Mobile Proppant Silo Layout for Low-Dust Rapid Unloading
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Solution Overview
Problem
Current proppant supply systems for hydraulic fracturing face challenges such as large footprints, high dust generation, and slow unloading times, which are inadequate for the increasing demand due to advancements in drilling and fracturing technologies.
Innovation Solution
A mobile proppant supply system featuring integrated bucket elevators, drive-over loaders, and dual conveyors that allow for vertical storage, rapid unloading, and flexible layout, reducing dust and footprint while ensuring redundancy and efficient proppant delivery to blenders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional proppant supply systems (FracSander, Containerized, or Silo Systems) are used, then proppant can be stored and delivered, but the system occupies a large footprint area
Solution Approach 1:
The patent transitions from horizontal proppant storage (conventional systems requiring large ground area) to vertical storage using silos arranged in a bank. The bucket elevator system vertically transports proppant from the conveyor level up to the silo storage chambers, effectively utilizing the vertical dimension to reduce the horizontal footprint while maintaining adequate storage capacity and system reliability
2Productivity
If pneumatic transport trailers are used to fill silos, then proppant can be loaded, but significant amounts of respirable silica dust are generated
Solution Approach 1:
The patent introduces a drive-over loader with conveyor as an intermediary device between the pneumatic transport trailer and the silo. The trailer dumps proppant onto the conveyor belt, which then transports it to the silo. This intermediary conveyor system contains the proppant throughout transport, preventing dust generation while maintaining efficient loading productivity
Solution Approach 2:
The patent employs an enclosed conveyor belt system with sides and a hood that acts as a flexible enclosure to contain proppant during transport. This physical barrier prevents proppant from becoming airborne and generating dust, while the enclosed design allows for efficient material handling
3Ease of operation
If manual gate control is used to regulate proppant flow, then delivery rate can be controlled, but the process is slow and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical gate control system with an automated variable-speed conveyor belt system. The conveyor motor speed is electronically controlled to regulate proppant flow rate from the silo to the blender, eliminating manual intervention while increasing delivery speed and productivity through automated control mechanisms
4Quantity of substance
If multiple pneumatic trailers are used simultaneously to meet proppant demand, then sufficient proppant supply is achieved, but dust generation and footprint area are compounded
Solution Approach 1:
The patent merges multiple proppant supply streams into a single centralized silo bank system. Instead of operating multiple separate pneumatic trailers simultaneously (each generating dust), the system consolidates proppant intake through one or a few trailers that load a shared bank of silos. The enclosed conveyor system then distributes proppant from the silos to the blender, achieving the required proppant quantity while minimizing dust generation through centralized enclosed handling
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 significantly reduces the well pad footprint, minimizes dust generation, and enhances unloading efficiency, accommodating increased proppant demand while maintaining system reliability and flexibility.
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.