US20160083177A9 - Methods and systems to transfer proppant for fracking with reduced risk of production and release of silica dust at a well site - Google Patents
Methods and systems to transfer proppant for fracking with reduced risk of production and release of silica dust at a well site Download PDFInfo
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- US20160083177A9 US20160083177A9 US14/676,039 US201514676039A US2016083177A9 US 20160083177 A9 US20160083177 A9 US 20160083177A9 US 201514676039 A US201514676039 A US 201514676039A US 2016083177 A9 US2016083177 A9 US 2016083177A9
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- proppant
- conveyor
- conveyor belt
- release
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Definitions
- the present invention relates to reducing the risk of production and release of silica dust at a well site during fracking operation. More particularly, the invention relates to methods and systems to enhance transfer of proppant for hydraulic fracking operations from a container while reducing the risk of production and release of silica dust at a well site.
- Fracking Hydraulic fracturing or “fracking” has been used for decades to stimulate production from conventional oil and gas wells. In recent years, the use of fracking has increased due to the development of new drilling technology such as horizontal drilling and multi-stage fracking. Such techniques reach previously-unavailable deposits of natural gas and oil. Fracking generally includes pumping fluid into a wellbore at high pressure. Inside the wellbore, the fluid is forced into the formation being produced. When the fluid enters the formation, it fractures, or creates fissures, in the formation. Water, as well as other fluids, and some solid proppants, are then pumped into the fissures to stimulate the release of oil and gas from the formation.
- proppant is silica sand, made up of ancient weathered quartz, the most common mineral in the Earth's continental crust. Unlike common sand, which often feels gritty when rubbed between your fingers, sand used as a proppant tends to roll to the touch as a result of its round, spherical shape and tightly-graded particle distribution. Sand quality is a function of both deposit and processing. Grain size is critical, as any given proppant should reliably fall within certain mesh ranges, subject to downhole conditions and completion design. Generally, coarser proppant allows a higher capacity due to the larger pore spaces between grains. This type of proppant, however, may break down or crush more readily under stress due to the relatively fewer grain-to-grain contact points to bear the stress often incurred in deep oil- and gas-bearing formations.
- Silicosis is a form of occupational lung disease caused by inhalation of crystalline silica dust, and is marked by inflammation and scarring in the form of nodular lesions in the upper lobes of the lungs. It is a type of pneumoconiosis, or lung disease caused by the inhalation of dust, usually from working in a mining operation. This dust has other effects, such as contaminating the atmospheric air, creating a nuisance to adjacent landowners, and damaging equipment on the well site. Bloggers and environmental groups have taken a stand against hydraulic fracturing, in part, because of the silica dust created at the well site.
- Embodiments of the present invention generally address problems associated with risk of inhalation of silica dust at a well site of a fracking operation. More particularly, embodiments of the present invention include methods and systems to transfer proppant from a closed container to a chute for delivery to a blender or other location at a well site while reducing the risk of production and release of silica dust.
- embodiments of the present invention include methods and systems to transfer proppant from a closed container to a chute for delivery to a blender or other location at a well site while reducing the risk of production and release of silica dust.
- a method includes positioning a plurality of sealed containers containing proppant for fracking such as by use of forklifts or other heavy machinery onto a conveyor with compartments adapted to receive the containers and which overlies one or more conveyor belts.
- a plurality of hoppers e.g., one positioned to underlie each container when positioned on the compartment of the conveyor, overlays one or more conveyor belts.
- proppant is funneled from the one or more outlets of each of the plurality of containers to and through the plurality of hoppers positioned to reduce the risk of production and release of silica dust.
- Proppant in turn, guidingly is received onto the one or more conveyor belts by a plurality of partitions associated with the one or more conveyor belts, e.g., the partitions can extend upwardly in a space-apart relation from the top surface of the one or more conveyor belts, such that the plurality of partitions is positioned to reduce production and release of silica dust into the air as proppant is positioned between the plurality of partitions and contacts the one or more conveyor belts.
- the one or more conveyor belts then convey the proppant to and through a shrouded portion of the conveyor, positioned to reduce the risk of release of silica dust, and toward a chute position along an end portion of the conveyor, for example.
- An embodiment of a chute for example, can be rotatably-positioned to direct the proppant into a blender hopper for use in a fracking operation, but the chute also can deposit the proppant anywhere on the well site.
- forklifts or other machinery can remove the empty containers for replacement with containers again being filled with and having proppant for fracking at the well site so that proppant continuously is supplied for and flows towards the chute for deposit into a blender hopper or other location when in operation.
- a method can include positioning a plurality of sealed containers containing proppant for fracking using forklifts or other heavy machinery onto a conveyor having compartments adapted to receive the containers.
- the conveyor in an embodiment, also can have a plurality of hoppers that overlays one or more conveyor belts.
- proppant can be downwardly discharged from each respective container until each respective container is substantially emptied of proppant.
- Proppant in this process, can be funneled from the one or more outlets of each of the plurality of containers to and through the plurality of hoppers so as to reduce the risk of production and release of silica dust.
- Proppant guidingly can be received onto the one or more conveyor belts by a plurality of partitions associated therewith, such that the plurality of partitions is positioned to reduce production and release of silica dust into the air as proppant is positioned on and contacts the conveyor belt.
- the one or more conveyor belts then convey the proppant to a blender hopper. Once the respective containers are substantially emptied of proppant, forklifts or other machinery remove the empty containers for replacement with containers having proppant for fracking at the well site so that proppant continuously is supplied and flows to the blender hopper during and for fracturing operations.
- Embodiments of a system can include a conveyor positioned at a well site and having compartments adapted to receive each respective container of the plurality of containers.
- the conveyor also has one or more conveyor hoppers that align closely with each respective outlet of the plurality of containers to assist in funneling and metering the proppant flowing from the containers.
- One or more conveyor belts are positioned to underlie the one or more conveyor hoppers to receive proppant as the proppant passes to and through the opening of each of the one or more respective conveyor hoppers.
- the one or more conveyor belts for example, can each have a first end, a second end, and a plurality of partitions associated therewith.
- An embodiment of a system also can include a shroud positioned to overlie a portion of the second end of the one or more conveyor belts thereby to define a shrouded portion of the one or more conveyor belts.
- the shroud according to an embodiment thereof, for example, substantially encloses the shrouded portion as the one or more conveyor belts convey proppant.
- the system further can include a chute having an inlet positioned to receive the second end of the conveyor belt conveying proppant and one or more outlets positioned such that proppant is deposited into the chute by gravity feed, and proppant, in turn, flows out of the one or more outlets of the chute to a blender hopper or other location at the well site.
- An embodiment of a system of the invention can have a conveyor positioned at a well site with compartments adapted to receive each respective container of the plurality of containers.
- the conveyor also can have one or more conveyor hoppers that align closely with each respective outlet of the plurality of containers when positioned on the conveyor and one or more conveyor belts positioned to underlie the one or more conveyor hoppers to receive proppant as the proppant passes to and through the opening of each of the one or more respective conveyor hoppers.
- the one or more conveyor belts for example, each can have a first end, a second end, and a plurality of partitions associated therewith.
- the system further can include a blender hopper having an inlet positioned to receive the second end of the one or more conveyor belts thereby to convey proppant by gravity feed.
- Embodiments of the system further can include a blender hopper cover positioned to reduce risk of production and release of silica dust as proppant flows between the one or more outlets of the chute and the one or more blender hoppers of the one or more blenders at a well site and a forklift positioned at a well site to load and unload each respective container onto and off of the conveyor by one or more slots.
- Each of the plurality of containers has one or more slots, for example, positioned adjacent a bottom portion of the respective container to enhance lifting and positioning of each container such as when being lifted by a forklift.
- the conveyor further can include one or more curtains positioned on or adjacent to the one or more sides of the conveyor to reduce risk of production and release of silica dust as proppant flows from the plurality of conveyor hoppers to the one or more conveyor belts.
- Embodiments of a system are adapted and positioned to reduce the risk of production and release of silica dust at a well site by reducing the fall height for proppant as it flows between one structure and another, for example, and substantially enclosing either the entire system or portions of the entire system to reduce the risk of the escape of silica dust as the system operates.
- embodiments of the system described herein have a host of other benefits directly to the fracking industry itself.
- embodiments of the system for example, also are adapted to prevent the wetting of proppant from rain or other precipitation, or the blowing of proppant by the wind from the one or more conveyor belts, for example, as proppant moves through the system.
- Other aspects of the embodiments of the system include, for example, the portability and stackability of the respective containers having proppant contained therein at a well site, which decreases the footprint of the proppant needed at the well site.
- the embodiments of the system for example, also decrease transportation costs with the ability to transport those containers to a well site by ordinary trucks or railcars.
- embodiments of the system of the present invention virtually eliminate the demurrage of trucks or rails at a well site that increased costs and time to provide sufficient proppant to enable the well site to continuously conduct fracking operations.
- FIG. 1 is an environmental perspective view of a well site for fracking using an embodiment of the system and method according to the present invention.
- FIG. 2 is a perspective view of a well site for fracking using a prior art system and method.
- FIG. 3 is a flow chart demonstrating steps of a method according to embodiments of the present invention.
- FIG. 4 is a perspective view of a forklift preparing to position a container having proppant for fracking onto a conveyor according to an embodiment of a system and method of the present invention.
- FIG. 5A is a fragmented perspective view of a container having proppant for fracking positioned on a conveyor according to an embodiment of a system and method of the present invention.
- FIG. 5B is an exploded perspective view of FIG. 5A of a container having proppant for fracking positioned on the conveyor according to an embodiment of a system and method of the present invention.
- FIG. 5C is a fragmented perspective view of a container having proppant for fracking positioned on a conveyor according to an embodiment of a the system and method of the present invention with portions of the container shown in break-away for clarity.
- FIG. 6A is a fragmented perspective view of a conveyor hopper substantially full of proppant for fracking according to an embodiment of a system and method of the present invention.
- FIG. 6B is a fragmented perspective view of a conveyor hopper partially full of proppant for fracking according to an embodiment of a system and method of the present invention.
- FIG. 6C is a fragmented perspective view of a conveyor hopper without proppant according to an embodiment of a system and method of the present invention.
- FIG. 7A is a fragmented perspective view of a conveyor belt having a plurality of partitions and a plurality of outside walls to convey proppant according to an embodiment of a system and method of the present invention.
- FIG. 7B is a fragmented perspective view of an alternative embodiment of a conveyor belt shown in FIG. 7A , having a plurality of partitions and a plurality of outside walls to convey proppant according to an embodiment of a system and method of the present invention.
- FIG. 8A is a fragmented perspective view of a second end of a conveyor according to an embodiment of a system and method of the present invention with a partial break-away view of the shroud for clarity further to show a conveyor belt.
- FIG. 8B is a fragmented perspective view of a second end of the conveyor according to an embodiment of a system and method of the present invention with a partial break-away view of a chute for clarity further to show the second end of the conveyor belt depositing proppant into the chute by gravity feed.
- FIG. 8C is a perspective view of an operator positioning a chute to deposit proppant into a blender hopper according to an embodiment of a system and method of the present invention.
- FIG. 8D is a perspective view of an alternative embodiment of a second end of a conveyor without a shroud according to an embodiment of a system and method of the present invention.
- FIG. 9A is a perspective view of a container according to an embodiment of a system and method of the present invention.
- FIG. 9B is a front elevation view of a container according to an embodiment of a system and method of the present invention.
- FIG. 9C is a perspective view of a container with portions broken away for clarity to show lower inner side portions of the container according to an embodiment of a system and method of the present invention.
- FIG. 9D is another perspective view of a container according to an embodiment of a system and method of the present invention.
- FIG. 9E is a bottom plan view of a container according to an embodiment of a system and method of the present invention.
- FIG. 10A is a side elevation view of a conveyor according to an embodiment of a system and method of the present invention.
- FIG. 10B is perspective view of a conveyor illustrating a container positioned above the conveyor according to an embodiment of a system and method of the present invention.
- FIG. 10C is a side elevation view of an alternative embodiment of a conveyor according to an embodiment of a system and method of the present invention.
- FIG. 11 is a side elevation view of a conveyor belt underlying a conveyor hopper with break-away portions of a front outer wall of the conveyor belt showing a plurality of partitions according to an embodiment of a system and method of the present invention.
- FIG. 12A is a side elevation view of a conveyor having a curtain and a blender hopper cover further to reduce the production and release of silica dust at a well site according to an embodiment of a system and method of the present invention.
- FIG. 12B is a perspective view of a curtain attached to the conveyor according to an embodiment of a system and method of the present invention.
- FIG. 12C is a perspective view of a blender hopper cover positioned between a chute and a blender hopper of a conveyor according to an embodiment of a system and method of the present invention.
- FIG. 12D is a perspective view of a blender hopper cover of a conveyor and being positioned between a second end of the conveyor and a blender hopper according to an embodiment of a system and method of the present invention.
- Embodiments of methods and systems are useful at a well site 30 of a hydraulic fracturing operation.
- These well sites 30 includes a removable floor 32 made of wooden pallets to facilitate the use of heavy machinery, including one or more forklifts 34 , cranes 35 , or other hydraulic movers, for loading and unloading containers 900 off of the railroad 46 or eighteen-wheeler trucks 44 .
- the railcars 48 are specially designed to accommodate four containers 900 in a side-by-side arrangement, for example, and containing proppant.
- the containers 900 are stackable; at the well site 30 , containers 900 S 1 can be stacked on top of other containers 900 S 2 so as to reduce the footprint of containers 900 at the well site 30 to thereby maximize the space available.
- Containers 900 can be stacked up to three-high, for example, at the well site 30 . Because all the proppant 38 is containerized, the logistics problems of the prior art where trucks and trains would demurrage and to unload proppant 38 at the well site 30 is eliminated.
- the well sites 30 also can include blenders 36 for combining proppant 38 , which is most ordinarily consisting of mined silica sand, but potentially comprising coated or treated sand, ceramic, or bauxite, with fracking fluids generally of a proprietary blend.
- the well site also can include fracking machinery 40 to pump the proppant 38 and other fracking fluids into the wellbore 42 at high pressure.
- fracking machinery 40 to pump the proppant 38 and other fracking fluids into the wellbore 42 at high pressure.
- Embodiments of systems can result in the transfer of fracking sand for depositing into a blender 36 or other desired location at the well site 30 with a reduced risk of the production and release of silica dust 50 into the air.
- prior art methods of transferring fracking sand or proppant 38 resulted in the production and release of harmful silica dust 50 at the well site.
- FIG. 2 for example, at a well site of the prior art 52 , operators or machines carry out prior art methods for transferring fracking sand or proppant from a huge pile of sand 54 on open conveyors 56 into a blender 36 so it can be useful for the fracking operation.
- the prior art methods of transferring proppant 38 at a well site 52 frequently involved a plurality of trucks 44 delivering proppant 38 to a well site 52 .
- the flow chart depicted in FIG. 3 and as shown in FIGS. 4 , 5 C, 6 A- 6 C, 7 A, and 8 A- 8 C, demonstrates embodiments of a method for transferring proppant 38 for fracking while reducing the risk of production and release of silica dust 50 into the air at a well site 30 .
- operators or machines position 100 a plurality of sealed containers 900 , each having proppant 38 for fracking contained therein, onto a conveyor 1000 adapted to receive the containers 900 and having a plurality of conveyor hoppers 600 that overlay one or more conveyor belts 700 .
- These containers 900 can be positioned 102 in a side-by-side arrangement, or positioned 104 adjacent each other on the conveyor 1000 . This positioning can, for example, maximize the amount of proppant 38 that can be transported to the wellbore 42 in the shortest amount of time possible for efficiency, while still reducing the risk of production and release of silica dust 50 .
- Operators or machines utilize hydraulics or electronics to selectively open a series of gates, for example, a flow gate 932 at the bottom 906 of each respective container 900 , and a conveyor hopper gate 612 at the bottom 608 of each respective conveyor hopper 600 , that control a series of openings, for example, one or more outlets 924 of a container 900 and one or more controllable openings 610 of a conveyor hopper 600 , through which the proppant 38 is funneled.
- the close positioning and design of the containers 900 and conveyor 1000 for example, minimize the risk of production and release of silica dust 50 as the proppant 38 is funneled to the conveyor belt 700 .
- Proppant 38 is received 130 onto the conveyor belt 700 by a plurality of partitions 712 associated therewith, such that the plurality of partitions 712 is positioned to reduce production and release of silica dust 50 into the air as proppant 38 contacts and is carried by the conveyor belt 700 .
- These plurality of partitions 712 include a plurality of fingers 714 spaced-apart from each other on the top surface 702 of the conveyor belt 700 .
- the plurality of partitions 712 further can include outside walls 716 of the conveyor belt.
- the plurality of partitions 712 therefore, can guidingly accept proppant onto the conveyor belt 700 while, for example, breaking up any clumps of proppant 38 , if any, that may pass through each respective conveyor hopper 600 , and further reduce any production and release of silica dust 50 as the proppant 38 contacts the conveyor belt 700 .
- the conveyor belt 700 is also closely positioned beneath or adjacent the bottom portion 608 of each conveyor hopper 600 to further reduce the fall-height for the proppant 38 to a matter of inches, for example, as it contacts and is transported by the conveyor belt 700 .
- the one or more conveyor belts 700 then conveys 140 the proppant 38 to and through a shrouded portion 802 adapted and positioned to reduce the risk of release of silica dust 50 to a chute 822 .
- This shrouded portion 802 can be optionally omitted if the conveyor 1000 is designed to directly deposit proppant 38 from the conveyor belt 700 into a blender hopper 810 , for example, as shown in embodiments described herein, including FIG. 8D , for example.
- the conveyor belt 700 travels in a continuous loop around a designated path controlled by rollers 708 and powered by one or more diesel or electric engines 710 . According to an embodiment, the conveyor belt 700 can be nearly enclosed or fully enclosed as it conveys the proppant 38 to the chute 822 .
- proppant 38 can be protected from the natural elements of rain and wind, for example, to avoid deteriorating the condition of the proppant 38 and to further minimize the production and release of silica dust 50 onto the well site 30 .
- Proppant 38 can be deposited 150 into the chute 822 by gravity feed 812 as the conveyor belt 700 turns about the rollers 708 of the conveyor 1000 .
- This chute 822 can be designed and rotatably-positioned to direct the proppant 38 into a blender hopper 810 for use in the fracking operation, but the chute 822 could deposit the proppant 38 anywhere on the well site 38 .
- the chute 822 can have handles 823 for an operator 806 at a well site 30 to direct proppant 38 from one or more outlets 826 of the chute 822 via gravity feed 812 into one or more blender hoppers 810 , for example.
- Containers can be stacked 900 S 1 , 900 S 1 at the well site 30 , for example, up to three-high to be refilled with proppant or transported off the well site 30 to be refilled with proppant 38 .
- the containerized aspects of the embodiments of the invention allow for the continuous flow of proppant 38 to the wellbore 42 at a well site 30 while the conveyor 1000 is in operation.
- Embodiments of containers 900 can be adapted for and positioned to reduce the risk of production and release of silica dust 50 at a well site 30 .
- each respective container 900 is in the nature of a box with an exterior frame 902 having two sets of parallel sides 901 A 1 , 901 A 2 , 901 B 1 , 901 B 2 that are each perpendicular to a top 904 and a bottom 906 .
- the container 900 can be a ten-foot ISO container.
- the container can have a ladder 903 for an operator to climb to the top 904 of the container 900 and inspect the contents within the container 900 , for example.
- the container 900 can have a length of ten feet, a width of eight feet, and a height of eight-and-a-half feet, for example.
- the height can also be nine-and-a-half feet.
- This embodiment for example, can hold approximately twenty-three tons of proppant 38 (approximately 43,000-48,000 lbs.), in each such container 900 .
- the containers 900 are designed to drain the proppant 38 contained therein in under two minutes, or at a rate of 25,000 pounds per minute.
- the container 900 is made of steel or other similar material and the exterior frame 902 is cage-like or lattice-like and useful for the structural support and positioning of each container 900 onto the compartments 1002 of the conveyor 1000 that are adapted to receive each respective container 900 .
- the frame 902 also includes a plurality of slots 901 , including, for example, two slots 901 , by which a forklift 34 can lift and position the plurality of containers 900 on the conveyor 1000 .
- each container 900 has an inlet 905 that may be opened and closed by a door 914 , hatch, gate, or other closing mechanism.
- This door 914 can provide a seal, or an air-tight and water-tight connection, to the container 900 , as it is preferable for the proppant 38 to remain substantially dry.
- proppant 38 can flow through embodiments of the system with some degree of moisture content, it is preferable to prevent the clumping of proppant 38 caused by moisture.
- the door 914 is also important to prevent the escape of silica dust 50 from the proppant 38 contained therein before and during the transfer of proppant 38 from the containers 900 through an embodiment of a system. A person having skill in the art can grasp the available options to design, affix, or attach a door 914 to accomplish this sealing function.
- the container 900 is made of steel or other similar material. As viewed from the outside of the container 900 , and as shown in FIGS. 9A-9E , the bottom portion 916 of the container 900 is open and looks like a funnel structure 918 enclosed within an open external frame 902 . Referring to FIG. 9D , the external frame 902 form's a bottom 906 that comprises a planar surface 920 perpendicular to the two pairs of parallel sides 901 A 1 , 901 A 2 , 901 B 1 , 901 B 2 . Referring to FIG. 9B , The bottom portion 916 is open to allow the cylindrical or angular funnel structure 918 to dispense the proppant 38 in the container 900 according to embodiments of methods and systems.
- Embodiments having the bottom portion feature 916 can be useful in international shipping. During the course of international shipping, for example, it is important to avoid closed spaces within such a container 900 . The exposure of the funnel shape 918 in the bottom portion 916 of the container 900 will allow inspectors to have visual access to the area adjacent the funnel shape 918 .
- the funnel structure 918 comprises a plurality of inclined lower inner portions 922 of the container 900 .
- the plurality of inclined lower inner portions 922 is roughly in the center 923 of the bottom 906 and has an opening or openings 924 .
- the plurality of inclined lower inner portions 922 is designed to ensure that when proppant 38 is directed out of the container 900 , proppant 38 flows from the container 900 until it is substantially empty.
- each respective container 900 are inclined inwardly from inner walls 926 of the respective container 900 toward a bottom 906 of the container at an angle 928 of about 31 degrees to about 37 degrees relative to a horizontal plane 920 of the bottom of each respective container 900 when each respective container 900 is level.
- this angle 928 is particularly effective in the full release of proppant 38 from the interior of the container 900 . Any remaining proppant 38 in the container 900 , for example, could risk posing a threat to workers in the vicinity of the container 900 during transport of the container 900 to another location. Additionally, because the plurality of inclined lower inner portions 922 is inclined in this respect, proppant 38 does not rush directly out of the interior, as it may otherwise do.
- proppant 38 flows along the plurality of inclined lower inner portions 922 , creating a sink hole or a funnel 930 , toward the one or more openings 924 so as to reduce the production and release of silica dust 50 as proppant 38 flows from the container 900 .
- a flow gate 932 is positioned within tracks 933 located on the bottom 906 over or adjacent the opening or openings 924 of the inclined lower inner portions 922 of each respective container 900 , as shown in FIGS. 9D-9E .
- the flow gate 932 can be planar and is designed to cover the opening or openings 924 .
- the flow gate 932 may be a metering gate or another structure capable of controlling the flow of proppant 38 from the opening or openings 924 that is known to a person skilled in the art.
- the flow gate 932 includes a handle 934 positioned outwardly from the flow gate 932 . Referring to FIGS.
- the handle 934 of the flow gate 932 is designed to sit in the one or more forks 500 of the conveyor 1000 , such that an actuator 502 connected to the forks 500 can move the flow gate 932 to enhance opening or closing the one or more openings 924 of the container 900 .
- the actuator 502 can be hydraulically- or electrically-controlled to enhance opening and closing of the flow gate 932 . If hydraulics are used, for example, a plurality of hydraulic pressure hoses 503 can connect the actuator to the one or more engines 710 .
- a plurality of wires 505 can be used to connect the actuator to the one or more engines 710 .
- Wireless connections are also contemplated.
- a person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the actuator 502 .
- the flow gate 932 can be controlled remotely via the interne, or locally on the well site 30 , either by an operator or a machine. This flow gate 932 also controls the rate at which proppant 38 flows from the container 900 to reduce the production and release of silica dust 50 associated with the proppant 38 into the air at the one or more openings 924 .
- an embodiment of a conveyor 1000 of embodiments of methods and systems includes a frame 1004 with a top 1006 , a bottom 1008 , two sides 1010 A & 1010 B, a first end 1012 , and a second end 1014 .
- the conveyor 1000 is made of steel or other similar material.
- It may be approximately forty feet in length, eight-and-a-half feet in width, four feet in height, and having wheels 1016 and controls 1017 on the first end 1012 , the second end 1014 , or both, but including, for example, on the second end 1014 , and a trailer hitch 1018 on the first end 1012 , the second end 1014 , or both, but including, for example, on the second end 1014 , such that an operator could attach the conveyor 1000 to the cab of an eighteen-wheeler truck 44 and pull the conveyor 1000 on a highway.
- the size of the conveyor 1000 is designed to be at or below the dimensions permitted by law for trailers of trucks 44 , so the dimensions may be adjusted as dimensions change for safe highway travel.
- the frame 1004 must be able to support up to several tons of proppant 38 housed in a plurality of containers 900 .
- the conveyor 1000 has one or more hydraulic or electric lifts 1019 to make sure that the frame 1004 is level because the well site may have uneven ground. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 1021 can connect the lifts 1019 to the one or more engines 710 and controls 1017 . If electronics are used, for example, a plurality of wires 1023 can be used to connect the lifts 1019 to the one or more engines 710 . Wireless connections are also contemplated. A person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the lifts 1019 . The one or more lifts 1019 also decrease the risk that the conveyor 1000 will tip over or become unstable on the well site 30 .
- the top 1006 of the frame 1004 comprises a top surface 1020 that is adapted to receive embodiments of the containers 900 described herein.
- the top surface 1020 has one or more compartments 1002 , each adapted to receive one or more containers 900 , an example of which can be seen in FIG. 6C .
- the conveyor 1000 has three to five compartments 1002 to receive three to five containers 900 having proppant 38 for fracking.
- the top surface 1020 can have four compartments 1002 to receive four containers 900 having proppant 38 for fracking.
- each container 900 is positioned on the conveyor 1000 such that each container 900 has either one or both parallel sides 901 A 1 and 901 A 2 adjacent the either one, or both parallel sides 901 A 1 and 901 A 2 of another container 900 , the top 904 and bottom 906 of each container 900 is perpendicular to the top surface 1020 of the conveyor 1000 , and the top 904 and bottom 906 of each container 900 is overlaying the conveyor belt 700 positioned below the top surface 1020 of the conveyor 1000 .
- each container 900 is positioned in a line such that the proppant 38 contained within each container 900 will flow out of each container 900 onto one or more conveyor belts 700 .
- the plurality of containers 900 are positioned in a side-by-side arrangement on the top surface 1020 of the conveyor 1000 overlaying one or more conveyor belts 700 .
- the one or more compartments 1002 of the conveyor 1000 can include corners 1022 , tracks, lock-and-key connections, and female-and-male connections, for example.
- These corners 1022 can be made of steel or other similar material.
- the container 900 need not fit tightly onto each compartment 1002 . Instead, for example, the corners 1022 need only to guide the container 900 into position onto the compartment 1002 such that the container 900 will not fall off of the conveyor 1000 . Alternatively, the container 900 may fit tightly on the compartment 1002 .
- a forklift 34 , crane 35 , or other heavy machinery lifts a container 900 having proppant 38 up and over the top of the respective compartment 1002 of the conveyor 1000 , comprising steel corners 1022 extending vertically from each respective corner of each respective compartment 1002 of the conveyor 1000 , and lowers the container 900 having proppant 38 into place onto the conveyor 1000 .
- the corners 1022 of the compartment 1002 guide the container 900 into place.
- the respective corners 1022 of the compartments have a plurality of load cells 1024 for determining the weight of each container 900 on each respective compartment 1002 of the conveyor 1000 .
- a load cell 1024 is positioned in each of the four corners of the compartment 1002 .
- These load cells 1024 inform an operator or machine how much proppant 38 is left in the respective container 900 by its weight so the operator or machine knows when to replace the respective empty container 900 with another container 900 filled with proppant 38 at a well site 30 .
- the respective load cells 1024 are in electric or wireless communication via wires 1025 or wirelessly with a light 1026 to indicate to the operator or machine that the container 900 is positioned properly onto the compartment 1002 .
- the light 1026 may change from red to green, for example.
- a forklift 34 need not lift the respective container 900 up and over the corners 1022 of the compartment 1002 of the conveyor 1000 if alternative structures are used instead of corners 1022 . In this way, the forklift 34 could, for example, lift the container 900 up to the height of the top surface 1020 of the conveyor 1000 and slide the container 900 onto the respective compartment 1002 .
- the conveyor 1000 having a plurality of compartments 1002 adapted to receive containers 900 , also can have a plurality of openings 1028 in the top surface 1020 of the conveyor 1000 .
- the plurality of openings 1028 is positioned beneath the respective plurality of containers 900 on the conveyor 1000 such that proppant 38 flowing from each respective container 900 will pass through each respective opening 1028 .
- Each opening 1028 has one or more forks 500 positioned above or adjacent the opening or openings 1028 , the one or more forks 500 adapted to receive a handle 934 of a flow gate 932 of a container 900 to engage, contact, or communicate with the corresponding handle 934 of the flow gate 932 of the container 900 , as shown in an embodiment depicted in FIGS.
- the handle 934 of the flow gate 932 , the one or more forks 500 , or both, are in electric or wireless communication with the light 1026 , along with the respective load cells 1024 of the corners 1022 via wires 1025 or wirelessly, to indicate to an operator or machine that the container 900 is in proper position when the handle 934 of the flow gate 932 is aligned or situated in the one or more forks 500 of the compartment 1002 .
- the variety of connections or contacts to secure or place the container 900 onto the top surface 1020 of the conveyor 1000 , such that the actuator 502 can operate the flow gate 932 of the container 900 will be apparent to a person having skill in the art.
- Embodiments of the conveyor 1000 also can include a plurality of conveyor hoppers 600 positioned adjacent or beneath the plurality of openings 1028 in the top surface 1020 of the conveyor 1000 .
- the plurality of conveyor hoppers 600 is positioned such that when containers 900 are placed onto the conveyor 1000 , each respective conveyor hopper 600 is beneath the flow gate 932 of the one or more openings 924 of each respective container 900 .
- each respective conveyor hopper 600 can include a plurality of inclined sides 602 to form a receptacle or funnel structure for proppant 38 to pass into and through as proppant 38 is discharged from each respective container 900 when in operation.
- the plurality of inclined sides 602 can include a pair of short sides 604 A 1 , 604 A 2 and a pair of long sides 604 B 1 , 604 B 2 .
- the short sides 604 A 1 -A 2 can have a funnel angle 605 A or slope of approximately 35 to 40 degrees relative to a horizontal plane 1020 , including, for example, 38 degrees
- the long sides 604 B 1 -B 2 can have a funnel angle 605 B or slope of approximately 28 to 33 degrees relative to a horizontal plane 1020 , including, for example, 31 degrees, to maximize the capacity of the conveyor hopper 600 and the flow of proppant 38 from the conveyor hopper 600 .
- the conveyor hopper 600 has a top portion 606 and a bottom portion 608 , and the bottom portion 608 can include one or more controllable openings 610 .
- the top portion 606 of the conveyor hopper 600 can be in the same plane, above it, or below the top surface 1020 of the conveyor 1000 .
- the top portion 606 of the conveyor hopper 600 can be in the same plane or higher than the top surface 1020 of the conveyor 1000 , as can be seen in FIGS. 10B , 10 C.
- Each conveyor hopper 600 for example, can be zero to two inches below the respective flow gate 932 of the one or more openings 924 of the bottom of each container 900 .
- the bottom portion 608 of the conveyor hopper 600 also can include one or more controllable openings 610 .
- the one or more controllable openings 610 can include a hopper gate 612 .
- the hopper gate for example, can be made of steel or similar material, and can be formed in the shape of an inverted “V” or other shape that facilitates the flow of proppant 38 through the bottom portion 608 of the conveyor hopper 600 .
- the hopper gate 612 can be connected to a hopper gate actuator 613 that can be optionally hydraulically- or electrically-controlled to enhance opening and closing of the one or more controllable openings 610 of the conveyor hopper 600 .
- a hopper gate actuator 613 can be optionally hydraulically- or electrically-controlled to enhance opening and closing of the one or more controllable openings 610 of the conveyor hopper 600 .
- hydraulics for example, a plurality of hydraulic pressure hoses 614 can connect the hopper gate actuator 613 to the one or more engines 710 and controls 1017 .
- a plurality of wires 616 can be used to connect the hopper gate 612 to the one or more engines 710 and controls 1017 .
- Wireless connections are also contemplated. A person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the hopper gate actuator 613 .
- proppant 38 is controllably discharged from the conveyor hopper 600 so that there is no excess proppant 38 discharged at any one time.
- This embodiment prevents the creation of a cloud of silica dust 50 in the area of the conveyor belt 700 , while maximizing the efficiency of the delivery of proppant 38 onto the conveyor belt 700 .
- Embodiments of methods and systems also can include one or more conveyor belts 700 .
- Each respective conveyor belt 700 has a top surface 702 , a bottom surface 704 , and two sides 706 A, 706 B.
- Each respective conveyor belt 700 is manufactured as one long piece, or is zippered together to form one long piece.
- Each respective conveyor belt 700 has a first end portion 705 and a second end portion 707 .
- Each respective conveyor belt 700 is suitably wound around rollers 708 to travel a desired path.
- Each respective conveyor belt 700 is powered by one or more engines 710 . These engines 710 can be diesel, electric, or a combination of the two. Diesel engines 710 have been used in the filed for many years and are reliable in remote locations.
- each respective conveyor belt is adapted to reduce the risk of production and release of silica dust 50 as proppant 38 guidingly falls from the plurality of conveyor hoppers 600 to the one or more conveyor belt 700 .
- the respective one or more conveyor belts 700 can include a plurality of partitions 712 .
- Embodiments of the plurality of partitions 712 can include a plurality of fingers 714 and an outside wall 716 on each side.
- Each respective conveyor belt 700 can be manufactured to include, or integrate, the plurality of fingers 714 and the outside walls 716 .
- the plurality of fingers 714 and the outside walls 716 can be connected to a top surface 702 of a conveyor belt using commercially-acceptable adhesive.
- the plurality of fingers 714 of the conveyor belt 700 connect to and extend upwardly from a top surface 702 toward the conveyor hopper 600 when positioned to underlie the conveyor hopper 600 , and each of the plurality of fingers 714 is spaced-apart from another one of the plurality of fingers 714 so that the top surface receives the proppant 38 thereon and between the plurality of fingers 714 .
- the plurality of fingers 714 are perpendicular or near-perpendicular to the top surface 702 of the one or more conveyor belts 700 .
- the plurality of fingers 714 are closely-spaced from one another, including from between one and four inches apart from one another.
- the plurality of fingers 714 may be arranged in a regular pattern or an irregular pattern on the top surface 702 of the respective conveyor belt 700 .
- the arrangement or pattern of the plurality of fingers 714 need only to fulfill the function of the plurality of fingers 714 , which is, for example, to separate out the proppant 38 and break up the clumps of proppant 38 , if any, falling from the conveyor hopper 600 .
- the plurality of fingers 714 also is useful in guiding the proppant onto the top surface 702 of the conveyor belt 700 to reduce the production of silica dust 50 .
- the plurality of fingers 714 may be cylindrical, angular, or flat.
- Each respective finger 714 has a top 718 that may be flat or rounded.
- the plurality of fingers 714 each may have a top 718 that is flat because, as the conveyor belt 700 is running, the vibrations from the engine or engines 710 do not permit the proppant 38 to remain on the top 718 of the plurality of fingers 714 . Rather, the proppant 38 will fall between the plurality of fingers 714 to the top surface 702 of the one or more conveyor belts 700 , as is shown in FIG. 7A .
- Each side 706 A, 706 B of the one or more conveyor belts 700 has an outside wall 716 positioned at or near the margin or edge of the respective side 706 A, 706 B.
- the outside wall 716 can be in a continuous “S” shape to permit the conveyor belt 700 to compress and flex around rollers 708 as the conveyor belt 700 is moving to prevent the escape of silica dust 50 .
- the outer wall 716 also prevents proppant 38 from spraying or falling out the sides 706 A, 706 B of the conveyor belt 700 as it is being conveyed to the chute 822 . It also prevents wind from blowing the proppant 38 or silica dust 50 off the conveyor belt 700 .
- the outer wall 716 may comprise a flat or rounded top 720 , much the same as the plurality of fingers 714 .
- the plurality of fingers 714 and the outer wall 716 are relatively the same height from the top surface 702 of the conveyor belt 700 .
- the height of the plurality of partitions 712 can be between four to eight inches, including, for example, six inches.
- the substantially similar height of the plurality of fingers 714 and the outer walls 716 allows the conveyor belt 700 to be positioned as closely to the bottom portion 608 of each respective conveyor hopper 600 to minimize the distance the proppant 38 has to fall as the proppant 38 flows from the plurality of conveyor hoppers 600 to the one or more conveyor belts 700 .
- This distance between the plurality of conveyor hoppers 600 , and the top 718 , 720 of the plurality of partitions 712 can be between zero and two inches. With this negligible gap, the risk of production and release of silica dust 50 is reduced.
- the conveyor belt 700 is positioned at or near the one or more controllable openings 610 of the plurality of conveyor hoppers 600 to reduce risk of production and release of silica dust 50 as proppant 38 flows from the plurality of containers 900 , to and through the plurality of conveyor hoppers 600 , onto the one or more conveyor belts 700 .
- the conveyor belt 700 is substantially enclosed.
- a curtain or curtains 1200 may be added to one or more sides 1010 A, 1010 B of the conveyor 1000 to fully enclose the one or more conveyor belts 700 .
- the curtain or curtains 1200 may include tarps 1202 , steel panels 1204 , or similar structures, that are removably or permanently attached to the conveyor 1000 using fasteners 1206 such as bungee cords, rope, zip ties, bolts, screws, welding, or other material adapted to be integral with or attached to the conveyor 1000 .
- the curtain or curtains 1200 further protect the proppant 38 from the wind at it is blowing across the well site 30 , from the rain or precipitation at the well site 30 , and from any incidental silica dust 50 or proppant 38 that may spray from the conveyor belt 700 , and thus further reduce the risk of the release of silica dust 50 into the air.
- an embodiment of the present invention can include a blender hopper cover 1208 .
- the blender hopper cover 1208 may be added to the one or more outlets 826 of the chute 822 or to the second end 1014 of the conveyor 1000 to fully enclose the path to the blender hopper 810 .
- the blender hopper cover 1208 may include tarps 1210 , steel panels 1212 , or similar structures, that are removably or permanently attached to the chute 822 or conveyor 1000 using fasteners 1214 such as bungee cords, rope, zip ties, bolts, screws, welding, or other material adapted to be integral with or attached to the chute 822 or the conveyor 1000 .
- fasteners 1214 such as bungee cords, rope, zip ties, bolts, screws, welding, or other material adapted to be integral with or attached to the chute 822 or the conveyor 1000 .
- the blender hopper cover 1208 further protects the proppant 38 from the wind at it is blowing across the well site 30 , from the rain or precipitation at the well site 30 , and from any incidental silica dust 50 or proppant 38 that may spray from chute 822 or conveyor belt 700 as proppant 38 is deposited into the blender hopper 810 , and thus further reduces the risk of the release of silica dust 50 into the air.
- a first end portion 705 can be parallel to the ground and positioned at the first end 1012 of the conveyor 1000 .
- a second end portion 707 of the conveyor belt 700 can be elevated relative to the first end portion 705 of the conveyor belt 700 and positioned between the last respective container 900 on the second end 1014 of the conveyor 1000 and the chute 822 , at an angle 805 above parallel with respect to the ground.
- Rollers 708 positioned within the conveyor 1000 control the path the one or more conveyor belts 700 travel.
- the conveyor belt 700 travels in a path that is level from the first end 1012 of the conveyor 1000 as the conveyor belt 700 passes beneath each of the plurality of conveyor hoppers 600 and containers 900 positioned thereabove, bends upward after the conveyor belt 700 has passed beneath the last container 900 positioned on the conveyor 1000 , and travels upward towards a second end 1014 of the conveyor 1000 , relative to a horizontal plane 1020 , to the chute 822 , where the conveyor belt 700 turns about a roller 708 and returns toward the first end 1012 of the conveyor 1000 .
- the second end 1014 of the conveyor 1000 can be elevated relative to the first end 1012 of the conveyor 1000 so that proppant 38 may be deposited off of the end of the conveyor belt 700 via gravity feed 812 into the chute 822 for deposit into the blender hopper 810 .
- the conveyor belt 700 is level with the ground as it passes beneath each of the plurality of containers 900 positioned on the conveyor 1000 .
- the conveyor belt 700 is directed by one or more rollers 708 in an upward direction towards the second end 1014 of the conveyor 1000 .
- This portion 802 of the conveyor belt 700 can travel upwards at an angle 805 of approximately thirty to sixty degrees with respect to a horizontal plane 1020 extending from the conveyor belt 700 as it is level with the ground.
- the portion 802 of the conveyor belt 700 that travels in an upward direction also passes through a shroud 800 , therein defining a shrouded portion 802 of the conveyor belt 700 , as shown in FIGS. 8A-8B .
- the shrouded portion 802 is positioned between a last respective container 900 on the conveyor 1000 and an inlet 824 of the chute 822 at an angle 805 of approximately 30 to 60 degrees from a horizontal plane 1020 when the conveyor 1000 is level.
- the one or more conveyor belts 700 turns about within the chute 822 that is substantially enclosed and travels downward towards a first end 1012 of the conveyor 1000 . As shown in FIG.
- the proppant 38 is deposited into a chute 822 that is enclosed by gravity feed 812 .
- the proppant 38 flows down the chute 822 and is deposited where the operator 806 or machine directs the proppant 38 from the outlet 826 of the chute 822 , but the chute 822 can be positioned to deposit proppant 38 into a blender hopper 810 at the well site 30 , as shown in FIG. 8C .
- the conveyor belt 700 need not travel in an upward direction at the second end 1014 of the conveyor 1000 , but rather, may stay level, or travel in a downward path, if the conveyor 1000 , the one or more conveyor belts 700 , or the chute 822 , is positioned to deposit proppant 38 into a blender hopper 810 that is at or below the one or more conveyor belts 700 , or if the chute 822 is positioned to deposit proppant 38 into a hole, for example.
- This embodiment of the present invention may include the one or more conveyor belts 700 traveling in a substantially level or downward path from the first end 1012 of the conveyor 1000 to the second end 1014 , underneath the plurality of conveyor hoppers 600 , and depositing the proppant 38 into a chute 822 or directly into a blender hopper 810 without passing through a shrouded portion 802 .
- the chute 822 or blender hopper 810 is adapted or positioned to remain lower to the ground than the top surface 702 of the conveyor belt 700 such that proppant 38 is deposited directly into either the chute 822 or the blender hopper 810 by gravity feed 812 as the conveyor belt 700 turns about around a roller 708 .
- This embodiment provides that the one or more engines 710 and the controls 1017 , if any, may need to be moved from the second end 1014 of the conveyor 1000 to the first end 1012 to accommodate the elimination of the shrouded portion 802 at the second end 1014 .
- the wheels 1016 of the conveyor 1000 may also move to the first end 1012 of the conveyor 1000 .
- This embodiment may also include a blender hopper cover 1208 and a plurality of curtains 1200 to reduce the risk of production and release of silica dust 50 at the well site 30 .
- the shroud 800 is a box, tube, or container structure that substantially or completely encloses a the shrouded portion 802 of the conveyor belt 700 while it is traveling in an upward direction towards the second end 1014 of the conveyor 1000 .
- the shroud 800 can be a closed and elongated box having four sides 816 A, 816 B, 816 C, 816 D, and a first end 818 A and a second end 818 B, each end being open to allow the conveyor belt to pass through.
- the sides 816 A-D of the shroud 800 can include a plurality of steel panels bolted together around the conveyor belt 700 , and bolted to the conveyor at a first end 818 A, and bolted to the chute 822 at a second end 818 B.
- the material need not be steel panels, but could also include a seamless steel box, or another structure made of a similar metal, plastic, cloth, tarp, or other sheets.
- the shroud 800 need not fully enclose the conveyor belt 700 .
- the shroud 800 may include a tarp covering the top surface 702 of the conveyor belt 700 having a plurality of partitions 712 , connected to the second end 1014 of the conveyor 1000 at the first end 818 A of the shroud 800 and the chute 822 at the second end 818 B of the shroud 800 , using fasteners 820 such as bungee cords, rope, zip ties, or other connection means.
- the shroud 800 and chute 822 may be integral with one another or fully connected by bolts, welding, or similar connection.
- the shroud 800 is adapted and positioned to reduce the risk of release of silica dust 50 associated with proppant 38 as it is conveyed along the conveyor belt 700 .
- the shroud 800 also prevents wind from blowing proppant 38 off of the conveyor belt 700 , and rain from wetting the proppant 38 that may hinder the proppant 38 from flowing properly.
- the chute 822 is positioned at the second end 1014 of the conveyor 1000 to receive the proppant 38 that is deposited by the conveyor belt 700 via gravity feed 812 .
- the chute 822 can be tube-shaped, but a chute 822 may alternatively have a bottom portion and a top portion, for example.
- the chute 822 has an inlet 824 and one or more outlets 826 , the inlet 824 positioned to receive the second end 1014 of the conveyor 1000 and the one or more conveyor belts 700 conveying proppant, and the one or more outlets 826 of the chute 822 positioned to deposit proppant 38 into a blender hopper 810 or another location on the well site 30 .
- the chute 822 is adapted and positioned to reduce the risk of release of silica dust 50 at the well site 30 , but also to prevent wind and rain from contacting the proppant 38 .
- the chute 822 in one embodiment, for example, is rotatably connected to the shrouded portion 802 of the conveyor belt 700 such that an operator 806 or a machine can hold on to handles 823 attached to the chute 822 for positioning the opening or openings 826 of the chute 822 towards a blender hopper 810 or another location at a well site 30 , as shown in FIG. 8C .
- the chute 822 may be controlled manually, by hydraulics, or by electronics via remote or wireless control, or via the internet.
- a plurality of hydraulic pressure hoses 819 can connect the chute 822 to the one or more engines 710 and controls 1017 .
- a plurality of wires 821 can be used to connect the chute 822 to the one or more engines 710 and controls 1017 .
- Wireless connections are also contemplated. A person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the chute 822 .
- Well site operators also may be concerned about reducing the silica dust 50 that may be produced or released as proppant 38 flows from the one or more openings 826 of the chute 822 into the one or more blender hoppers 810 of one or more blenders 36 at a well site 30 .
- a blender hopper cover 1208 may be attached to, or positioned over the one or more openings 826 of the chute 822 to substantially or completely enclose the path between the one or more openings 826 of the chute 822 to the blender hopper 810 .
- the blender hopper cover 1208 may be adapted to connect more than one chute 822 into the same blender hopper 810 , for instance, where two conveyors 1000 of the present invention are positioned adjacent each other at a well site 30 .
- the blender hopper cover 1208 may be attached or positioned over the second end 1014 of the conveyor 1000 and the one or more conveyor belts 700 to substantially enclose the path between the second end 1014 of the conveyor 1000 and the one or more conveyor belts 700 to the blender hopper 810 .
- the blender hopper cover may be adapted to connect more than one second end 1014 of the conveyor 1000 and conveyor belt 700 to the same blender hopper 810 , for instance, where two conveyors 1000 of the present invention are positioned adjacent each other at a well site 30 .
- the blender hopper 1208 cover may include tarps 1210 , steel panels 1212 , or panels of similar metals, plastic, or similar material.
- the blender hopper cover can be manufactured to fit over or attach to the one or more openings 826 of the chute 822 and to the one or more blender hoppers 810 of the one or more blenders 36 at a well site 30 .
- the blender hopper cover 1208 may include a window portion 1216 so the operator 806 may inspect the progress of proppant 38 as it fills up the blender hopper 810 .
- the blender hopper 810 may also include electronic or wireless transmission signals to an operator 806 or machine to indicate a problem or that the blender hopper 810 is full.
- the blender hopper cover 1208 reduces the risk of production and release of silica dust 50 at the well site 30 as proppant flows out of an embodiment of a system to one or more blenders 36 .
- an embodiment of the method of the present invention includes, for example, positioning 100 a plurality of containers 900 each having proppant 38 for fracking contained therein onto a conveyor 1000 at a well site 30 , the conveyor 1000 having a plurality of conveyor hoppers 600 and each of the plurality of conveyor hoppers 600 overlaying one or more conveyor belts 700 , each respective container 900 having a sealed top 904 , 914 to reduce risk of release of silica dust 50 associated with proppant 38 into the air.
- each respective container 900 further includes downwardly discharging 110 proppant 38 from each respective container 900 of the plurality of containers 900 , each respective container 900 further having inclined lower inner portions 922 and one or more outlets 924 positioned at a bottom 906 of each respective container 900 , such that as proppant 38 flows by gravity feed 812 along the inclined lower inner portions 922 to and through the one or more outlets 924 , the risk of production and release of silica dust 50 into the air is reduced, and the respective container 900 is substantially emptied of proppant 38 .
- the method further can include removing 160 the respective container 900 from the conveyor 1000 for replacement with another respective container 900 filled with proppant 38 , such that the conveyor belt 700 continuously conveys proppant 38 at the well site 30 from the plurality of containers 900 to the blender 36 .
- An operator 806 or machine may use a forklift 34 , crane 35 , or other heavy machinery to move containers 900 at the well site 30 .
- a flow gate 932 and inclined lower inner portions 922 of each respective container 900 help to control the flow of proppant 38 from the container 900 and thereby reduce the risk of production of silica dust 50 from the container 900 .
- An embodiment of the method further can include controlling 170 the rate of proppant 38 as it flows through the one or more outlets 924 of each respective container 900 by one or more flow gates 932 positioned at the one or more outlets 924 to reduce the risk of production and release of silica dust 50 into the air through the one or more outlets 924 .
- the flow gate 932 can be connected to an actuator 502 thereby to enhance opening and closing of the flow gate 932 .
- the actuator 502 may be optionally controlled by hydraulics or electronics.
- a plurality of hydraulic pressure hoses 503 can connect the actuator 502 to the one or more engines 710 and controls 1017 .
- a plurality of wires 505 can be used to connect the actuator 502 to the one or more engines 710 and controls 1017 .
- Wireless connections are also contemplated.
- a person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the actuator 502 .
- the inclined lower inner portions 922 of each respective container 900 are inclined inwardly from inner walls of the respective container toward a bottom of the container at an angle 928 of about 31 degrees to about 37 degrees relative to a horizontal plane 920 of the bottom of each respective container 900 when each respective container 900 is level. This angle 928 helps to empty the container 900 of proppant 38 to reduce the risk of silica exposure for well site workers.
- a hopper gate 612 , a hopper gate actuator 613 , and a plurality of inclined sides 602 of each respective conveyor hopper 600 help to control the flow of proppant 38 from each respective conveyor hopper 600 and thereby reduce the risk of production and release of silica dust 50 from the conveyor hopper 600 .
- the method can also further include controlling 180 the rate of proppant 38 as the proppant 38 flows from the one or more controllable openings 610 of each respective conveyor hopper 600 to reduce the risk of production and release of silica dust 50 into the air through the one or more controllable openings 610 , the one or more controllable openings 610 having a hopper gate 612 connected to a hopper gate actuator 613 .
- the hopper gate actuator 613 is optionally controlled by hydraulics or electronics to enhance opening and closing of the one or more controllable openings 610 via the hopper gate 612 . If hydraulics are used, for example, a plurality of hydraulic pressure hoses 614 can connect the hopper gate actuator 613 to the one or more engines 710 and controls 1017 . If electronics are used, for example, a plurality of wires 616 can be used to connect the hopper gate 612 to the one or more engines 710 and controls 1017 . Wireless connections are also contemplated. A person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the hopper gate actuator 613 .
- the plurality of inclined sides 602 can include, for example, a pair of short sides 604 A 1 , 604 A 2 representing the depth of the conveyor hopper 600 , and a pair of long sides 604 B 1 , 604 B 2 representing the length of the conveyor hopper 600 .
- the plurality of inclined sides 602 are positioned wherein pair of short sides 604 A 1 , 604 A 2 have a funnel angle 605 A or slope of approximately 35 to 40 degrees relative to a horizontal plane, and a pair of long sides 604 B 1 , 604 B 2 have a funnel angle 605 B or slope of approximately 28 to 33 degrees relative to a horizontal plane, in order to maximize the capacity of the conveyor hopper 600 and the flow of proppant 38 from the conveyor hopper 600 , and to reduce the risk of production and release of silica dust 50 from each respective conveyor hopper 600 .
- the method can include utilizing a plurality of containers 900 having proppant 38 for fracking contained therein, each respective container 900 having an outlet 924 and a sealed top 904 , 914 , the sealed top 904 , 914 positioned to reduce risk of release of silica dust 50 associated with proppant 38 from the sealed top 904 , 914 of each respective container 900 .
- each respective container 900 on a conveyor 1000 at a well site 30 , the conveyor 1000 having a plurality of conveyor hoppers 600 and each of the plurality of conveyor hoppers 600 having one or more controllable openings 610 that is in fluid communication with a conveyor belt 700 that underlies the conveyor 1000 to reduce risk of production and release of silica dust 50 associated with proppant 38 as the proppant 38 flows from each respective container 900 .
- the method also can include, for example, removing 160 each respective container 900 that has been substantially emptied of proppant 38 from the conveyor 1000 at the well site 30 with a forklift 34 for replacement with a second respective container 900 filled with proppant 38 for fracking contained therein such that the conveyor belt 700 is continuously conveying proppant 38 when in operation to the chute 822 .
- the method also can include, for example, controlling 170 the rate of proppant 38 flowing from each respective container 900 using a flow gate 932 positioned at the one or more outlets 924 of each respective container 900 to reduce risk of production and release of silica dust 50 associated with proppant 38 into the air as proppant 38 flows out of the one or more outlets 924 , as shown in FIG. 5B .
- the method also can include, for example, controlling 180 the rate of proppant 38 downwardly flowing from each respective conveyor hopper 600 using a hopper gate 612 with a hopper gate actuator 613 positioned at the one or more controllable openings 610 of each respective conveyor hopper 600 , and optionally controlling the hopper gate actuator 613 by hydraulics or electronics to enhance opening and closing of the hopper gate 612 to reduce risk of production and release of silica dust 50 associated with proppant 38 into the air as proppant 38 flows out of the one or more controllable opening 610 , as shown in FIG. 11 and FIG. 7A .
- a plurality of hydraulic pressure hoses 614 can connect the hopper gate actuator 613 to the one or more engines 710 and controls 1017 .
- a plurality of wires 616 can be used to connect the hopper gate 612 to the one or more engines 710 and controls 1017 .
- Wireless connections are also contemplated. A person of skill in the art would understand the various connections to engines 710 and controls 1017 available for powering the hopper gate actuator 613 .
- the method also can include, for example, positioning 245 a shroud 800 over a portion 802 of the second end 707 of the conveyor belt 700 thereby to define a shrouded portion 802 , the shrouded portion 802 positioned between the last respective container 900 on the conveyor 1000 and the chute 822 at an angle 805 of approximately 30 to 60 degrees from a horizontal plane 1020 when the conveyor is level.
- the shroud 800 substantially encloses the one or more conveyor belts 700 to reduce the risk of release of silica dust 50 associated with proppant 38 in the air.
- the method also can include, for example, positioning 102 each of the plurality of containers 900 side-by-side on the conveyor 1000 .
- the method also can include, for example, positioning 104 the plurality of containers 900 adjacent each other on the conveyor 1000 , wherein each of the plurality of partitions 712 of the conveyor belt 700 extend upwardly from a top surface 702 of the conveyor belt 700 toward the conveyor hopper 600 when positioned to underlie the conveyor hopper 600 and each of the plurality of fingers 714 is spaced-apart from another one of the plurality of fingers 714 so that the top surface 702 of the conveyor belt 700 guidingly receives the proppant 38 thereon and between the plurality of partitions 714 .
- An embodiment of the system of the present invention can include, for example, a plurality of containers 900 each adapted to have proppant 38 for fracking contained therein, each respective container 900 having a sealed top 904 , 914 to reduce risk of release of silica dust 50 associated with proppant 38 into the air when positioned therein.
- Each respective container 900 has interior portions 922 inclined toward an outlet 924 at a bottom 916 of each respective container 900 to reduce risk of production and release of silica dust 50 associated with proppant 38 as the proppant 38 flows from each respective container 900 until each respective container 900 is substantially empty.
- the system further can include a conveyor 1000 positioned at a well site 30 and to receive each respective container 900 of the plurality of containers 900 , the conveyor 1000 having one or more conveyor hoppers 600 that align closely with each respective outlet 924 of the plurality of containers 900 to reduce risk of production and release of silica dust 50 into the air, each of the one or more respective conveyor hoppers 600 having a lower portion 608 including an opening 610 , such that when proppant 38 downwardly flows through each respective outlet 924 of each respective container 900 of the plurality of containers 900 when positioned therein, the proppant 38 passes to and through the opening 610 of each of the one or more respective conveyor hoppers 610 .
- the system further can include one or more conveyor belts 700 positioned to underlie the one or more conveyor hoppers 600 to receive proppant 38 as the proppant 38 passes to and through the opening 610 of each of the one or more respective conveyor hoppers 600 , the conveyor belt 700 having a first end 705 , a second end 707 , and a plurality of partitions 714 associated therewith, such that the plurality of partitions 714 are positioned to reduce risk of production and release of silica dust 50 as proppant 38 contacts and is carried by the conveyor belt 700 .
- the system further can include a shroud 800 positioned to overlie a portion of the second end 705 of the conveyor belt 700 thereby to define a shrouded portion 802 of the conveyor belt 700 , the shroud 800 substantially enclosing the shrouded portion 802 as the conveyor belt 700 conveys proppant 38 when positioned thereon from the plurality of containers 900 to reduce risk of release of silica dust 50 associated with proppant 38 into the air from the shrouded portion 802 .
- the system further can include a chute 822 having an inlet 824 positioned to receive the second end 707 of the conveyor belt 700 conveying proppant 38 and one or more outlets 826 positioned such that as proppant 38 is deposited into the chute 822 by gravity feed 812 , proppant 38 flows out of the one or more outlets 826 to a blender hopper 810 or other location at the well site 30 .
- the system also further can include a blender hopper cover 1208 positioned to reduce risk of production and release of silica dust 50 as proppant 38 flows between the one or more outlets 826 of the chute 822 and the one or more blender hoppers 810 of the one or more blenders 36 at a well site 30 .
- the system also further can include a forklift 34 positioned at a well site 30 to load and unload each respective container 900 onto and off of the conveyor 1000 by one or more slots 901 , wherein each of the plurality of containers 900 has one or more slots 901 positioned adjacent a bottom portion 906 of the respective container 900 .
- the system also further can include a plurality of curtains 1200 positioned on or adjacent the conveyor 1000 to reduce risk of production and release of silica dust 50 as proppant 38 flows from the plurality of conveyor hoppers 600 to the one or more conveyor belts 700 .
- Another embodiment of the system can include a plurality of containers 900 each adapted to have proppant 38 for fracking contained therein, each respective container 900 having a sealed top 904 , 914 to reduce risk of release of silica dust 50 associated with proppant 38 into the air when positioned therein.
- Each respective container 900 has interior portions 922 inclined toward an outlet 924 at a bottom 906 of each respective container to reduce risk of production and release of silica dust 50 associated with proppant 38 as the proppant 38 flows from each respective container 900 until each respective container 900 is substantially empty.
- the system further can include a conveyor 1000 positioned at a well site 30 and to receive each respective container 900 of the plurality of containers 900 , the conveyor 1000 having one or more conveyor hoppers 600 that align closely with each respective outlet 924 of the plurality of containers 900 to reduce risk of production and release of silica dust 50 into the air, each of the one or more respective conveyor hoppers 600 having a lower portion 608 including an opening 610 , such that when proppant 38 downwardly flows through each respective outlet 924 of each respective container 900 of the plurality of containers 900 when positioned therein, the proppant 38 passes to and through the opening 610 of each of the one or more respective conveyor hoppers 600 .
- the system further can include one or more conveyor belts 700 positioned to underlie the one or more conveyor hoppers 600 to receive proppant 38 as the proppant 38 passes to and through the opening 610 of each of the one or more respective conveyor hoppers 600 , the conveyor belt 700 having a first end 705 , a second end 707 , and a plurality of partitions 714 associated therewith, such that the plurality of partitions 714 are positioned to reduce risk of production and release of silica dust 50 as proppant 38 contacts and is carried by the conveyor belt 700 .
- the system further can include a blender hopper 810 positioned to underlie the second end 707 of the conveyor belt 700 conveying proppant 38 such that proppant 38 is deposited into the blender hopper 810 by gravity feed 812 .
- the system also further can include a blender hopper cover 1208 positioned to reduce risk of production and release of silica dust 50 as proppant 38 flows between the one or more outlets 808 of the chute 822 and the one or more blender hoppers 810 of the one or more blenders 36 at a well site 30 .
- a blender hopper cover 1208 positioned to reduce risk of production and release of silica dust 50 as proppant 38 flows between the one or more outlets 808 of the chute 822 and the one or more blender hoppers 810 of the one or more blenders 36 at a well site 30 .
- the system also further can include a forklift 34 positioned at a well site 30 to load and unload each respective container 900 onto and off of the conveyor 1000 by one or more slots 901 , wherein each of the plurality of containers 900 has one or more slots 901 positioned adjacent a bottom portion 916 of the respective container 900 .
- the system also further can include a plurality of curtains 1200 positioned on or adjacent the sides of the conveyor 1000 to reduce risk of production and release of silica dust 50 as proppant 38 flows from the plurality of conveyor hoppers 600 to the conveyor belt 700 .
- the owner of the present application conducted experiments to determine the amount of reduction to respirable crystalline silica particles using an embodiments of method and systems relative to conventional pneumatic delivery.
- the testing was carried out by Weston Solutions, Inc. of Lakewood, Colo.
- the tests were based on samples collected for personal breathing zone samples to assess likely employee exposure to respirable crystalline silica by job category at a well site.
- Personal breathing zone samples were collected in order to compare the results to those found in the NIOSH study.
Abstract
Description
- This application is related to and claims priority to, and the benefit of, U.S. Provisional Application No. 62/012,160, filed Jun. 13, 2014, titled “Process and Apparatus for Reducing Silica Exposure During the Delivery of Proppants to a Mine,” U.S. Provisional Application No. 62/014,479, filed on Jun. 19, 2014, titled “System and Methods for Reducing Silica Exposure at a Well Site,” and U.S. Provisional Application No. 62/114,614, filed Feb. 11, 2015, titled “Methods and Systems to Transfer Proppant for Fracking with Reduced Risk of Production and Release of Silica Dust at a Well Site,” each of which are incorporated herein in their entireties by reference.
- 1. Field of the Invention
- The present invention relates to reducing the risk of production and release of silica dust at a well site during fracking operation. More particularly, the invention relates to methods and systems to enhance transfer of proppant for hydraulic fracking operations from a container while reducing the risk of production and release of silica dust at a well site.
- 2. Description of Related Art
- Hydraulic fracturing or “fracking” has been used for decades to stimulate production from conventional oil and gas wells. In recent years, the use of fracking has increased due to the development of new drilling technology such as horizontal drilling and multi-stage fracking. Such techniques reach previously-unavailable deposits of natural gas and oil. Fracking generally includes pumping fluid into a wellbore at high pressure. Inside the wellbore, the fluid is forced into the formation being produced. When the fluid enters the formation, it fractures, or creates fissures, in the formation. Water, as well as other fluids, and some solid proppants, are then pumped into the fissures to stimulate the release of oil and gas from the formation.
- By far the dominant proppant is silica sand, made up of ancient weathered quartz, the most common mineral in the Earth's continental crust. Unlike common sand, which often feels gritty when rubbed between your fingers, sand used as a proppant tends to roll to the touch as a result of its round, spherical shape and tightly-graded particle distribution. Sand quality is a function of both deposit and processing. Grain size is critical, as any given proppant should reliably fall within certain mesh ranges, subject to downhole conditions and completion design. Generally, coarser proppant allows a higher capacity due to the larger pore spaces between grains. This type of proppant, however, may break down or crush more readily under stress due to the relatively fewer grain-to-grain contact points to bear the stress often incurred in deep oil- and gas-bearing formations.
- Along with increased access to fossil fuels comes new and added challenges for the industry. Exposure to airborne silica has been identified by studies as a health hazard to workers conducting some fracking operations. These studies show that workers may be exposed to dust with high levels of respirable crystalline silica (“silica dust”) during fracking operations. See Eric J. Esswein, Michael Breitenstein, John Snawder, Max Kiefer & W. Karl Sieber (2013): Occupational Exposures to Respirable Crystalline Silica During Hydraulic Fracturing, Journal of Occupational and Environmental Hygiene, 10:7, 347-356. The National Institute for Occupational Safety (“NIOSH”) published a hazard alert along with OSHA relating to the health hazards particular to the fracking industry. The hazard alert explains that “[t]ransporting, moving, and refilling silica sand into and through sand movers, along transfer belts, and into blender hoppers can release dust containing silica into the air.”
- Workers use many tons of proppant at a well site for fracking. These workers risk being exposed to silica dust, which, risks eventually leading to a disease called silicosis, or “Potter's Rot.” Silicosis is a form of occupational lung disease caused by inhalation of crystalline silica dust, and is marked by inflammation and scarring in the form of nodular lesions in the upper lobes of the lungs. It is a type of pneumoconiosis, or lung disease caused by the inhalation of dust, usually from working in a mining operation. This dust has other effects, such as contaminating the atmospheric air, creating a nuisance to adjacent landowners, and damaging equipment on the well site. Bloggers and environmental groups have taken a stand against hydraulic fracturing, in part, because of the silica dust created at the well site.
- Throughout the process of delivering, blending, and mixing proppant at a well site, there is substantial production and release of silica dust. A large amount of proppant is delivered by pneumatic tankers. It is then blown into proppant storage containers. These storage devices can be pre-filled with proppant, either by dumping proppant into storage devices, or pneumatically conducting proppant to the storage devices, and then delivered to a well site for fracking. Once on the well site, various storage containers have openings in the top which allow air flow to the atmosphere. The flow of air creates a large dust cloud formed of silica dust, which blows out of access doors. This especially risks being a problem for workers who are looking into the interior of a storage container to monitor the appropriate fill level. As proppant is dispensed from the storage device, additional silica dust is produced and released. As the proppant is dumped into a blender, further silica dust is produced and released. As a result, dust often is produced and released at many different stages of the process at a well site.
- During this process, if workers are at the well site, they also often stand near or directly in the path of a cloud of airborne silica dust. If workers inhale these small particles of silica dust, the each worker risks particles being embedded deeply into the tiny alveolar sacs and ducts in the worker's lungs, where oxygen and carbon dioxide gases are exchanged. The lungs may not be able to clear out the embedded dust by mucus or coughing. Substantial and concentrated exposure to silica dust therefore risks leading to silicosis.
- Applicants recognized the problems noted above herein and conceived and developed embodiments of systems and methods, according to the present invention, to reduce risk of production and release of silica dust at a well site. Embodiments of the present invention generally address problems associated with risk of inhalation of silica dust at a well site of a fracking operation. More particularly, embodiments of the present invention include methods and systems to transfer proppant from a closed container to a chute for delivery to a blender or other location at a well site while reducing the risk of production and release of silica dust. By uniquely designing, developing, interfacing, and positioning equipment into a system for transferring proppant, applicants have reduced the production and release of silica dust at a well site of a fracking operation.
- In an embodiment, for example, a method includes positioning a plurality of sealed containers containing proppant for fracking such as by use of forklifts or other heavy machinery onto a conveyor with compartments adapted to receive the containers and which overlies one or more conveyor belts. A plurality of hoppers, e.g., one positioned to underlie each container when positioned on the compartment of the conveyor, overlays one or more conveyor belts. Once the sealed containers are positioned on the compartments of the conveyor, the proppant can be hydraulically or electrically released from the containers and be downwardly discharged from each respective container until each respective container is substantially emptied of proppant. After release, in this embodiment, for example, proppant is funneled from the one or more outlets of each of the plurality of containers to and through the plurality of hoppers positioned to reduce the risk of production and release of silica dust. Proppant, in turn, guidingly is received onto the one or more conveyor belts by a plurality of partitions associated with the one or more conveyor belts, e.g., the partitions can extend upwardly in a space-apart relation from the top surface of the one or more conveyor belts, such that the plurality of partitions is positioned to reduce production and release of silica dust into the air as proppant is positioned between the plurality of partitions and contacts the one or more conveyor belts. The one or more conveyor belts then convey the proppant to and through a shrouded portion of the conveyor, positioned to reduce the risk of release of silica dust, and toward a chute position along an end portion of the conveyor, for example. An embodiment of a chute, for example, can be rotatably-positioned to direct the proppant into a blender hopper for use in a fracking operation, but the chute also can deposit the proppant anywhere on the well site. Once the respective containers are substantially emptied of proppant, forklifts or other machinery can remove the empty containers for replacement with containers again being filled with and having proppant for fracking at the well site so that proppant continuously is supplied for and flows towards the chute for deposit into a blender hopper or other location when in operation.
- In another embodiment, for example, a method can include positioning a plurality of sealed containers containing proppant for fracking using forklifts or other heavy machinery onto a conveyor having compartments adapted to receive the containers. The conveyor, in an embodiment, also can have a plurality of hoppers that overlays one or more conveyor belts. Once the sealed containers are positioned on the conveyor, proppant can be downwardly discharged from each respective container until each respective container is substantially emptied of proppant. Proppant, in this process, can be funneled from the one or more outlets of each of the plurality of containers to and through the plurality of hoppers so as to reduce the risk of production and release of silica dust. Proppant guidingly can be received onto the one or more conveyor belts by a plurality of partitions associated therewith, such that the plurality of partitions is positioned to reduce production and release of silica dust into the air as proppant is positioned on and contacts the conveyor belt. The one or more conveyor belts then convey the proppant to a blender hopper. Once the respective containers are substantially emptied of proppant, forklifts or other machinery remove the empty containers for replacement with containers having proppant for fracking at the well site so that proppant continuously is supplied and flows to the blender hopper during and for fracturing operations.
- Embodiments of a system, for example, can include a conveyor positioned at a well site and having compartments adapted to receive each respective container of the plurality of containers. The conveyor also has one or more conveyor hoppers that align closely with each respective outlet of the plurality of containers to assist in funneling and metering the proppant flowing from the containers. One or more conveyor belts are positioned to underlie the one or more conveyor hoppers to receive proppant as the proppant passes to and through the opening of each of the one or more respective conveyor hoppers. The one or more conveyor belts, for example, can each have a first end, a second end, and a plurality of partitions associated therewith. An embodiment of a system also can include a shroud positioned to overlie a portion of the second end of the one or more conveyor belts thereby to define a shrouded portion of the one or more conveyor belts. The shroud, according to an embodiment thereof, for example, substantially encloses the shrouded portion as the one or more conveyor belts convey proppant. The system further can include a chute having an inlet positioned to receive the second end of the conveyor belt conveying proppant and one or more outlets positioned such that proppant is deposited into the chute by gravity feed, and proppant, in turn, flows out of the one or more outlets of the chute to a blender hopper or other location at the well site.
- An embodiment of a system of the invention, for example, can have a conveyor positioned at a well site with compartments adapted to receive each respective container of the plurality of containers. The conveyor also can have one or more conveyor hoppers that align closely with each respective outlet of the plurality of containers when positioned on the conveyor and one or more conveyor belts positioned to underlie the one or more conveyor hoppers to receive proppant as the proppant passes to and through the opening of each of the one or more respective conveyor hoppers. The one or more conveyor belts, for example, each can have a first end, a second end, and a plurality of partitions associated therewith. The system further can include a blender hopper having an inlet positioned to receive the second end of the one or more conveyor belts thereby to convey proppant by gravity feed.
- Embodiments of the system further can include a blender hopper cover positioned to reduce risk of production and release of silica dust as proppant flows between the one or more outlets of the chute and the one or more blender hoppers of the one or more blenders at a well site and a forklift positioned at a well site to load and unload each respective container onto and off of the conveyor by one or more slots. Each of the plurality of containers has one or more slots, for example, positioned adjacent a bottom portion of the respective container to enhance lifting and positioning of each container such as when being lifted by a forklift. The conveyor further can include one or more curtains positioned on or adjacent to the one or more sides of the conveyor to reduce risk of production and release of silica dust as proppant flows from the plurality of conveyor hoppers to the one or more conveyor belts.
- Embodiments of a system, for example, are adapted and positioned to reduce the risk of production and release of silica dust at a well site by reducing the fall height for proppant as it flows between one structure and another, for example, and substantially enclosing either the entire system or portions of the entire system to reduce the risk of the escape of silica dust as the system operates. In addition to the potential health benefits for workers at a well site, and the potential environmental benefits for the areas around a well site, by reducing the risk of production and release of silica dust, embodiments of the system described herein have a host of other benefits directly to the fracking industry itself. Well sites frequently are set up on an open plain without much protection from the natural elements, and embodiments of the system, for example, also are adapted to prevent the wetting of proppant from rain or other precipitation, or the blowing of proppant by the wind from the one or more conveyor belts, for example, as proppant moves through the system. Other aspects of the embodiments of the system include, for example, the portability and stackability of the respective containers having proppant contained therein at a well site, which decreases the footprint of the proppant needed at the well site. The embodiments of the system, for example, also decrease transportation costs with the ability to transport those containers to a well site by ordinary trucks or railcars. Additionally, because the proppant is containerized, trucks or rails need not wait to be unloaded at the well site. As such, embodiments of the system of the present invention virtually eliminate the demurrage of trucks or rails at a well site that increased costs and time to provide sufficient proppant to enable the well site to continuously conduct fracking operations.
- The foregoing aspects, features, and advantages of the present invention will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the invention illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
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FIG. 1 is an environmental perspective view of a well site for fracking using an embodiment of the system and method according to the present invention. -
FIG. 2 is a perspective view of a well site for fracking using a prior art system and method. -
FIG. 3 is a flow chart demonstrating steps of a method according to embodiments of the present invention. -
FIG. 4 is a perspective view of a forklift preparing to position a container having proppant for fracking onto a conveyor according to an embodiment of a system and method of the present invention. -
FIG. 5A is a fragmented perspective view of a container having proppant for fracking positioned on a conveyor according to an embodiment of a system and method of the present invention. -
FIG. 5B is an exploded perspective view ofFIG. 5A of a container having proppant for fracking positioned on the conveyor according to an embodiment of a system and method of the present invention. -
FIG. 5C is a fragmented perspective view of a container having proppant for fracking positioned on a conveyor according to an embodiment of a the system and method of the present invention with portions of the container shown in break-away for clarity. -
FIG. 6A is a fragmented perspective view of a conveyor hopper substantially full of proppant for fracking according to an embodiment of a system and method of the present invention. -
FIG. 6B is a fragmented perspective view of a conveyor hopper partially full of proppant for fracking according to an embodiment of a system and method of the present invention. -
FIG. 6C is a fragmented perspective view of a conveyor hopper without proppant according to an embodiment of a system and method of the present invention. -
FIG. 7A is a fragmented perspective view of a conveyor belt having a plurality of partitions and a plurality of outside walls to convey proppant according to an embodiment of a system and method of the present invention. -
FIG. 7B is a fragmented perspective view of an alternative embodiment of a conveyor belt shown inFIG. 7A , having a plurality of partitions and a plurality of outside walls to convey proppant according to an embodiment of a system and method of the present invention. -
FIG. 8A is a fragmented perspective view of a second end of a conveyor according to an embodiment of a system and method of the present invention with a partial break-away view of the shroud for clarity further to show a conveyor belt. -
FIG. 8B is a fragmented perspective view of a second end of the conveyor according to an embodiment of a system and method of the present invention with a partial break-away view of a chute for clarity further to show the second end of the conveyor belt depositing proppant into the chute by gravity feed. -
FIG. 8C is a perspective view of an operator positioning a chute to deposit proppant into a blender hopper according to an embodiment of a system and method of the present invention. -
FIG. 8D is a perspective view of an alternative embodiment of a second end of a conveyor without a shroud according to an embodiment of a system and method of the present invention. -
FIG. 9A is a perspective view of a container according to an embodiment of a system and method of the present invention. -
FIG. 9B is a front elevation view of a container according to an embodiment of a system and method of the present invention. -
FIG. 9C is a perspective view of a container with portions broken away for clarity to show lower inner side portions of the container according to an embodiment of a system and method of the present invention. -
FIG. 9D is another perspective view of a container according to an embodiment of a system and method of the present invention. -
FIG. 9E is a bottom plan view of a container according to an embodiment of a system and method of the present invention. -
FIG. 10A is a side elevation view of a conveyor according to an embodiment of a system and method of the present invention. -
FIG. 10B is perspective view of a conveyor illustrating a container positioned above the conveyor according to an embodiment of a system and method of the present invention. -
FIG. 10C is a side elevation view of an alternative embodiment of a conveyor according to an embodiment of a system and method of the present invention. -
FIG. 11 is a side elevation view of a conveyor belt underlying a conveyor hopper with break-away portions of a front outer wall of the conveyor belt showing a plurality of partitions according to an embodiment of a system and method of the present invention. -
FIG. 12A is a side elevation view of a conveyor having a curtain and a blender hopper cover further to reduce the production and release of silica dust at a well site according to an embodiment of a system and method of the present invention. -
FIG. 12B is a perspective view of a curtain attached to the conveyor according to an embodiment of a system and method of the present invention. -
FIG. 12C is a perspective view of a blender hopper cover positioned between a chute and a blender hopper of a conveyor according to an embodiment of a system and method of the present invention. -
FIG. 12D is a perspective view of a blender hopper cover of a conveyor and being positioned between a second end of the conveyor and a blender hopper according to an embodiment of a system and method of the present invention. - The foregoing aspects, features, and advantages of the present invention will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the invention illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
- Embodiments of methods and systems are useful at a
well site 30 of a hydraulic fracturing operation. These wellsites 30, as shown inFIG. 1 , for example, includes aremovable floor 32 made of wooden pallets to facilitate the use of heavy machinery, including one ormore forklifts 34, cranes 35, or other hydraulic movers, for loading and unloadingcontainers 900 off of therailroad 46 or eighteen-wheeler trucks 44. Therailcars 48 are specially designed to accommodate fourcontainers 900 in a side-by-side arrangement, for example, and containing proppant. Thecontainers 900 are stackable; at thewell site 30, containers 900S 1 can be stacked on top of other containers 900S2 so as to reduce the footprint ofcontainers 900 at thewell site 30 to thereby maximize the space available.Containers 900 can be stacked up to three-high, for example, at thewell site 30. Because all theproppant 38 is containerized, the logistics problems of the prior art where trucks and trains would demurrage and to unloadproppant 38 at thewell site 30 is eliminated. Thewell sites 30 also can includeblenders 36 for combiningproppant 38, which is most ordinarily consisting of mined silica sand, but potentially comprising coated or treated sand, ceramic, or bauxite, with fracking fluids generally of a proprietary blend. The well site also can includefracking machinery 40 to pump theproppant 38 and other fracking fluids into thewellbore 42 at high pressure. Embodiments of systems, for example, can result in the transfer of fracking sand for depositing into ablender 36 or other desired location at thewell site 30 with a reduced risk of the production and release ofsilica dust 50 into the air. - As described in detail in the background section, prior art methods of transferring fracking sand or
proppant 38 resulted in the production and release ofharmful silica dust 50 at the well site. As shown inFIG. 2 , for example, at a well site of theprior art 52, operators or machines carry out prior art methods for transferring fracking sand or proppant from a huge pile ofsand 54 onopen conveyors 56 into ablender 36 so it can be useful for the fracking operation. The prior art methods oftransferring proppant 38 at awell site 52 frequently involved a plurality oftrucks 44 deliveringproppant 38 to awell site 52. Thesetrucks 44, however, often had to wait, or demurrage, for long periods of time to deliver the load ofsand 54 at thewell site 32. As can be seen inFIG. 2 , the methods used in the prior art result in the significant production and release ofsilica dust 50, which is known to pose significant health risk to well site workers and have a potentially negative effect on the environment. - The flow chart depicted in
FIG. 3 , and as shown inFIGS. 4 , 5C, 6A-6C, 7A, and 8A-8C, demonstrates embodiments of a method for transferringproppant 38 for fracking while reducing the risk of production and release ofsilica dust 50 into the air at awell site 30. Usingforklifts 34, cranes 35, or other heavy machinery, operators or machines position 100 a plurality of sealedcontainers 900, each havingproppant 38 for fracking contained therein, onto aconveyor 1000 adapted to receive thecontainers 900 and having a plurality ofconveyor hoppers 600 that overlay one ormore conveyor belts 700. Thesecontainers 900 can be positioned 102 in a side-by-side arrangement, or positioned 104 adjacent each other on theconveyor 1000. This positioning can, for example, maximize the amount ofproppant 38 that can be transported to thewellbore 42 in the shortest amount of time possible for efficiency, while still reducing the risk of production and release ofsilica dust 50. - Operators or machines utilize hydraulics or electronics to selectively open a series of gates, for example, a
flow gate 932 at the bottom 906 of eachrespective container 900, and aconveyor hopper gate 612 at the bottom 608 of eachrespective conveyor hopper 600, that control a series of openings, for example, one or more outlets 924 of acontainer 900 and one or morecontrollable openings 610 of aconveyor hopper 600, through which theproppant 38 is funneled. The close positioning and design of thecontainers 900 andconveyor 1000, for example, minimize the risk of production and release ofsilica dust 50 as theproppant 38 is funneled to theconveyor belt 700. For example, once the sealedcontainers 900 are positioned on theconveyor 1000, operators or machines downwardly discharge 110 the proppant 38 from eachrespective container 900 until eachrespective container 900 is substantially emptied ofproppant 38.Proppant 38 then is funneled 120 from the one or more openings 924 of each of the plurality ofcontainers 900 to and through the plurality ofconveyor hoppers 600 that are adapted and positioned to reduce the risk of production and release ofsilica dust 50. -
Proppant 38 is received 130 onto theconveyor belt 700 by a plurality ofpartitions 712 associated therewith, such that the plurality ofpartitions 712 is positioned to reduce production and release ofsilica dust 50 into the air asproppant 38 contacts and is carried by theconveyor belt 700. These plurality ofpartitions 712, for example, include a plurality offingers 714 spaced-apart from each other on thetop surface 702 of theconveyor belt 700. The plurality ofpartitions 712 further can includeoutside walls 716 of the conveyor belt. The plurality ofpartitions 712, therefore, can guidingly accept proppant onto theconveyor belt 700 while, for example, breaking up any clumps ofproppant 38, if any, that may pass through eachrespective conveyor hopper 600, and further reduce any production and release ofsilica dust 50 as the proppant 38 contacts theconveyor belt 700. Theconveyor belt 700 is also closely positioned beneath or adjacent thebottom portion 608 of eachconveyor hopper 600 to further reduce the fall-height for theproppant 38 to a matter of inches, for example, as it contacts and is transported by theconveyor belt 700. - The one or
more conveyor belts 700 then conveys 140 theproppant 38 to and through a shroudedportion 802 adapted and positioned to reduce the risk of release ofsilica dust 50 to achute 822. This shroudedportion 802 can be optionally omitted if theconveyor 1000 is designed to directly depositproppant 38 from theconveyor belt 700 into ablender hopper 810, for example, as shown in embodiments described herein, includingFIG. 8D , for example. Theconveyor belt 700 travels in a continuous loop around a designated path controlled byrollers 708 and powered by one or more diesel orelectric engines 710. According to an embodiment, theconveyor belt 700 can be nearly enclosed or fully enclosed as it conveys theproppant 38 to thechute 822. In an embodiment, for example,proppant 38 can be protected from the natural elements of rain and wind, for example, to avoid deteriorating the condition of theproppant 38 and to further minimize the production and release ofsilica dust 50 onto thewell site 30.Proppant 38 can be deposited 150 into thechute 822 bygravity feed 812 as theconveyor belt 700 turns about therollers 708 of theconveyor 1000. Thischute 822 can be designed and rotatably-positioned to direct theproppant 38 into ablender hopper 810 for use in the fracking operation, but thechute 822 could deposit theproppant 38 anywhere on thewell site 38. Thechute 822 can havehandles 823 for anoperator 806 at awell site 30 to directproppant 38 from one ormore outlets 826 of thechute 822 viagravity feed 812 into one ormore blender hoppers 810, for example. - Once the
respective containers 900 are substantially emptied ofproppant 38, forklifts 34, cranes 35, or other machinery can remove 160 theempty containers 900 for replacement withcontainers 900 havingproppant 38 for fracking at thewell site 30 so thatproppant 38 is continuously flowing toward theblender hopper 810 or other location at thewell site 30 while in operation. Containers can be stacked 900S1, 900S1 at thewell site 30, for example, up to three-high to be refilled with proppant or transported off thewell site 30 to be refilled withproppant 38. The containerized aspects of the embodiments of the invention allow for the continuous flow ofproppant 38 to thewellbore 42 at awell site 30 while theconveyor 1000 is in operation. - Embodiments of
containers 900, for example, can be adapted for and positioned to reduce the risk of production and release ofsilica dust 50 at awell site 30. As depicted inFIGS. 9A-9E , eachrespective container 900 is in the nature of a box with anexterior frame 902 having two sets of parallel sides 901A1, 901A2, 901B1, 901B2 that are each perpendicular to a top 904 and a bottom 906. Thecontainer 900 can be a ten-foot ISO container. The container can have aladder 903 for an operator to climb to the top 904 of thecontainer 900 and inspect the contents within thecontainer 900, for example. This means that thecontainer 900 can have a length of ten feet, a width of eight feet, and a height of eight-and-a-half feet, for example. The height can also be nine-and-a-half feet. This embodiment, for example, can hold approximately twenty-three tons of proppant 38 (approximately 43,000-48,000 lbs.), in eachsuch container 900. Thecontainers 900 are designed to drain theproppant 38 contained therein in under two minutes, or at a rate of 25,000 pounds per minute. Because of the weight and magnitude of theproppant 38, thecontainer 900 is made of steel or other similar material and theexterior frame 902 is cage-like or lattice-like and useful for the structural support and positioning of eachcontainer 900 onto thecompartments 1002 of theconveyor 1000 that are adapted to receive eachrespective container 900. Theframe 902 also includes a plurality ofslots 901, including, for example, twoslots 901, by which aforklift 34 can lift and position the plurality ofcontainers 900 on theconveyor 1000. - The top 904 of each
container 900 has aninlet 905 that may be opened and closed by adoor 914, hatch, gate, or other closing mechanism. Thisdoor 914 can provide a seal, or an air-tight and water-tight connection, to thecontainer 900, as it is preferable for theproppant 38 to remain substantially dry. Althoughproppant 38 can flow through embodiments of the system with some degree of moisture content, it is preferable to prevent the clumping ofproppant 38 caused by moisture. Thedoor 914 is also important to prevent the escape ofsilica dust 50 from theproppant 38 contained therein before and during the transfer ofproppant 38 from thecontainers 900 through an embodiment of a system. A person having skill in the art can grasp the available options to design, affix, or attach adoor 914 to accomplish this sealing function. - The
container 900 is made of steel or other similar material. As viewed from the outside of thecontainer 900, and as shown inFIGS. 9A-9E , thebottom portion 916 of thecontainer 900 is open and looks like afunnel structure 918 enclosed within an openexternal frame 902. Referring toFIG. 9D , theexternal frame 902 form's a bottom 906 that comprises aplanar surface 920 perpendicular to the two pairs of parallel sides 901A1, 901A2, 901B1, 901B2. Referring toFIG. 9B , Thebottom portion 916 is open to allow the cylindrical orangular funnel structure 918 to dispense theproppant 38 in thecontainer 900 according to embodiments of methods and systems. Embodiments having thebottom portion feature 916 can be useful in international shipping. During the course of international shipping, for example, it is important to avoid closed spaces within such acontainer 900. The exposure of thefunnel shape 918 in thebottom portion 916 of thecontainer 900 will allow inspectors to have visual access to the area adjacent thefunnel shape 918. - As can be seen in from the partial break-away view of a
container 900 shown inFIG. 9C and the series of cross-section views of the container inFIGS. 5A-5C , thefunnel structure 918 comprises a plurality of inclined lowerinner portions 922 of thecontainer 900. The plurality of inclined lowerinner portions 922 is roughly in thecenter 923 of the bottom 906 and has an opening or openings 924. The plurality of inclined lowerinner portions 922 is designed to ensure that whenproppant 38 is directed out of thecontainer 900, proppant 38 flows from thecontainer 900 until it is substantially empty. The inclined lowerinner portions 922 of eachrespective container 900 are inclined inwardly frominner walls 926 of therespective container 900 toward abottom 906 of the container at anangle 928 of about 31 degrees to about 37 degrees relative to ahorizontal plane 920 of the bottom of eachrespective container 900 when eachrespective container 900 is level. Experiments have shown that thisangle 928 is particularly effective in the full release ofproppant 38 from the interior of thecontainer 900. Any remainingproppant 38 in thecontainer 900, for example, could risk posing a threat to workers in the vicinity of thecontainer 900 during transport of thecontainer 900 to another location. Additionally, because the plurality of inclined lowerinner portions 922 is inclined in this respect,proppant 38 does not rush directly out of the interior, as it may otherwise do. Rather, proppant 38 flows along the plurality of inclined lowerinner portions 922, creating a sink hole or afunnel 930, toward the one or more openings 924 so as to reduce the production and release ofsilica dust 50 asproppant 38 flows from thecontainer 900. - A
flow gate 932 is positioned withintracks 933 located on the bottom 906 over or adjacent the opening or openings 924 of the inclined lowerinner portions 922 of eachrespective container 900, as shown inFIGS. 9D-9E . Theflow gate 932 can be planar and is designed to cover the opening or openings 924. Theflow gate 932 may be a metering gate or another structure capable of controlling the flow ofproppant 38 from the opening or openings 924 that is known to a person skilled in the art. Theflow gate 932 includes ahandle 934 positioned outwardly from theflow gate 932. Referring toFIGS. 5A-5C , in an embodiment of the system, for example, thehandle 934 of theflow gate 932 is designed to sit in the one ormore forks 500 of theconveyor 1000, such that anactuator 502 connected to theforks 500 can move theflow gate 932 to enhance opening or closing the one or more openings 924 of thecontainer 900. For acontainer 900 of this size and magnitude that holds approximately two tons ofproppant 38, theactuator 502 can be hydraulically- or electrically-controlled to enhance opening and closing of theflow gate 932. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 503 can connect the actuator to the one ormore engines 710. If electronics are used, for example, a plurality ofwires 505 can be used to connect the actuator to the one ormore engines 710. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering theactuator 502. Theflow gate 932 can be controlled remotely via the interne, or locally on thewell site 30, either by an operator or a machine. Thisflow gate 932 also controls the rate at which proppant 38 flows from thecontainer 900 to reduce the production and release ofsilica dust 50 associated with theproppant 38 into the air at the one or more openings 924. - The
containers 900 described herein are adapted to fit ontocompartments 1002 of aconveyor 1000 adapted to receive thecontainers 900 thereon. As shown inFIGS. 10A , 10B, and 12B, an embodiment of aconveyor 1000 of embodiments of methods and systems includes aframe 1004 with a top 1006, a bottom 1008, twosides 1010A & 1010B, afirst end 1012, and asecond end 1014. Theconveyor 1000 is made of steel or other similar material. It may be approximately forty feet in length, eight-and-a-half feet in width, four feet in height, and havingwheels 1016 and controls 1017 on thefirst end 1012, thesecond end 1014, or both, but including, for example, on thesecond end 1014, and atrailer hitch 1018 on thefirst end 1012, thesecond end 1014, or both, but including, for example, on thesecond end 1014, such that an operator could attach theconveyor 1000 to the cab of an eighteen-wheeler truck 44 and pull theconveyor 1000 on a highway. The size of theconveyor 1000 is designed to be at or below the dimensions permitted by law for trailers oftrucks 44, so the dimensions may be adjusted as dimensions change for safe highway travel. Theframe 1004 must be able to support up to several tons ofproppant 38 housed in a plurality ofcontainers 900. Theconveyor 1000 has one or more hydraulic orelectric lifts 1019 to make sure that theframe 1004 is level because the well site may have uneven ground. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 1021 can connect thelifts 1019 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality of wires 1023 can be used to connect thelifts 1019 to the one ormore engines 710. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering thelifts 1019. The one ormore lifts 1019 also decrease the risk that theconveyor 1000 will tip over or become unstable on thewell site 30. - As shown in
FIG. 10B , the top 1006 of theframe 1004 comprises atop surface 1020 that is adapted to receive embodiments of thecontainers 900 described herein. Thetop surface 1020 has one ormore compartments 1002, each adapted to receive one ormore containers 900, an example of which can be seen inFIG. 6C . In an embodiment, for example, theconveyor 1000 has three to fivecompartments 1002 to receive three to fivecontainers 900 havingproppant 38 for fracking. As shown inFIG. 10B andFIG. 12A , thetop surface 1020 can have fourcompartments 1002 to receive fourcontainers 900 havingproppant 38 for fracking. In the same embodiment, for example, the fourcontainers 900 are positioned on theconveyor 1000 such that eachcontainer 900 has either one or both parallel sides 901A1 and 901A2 adjacent the either one, or both parallel sides 901A1 and 901A2 of anothercontainer 900, the top 904 andbottom 906 of eachcontainer 900 is perpendicular to thetop surface 1020 of theconveyor 1000, and the top 904 andbottom 906 of eachcontainer 900 is overlaying theconveyor belt 700 positioned below thetop surface 1020 of theconveyor 1000. In this embodiment, for example, eachcontainer 900 is positioned in a line such that theproppant 38 contained within eachcontainer 900 will flow out of eachcontainer 900 onto one ormore conveyor belts 700. In another embodiment, the plurality ofcontainers 900 are positioned in a side-by-side arrangement on thetop surface 1020 of theconveyor 1000 overlaying one ormore conveyor belts 700. - As can be seen in
FIGS. 4 , 5A, 5C, 6A-6C, the one ormore compartments 1002 of theconveyor 1000 can includecorners 1022, tracks, lock-and-key connections, and female-and-male connections, for example. Thesecorners 1022, for example, can be made of steel or other similar material. Thecontainer 900 need not fit tightly onto eachcompartment 1002. Instead, for example, thecorners 1022 need only to guide thecontainer 900 into position onto thecompartment 1002 such that thecontainer 900 will not fall off of theconveyor 1000. Alternatively, thecontainer 900 may fit tightly on thecompartment 1002. The sheer weight of thecontainer 900, however, would usually prevent thecontainer 900 from moving once it is positioned on thecompartment 1002, even without anysuch corners 1022, and thecompartment 1002 need not have anysuch corners 1022 as described herein. In an embodiment of a system, and as shown inFIG. 4 , for example, aforklift 34, crane 35, or other heavy machinery lifts acontainer 900 havingproppant 38 up and over the top of therespective compartment 1002 of theconveyor 1000, comprisingsteel corners 1022 extending vertically from each respective corner of eachrespective compartment 1002 of theconveyor 1000, and lowers thecontainer 900 havingproppant 38 into place onto theconveyor 1000. Thecorners 1022 of thecompartment 1002 guide thecontainer 900 into place. Referring toFIG. 5C , therespective corners 1022 of the compartments have a plurality ofload cells 1024 for determining the weight of eachcontainer 900 on eachrespective compartment 1002 of theconveyor 1000. In an embodiment of the present invention, for example, aload cell 1024 is positioned in each of the four corners of thecompartment 1002. Theseload cells 1024 inform an operator or machine howmuch proppant 38 is left in therespective container 900 by its weight so the operator or machine knows when to replace the respectiveempty container 900 with anothercontainer 900 filled withproppant 38 at awell site 30. Therespective load cells 1024 are in electric or wireless communication viawires 1025 or wirelessly with a light 1026 to indicate to the operator or machine that thecontainer 900 is positioned properly onto thecompartment 1002. When acontainer 900 is positioned properly on thecompartment 1002, for example, the light 1026 may change from red to green, for example. It should be understood that aforklift 34 need not lift therespective container 900 up and over thecorners 1022 of thecompartment 1002 of theconveyor 1000 if alternative structures are used instead ofcorners 1022. In this way, theforklift 34 could, for example, lift thecontainer 900 up to the height of thetop surface 1020 of theconveyor 1000 and slide thecontainer 900 onto therespective compartment 1002. - The
conveyor 1000, having a plurality ofcompartments 1002 adapted to receivecontainers 900, also can have a plurality ofopenings 1028 in thetop surface 1020 of theconveyor 1000. The plurality ofopenings 1028 is positioned beneath the respective plurality ofcontainers 900 on theconveyor 1000 such thatproppant 38 flowing from eachrespective container 900 will pass through eachrespective opening 1028. Eachopening 1028 has one ormore forks 500 positioned above or adjacent the opening oropenings 1028, the one ormore forks 500 adapted to receive ahandle 934 of aflow gate 932 of acontainer 900 to engage, contact, or communicate with thecorresponding handle 934 of theflow gate 932 of thecontainer 900, as shown in an embodiment depicted inFIGS. 5A-5C and 10C. Thehandle 934 of theflow gate 932, the one ormore forks 500, or both, are in electric or wireless communication with the light 1026, along with therespective load cells 1024 of thecorners 1022 viawires 1025 or wirelessly, to indicate to an operator or machine that thecontainer 900 is in proper position when thehandle 934 of theflow gate 932 is aligned or situated in the one ormore forks 500 of thecompartment 1002. The variety of connections or contacts to secure or place thecontainer 900 onto thetop surface 1020 of theconveyor 1000, such that theactuator 502 can operate theflow gate 932 of thecontainer 900, will be apparent to a person having skill in the art. - Embodiments of the
conveyor 1000, for example, also can include a plurality ofconveyor hoppers 600 positioned adjacent or beneath the plurality ofopenings 1028 in thetop surface 1020 of theconveyor 1000. The plurality ofconveyor hoppers 600 is positioned such that whencontainers 900 are placed onto theconveyor 1000, eachrespective conveyor hopper 600 is beneath theflow gate 932 of the one or more openings 924 of eachrespective container 900. As shown inFIGS. 5A-C andFIGS. 6A-6C , eachrespective conveyor hopper 600 can include a plurality ofinclined sides 602 to form a receptacle or funnel structure forproppant 38 to pass into and through asproppant 38 is discharged from eachrespective container 900 when in operation. The plurality ofinclined sides 602 can include a pair of short sides 604A1, 604A2 and a pair of long sides 604B1, 604B2. Based on experimental results, the short sides 604A1-A2 can have afunnel angle 605A or slope of approximately 35 to 40 degrees relative to ahorizontal plane 1020, including, for example, 38 degrees, and the long sides 604B1-B2 can have afunnel angle 605B or slope of approximately 28 to 33 degrees relative to ahorizontal plane 1020, including, for example, 31 degrees, to maximize the capacity of theconveyor hopper 600 and the flow ofproppant 38 from theconveyor hopper 600. - The
conveyor hopper 600 has atop portion 606 and abottom portion 608, and thebottom portion 608 can include one or morecontrollable openings 610. Thetop portion 606 of theconveyor hopper 600 can be in the same plane, above it, or below thetop surface 1020 of theconveyor 1000. Thetop portion 606 of theconveyor hopper 600 can be in the same plane or higher than thetop surface 1020 of theconveyor 1000, as can be seen inFIGS. 10B , 10C. Eachconveyor hopper 600, for example, can be zero to two inches below therespective flow gate 932 of the one or more openings 924 of the bottom of eachcontainer 900. In this embodiment, for example, the distance the flowingproppant 38 has to pass from the one or more openings 924 of thecontainer 900 into theconveyor hopper 600 is minimized to reduce the risk of production and release ofsilica dust 50. This close proximity further limits the risk of exposure tosilica dust 50 by workers at thewell site 30. Thebottom portion 608 of theconveyor hopper 600 also can include one or morecontrollable openings 610. The one or morecontrollable openings 610 can include ahopper gate 612. The hopper gate, for example, can be made of steel or similar material, and can be formed in the shape of an inverted “V” or other shape that facilitates the flow ofproppant 38 through thebottom portion 608 of theconveyor hopper 600. Thehopper gate 612 can be connected to ahopper gate actuator 613 that can be optionally hydraulically- or electrically-controlled to enhance opening and closing of the one or morecontrollable openings 610 of theconveyor hopper 600. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 614 can connect thehopper gate actuator 613 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality of wires 616 can be used to connect thehopper gate 612 to the one ormore engines 710 and controls 1017. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering thehopper gate actuator 613. In the embodiments shown in the series fromFIGS. 6A to 6C , for example,proppant 38 is controllably discharged from theconveyor hopper 600 so that there is noexcess proppant 38 discharged at any one time. This embodiment prevents the creation of a cloud ofsilica dust 50 in the area of theconveyor belt 700, while maximizing the efficiency of the delivery ofproppant 38 onto theconveyor belt 700. - Embodiments of methods and systems, for example, also can include one or
more conveyor belts 700. Eachrespective conveyor belt 700 has atop surface 702, abottom surface 704, and twosides respective conveyor belt 700 is manufactured as one long piece, or is zippered together to form one long piece. Eachrespective conveyor belt 700 has a first end portion 705 and a second end portion 707. Eachrespective conveyor belt 700 is suitably wound aroundrollers 708 to travel a desired path. Eachrespective conveyor belt 700 is powered by one ormore engines 710. Theseengines 710 can be diesel, electric, or a combination of the two.Diesel engines 710 have been used in the filed for many years and are reliable in remote locations.Electric engines 710, however, are cleaner to use but may require, for example, an on-site generator, batteries, or access to electric power to run. The industry, however, is moving towards cleaner power sources, and thevarious engines 710 available will be known to a person of skill in the art. As shown inFIGS. 7A-7B and 8A-8D, each respective conveyor belt is adapted to reduce the risk of production and release ofsilica dust 50 asproppant 38 guidingly falls from the plurality ofconveyor hoppers 600 to the one ormore conveyor belt 700. The respective one ormore conveyor belts 700 can include a plurality ofpartitions 712. Embodiments of the plurality ofpartitions 712 can include a plurality offingers 714 and anoutside wall 716 on each side. Eachrespective conveyor belt 700 can be manufactured to include, or integrate, the plurality offingers 714 and theoutside walls 716. Alternatively, the plurality offingers 714 and theoutside walls 716 can be connected to atop surface 702 of a conveyor belt using commercially-acceptable adhesive. - Referring to
FIG. 11 , the plurality offingers 714 of theconveyor belt 700 connect to and extend upwardly from atop surface 702 toward theconveyor hopper 600 when positioned to underlie theconveyor hopper 600, and each of the plurality offingers 714 is spaced-apart from another one of the plurality offingers 714 so that the top surface receives theproppant 38 thereon and between the plurality offingers 714. The plurality offingers 714 are perpendicular or near-perpendicular to thetop surface 702 of the one ormore conveyor belts 700. The plurality offingers 714 are closely-spaced from one another, including from between one and four inches apart from one another. The plurality offingers 714 may be arranged in a regular pattern or an irregular pattern on thetop surface 702 of therespective conveyor belt 700. The arrangement or pattern of the plurality offingers 714 need only to fulfill the function of the plurality offingers 714, which is, for example, to separate out theproppant 38 and break up the clumps ofproppant 38, if any, falling from theconveyor hopper 600. The plurality offingers 714 also is useful in guiding the proppant onto thetop surface 702 of theconveyor belt 700 to reduce the production ofsilica dust 50. As can be seen in the embodiments shown inFIGS. 7A and 7B , for example, the plurality offingers 714 may be cylindrical, angular, or flat. Eachrespective finger 714 has a top 718 that may be flat or rounded. The plurality offingers 714 each may have a top 718 that is flat because, as theconveyor belt 700 is running, the vibrations from the engine orengines 710 do not permit theproppant 38 to remain on the top 718 of the plurality offingers 714. Rather, theproppant 38 will fall between the plurality offingers 714 to thetop surface 702 of the one ormore conveyor belts 700, as is shown inFIG. 7A . - Each
side more conveyor belts 700 has anoutside wall 716 positioned at or near the margin or edge of therespective side outside wall 716 can be in a continuous “S” shape to permit theconveyor belt 700 to compress and flex aroundrollers 708 as theconveyor belt 700 is moving to prevent the escape ofsilica dust 50. Theouter wall 716 also prevents proppant 38 from spraying or falling out thesides conveyor belt 700 as it is being conveyed to thechute 822. It also prevents wind from blowing theproppant 38 orsilica dust 50 off theconveyor belt 700. Other shapes, for example, a wave or triangular shape, of theouter wall 716 are acceptable so long as theconveyor belt 700 does not releasesilica dust 50 orproppant 38 through theouter wall 716 as it passes along therollers 708. Theouter wall 716 may comprise a flat or rounded top 720, much the same as the plurality offingers 714. As can be seen in an embodiment shown inFIG. 11 , for example, the plurality offingers 714 and theouter wall 716 are relatively the same height from thetop surface 702 of theconveyor belt 700. In the embodiment shown inFIG. 11 , the height of the plurality ofpartitions 712 can be between four to eight inches, including, for example, six inches. The substantially similar height of the plurality offingers 714 and theouter walls 716 allows theconveyor belt 700 to be positioned as closely to thebottom portion 608 of eachrespective conveyor hopper 600 to minimize the distance theproppant 38 has to fall as theproppant 38 flows from the plurality ofconveyor hoppers 600 to the one ormore conveyor belts 700. This distance between the plurality ofconveyor hoppers 600, and the top 718, 720 of the plurality ofpartitions 712 can be between zero and two inches. With this negligible gap, the risk of production and release ofsilica dust 50 is reduced. - As shown in the embodiments of
FIGS. 7A-7B and 8A-8D, theconveyor belt 700 is positioned at or near the one or morecontrollable openings 610 of the plurality ofconveyor hoppers 600 to reduce risk of production and release ofsilica dust 50 asproppant 38 flows from the plurality ofcontainers 900, to and through the plurality ofconveyor hoppers 600, onto the one ormore conveyor belts 700. In an embodiment, for example, theconveyor belt 700 is substantially enclosed. In an embodiment shown inFIGS. 12A and 12B , a curtain orcurtains 1200 may be added to one ormore sides conveyor 1000 to fully enclose the one ormore conveyor belts 700. The curtain orcurtains 1200 may includetarps 1202,steel panels 1204, or similar structures, that are removably or permanently attached to theconveyor 1000 usingfasteners 1206 such as bungee cords, rope, zip ties, bolts, screws, welding, or other material adapted to be integral with or attached to theconveyor 1000. The curtain orcurtains 1200 further protect the proppant 38 from the wind at it is blowing across thewell site 30, from the rain or precipitation at thewell site 30, and from anyincidental silica dust 50 orproppant 38 that may spray from theconveyor belt 700, and thus further reduce the risk of the release ofsilica dust 50 into the air. - Similarly to the curtain or
curtains 1200 of an embodiment shown inFIG. 12A-12B , an embodiment of the present invention can include ablender hopper cover 1208. Like the curtain orcurtains 1200, theblender hopper cover 1208 may be added to the one ormore outlets 826 of thechute 822 or to thesecond end 1014 of theconveyor 1000 to fully enclose the path to theblender hopper 810. Theblender hopper cover 1208 may includetarps 1210, steel panels 1212, or similar structures, that are removably or permanently attached to thechute 822 orconveyor 1000 usingfasteners 1214 such as bungee cords, rope, zip ties, bolts, screws, welding, or other material adapted to be integral with or attached to thechute 822 or theconveyor 1000. Theblender hopper cover 1208 further protects the proppant 38 from the wind at it is blowing across thewell site 30, from the rain or precipitation at thewell site 30, and from anyincidental silica dust 50 orproppant 38 that may spray fromchute 822 orconveyor belt 700 asproppant 38 is deposited into theblender hopper 810, and thus further reduces the risk of the release ofsilica dust 50 into the air. - In an embodiment shown in
FIG. 10A , for example, a first end portion 705 can be parallel to the ground and positioned at thefirst end 1012 of theconveyor 1000. A second end portion 707 of theconveyor belt 700 can be elevated relative to the first end portion 705 of theconveyor belt 700 and positioned between the lastrespective container 900 on thesecond end 1014 of theconveyor 1000 and thechute 822, at anangle 805 above parallel with respect to the ground.Rollers 708 positioned within theconveyor 1000 control the path the one ormore conveyor belts 700 travel. In an embodiment, for example, theconveyor belt 700 travels in a path that is level from thefirst end 1012 of theconveyor 1000 as theconveyor belt 700 passes beneath each of the plurality ofconveyor hoppers 600 andcontainers 900 positioned thereabove, bends upward after theconveyor belt 700 has passed beneath thelast container 900 positioned on theconveyor 1000, and travels upward towards asecond end 1014 of theconveyor 1000, relative to ahorizontal plane 1020, to thechute 822, where theconveyor belt 700 turns about aroller 708 and returns toward thefirst end 1012 of theconveyor 1000. In an embodiment, for example, thesecond end 1014 of theconveyor 1000 can be elevated relative to thefirst end 1012 of theconveyor 1000 so thatproppant 38 may be deposited off of the end of theconveyor belt 700 viagravity feed 812 into thechute 822 for deposit into theblender hopper 810. - In an embodiment of a method, for example, where a
conveyor 1000 is holding all of thecontainers 900 it is designed to hold, as shown, for example, inFIG. 12A , theconveyor belt 700 is level with the ground as it passes beneath each of the plurality ofcontainers 900 positioned on theconveyor 1000. As shown by the break-away portions ofFIG. 8A , once theconveyor belt 700 passes the end of the lastrespective container 900 positioned on theconveyor 1000, theconveyor belt 700 is directed by one ormore rollers 708 in an upward direction towards thesecond end 1014 of theconveyor 1000. Thisportion 802 of theconveyor belt 700 can travel upwards at anangle 805 of approximately thirty to sixty degrees with respect to ahorizontal plane 1020 extending from theconveyor belt 700 as it is level with the ground. Theportion 802 of theconveyor belt 700 that travels in an upward direction also passes through ashroud 800, therein defining a shroudedportion 802 of theconveyor belt 700, as shown inFIGS. 8A-8B . The shroudedportion 802 is positioned between a lastrespective container 900 on theconveyor 1000 and an inlet 824 of thechute 822 at anangle 805 of approximately 30 to 60 degrees from ahorizontal plane 1020 when theconveyor 1000 is level. At thesecond end 1014 of theconveyor 1000, the one ormore conveyor belts 700 turns about within thechute 822 that is substantially enclosed and travels downward towards afirst end 1012 of theconveyor 1000. As shown inFIG. 8B , as theconveyor belt 700 turns about, theproppant 38 is deposited into achute 822 that is enclosed bygravity feed 812. Theproppant 38 flows down thechute 822 and is deposited where theoperator 806 or machine directs the proppant 38 from theoutlet 826 of thechute 822, but thechute 822 can be positioned to depositproppant 38 into ablender hopper 810 at thewell site 30, as shown inFIG. 8C . - In an embodiment, for example, shown in
FIGS. 8D and 10C , theconveyor belt 700 need not travel in an upward direction at thesecond end 1014 of theconveyor 1000, but rather, may stay level, or travel in a downward path, if theconveyor 1000, the one ormore conveyor belts 700, or thechute 822, is positioned to depositproppant 38 into ablender hopper 810 that is at or below the one ormore conveyor belts 700, or if thechute 822 is positioned to depositproppant 38 into a hole, for example. This embodiment of the present invention may include the one ormore conveyor belts 700 traveling in a substantially level or downward path from thefirst end 1012 of theconveyor 1000 to thesecond end 1014, underneath the plurality ofconveyor hoppers 600, and depositing theproppant 38 into achute 822 or directly into ablender hopper 810 without passing through a shroudedportion 802. In this embodiment, thechute 822 orblender hopper 810 is adapted or positioned to remain lower to the ground than thetop surface 702 of theconveyor belt 700 such thatproppant 38 is deposited directly into either thechute 822 or theblender hopper 810 bygravity feed 812 as theconveyor belt 700 turns about around aroller 708. This embodiment, for example, provides that the one ormore engines 710 and thecontrols 1017, if any, may need to be moved from thesecond end 1014 of theconveyor 1000 to thefirst end 1012 to accommodate the elimination of the shroudedportion 802 at thesecond end 1014. In this embodiment, thewheels 1016 of theconveyor 1000 may also move to thefirst end 1012 of theconveyor 1000. This embodiment may also include ablender hopper cover 1208 and a plurality ofcurtains 1200 to reduce the risk of production and release ofsilica dust 50 at thewell site 30. - Referring to
FIGS. 8A-8B , theshroud 800 is a box, tube, or container structure that substantially or completely encloses a the shroudedportion 802 of theconveyor belt 700 while it is traveling in an upward direction towards thesecond end 1014 of theconveyor 1000. Theshroud 800 can be a closed and elongated box having foursides sides 816A-D of theshroud 800 can include a plurality of steel panels bolted together around theconveyor belt 700, and bolted to the conveyor at a first end 818A, and bolted to thechute 822 at a second end 818B. The material need not be steel panels, but could also include a seamless steel box, or another structure made of a similar metal, plastic, cloth, tarp, or other sheets. Theshroud 800 need not fully enclose theconveyor belt 700. For example, theshroud 800 may include a tarp covering thetop surface 702 of theconveyor belt 700 having a plurality ofpartitions 712, connected to thesecond end 1014 of theconveyor 1000 at the first end 818A of theshroud 800 and thechute 822 at the second end 818B of theshroud 800, using fasteners 820 such as bungee cords, rope, zip ties, or other connection means. Alternatively, theshroud 800 andchute 822 may be integral with one another or fully connected by bolts, welding, or similar connection. Theshroud 800 is adapted and positioned to reduce the risk of release ofsilica dust 50 associated withproppant 38 as it is conveyed along theconveyor belt 700. Theshroud 800 also prevents wind from blowingproppant 38 off of theconveyor belt 700, and rain from wetting theproppant 38 that may hinder the proppant 38 from flowing properly. - The
chute 822 is positioned at thesecond end 1014 of theconveyor 1000 to receive theproppant 38 that is deposited by theconveyor belt 700 viagravity feed 812. Thechute 822 can be tube-shaped, but achute 822 may alternatively have a bottom portion and a top portion, for example. Thechute 822 has an inlet 824 and one ormore outlets 826, the inlet 824 positioned to receive thesecond end 1014 of theconveyor 1000 and the one ormore conveyor belts 700 conveying proppant, and the one ormore outlets 826 of thechute 822 positioned to depositproppant 38 into ablender hopper 810 or another location on thewell site 30. Thechute 822, like theshroud 800, is adapted and positioned to reduce the risk of release ofsilica dust 50 at thewell site 30, but also to prevent wind and rain from contacting theproppant 38. Thechute 822, in one embodiment, for example, is rotatably connected to the shroudedportion 802 of theconveyor belt 700 such that anoperator 806 or a machine can hold on tohandles 823 attached to thechute 822 for positioning the opening oropenings 826 of thechute 822 towards ablender hopper 810 or another location at awell site 30, as shown inFIG. 8C . Thechute 822 may be controlled manually, by hydraulics, or by electronics via remote or wireless control, or via the internet. If hydraulics are used, for example, a plurality ofhydraulic pressure hoses 819 can connect thechute 822 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality ofwires 821 can be used to connect thechute 822 to the one ormore engines 710 and controls 1017. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering thechute 822. - Well site operators also may be concerned about reducing the
silica dust 50 that may be produced or released asproppant 38 flows from the one ormore openings 826 of thechute 822 into the one ormore blender hoppers 810 of one ormore blenders 36 at awell site 30. As shown inFIGS. 12A and 12C , ablender hopper cover 1208 may be attached to, or positioned over the one ormore openings 826 of thechute 822 to substantially or completely enclose the path between the one ormore openings 826 of thechute 822 to theblender hopper 810. Theblender hopper cover 1208 may be adapted to connect more than onechute 822 into thesame blender hopper 810, for instance, where twoconveyors 1000 of the present invention are positioned adjacent each other at awell site 30. In another embodiment, and as shown inFIG. 8D andFIG. 10C , for example, theblender hopper cover 1208 may be attached or positioned over thesecond end 1014 of theconveyor 1000 and the one ormore conveyor belts 700 to substantially enclose the path between thesecond end 1014 of theconveyor 1000 and the one ormore conveyor belts 700 to theblender hopper 810. In this embodiment, as well, the blender hopper cover may be adapted to connect more than onesecond end 1014 of theconveyor 1000 andconveyor belt 700 to thesame blender hopper 810, for instance, where twoconveyors 1000 of the present invention are positioned adjacent each other at awell site 30. Theblender hopper 1208 cover may includetarps 1210, steel panels 1212, or panels of similar metals, plastic, or similar material. The blender hopper cover can be manufactured to fit over or attach to the one ormore openings 826 of thechute 822 and to the one ormore blender hoppers 810 of the one ormore blenders 36 at awell site 30. Theblender hopper cover 1208 may include awindow portion 1216 so theoperator 806 may inspect the progress ofproppant 38 as it fills up theblender hopper 810. Theblender hopper 810 may also include electronic or wireless transmission signals to anoperator 806 or machine to indicate a problem or that theblender hopper 810 is full. Theblender hopper cover 1208 reduces the risk of production and release ofsilica dust 50 at thewell site 30 as proppant flows out of an embodiment of a system to one ormore blenders 36. - As demonstrated in
FIGS. 1 , 3, 4, 5C, 6A-6C, 7A, and 8A-8C, an embodiment of the method of the present invention includes, for example, positioning 100 a plurality ofcontainers 900 each havingproppant 38 for fracking contained therein onto aconveyor 1000 at awell site 30, theconveyor 1000 having a plurality ofconveyor hoppers 600 and each of the plurality ofconveyor hoppers 600 overlaying one ormore conveyor belts 700, eachrespective container 900 having a sealedtop silica dust 50 associated withproppant 38 into the air. It further includes downwardly discharging 110proppant 38 from eachrespective container 900 of the plurality ofcontainers 900, eachrespective container 900 further having inclined lowerinner portions 922 and one or more outlets 924 positioned at a bottom 906 of eachrespective container 900, such that asproppant 38 flows bygravity feed 812 along the inclined lowerinner portions 922 to and through the one or more outlets 924, the risk of production and release ofsilica dust 50 into the air is reduced, and therespective container 900 is substantially emptied ofproppant 38. It further comprises funneling 120proppant 38 from the one or more outlets 924 of each of the plurality ofcontainers 900 through a plurality ofconveyor hoppers 600, eachrespective conveyor hopper 600 having inclinedsides 602 and one or morecontrollable openings 610 positioned adjacent and overlying the one ormore conveyor belts 700, such that asproppant 38 flows bygravity feed 812 along theinclined sides 902 of each of the plurality ofconveyor hoppers 600 through the one or morecontrollable openings 610 to theconveyor belt 700, the risk of production and release ofsilica dust 50 into the air through the one or morecontrollable openings 610 is reduced. It further comprises receiving 130 proppant onto the one ormore conveyor belts 700, theconveyor belt 700 having a plurality ofpartitions 712 associated therewith, such that the plurality ofpartitions 712 are positioned to reduce risk of production and release ofsilica dust 50 into the air asproppant 38 contacts and is carried by theconveyor belt 700. It further comprises conveying 140proppant 38 on theconveyor belt 700 to achute 822, theconveyor belt 700 having a first end portion 705 and a second end portion 707, the second end portion 707 of theconveyor belt 700 including a shroudedportion 802 that has ashroud 800 substantially enclosing theconveyor belt 700 and positioned to substantially reduce risk of release ofsilica dust 50 associated withproppant 38 into the air as theproppant 38 is conveyed through the shroudedportion 802. It further comprises depositing 150 the proppant 38 from the second end portion 707 of theconveyor belt 700 to thechute 822 for depositing into ablender hopper 810 or another location at thewell site 30. - After
proppant 38 has been discharged from arespective container 900 of the plurality ofcontainers 900, the method further can include removing 160 therespective container 900 from theconveyor 1000 for replacement with anotherrespective container 900 filled withproppant 38, such that theconveyor belt 700 continuously conveysproppant 38 at thewell site 30 from the plurality ofcontainers 900 to theblender 36. Anoperator 806 or machine may use aforklift 34, crane 35, or other heavy machinery to movecontainers 900 at thewell site 30. - A
flow gate 932 and inclined lowerinner portions 922 of eachrespective container 900 help to control the flow ofproppant 38 from thecontainer 900 and thereby reduce the risk of production ofsilica dust 50 from thecontainer 900. An embodiment of the method further can include controlling 170 the rate ofproppant 38 as it flows through the one or more outlets 924 of eachrespective container 900 by one ormore flow gates 932 positioned at the one or more outlets 924 to reduce the risk of production and release ofsilica dust 50 into the air through the one or more outlets 924. Theflow gate 932 can be connected to anactuator 502 thereby to enhance opening and closing of theflow gate 932. Theactuator 502 may be optionally controlled by hydraulics or electronics. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 503 can connect theactuator 502 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality ofwires 505 can be used to connect theactuator 502 to the one ormore engines 710 and controls 1017. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering theactuator 502. The inclined lowerinner portions 922 of eachrespective container 900 are inclined inwardly from inner walls of the respective container toward a bottom of the container at anangle 928 of about 31 degrees to about 37 degrees relative to ahorizontal plane 920 of the bottom of eachrespective container 900 when eachrespective container 900 is level. Thisangle 928 helps to empty thecontainer 900 ofproppant 38 to reduce the risk of silica exposure for well site workers. - A
hopper gate 612, ahopper gate actuator 613, and a plurality ofinclined sides 602 of eachrespective conveyor hopper 600 help to control the flow ofproppant 38 from eachrespective conveyor hopper 600 and thereby reduce the risk of production and release ofsilica dust 50 from theconveyor hopper 600. The method can also further include controlling 180 the rate ofproppant 38 as theproppant 38 flows from the one or morecontrollable openings 610 of eachrespective conveyor hopper 600 to reduce the risk of production and release ofsilica dust 50 into the air through the one or morecontrollable openings 610, the one or morecontrollable openings 610 having ahopper gate 612 connected to ahopper gate actuator 613. Thehopper gate actuator 613 is optionally controlled by hydraulics or electronics to enhance opening and closing of the one or morecontrollable openings 610 via thehopper gate 612. If hydraulics are used, for example, a plurality of hydraulic pressure hoses 614 can connect thehopper gate actuator 613 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality of wires 616 can be used to connect thehopper gate 612 to the one ormore engines 710 and controls 1017. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering thehopper gate actuator 613. The plurality ofinclined sides 602 can include, for example, a pair of short sides 604A1, 604A2 representing the depth of theconveyor hopper 600, and a pair of long sides 604B1, 604B2 representing the length of theconveyor hopper 600. The plurality ofinclined sides 602 are positioned wherein pair of short sides 604A1, 604A2 have afunnel angle 605A or slope of approximately 35 to 40 degrees relative to a horizontal plane, and a pair of long sides 604B1, 604B2 have afunnel angle 605B or slope of approximately 28 to 33 degrees relative to a horizontal plane, in order to maximize the capacity of theconveyor hopper 600 and the flow ofproppant 38 from theconveyor hopper 600, and to reduce the risk of production and release ofsilica dust 50 from eachrespective conveyor hopper 600. - In another embodiment, for example, and as illustrated in
FIGS. 1 , 3, 4, 5C, 6A-6C, 7A, and 8D, the method can include utilizing a plurality ofcontainers 900 havingproppant 38 for fracking contained therein, eachrespective container 900 having an outlet 924 and a sealedtop top silica dust 50 associated withproppant 38 from the sealedtop respective container 900. It further comprises positioning 100 eachrespective container 900 on aconveyor 1000 at awell site 30, theconveyor 1000 having a plurality ofconveyor hoppers 600 and each of the plurality ofconveyor hoppers 600 having one or morecontrollable openings 610 that is in fluid communication with aconveyor belt 700 that underlies theconveyor 1000 to reduce risk of production and release ofsilica dust 50 associated withproppant 38 as theproppant 38 flows from eachrespective container 900. It further comprises downwardly discharging 110 the proppant 38 from eachrespective container 900 through each respectivecontrollable opening 610 of eachrespective conveyor hopper 600 onto theconveyor belt 700, theconveyor belt 700 having a first end portion 705, a second end portion 707, and a plurality ofpartitions 712 associated therewith, the plurality ofpartitions 712 of theconveyor belt 700 positioned to enhance reduction of production and release ofsilica dust 50 as the proppant 38 contacts and is carried by theconveyor belt 700. It further comprises conveying 240 the proppant to one ormore blender hoppers 810, and depositing 250 theproppant 38 into the one ormore blender hoppers 810 bygravity feed 812. - The method also can include, for example, removing 160 each
respective container 900 that has been substantially emptied ofproppant 38 from theconveyor 1000 at thewell site 30 with aforklift 34 for replacement with a secondrespective container 900 filled withproppant 38 for fracking contained therein such that theconveyor belt 700 is continuously conveyingproppant 38 when in operation to thechute 822. - The method also can include, for example, controlling 170 the rate of
proppant 38 flowing from eachrespective container 900 using aflow gate 932 positioned at the one or more outlets 924 of eachrespective container 900 to reduce risk of production and release ofsilica dust 50 associated withproppant 38 into the air asproppant 38 flows out of the one or more outlets 924, as shown inFIG. 5B . - The method also can include, for example, controlling 180 the rate of
proppant 38 downwardly flowing from eachrespective conveyor hopper 600 using ahopper gate 612 with ahopper gate actuator 613 positioned at the one or morecontrollable openings 610 of eachrespective conveyor hopper 600, and optionally controlling thehopper gate actuator 613 by hydraulics or electronics to enhance opening and closing of thehopper gate 612 to reduce risk of production and release ofsilica dust 50 associated withproppant 38 into the air asproppant 38 flows out of the one or morecontrollable opening 610, as shown inFIG. 11 andFIG. 7A . If hydraulics are used, for example, a plurality of hydraulic pressure hoses 614 can connect thehopper gate actuator 613 to the one ormore engines 710 and controls 1017. If electronics are used, for example, a plurality of wires 616 can be used to connect thehopper gate 612 to the one ormore engines 710 and controls 1017. Wireless connections are also contemplated. A person of skill in the art would understand the various connections toengines 710 andcontrols 1017 available for powering thehopper gate actuator 613. - The method also can include, for example, positioning 245 a
shroud 800 over aportion 802 of the second end 707 of theconveyor belt 700 thereby to define a shroudedportion 802, the shroudedportion 802 positioned between the lastrespective container 900 on theconveyor 1000 and thechute 822 at anangle 805 of approximately 30 to 60 degrees from ahorizontal plane 1020 when the conveyor is level. Theshroud 800 substantially encloses the one ormore conveyor belts 700 to reduce the risk of release ofsilica dust 50 associated withproppant 38 in the air. - The method also can include, for example, positioning 102 each of the plurality of
containers 900 side-by-side on theconveyor 1000. - The method also can include, for example, positioning 104 the plurality of
containers 900 adjacent each other on theconveyor 1000, wherein each of the plurality ofpartitions 712 of theconveyor belt 700 extend upwardly from atop surface 702 of theconveyor belt 700 toward theconveyor hopper 600 when positioned to underlie theconveyor hopper 600 and each of the plurality offingers 714 is spaced-apart from another one of the plurality offingers 714 so that thetop surface 702 of theconveyor belt 700 guidingly receives theproppant 38 thereon and between the plurality ofpartitions 714. - An embodiment of the system of the present invention can include, for example, a plurality of
containers 900 each adapted to haveproppant 38 for fracking contained therein, eachrespective container 900 having a sealedtop silica dust 50 associated withproppant 38 into the air when positioned therein. Eachrespective container 900 hasinterior portions 922 inclined toward an outlet 924 at a bottom 916 of eachrespective container 900 to reduce risk of production and release ofsilica dust 50 associated withproppant 38 as theproppant 38 flows from eachrespective container 900 until eachrespective container 900 is substantially empty. - The system further can include a
conveyor 1000 positioned at awell site 30 and to receive eachrespective container 900 of the plurality ofcontainers 900, theconveyor 1000 having one ormore conveyor hoppers 600 that align closely with each respective outlet 924 of the plurality ofcontainers 900 to reduce risk of production and release ofsilica dust 50 into the air, each of the one or morerespective conveyor hoppers 600 having alower portion 608 including anopening 610, such that whenproppant 38 downwardly flows through each respective outlet 924 of eachrespective container 900 of the plurality ofcontainers 900 when positioned therein, the proppant 38 passes to and through theopening 610 of each of the one or morerespective conveyor hoppers 610. - The system further can include one or
more conveyor belts 700 positioned to underlie the one ormore conveyor hoppers 600 to receiveproppant 38 as the proppant 38 passes to and through theopening 610 of each of the one or morerespective conveyor hoppers 600, theconveyor belt 700 having a first end 705, a second end 707, and a plurality ofpartitions 714 associated therewith, such that the plurality ofpartitions 714 are positioned to reduce risk of production and release ofsilica dust 50 asproppant 38 contacts and is carried by theconveyor belt 700. - The system further can include a
shroud 800 positioned to overlie a portion of the second end 705 of theconveyor belt 700 thereby to define a shroudedportion 802 of theconveyor belt 700, theshroud 800 substantially enclosing the shroudedportion 802 as theconveyor belt 700 conveysproppant 38 when positioned thereon from the plurality ofcontainers 900 to reduce risk of release ofsilica dust 50 associated withproppant 38 into the air from the shroudedportion 802. - The system further can include a
chute 822 having an inlet 824 positioned to receive the second end 707 of theconveyor belt 700 conveyingproppant 38 and one ormore outlets 826 positioned such that asproppant 38 is deposited into thechute 822 bygravity feed 812, proppant 38 flows out of the one ormore outlets 826 to ablender hopper 810 or other location at thewell site 30. - The system also further can include a
blender hopper cover 1208 positioned to reduce risk of production and release ofsilica dust 50 asproppant 38 flows between the one ormore outlets 826 of thechute 822 and the one ormore blender hoppers 810 of the one ormore blenders 36 at awell site 30. - The system also further can include a
forklift 34 positioned at awell site 30 to load and unload eachrespective container 900 onto and off of theconveyor 1000 by one ormore slots 901, wherein each of the plurality ofcontainers 900 has one ormore slots 901 positioned adjacent abottom portion 906 of therespective container 900. - The system also further can include a plurality of
curtains 1200 positioned on or adjacent theconveyor 1000 to reduce risk of production and release ofsilica dust 50 asproppant 38 flows from the plurality ofconveyor hoppers 600 to the one ormore conveyor belts 700. - Another embodiment of the system, for example, can include a plurality of
containers 900 each adapted to haveproppant 38 for fracking contained therein, eachrespective container 900 having a sealedtop silica dust 50 associated withproppant 38 into the air when positioned therein. Eachrespective container 900 hasinterior portions 922 inclined toward an outlet 924 at a bottom 906 of each respective container to reduce risk of production and release ofsilica dust 50 associated withproppant 38 as theproppant 38 flows from eachrespective container 900 until eachrespective container 900 is substantially empty. - The system further can include a
conveyor 1000 positioned at awell site 30 and to receive eachrespective container 900 of the plurality ofcontainers 900, theconveyor 1000 having one ormore conveyor hoppers 600 that align closely with each respective outlet 924 of the plurality ofcontainers 900 to reduce risk of production and release ofsilica dust 50 into the air, each of the one or morerespective conveyor hoppers 600 having alower portion 608 including anopening 610, such that whenproppant 38 downwardly flows through each respective outlet 924 of eachrespective container 900 of the plurality ofcontainers 900 when positioned therein, the proppant 38 passes to and through theopening 610 of each of the one or morerespective conveyor hoppers 600. - The system further can include one or
more conveyor belts 700 positioned to underlie the one ormore conveyor hoppers 600 to receiveproppant 38 as the proppant 38 passes to and through theopening 610 of each of the one or morerespective conveyor hoppers 600, theconveyor belt 700 having a first end 705, a second end 707, and a plurality ofpartitions 714 associated therewith, such that the plurality ofpartitions 714 are positioned to reduce risk of production and release ofsilica dust 50 asproppant 38 contacts and is carried by theconveyor belt 700. - As shown in
FIG. 8D , the system further can include ablender hopper 810 positioned to underlie the second end 707 of theconveyor belt 700 conveyingproppant 38 such thatproppant 38 is deposited into theblender hopper 810 bygravity feed 812. - As shown in
FIG. 12D , the system also further can include ablender hopper cover 1208 positioned to reduce risk of production and release ofsilica dust 50 asproppant 38 flows between the one or more outlets 808 of thechute 822 and the one ormore blender hoppers 810 of the one ormore blenders 36 at awell site 30. - The system also further can include a
forklift 34 positioned at awell site 30 to load and unload eachrespective container 900 onto and off of theconveyor 1000 by one ormore slots 901, wherein each of the plurality ofcontainers 900 has one ormore slots 901 positioned adjacent abottom portion 916 of therespective container 900. - The system also further can include a plurality of
curtains 1200 positioned on or adjacent the sides of theconveyor 1000 to reduce risk of production and release ofsilica dust 50 asproppant 38 flows from the plurality ofconveyor hoppers 600 to theconveyor belt 700. - The owner of the present application conducted experiments to determine the amount of reduction to respirable crystalline silica particles using an embodiments of method and systems relative to conventional pneumatic delivery. The testing was carried out by Weston Solutions, Inc. of Lakewood, Colo. The tests were based on samples collected for personal breathing zone samples to assess likely employee exposure to respirable crystalline silica by job category at a well site. Personal breathing zone samples were collected in order to compare the results to those found in the NIOSH study.
- Personal breathing zone samples were collected using conventional industrial hygiene techniques. A filter cassette and a particle sizing cyclone were affixed to each monitored worker's collar or shoulder seam within ten inches of the mouth and nose. A Tygon™ tube conducted airflow from the breathing zone collection device to a hygiene sampling pump worn in a pouch affixed to a belt around the worker's waist. Sample flow rates were determined before and after sampling using a primary standard flow calibrator.
- Sixteen personal breathing zone monitoring samples were collected over three days, and during four work shifts. Three of the sixteen samples exceeded the OSHA Permissable Exposure Limit (“PEL”) for respirable dust containing silica, or about 19%. These were notably fewer results from this assessment above the PEL than in the NIOSH study cited in the Silica Hazard Alert, discussed in the background section, where 51.4% of breathing zone samples exceeded the PEL. No breathing zone sample in this assessment exceeded the PEL by more than a factor of five, whereas six breathing zone exposure monitoring results of forty total from a Minot area well fracture job using pneumatic sand delivery exceeded the PEL by a factor of ten or more. Four of the sixteen personal breathing zone samples, or 25%, exceeded the NIOSH Recommended Exploded Limit (“REL”). On a pneumatic delivery fracture job near Minot, twenty-four of the forty breathing zone samples, or 60%, exceeded the NIOSH REL. That result was somewhat less than in the NIOSH study where 68.5% of all samples exceeded the REL. In summary, the geometric mean result for breathing zone samples from t-belt operators in the NIOSH study was 0.327 mg/m3 as the REL, whereas the geometric mean exposure for sand workers in this assessment was 0.0874 mg/m3, a roughly four-fold reduction.
- This application is related to and claims priority to, and the benefit of, U.S. Provisional Application No. 62/012,160, filed Jun. 13, 2014, titled “Process and Apparatus for Reducing Silica Exposure During the Delivery of Proppants to a Mine,” U.S. Provisional Application No. 62/014,479, filed on Jun. 19, 2014, titled “System and Methods for Reducing Silica Exposure at a Well Site,” and U.S. Provisional Application No. 62/114,614, filed Feb. 11, 2015, titled “Methods and Systems to Transfer Proppant for Fracking with Reduced Risk of Production and Release of Silica Dust at a Well Site,” each of which are incorporated herein in their entireties by reference.
- The foregoing disclosure and description of the invention is illustrative and explanatory of the embodiments of the invention. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the invention. The embodiments of the present invention should only be limited by the following claims and their legal equivalents.
Claims (31)
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BR112016029185-9A BR112016029185B1 (en) | 2014-06-13 | 2015-04-08 | Methods for transferring proppant for hydraulic fracturing and system for transporting proppant for hydraulic fracturing |
CN201580031788.5A CN106460495B (en) | 2014-06-13 | 2015-04-08 | Methods and systems for transferring proppant for fracturing at a well site that reduce the risk of production and release of silica dust |
MX2016016439A MX2016016439A (en) | 2014-06-13 | 2015-04-08 | Methods and systems to transfer proppant for fracking. |
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AU2015318272A AU2015318272B2 (en) | 2014-09-15 | 2015-09-09 | Cradle for proppant container having tapered box guides |
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US14/848,447 US20190135535A9 (en) | 2012-07-23 | 2015-09-09 | Cradle for proppant container having tapered box guides |
BR112017005278A BR112017005278A2 (en) | 2014-09-15 | 2015-09-09 | apparatus for supporting a proppant container, system for storing and supporting proppant containers and method for moving and supporting proppant containers |
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US14/943,182 US9969564B2 (en) | 2012-07-23 | 2015-11-17 | Methods and systems to transfer proppant for fracking with reduced risk of production and release of silica dust at a well site |
US14/986,826 US9624030B2 (en) | 2014-06-13 | 2016-01-04 | Cradle for proppant container having tapered box guides |
CONC2017/0000216A CO2017000216A2 (en) | 2014-06-13 | 2017-01-11 | Methods and systems to transfer proppant material for fracturing with reduced risk of production and release of silica dust in a well |
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US9340353B2 (en) | 2016-05-17 |
US20160046438A1 (en) | 2016-02-18 |
WO2015191150A1 (en) | 2015-12-17 |
BR112016029185B1 (en) | 2022-04-05 |
US20160068342A1 (en) | 2016-03-10 |
US20150360856A1 (en) | 2015-12-17 |
CA2950899A1 (en) | 2015-12-17 |
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