Proppant Conveyor System for Silica Dust Control

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Solution Overview

Problem

Hydraulic fracturing operations face significant challenges in reducing the risk of silica dust exposure for workers, as existing methods lead to substantial production and release of respirable crystalline silica during the delivery, blending, and mixing of proppants, posing health hazards and environmental concerns.

Innovation Solution

The development of a system and method that involves positioning sealed containers of proppant on a conveyor with hoppers and partitions to funnel proppant onto a conveyor belt, which is then conveyed through a shrouded portion to a chute, minimizing the release of silica dust through controlled discharge and gravity feed, thereby reducing exposure risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pneumatic delivery methods are used to transport proppant, then delivery speed and efficiency are improved, but silica dust is generated and released into the air

Engineering Contradiction:

Improveproppant delivery efficiencyVSAvoidsilica dust release

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a closed-loop conveyor system as an intermediary between the proppant source and the well site. This conveyor system includes enclosed belts, hoppers, and transfer mechanisms that mediate the proppant movement without exposing it to the air, thereby eliminating dust generation while maintaining efficient delivery

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a controlled, enclosed environment for proppant handling where the proppant moves through sealed conveyors, hoppers, and transfer mechanisms. This enclosed atmosphere prevents silica dust from mixing with the air, effectively eliminating the harmful release of respirable crystalline silica while maintaining productivity

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Ease of operation

If proppant is handled and transferred through open conveyors, then ease of operation is improved, but silica dust is produced and released

Engineering Contradiction:

Improveproppant handling simplicityVSAvoidsilica dust production

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent employs flexible enclosed conveyor belts and sealed hopper structures that wrap around and contain the proppant during handling and transfer. These enclosed structures prevent silica dust from escaping into the air while maintaining the operational simplicity of conveyor-based handling through automated mechanisms

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If proppant is discharged through gravity feed, then device complexity is reduced, but silica dust may be released into the air

Engineering Contradiction:

Improvedischarge system simplicityVSAvoidairborne silica particles

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent maintains a closed, controlled environment throughout the gravity feed discharge process. The proppant moves through enclosed hoppers and discharge mechanisms where the enclosed structure prevents silica dust from becoming airborne, eliminating the harmful effect while preserving the simplicity of gravity-based discharge

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 significantly reduces the production and release of silica dust, enhancing worker safety and environmental protection by minimizing airborne silica particles, as demonstrated by a four-fold reduction in respirable crystalline silica exposure compared to conventional pneumatic delivery methods.

Implementation Method 1

conveyed through a shrouded portion to a chute, minimizing the release of silica dust through controlled discharge and gravity feed

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

downwardly discharging proppant from each respective container... as proppant flows by gravity feed along the inclined lower inner portions

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS9969564B2Methods and systems to transfer proppant for fracking with reduced risk of production and release of silica dust at a well site

Publication Date: 2018.05.15 SANDBOX ENTERPRISES LLC

AI summary

Embodiments of methods and systems of transferring proppant for fracking to reduce risk of production and release of silica dust at a well site are provided. An embodiment of a method can include positioning a plurality of containers each having proppant for fracking contained therein onto a conveyor at a well site, downwardly discharging proppant from each respective container of the plurality of containers, funneling proppant from the one or more outlets of each of the plurality of containers through a plurality of conveyor hoppers, receiving proppant onto the conveyor belt, conveying proppant on the conveyor to a chute, and depositing the proppant into the chute for use in a blender or other location at the well site.