Wet Sand Storage Containers With Slip Coating And Vibration Hopper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The logistics of storing, transporting, and dispensing wet sand as a proppant in hydraulic fracturing operations are challenging due to the higher moisture content, which affects weight, packing characteristics, and fluidity, leading to increased costs and complexities.
Innovation Solution
The development of containerized units with friction-reducing layers and modified material handling/conveyor systems, including a hopper assembly with a reduced outlet area and a vibration mechanism, to efficiently handle and dispense wet sand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet sand is used directly from mining operation without drying, then processing cost and time are reduced, but storage and transportation logistics become more difficult due to higher moisture content affecting weight, packing characteristics and fluidity
Solution Approach 1:
The patent changes the physical parameters of sand by maintaining controlled moisture content ranges (10-40% by weight) rather than drying to conventional standards. This parameter change allows wet sand to be used directly from mining operations, eliminating costly drying processes while managing the effects of moisture on weight, packing characteristics, and fluidity through adjusted handling procedures
Solution Approach 2:
The patent employs disposable or single-use liner materials within containerized units that can be discarded after one use. These liners prevent wet sand from damaging container interiors and simplify cleaning/maintenance requirements, making the system economically viable for handling wet sand without extensive processing infrastructure
2Loss of time
If conventional drying and grading processes are eliminated, then processing time and cost are reduced, but sand packing characteristics and fluidity become unpredictable due to higher moisture content
Solution Approach 1:
The patent establishes acceptable ranges for moisture content (10-40% by weight) and adjusts other parameters such as particle size distribution and compaction density to compensate for the absence of drying. This allows sand to be used directly from mining operations while maintaining predictable packing characteristics and fluidity for hydraulic fracturing applications
Solution Approach 2:
The patent implements dynamic adjustment of handling procedures based on actual sand moisture content and flow characteristics. Material handling systems are configured to adaptively control discharge rates, conveyor speeds, and compaction forces to maintain consistent packing density and fluidity despite variations in moisture content, eliminating the need for static drying processes
3Productivity
If containerized units are used for storing and transporting wet sand, then storage and transportation efficiency are improved, but friction and metal deterioration increase due to higher moisture content
Solution Approach 1:
The patent employs disposable or single-use liner materials within containerized units that can be discarded after one use. These liners act as a barrier between wet sand and metal surfaces, preventing corrosion and deterioration while maintaining the efficiency benefits of containerized storage and transportation. The low cost of these liners makes them economically viable for repeated use
Solution Approach 2:
The patent introduces liner materials as an intermediary layer between wet sand and container walls. This intermediary prevents direct contact between moisture and metal surfaces, eliminating corrosion while allowing the containerized system to function efficiently for storage and transportation of wet sand
4Productivity
If material handling systems are modified to handle wet sand, then dispensing efficiency is improved, but system complexity and cost increase
Solution Approach 1:
The patent implements dynamic adjustment of material handling parameters such as conveyor belt speed, discharge gate opening, and compaction force based on real-time monitoring of sand flow characteristics. This allows the system to maintain optimal dispensing efficiency across varying moisture content levels without requiring complex mechanical modifications, achieving adaptability through control system adjustments rather than structural complexity
Solution Approach 2:
The patent designs material handling systems with multi-functional components that can handle both dry and wet sand without requiring complete system redesign. Existing conveyor, storage, and dispensing equipment is modified with adjustable parameters and optional liners to accommodate wet sand, maintaining system versatility while reducing overall complexity compared to dedicated wet sand handling systems
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 proposed solution improves the efficiency and cost-effectiveness of storing, transporting, and dispensing wet sand by reducing friction, preventing metal deterioration, and ensuring precise control over the discharge process, thus enhancing the overall hydraulic fracturing operation.
Implementation Method 1
a friction-reducing layer (or simply slip coating) is provided on the interior surfaces of containers and the hoppers and chutes of the material handling/conveyor system for encouraging sand to move through these components
Implementation Method 2
a vibration mechanism is provided on a stationary component of the system such as a conveyor hopper... operates to shake the hopper assembly for breaking up larger sand masses and minimizing bridging
Data Source
AI summary
Described is a system for conveying wet sand. The system includes containers with a slip coating for storing wet sand. Each container includes an outlet formed in a bottom portion to facilitate removal of the wet sand from the container to a hopper. Each hopper has end walls, side walls, and an interior wall extending at an angle from the top to the bottom of the hopper to reduce an area of the outlet. A flow gate over the outlet controls discharge of the wet sand from the hopper onto a conveyor belt of a conveyor system. The hopper also includes a vibration system coupled to its exterior surface for shaking the hopper to assist in releasing sand. A discharge assembly is located at the end of the conveyor system for directing wet sand from the conveyor belt.