Wet Sand Proppant Processing System with Vibration Flow Control
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Solution Overview
Problem
Conventional methods for processing proppants, such as sand, in hydraulic fracturing operations are inefficient as they require drying sand before transportation to the wellsite, which increases costs and logistical challenges, and existing solutions, like the system by Morris, are not economically viable.
Innovation Solution
A system comprising in-feed and out-feed conveyors, primary and secondary feed bin assemblies, a final transport conveyor, and a control unit, allowing for the direct transportation and processing of wet sand from an offsite facility to the wellsite, with vibration units and flow control mechanisms to manage the sand flow efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sand is dried before transportation to the wellsite, then the sand can be stored and transported more efficiently, but the processing time and costs increase significantly
Solution Approach 1:
The system performs the drying action at the offsite facility before delivery, so that when the sand reaches the wellsite it is already in the desired dry state. This preliminary processing eliminates the need for time-consuming drying operations at the wellsite, directly resolving the contradiction between storage efficiency and processing time.
Solution Approach 2:
The patent introduces an intermediary drying facility located offsite that serves as a intermediate processing point. This intermediary structure allows sand to be dried in a controlled environment before final delivery to the wellsite, separating the drying function from the wellsite operations and reducing overall processing time.
2Loss of time
If wet sand is transported directly to the wellsite, then processing time is reduced, but the sand flow control and handling become more difficult
Solution Approach 1:
The system employs vibration units that mechanically vibrate the sand as it moves through the conveyors and bins. This vibration prevents wet sand from sticking to surfaces, maintains proper flow characteristics, and enables effective flow control despite the sand's wet state, thus resolving the contradiction between reduced processing time and ease of operation.
Solution Approach 2:
The patent replaces traditional mechanical flow control mechanisms with a combination of vibration-based flow management and controlled gate openings. This substitution allows wet sand to be moved and controlled more effectively without relying solely on mechanical conveyance, addressing the flow control difficulties associated with wet sand transport.
3Quantity of substance
If conventional drying and storage facilities are used, then sand can be stored efficiently, but the equipment complexity and costs increase
Solution Approach 1:
The system divides the sand handling operation into separate functional segments: offsite drying facility, transport conveyors, and wellsite receiving bin. This segmentation allows each component to be optimized independently, reducing overall equipment complexity while maintaining efficient storage and processing capabilities.
Solution Approach 2:
The vibration units and flow control mechanisms are designed to handle both wet and dry sand conditions, providing multi-functional capability. This universality reduces the need for separate equipment for different sand states, thereby reducing overall equipment complexity and costs while maintaining storage efficiency.
4Ease of manufacture
If wet sand is processed directly at the wellsite, then logistical costs are reduced, but the processing efficiency decreases
Solution Approach 1:
The system performs the drying action at the offsite facility before delivery, so that when the sand reaches the wellsite it is already in the desired dry state. This preliminary processing enables efficient wellsite operations while maintaining cost-effectiveness through reduced logistical requirements, resolving the contradiction between logistical costs and processing efficiency.
Solution Approach 2:
The patent establishes a continuous flow system where sand moves seamlessly from the offsite facility through conveyors to the wellsite bin without interruption. This continuity eliminates idle time and inefficiencies, maintaining high processing efficiency while reducing logistical costs through streamlined operations.
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
Enables the efficient and cost-effective delivery and use of wet sand in hydraulic fracturing operations by controlling the sand flow and processing it directly at the wellsite, reducing the need for pre-drying and enhancing operational efficiency.
Implementation Method 1
Vibration units positioned proximate to the respective bins are adapted, along with the gates, to be selectively controlled by an operator
Data Source
AI summary
The proppants processing system comprises one or more in-feed conveyors, one or more out-feed conveyors, one or more primary feed bin assemblies, one or more secondary bin assemblies, the primary and secondary bin assemblies each comprising one or more bins and one or more bin conveyors. The proppants processing system further comprises a final transport conveyor and a control unit adapted to control flow of the proppants. A method of processing proppants, the method comprising the steps of providing proppants comprising dry or wet sand; using an in-feed conveyor, transferring the proppants from a transport vehicle to one or more bins of a primary feed bin assembly; moving the proppants from the one or more bins to a feed bin conveyor; moving the proppants from the feed bin conveyor to a final transport conveyor; and using the final transport conveyor, moving the proppants to a blender.