Mobile Proppant Handling Layout for Dust-Free Fast Unloading
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Solution Overview
Problem
Current proppant supply systems for hydraulic fracturing face challenges including dust generation, large footprint, and slow unloading times, which are inadequate to meet the increased demand for proppant due to advancements in drilling and fracturing technology.
Innovation Solution
A mobile proppant supply system featuring integrated bucket elevators, drive-over loaders, and dual conveyor systems that allow for gravity feeding and redundant proppant distribution, reducing dust and footprint while enhancing unloading efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pneumatic transport trailers are used to fill silos, then proppant can be transported to the frac site, but significant amounts of respirable silica dust are generated
Solution Approach 1:
The patent extracts the harmful pneumatic transport process and replaces it with a gravity-fed conveyance system. Proppant is loaded into enclosed containers at the source, transported to the frac site, and then discharged through enclosed chutes directly into the silo, eliminating the dust-generating pneumatic injection process entirely.
Solution Approach 2:
The patent employs enclosed conveyor systems and sealed chutes to contain proppant during transfer operations. These enclosed structures prevent proppant from becoming airborne and generating dust, while still allowing efficient gravity-fed movement of material from transport containers into storage silos.
2Productivity
If multiple pneumatic transport trailers are used simultaneously to unload silos, then unloading speed increases, but dust generation is compounded and pad footprint increases
Solution Approach 1:
The patent implements a continuous gravity-fed conveyance system that maintains steady proppant flow from transport containers through enclosed chutes into silos. This continuous enclosed operation eliminates intermittent dust generation events associated with pneumatic unloading, while maintaining high productivity through efficient gravity-based material movement.
Solution Approach 2:
The patent introduces enclosed conveyor systems and sealed transfer chutes as intermediary structures between transport containers and silos. These intermediaries provide a dust-free pathway for proppant transfer, allowing multiple containers to be unloaded simultaneously without compounding dust generation.
3Productivity
If proppant is drop-discharged from height between transfer points, then material can be moved efficiently, but dust forms due to aeration and splashing
Solution Approach 1:
The patent replaces open drop-discharge with enclosed conveyor systems and sealed chutes that contain proppant throughout the transfer process. This enclosure prevents aeration and splashing that would otherwise generate dust, while maintaining efficient material movement through gravity-fed conveyance.
4Productivity
If conventional silo systems are used with conveyors arranged between silos, then proppant can be delivered to the blender, but a relatively large pad footprint is required
Solution Approach 1:
The patent repositions conveyors from a horizontal arrangement between silos to a vertical arrangement beneath the silos. This dimensional change allows proppant to be discharged vertically from silos onto conveyors that run underneath, then transported horizontally to the blender. This configuration significantly reduces the horizontal space required, minimizing pad footprint while maintaining 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 minimizes dust generation, reduces the well pad footprint, and significantly improves unloading times, ensuring efficient proppant delivery and storage to meet the demands of hydraulic fracturing operations.
Implementation Method 1
a drive-over loader configured for gravity feeding of proppant by transports and for conveying the proppant to the silo
Data Source
AI summary
A mobile proppant delivery system may include a system for unloading proppant transport trailers, storing proppant in silos, and feeding proppant to frac operations. The system may include drive-over conveyors, swiveling distribution heads, internal silo bucket elevators, gravity feed, choke filling, and bases designed with internal conveying systems.