Wet Sand Proppant Dispensing System with Vibration and Dust Control
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Solution Overview
Problem
The hydraulic fracturing industry faces challenges in transporting and dispensing sand due to the cohesiveness of wet sand, which leads to discharge issues and increased costs, and there is a need to address dust mitigation and compliance with emerging regulatory requirements regarding silica dust exposure.
Innovation Solution
The system utilizes a vibrator assembly in proppant containers to facilitate the use of wet sand, combined with a wash system and automated flow control to ensure proper dispensation and flow rate management, and incorporates dust mitigation strategies such as misting systems, baghouses, and agglomerating yokes to manage dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If wet sand is used in containers for transport, then transportation costs are reduced and dust emissions are minimized, but the sand agglomerates into a mass that will not discharge properly from the container
Solution Approach 1:
The patent applies a vibrator assembly that generates mechanical vibrations to disrupt the cohesive bonds between wet sand particles. The vibrator contacts the sand mass and creates oscillatory forces that break agglomerations and enable proper discharge through the discharge gate, resolving the contradiction between using wet sand for cost reasons and achieving easy discharge operation
2Ease of operation
If sand is dried before use in hydraulic fracturing, then discharge problems are eliminated, but the cost of recouping capital investment in drying equipment increases
Solution Approach 1:
Instead of drying the sand, the invention uses a vibrator assembly to mechanically disrupt the cohesive bonds in wet sand, eliminating the need for expensive drying equipment. The vibrator contacts the sand mass and creates oscillatory forces that prevent agglomeration and enable smooth discharge, achieving easy operation without the capital investment cost of drying infrastructure
Solution Approach 2:
The invention converts the harmful effect of wet sand agglomeration into a beneficial state by using vibration to control the sand flow. Rather than removing water through drying, the system uses vibrational energy to manage the cohesive properties of wet sand, turning a problem into a controllable characteristic that enables discharge without expensive processing equipment
3Productivity
If workers are exposed to sand dust during handling, then productivity is maintained, but regulatory compliance with silica dust exposure limits becomes problematic
Solution Approach 1:
The invention converts the harmful dust-generating effect of dry sand handling into a beneficial approach by using wet sand. The vibrator assembly enables efficient handling of wet sand without creating airborne dust, thus maintaining productivity while eliminating the harmful silica dust exposure that would require regulatory compliance measures
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 allows for the efficient transportation and dispensing of wet sand without the need for expensive drying equipment, reduces dust exposure, and ensures compliance with regulatory standards by improving sand flow and handling while minimizing dust emissions.
Implementation Method 1
A vibrator assembly may be used on these containers in a manner that permits utilization of wet sand
Implementation Method 2
A wash system may be utilized alone or in combination with the vibrator. The wash system sprays into a container inlet and washes sand towards a container outlet
Implementation Method 3
A misting system is provided for the mitigation of dust. The spray head assembly is configured to emit a fine mist encompassing the discharge area such that water droplets coalesce on dust particles
Implementation Method 4
A cover is provided that encompasses the discharge area for containment of dust... A blower is deployed on the cover to pull outside air along a pathway through the opening, into the interior space, through a filter
Implementation Method 5
An agglomerating yoke is provided that causes dust particles to clump together
Data Source
AI summary
A proppant container facilitates the transportation of wet sand for use in a hydraulic fracturing operation. The proppant container is provided with a system for dislodging the wet sand for subsequent use. This may be done by use of a vibrator or an umbrella valve. In another aspect, the proppant container may be used in combination with a rack having a wash system that slurries the proppant for delivery to a blender tub without necessarily resorting to use of a conveyor belt.