to a vertical gravity-fed configuration where material flows downward through elevated containers and surge hoppers. This dimensional change eliminates complex mechanical conveyance while achieving higher delivery rates through gravitational acceleration and optimized flow paths.
2Productivity
If conveyor systems are used for proppant delivery, then material transport is achieved, but the system requires a large footprint on the work site
Solution Approach 1:
The system utilizes vertical stacking of containers and surge hoppers to achieve high delivery capacity within a compact horizontal footprint. By transitioning from horizontal material flow to vertical gravity-fed configuration, the system minimizes ground space requirements while maintaining or improving delivery capability.
Solution Approach 2:
The modular components are designed to be stacked and nested vertically, with containers positioned on surge modules that are themselves supported by base modules. This nested arrangement maximizes vertical space utilization and minimizes the horizontal footprint while preserving delivery capacity.
3Productivity
If conveyor systems are used to deliver proppant, then material can be transported, but power consumption increases
Solution Approach 1:
The system is configured to utilize gravitational potential energy by elevating containers and surge hoppers above the blender hopper. Material flows downward through gravity-fed chutes and discharge gates, eliminating the need for powered conveyor mechanisms and significantly reducing power consumption while maintaining material transport capability.
Solution Approach 2:
The gravity-fed design allows the system to self-transport material without external power input. The elevated position of containers and surge hoppers creates natural gravitational flow that moves proppant through the system and into the blender hopper, making the system self-sufficient regarding power consumption.
4Productivity
If conveyor systems are used for proppant delivery, then material transport is achieved, but silica dust is ejected and proppant loss occurs
Solution Approach 1:
The system converts the potential harm of dust generation into a benefit by using enclosed gravity-fed chutes and controlled discharge gates. The enclosed flow paths contain dust within the system while gravity ensures complete material delivery, transforming what could be a harmful dust-generating open conveyor system into a contained, efficient delivery system that prevents both dust ejection and material loss.
5Productivity
If conveyor systems are used to deliver proppant, then material can be transported, but the likelihood of breakdown increases due to complex mechanical structures
Solution Approach 1:
The system replaces complex mechanical conveyor systems with a gravity-fed design that eliminates motors, belts, chains, and other powered mechanical components. Material transport is achieved through gravitational force and controlled discharge mechanisms, significantly reducing moving parts and potential failure points while maintaining material delivery 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
The system achieves a 200% faster delivery rate compared to existing systems, reduces downtime and dust generation, and can store up to 120 tons of material for immediate gravity-fed use, enhancing operational efficiency and safety.
Implementation Method 1
direct gravity-fed delivery to a blender hopper
Implementation Method 2
direct gravity-fed delivery to a blender hopper
Data Source
AI summary
The present invention is a modular system for delivering material directly to a blender hopper. The system includes primary base and optional secondary base modules supporting surge hoppers which receive material from material containers. The surge hopper may then dispense the material directly and rapidly to the blender hopper by gravity feed. During continuous operation, exhausted material containers may be removed from the surge hoppers and replaced with full material containers as material empties from the surge hoppers. This allows steady, high-volume flow of material to the blender hopper.