WO2017044921A1

WO2017044921A1 - Dry bulk material transportation

Info

Publication number: WO2017044921A1
Application number: PCT/US2016/051206
Authority: WO
Inventors: Pedro Antonio VERGEL; Luis Gonzalez
Original assignee: Schlumberger Technology Corporation; Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2015-09-11
Filing date: 2016-09-12
Publication date: 2017-03-16

Abstract

Systems and methods for transporting dry bulk material between a dry bulk material storage facility and a wellsite. A dry bulk material transport system may include a plurality of container units each operable to contain the dry bulk material and be transported between the dry bulk material storage facility and the wellsite via a truck trailer. The dry bulk material transport system may further include an unloading system located at the wellsite and operable to pneumatically connect with one or more of the container units, pneumatically unload the dry bulk material out of the one or more of the container units, and move the dry bulk material into a mixer.

Description

DRY BULK MATERIAL TRANSPORTATION

Cross-Reference to Related Applications

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 62/217,456, titled "Dust-free Sand Distribution," filed September 11, 2015, the entire disclosure of which is hereby incorporated herein by reference.

Background of the Disclosure

[0002] Advanced petroleum and natural gas production technologies are increasingly used to help meet the demand for energy in both the United States and globally. As conventional resources become scarcer, research and innovation by oil and gas industry has resulted in techniques for tapping unconventional resources, including hydrocarbons trapped in shale formations found in a number of locations throughout the United States. One technology for accessing such resources is hydraulic fracturing, which has transformed natural gas production over the past several years and is also being applied to increase petroleum production. However, new energy supply technologies also bring new environmental management challenges. Among the issues of concern are air pollution emissions from fracturing and other wellsite operations and whether the emissions can potentially impact air quality at wellsites and in surrounding communities.

[0003] Wellsite emissions may include dry particulate materials released into the airspace surrounding the wellsite during fracturing and other wellsite operations. The airborne materials may be or comprise compositional components of subterranean formation treatment fluids that are formed or mixed at the wellsites. Such compositional components may become airborne when loading and unloading the compositional components into and out of various mixing, handling, and transportation equipment at the wellsite and other facilities. For example, the compositional components may be transported to the wellsite via large sacks (i.e., super sacks), which may be cut open and the contents directed to various material handling and mixing equipment. During such operations, a substantial portion of the dry particulate material may become airborne and dispersed into the airspace surrounding the wellsite. Summary of the Disclosure

[0004] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

[0005] The present disclosure introduces an apparatus that includes a dry bulk material transport system. The dry bulk material transport system includes container units each operable to contain dry bulk material and be transported between a dry bulk material storage facility and a wellsite via a truck trailer. The dry bulk material transport system also includes an unloading system located at the wellsite. The unloading system is operable to pneumatically connect with one or more of the container units, pneumatically unload the dry bulk material out of the one or more of the container units, and move the dry bulk material into a mixer.

[0006] The present disclosure also introduces an apparatus including a dry bulk material unloading system that includes a transportable container unit, a material handling unit located at a wellsite, and a gas source. The transportable container unit is operable to contain dry bulk material. The material handling unit is operable to pneumatically connect with the container unit, pneumatically receive the dry bulk material from the container unit, and move the dry bulk material into a mixer. The gas source is operable to pneumatically connect with the container unit and introduce gas into the container unit to cause the dry bulk material to move from the container unit into the material handling unit.

[0007] The present disclosure also introduces a method including loading dry bulk material into a container unit at a dry bulk material storage facility, and transporting the container unit to a wellsite via a truck trailer. The method also includes pneumatically connecting the container unit with a material handling unit at the wellsite, pneumatically unloading the dry bulk material out of the container unit, and moving the dry bulk material into a mixer.

[0008] These and additional aspects of the present disclosure are set forth in the description that follows, and/or may be learned by a person having ordinary skill in the art by reading the material herein and/or practicing the principles described herein. At least some aspects of the present disclosure may be achieved via means recited in the attached claims. Brief Description of the Drawings

[0009] The present disclosure is understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0010] FIG. 1 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0011] FIG. 2 is a perspective view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0012] FIG. 3 is a front view of the apparatus shown in FIG. 2 according to one or more aspects of the present disclosure.

[0013] FIG. 4 is a side view of the apparatus shown in FIGS. 2 and 3 according to one or more aspects of the present disclosure.

[0014] FIG. 5 is a schematic view of a portion the apparatus shown in FIGS. 2-4 according to one or more aspects of the present disclosure.

[0015] FIG. 6 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0016] FIG. 7 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0017] FIG. 8 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0018] FIG. 9 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0019] FIG. 10 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0020] FIG. 11 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0021] FIG. 12 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure. Detailed Description

[0022] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments.

Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for simplicity and clarity, and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

[0023] As introduced herein, a dry bulk material transport system within the scope of the present disclosure may be operable to transport dry bulk material between a dry bulk material storage facility and a wellsite while minimizing the amount of the dry bulk material released into the airspace around the dry bulk material storage facility and the wellsite. The transport system may comprise a plurality of container units each operable to contain the dry bulk material and be transported between the dry bulk material storage facility and the wellsite via a truck trailer. The transport system may further comprise an unloading system located at the wellsite and operable to pneumatically connect with one or more of the container units and pneumatically unload the dry bulk material out of the one or more of the container units and move the dry bulk material into a mixer.

[0024] FIG. 1 is a schematic view of at least a portion of an example implementation of an oil and gas wellsite system 100 that provides at least a portion of an example environment utilized in conjunction with a dry bulk material transport system according to one or more aspects of the present disclosure. The figure depicts a wellsite surface 102 adjacent to a wellbore 104 and a partial sectional view of a subterranean formation 106 penetrated by the wellbore 104 below the wellsite surface 102. The wellsite system 100 may be an additive system, such as a hydraulic fracturing system, a cementing system, or another additive system operable to transfer an additive or other material from a source location to a destination location for blending or mixing with another additive or material and eventual injection into the wellbore 104.

[0025] The wellsite system 100 may comprise a mixer 108 operatively connected with one or more liquid containers 110 and a dry material container 112. The container 112 may contain a first additive and the containers 110 may contain water or another liquid comprising water.

When the wellsite system 100 is operable as a fracturing system, the first additive may be or comprise a compositional component of a fracturing fluid, such as a hydratable material or gelling agent, including guar, a polymer, a synthetic polymer, a galactomannan, a polysaccharide, a cellulose, and/or a clay, among other examples, and the liquid may be or comprise an aqueous fluid, which may comprise water or an aqueous solution comprising water, among other examples. When the wellsite system 100 is operable as a cementing system, the first additive may be or comprise a compositional component of a cement slurry, such as cement powder.

[0026] The liquid may be transferred from the containers 110 to the mixer 108 by a material handling device 114 via a conduit 118. The material handling device 114, such as a pump, may be driven or actuated by a prime mover 115, which may be or comprise an electric motor, an engine, or another rotary actuator. The first additive may be transferred from the container 112 to the mixer 108 by a material transfer or handling device 116, such as a material handler or mover, via a conduit 120. The conduit 120 may be or comprise a hose, a tube, a conveyer, a transfer belt, a bucket elevator, or a feeding screw. The material handling device 116 and/or conduit 120 may be driven or actuated by a prime mover 117, which may be or comprise an electric motor, an engine, or another rotary actuator. The mixer 108 may be operable to receive the first additive and the liquid and mix or otherwise combine the first additive and the liquid to form a base fluid. The mixer 108 may then discharge the base fluid via a conduit 122.

[0027] The mixer 108 and the container 112 may each be disposed on corresponding trucks, trailers, and/or other mobile carriers 124, 126, respectively, to permit their transportation to the wellsite surface 102. However, the mixer 108 and/or container 112 may be skidded or otherwise stationary, and/or may be temporarily or permanently installed at the wellsite surface 102.

[0028] The wellsite system 100 may further comprise a mixer 128 fluidly connected with the mixer 108 and a dry material container 130. The container 130 may contain a second additive that may be substantially different than the first additive. When the wellsite system 100 is operable as the hydraulic fracturing system, the second additive may be or comprise a compositional component of the fracturing fluid, such as a proppant material, including sand, sand-like particles, silica, quartz, and/or propping agents, as well as fiber, such as fiberglass, phenol formaldehydes, polyesters, polylactic acid, cedar bark, shredded cane stalks, and mineral fiber. Whether the wellsite system 100 is operable as the hydraulic fracturing or cementing system, the second additive may also include dry oilfield chemical additives, such as friction reducers, accelerators, retarders, fluid-loss additives, dispersants, extenders, weighting agents, lost circulation additives and/or other chemical compositional components operable to modify the characteristics of the fracturing fluid and cement slurry. The second additives may be provided in a solid or dry form, such as a powder or particulate material.

[0029] The second additives may be transferred from the container 130 to the mixer 128 by a material transfer or handling device 131, such as a material handler or mover, via a conduit 133. The conduit 133 may be or comprise a hose, a tube, a conveyer, a transfer belt, a bucket elevator, or a feeding screw. The material handling device 131 and/or conduit 133 may be driven or actuated by a prime mover 132, which may be or comprise an electric motor, an engine, or another rotary actuator. The mixer 128 may be operable to receive the base fluid from the mixer 108 via the conduit 122, and the second additive from the container 130 via the conduit 133, and mix or otherwise combine the base fluid and the second additive to form a mixture. The mixture may comprise the fracturing fluid when the wellsite system 100 is operable as a hydraulic fracturing system, or the mixture may comprise the cement slurry when the wellsite system 100 is operable as a cementing system. The mixer 128 may then discharge the mixture via a conduit 134.

[0030] The mixer 128 and the container 130 may each be disposed on corresponding trucks, trailers, and/or other mobile carriers 136, 138, respectively, to permit their transportation to the wellsite surface 102. However, the mixer 128 and/or container 130 may be skidded or otherwise stationary, and/or may be temporarily or permanently installed at the wellsite surface 102.

[0031] The mixture may be communicated from the mixer 128 to a container 140, which may be or comprise a mixing, displacement, or storage tank for the mixture prior to being injected into the wellbore 104. The mixture may be communicated from the container 140 to a common manifold 142 via a conduit 144. The common manifold 142 may comprise a combination of valves and/or diverters, as well as a suction line 146 and a discharge line 148, such as may be collectively operable to direct flow of the mixture in a selected or predetermined manner. The common manifold 142, which may be known in the art as a missile or a missile trailer, may distribute the mixture to a pump fleet. The pump fleet may comprise multiple pumping units 150 each comprising a pump 152, a prime mover 154, and a heat exchanger 156. Each pumping unit 150 may receive the mixture from the suction line 146 of the common manifold 142, via a conduit 158, and discharge the mixture under pressure to the discharge line 148 of the common manifold 142, via a conduit 160.

[0032] The pumping units 150 may each be mounted on corresponding trucks, trailers, and/or other mobile carriers 164, such as may permit their transportation to the wellsite surface 102. However, the pumping units 150 may be skidded or otherwise stationary, and/or may be temporarily or permanently installed at the wellsite surface 102.

[0033] The mixture may then be discharged from the common manifold 142 into the wellbore 104 via a conduit 162, such as may include various valves, conduits, and/or other hydraulic circuitry fluidly connected between the common manifold 142 and the wellbore 104. During operations, the mixture and/or wellbore fluid may be ejected from the wellbore 104 and communicated to a container 166 via a conduit 168. Although the wellsite system 100 is shown comprising the container 140, it is to be understood that the container 140 may not be included as part of the wellsite system 100, such that the mixture may be communicated from the mixer 128 directly to the common manifold 142. The wellsite system 100 may also omit the common manifold 142, and the conduits 160 may be fluidly connected to the wellbore 104 via a wellhead 105 (not shown) and/or other means.

[0034] The wellsite system 100 may also comprise a control center 170, which may be operable to monitor and control at least a portion of the wellsite system 100 during wellsite operations. Signals may be communicated between the control center 170 and other components of the wellsite system 100 via a communication system including wired connections, wireless communication, or a combination of these. The control center 170 may be operable to monitor temperature, viscosity, density, and composition of the liquid contained in the containers 110, the first additive, the second additive, and/or the mixture. The control center 170 may also be operable to monitor and/or control the production rate of the mixture, such as by increasing or decreasing the flow of the liquid from the containers 110, the first additive from the container 112, the base fluid from the mixer 108, the second additive from the container 130, and/or the mixture from the mixer 128. Accordingly, the control center 170 may be operable to monitor and/or control operational parameters associated with the containers 110, 112, 130, 140, 166, the mixers 108, 128, the material handling devices 114, 116, 131, the pumping units 150, as well as other pieces of wellsite equipment and/or devices utilized in association with the wellsite system 100.

[0035] The control center 170 may be disposed on a corresponding truck, trailer, cabin, and/or other mobile carrier 172, such as may permit its transportation to the wellsite surface 102. However, the control center 170 may be skidded or otherwise stationary, and/or may be temporarily or permanently installed at the wellsite surface 102. [0036] FIG. 1 depicts the wellsite system 100 as being operable to transfer additives and produce mixtures that may be pressurized and injected into the wellbore 104 during hydraulic fracturing or cementing operations. However, it is to be understood that the wellsite system 100 may be operable to transfer other additives and produce other mixtures that may be pressurized and injected into the wellbore 104 during other oilfield operations, such as drilling, acidizing, chemical injecting, an d/or water jet cutting operations, among other examples.

[0037] During various wellsite operations, the wellsite system 100 may generate or release emissions into the airspace or atmosphere around the wellsite system 100 above the wellsite surface 102. Such emissions may include airborne particulate material, which may include dust, dirt, soot, and smoke emitted into the air and small enough to be suspended in the atmosphere. The dry bulk material transport system (referred to hereinafter as a "transport system") within the scope of the present disclosure may be provided to transport one or more of the compositional components (collectively referred to hereinafter as a "dry bulk material") of the subterranean formation treatment fluids or mixtures from a storage and distribution facility located at a distance from the wellsite system 100, while reducing emissions of the dry bulk material into the atmosphere.

[0038] FIGS. 2-4 are perspective, front, and side views, respectively, of an example implementation of the containers 112, 130 shown in FIG. 1, designated in FIGS. 2-4 by reference numeral 200, and referred to hereinafter as a "container unit." The following description refers to FIGS. 1-4, collectively.

[0039] The container unit 200 may be a loadable and reusable transport or container unit operable to store the dry bulk material and be transported via various modes of transport. The container unit 200 may comprise one or more containers, bins, or vessels 202 operable to hold or contain therein the dry bulk material. Each vessel 202 may comprise an upper portion 204 having a generally cylindrical geometry and a lower portion 206 having a generally conical or otherwise converging or tapered geometry. An upper wall or surface 208 of each vessel 202 may comprise a top material loading hatch or inlet 210 operable to receive the dry bulk material into the corresponding vessel 202. Each material inlet 210 may be selectively opened to permit the dry bulk material to be received and closed via an enclosure 211 to seal the corresponding vessel 202 from external environment. Each lower portion 206 may converge or terminate at a material outlet 212 operable to discharge the dry bulk material out of the corresponding vessel 202. Each material outlet 212 may be selectively opened and closed via a flow control valve 216. Accordingly, the valve 216 may selectively opened to permit the dry bulk material to be discharged and closed to seal the corresponding vessel 202 from a discharge conduit 214.

[0040] The upper and lower portions 204, 206 may comprise a shorter or reduced height to reduce the overall height of the container unit 200 and a smaller or reduced diameter to reduce the overall footprint of the container unit 200. The reduced footprint may permit the container unit 200 to be mounted or carried by a smaller and/or shorter trailer while the reduced height may lower the center of gravity of the container unit 200 to facilitate increased stability of the truck trailer during transport. Shortening the trailer length combined with lowered center of gravity may result in a more maneuverable and safer truck trailer assembly and permit the use of semi-trailers and combinations of trailers, as described below. In an example implementation, the container unit 200 may hold between about 40,000 pounds and about 50,000 pounds of dry bulk material, reducing the number of trips each truck trailer has to make to deliver the total amount of dry bulk material utilized during a wellsite job.

[0041] The discharge conduit 214 may be fluidly or pneumatically connected with the material outlet 212 of each vessel 202 and terminate with an end connector or coupling 218 operable to fluidly or pneumatically connect with a corresponding end connector or coupling (not shown) of one of the conduits 120, 133, such as may permit the dry bulk material to be pneumatically transferred or otherwise moved to one of the mixers 108, 128. Although the container unit 200 is shown comprising three vessels 202, it is to be understood that a container unit 200 within the scope of the present disclosure may comprise one, two, four, or more vessels.

[0042] FIG. 5 is a schematic sectional view of one of the vessels 202 shown in FIGS. 2-4 containing therein the dry bulk material 201 according to one or more aspects of the present disclosure. Referring collectively to FIGS. 1-5, the upper wall or surface 208 of each vessel 202 is further shown comprising a gas inlet 220, which may be operable to introduce pressurized gas into the vessel 202. The gas inlet 220 may be fluidly or pneumatically connected with a corresponding conduit of a conduit assembly or system 222 operable to communicate the pressurized gas, such as air, nitrogen, or another gas, from a gas source 290 (shown in FIG. 1 1) into each vessel 202 via the gas inlet 220. The vessels 202 of the container unit 200 may be fluidly or pneumatically connected in parallel with the gas source 290 via the conduit system 222.

[0043] The gas injected into each vessel 202 may increase pressure within the vessel 202 in an area above the dry bulk material 201 to push or force the dry bulk material downwardly, as indicated by arrows 221, and out of the vessel 202 through the outlet 212. The dry bulk material 201 from each vessel 202 may move through the corresponding valves 216 and into the conduit 214 to be discharged from the container unit 200. The rate at which the dry bulk material 201 may be discharged into the conduit 214 via the outlet 212 may be controlled by adjusting pressure of the gas within the vessel 202 and/or flow rate of the gas into the vessel 202. The rate at which the dry bulk material is discharged from the container unit 200 via the conduit 214 may be controlled by selectively opening one or more of the valves 216 to adjust the number of vessels 202 from which the dry bulk material is discharged. In an example implementation, the dry bulk material may be evacuated from the container unit in about 20 to 30 minutes. The gas inlets 220 may be selectively fluidly isolated from the gas source 290 by fluid valves 226 operable to selectively permit and prevent gas flow between the gas source 290 and the gas inlets 220. The gas conduit system 222 may terminate with one or more end connectors or couplings 228 operable to fluidly or pneumatically connect with the gas source 290 or a corresponding end connector or coupling (not shown) of a fluid conduit fluidly or pneumatically connected with the gas source 290.

[0044] The lower portion 206 of each vessel 202 may also comprise one or more gas inlets 230 located adjacent the material outlet 212. Each gas inlet 230 may be fluidly or pneumatically connected with a corresponding conduit of the conduit system 222 and operable to introduce the pressurized gas into the vessel 202 around or adjacent the material outlet 212. The ports 230 may inject the gas, as indicated by arrows 232, into a zone 234 extending around or adjacent the material outlet 212 to cause the dry bulk material located within the zone 234 to be fluidized, which may prevent the dry bulk material from clumping or becoming stuck at the material outlet 212. The gas inlets 230 may be selectively fluidly isolated from the gas source 290 via corresponding fluid valves 236 operable to selectively permit and prevent the flow of gas between the gas source 290 and the gas inlets 230.

[0045] The fluid valves 216, 226, 236 may be or comprise fluid shut-off valves, such as ball valves, globe valves, butterfly valves, and/or other types of fluid valves, which may be selectively opened and closed to permit and prevent the flow of gas. The fluid valves 216, 226, 236 may also be or comprise flow rate control valves, such as needle valves, metering valves, butterfly valves, globe valves, or other valves operable to progressively or gradually open and close to control the flow rate of gas. Each fluid valve 216, 226, 236 may be actuated remotely by a corresponding actuator 238 operatively coupled with the fluid valve 216, 226, 236. The actuators may be or comprise electric actuators, such as solenoids or motors, or fluid actuators, such as pneumatic or hydraulic cylinders or rotary actuators. The fluid valves 216, 226, 236 may also be actuated manually, such as by a lever (not shown).

[0046] The container unit 200 may further comprise a frame assembly 240 extending around the vessels 202 and the conduit system 222 and operable to maintain the vessels 202 and the conduit system 222 operatively connected and/or in relative positions. The frame assembly 240 may also protect the various components of the container unit 200 and permit transportation of the container unit 200. The frame assembly 240 may be or comprise a plurality of

interconnected structural steel members or beams extending about and connected with the vessels 202 and the conduit system 222. The frame assembly 240 may be a load-bearing frame assembly operable to support the weight of the vessels 202 filled with the dry bulk material and/or the weight of one or more additional instances of the container unit 200 vertically stacked on top of the container unit 200.

[0047] The frame assembly 240 and/or other portions of the container unit 200 may be constructed pursuant to International Organization for Standardization (ISO) specifications, permitting the container unit 200 to be transported like an intermodal ISO container.

Accordingly, the frame assembly 240 or other portions of the container unit 200 may form or comprise corner castings 242, such as may facilitate the container unit 200 to be fixedly mounted on a transport surface, such as a trailer 252, 254 (shown in FIGS. 6-9) and/or multiple container units 200 to be stacked vertically on top of each other (shown in FIGS. 7 and 9) or connected together horizontally. The corner castings 242 and/or the frame assembly 240 may be constructed pursuant to ISO specifications, such as may permit the container unit 200 to be transported across different modes of transport within the global containerized intermodal freight transport system or other transport means adapted to receive standardized ISO containers. The frame assembly 242 may further comprise or form forklift or grappler pockets 244, such as may permit the container unit 200 to be picked up and moved by a forklift, a grappler, and/or a crane equipped with grappler tongs. The frame assembly 240 may also support a catwalk 246, such as may support wellsite operators or other workers while inspecting the vessels 202 and/or facilitating mounting of the container unit 200 for transportation.

[0048] FIGS. 6-9 are schematic views of various means or configurations for transporting one or more container units 200 via a truck trailer according to one or more aspects of the present disclosure. Depending on road limitations (e.g., dimensions, total allowable load per axle and vehicle, maximum length) and conditions (e.g., asphalt, gravel, hills, planes), the container unit 200 offers flexibility and adaptability of transportation. The following description refers to FIGS. 6-9, collectively.

[0049] FIG. 6 shows a truck 250 (e.g., truck 126, 138 in FIG. 1) coupled with a flatbed trailer 252 carrying a single container unit 200. The flatbed 252 offers high ground clearance and versatility, such as may permit container transportation over rough or uneven terrain, winding roads, and/or when load height is not an issue.

[0050] FIG. 7 shows the truck 250 coupled with a double-drop trailer 254 carrying two container units 200 stacked vertically. The double-drop trailer 254 offers a lower loading deck and a lower center of gravity. The double-drop trailer 254 may permit container stacking or transportation of a single container along a route where load height may be a problem, such as due to low overpasses.

[0051] FIGS. 8 and 9 show the truck 250 coupled with multiple flatbed trailers 252 and a combination of flatbed trailer 252 and a double-drop trailer 254, respectively. Ability to couple two or more trailers 252, 254 in various combinations may permit two, three, or more container units 200 to be transporter simultaneously, reducing the total number of trips the truck 250 has to complete between a dry bulk material distribution facility and the wellsite system 100 to facilitate wellsite operations. When utilizing two trailers 252, 254, the trailers 252, 254 may be linked together in a B-Train configuration, such as may permit increased stability and backing-up maneuverability.

[0052] FIG. 10 is a schematic view of at least a portion of an example implementation of a dry bulk material transport system 260 according to one or more aspects of the present disclosure and operable in conjunction with or comprising at least a portion of the wellsite system 100 and a dry bulk material storage and distribution facility 270. The wellsite system 100 and the distribution facility 270 may be located at a substantial distance from each other. The transport system 260 may further comprise a plurality of the container units 200 described herein and be operable to move the dry bulk material from the distribution facility 270 to the wellsite system 100 via the container units 200 while minimizing emission of the dry bulk material into airspace or atmosphere surrounding the distribution facility 270 and the wellsite system 100, as well as during transit between the distribution facility 270 and the wellsite system 100. Although not shown in FIG. 10 for clarity, each container unit 200 may be transported or moved between the wellsite system 100 and the distribution facility 270 via the truck 250 and trailer 252, 254 (collectively referred to herein as a "truck trailer"), as indicated by arrows 262.

[0053] The distribution facility 270 may be operable to store the bulk dry material within super sacks, silos, hoppers, or other containment units 272 located within the distribution facility 270. Each containment unit 272 may contain the same or different dry bulk material utilized by wellsite system 100. The distribution facility 270 may store a plurality of empty container units 200 within one or more storage areas 274 and/or a plurality of filled container units 200 within one or more storage areas 276. In an example implementation, empty container units 200 may be mounted onto corresponding truck trailers and driven or otherwise moved (e.g., via a crane) from one of the storage areas 274 to or underneath the containment unit 272 and filled with the dry bulk material. Empty container units 200 returning from the wellsite system 100 via truck trailers may also be received into the distribution facility 270, driven to or underneath the containment unit 272, and filled with the dry bulk material. The container units 200 may be filled with the dry bulk material by various means, such as by positioning the container inlets 210 of the container units 200 beneath an outlet (not shown) of one of the containment units 272 or positioning the container inlets 210 beneath a conveyor belt, elevator, feeder, or other transfer mechanism (not shown) that directs the dry bulk material from one of the containment units 272 into each vessel 202 of the container unit 200. Thereafter, the filled container units 200 may depart from the distribution facility 270 to the wellsite system 100 or be stored in one of the storage areas 276 for later transport. The empty and filled container units 200 may be stacked vertically and/or horizontally within the respective storage areas 274, 276 to conserve space. Movement of the empty and filled container units 200 through the distribution facility 270 is indicated by arrows 275.

[0054] At least a portion of the distribution facility 270 may be enclosed or comprise an enclosed structure 271 encompassing the containment units 272, such as may prevent airborne dry bulk material from being discharged into the atmosphere outside of the enclosed structure 271 during container unit filling operations. For example, when the super sacks are cut and the dry bulk material is unloaded into the containment units 272, onto a conveyor belt, and/or directly into the container units 200, the airborne dry bulk material may not be discharged into the atmosphere outside of the enclosed structure 271. The distribution facility 270 may also be equipped with or comprise a vacuum/filtration system 278 operable to draw in the airborne dry bulk material at the point of dispersion or other locations within the enclosed structure 271 and filter out the airborne dry bulk material from the air circulated through the enclosed structure 271.

[0055] The filled container units 200 may be transported to the wellsite system 100 and disposed within an unloading area 282 located adjacent to or along a corresponding dry bulk material unloading system 280 of the transport system 260 operable to unload and transfer the dry bulk material from the container units 200 to the corresponding mixer 108, 124. Each unloading system 280 may be operable to fluidly, pneumatically, or otherwise operatively connect with one or more container units 200 and pneumatically unload the dry bulk material from the container units 200. Each unloading system 280 may be further operable to fluidly, pneumatically, or otherwise operatively connect with one of the mixers 108, 124 and

pneumatically or mechanically move the dry bulk material into the mixer 108, 124. The material unloading systems 280 may comprise the material handling devices 116, 131 and/or conduits 120, 133 (shown in FIG. 1). As described above, the material handling devices 116, 131 may be or comprise material handlers or movers and the conduits 120, 133 may be or comprise hoses, tubes, conveyers, transfer belts, bucket elevators, or feeding screws.

[0056] The filled container units 200 arriving from the distribution facility 270 may also be stored within a storage area 277 to be unloaded in due course at a later time. The filled container units 200 may be stacked vertically and/or horizontally within the storage area 277 to conserve space.

[0057] Lean process logistics, such as just-in-time (JIT) operations, may be utilized to control the movement of the container units 200 between the distribution facility 270 and the wellsite system 100 to eliminate or reduce costly standby time, reduce operating time and carrying costs, improve asset turns, and/or debottleneck "proppant logistics." For example, the movement of the container units 200 may be timed such that when one or more container units 200 are emptied, one or more filled container units 200 will substantially simultaneously arrive at the wellsite 100 and move into the unloading areas 282 so that the dry bulk material may be unloaded. Such timing may eliminate or reduce time during which the container units 200, the corresponding truck trailers, and the drivers are waiting. Instead of waiting, the container units 200 may be unloaded from the truck trailers and stored in the storage area 277, while the truck trailers may be driven back to the distribution facility 270 to receive filled container units 200 to be transported to the wellsite 100. [0058] FIG. 1 1 is a schematic view of an example implementation of an unloading system 280 of the transport system 260 shown in FIG. 10 according to one or more aspects of the present disclosure. The following description refers to FIGS. 10 and 1 1, collectively.

[0059] The unloading system 280 may comprise one or more material transfer or handling units 284 (e.g., material handling devices 1 16, 131) disposed at the wellsite 102 and operable to pneumatically and/or mechanically move the dry bulk material from one or more container units 200 into the mixer 286 (e.g., mixer 108, 124). For example, filled container units 200 transported to the wellsite system 100 via corresponding truck trailers may be parked or disposed within the unloading areas 282 located adjacent to or along the material handling units 284. Each container unit 200 may be pneumatically connected with one or more material handling units 284 via a conduit 288, such as a hose or tube. One end of the conduit 288 may be connected with the connector or coupling 218 (shown in FIGS. 2 and 4) of the container unit 200 and the other end of the conduit 288 may be connected with a dry bulk material inlet (not shown) of the material handling unit 284. During dry bulk material unloading operations, each material handling unit 284 may draw or otherwise receive the dry bulk material from the corresponding container unit 200 and transfer the dry bulk material onto a conveyor belt 285, which may direct the dry bulk material into a chute 287 of the mixer 286. As shown in FIG. 1 1, multiple container units 200 may be simultaneously unloaded via the material handling units 284. Furthermore, one or more empty container units 200 may be disconnected from the material handling units 284 and replaced with filled container units 200 while the remaining container units 200 are being unloaded.

[0060] The unloading system 280 may further comprise one or more gas sources 290, such as compressors or blowers, operable to fluidly or pneumatically connect with and provide pressurized gas, such as air, nitrogen, or another gas, to one or more of the container units 200. Each gas source 290 may supply pressurized gas to the gas inlets 220, 230 (shown in FIGS. 2-5) via the conduit system 222. As described above, the gas source 290 may increase the pressure within each vessel 202 to push or force the dry bulk material downwardly and out of the vessel 202, into the conduit 214, and out of the container unit 200 via the conduit 288. The gas source 290 may further supply the pressurized gas to the dry bulk material at or adjacent the material outlet 212 to cause the dry bulk material to be fluidized, which may prevent the dry bulk material from clumping or becoming stuck at the material outlet 212. Each gas source 290 may be pneumatically connected with one or more container units 200 via a conduit 292, such as a hose or tube. One end of the conduit 292 may be connected with the connector or coupling 228 (shown in FIGS. 2-4) of the container unit 200 and the other end of the conduit 292 may be connected with a gas outlet (not shown) of the gas source 290. Although the gas sources 290 are shown being or comprising standalone or separate units, the gas sources 290 may be included as part of another piece of wellsite equipment, such as a material handling unit 284 or the container unit 200.

[0061] Each material handling unit 284 may also be pneumatically connected with one or more filtration devices 293 operable to receive and filter out airborne dry particulate material from the gas discharged from the material handling unit 284. Each filtration device 293, such as a dry or wet filter, may be pneumatically connected with the material handling device via a conduit 294, such as a hose or tube. One end of the conduit 294 may be connected with an inlet (not shown) of the filtration device 293 and the other end of the conduit 294 may be connected with an internal dry bulk material receiving area of the material handling unit 284. The filtered gas may be discharged from each filtration device 293 into the atmosphere, as indicated by arrows 295.

[0062] The wellsite system 100 may also be equipped with or comprise a vacuum/filtration system 279 operable to draw in the air containing the airborne dry bulk material and filter out or retain the dry bulk material. The vacuum/filtration system 279 may be disposed at points of emission of the dry bulk material, such as the conveyor belts 285, the chute 287, or other locations of the dry bulk material unloading system 280.

[0063] FIG. 12 is a schematic view of a portion of one of the material handling units 284 shown in FIG. 1 1 according to one or more aspects of the present disclosure. The following description refers to FIGS. 11 and 12, collectively.

[0064] Each material handling unit 284 may comprise one or more material receiving bins or vessels 281 operable to receive via a material inlet 283 the dry bulk material pneumatically discharged from one or more container units 200. Each vessel 281 may also comprise a top material loading hatch or opening 297 and a bottom material outlet 289. In an example implementation, each conduit 294 may terminate with a connector or coupling 296 operable to pneumatically connect with or engage the opening 297 in the vessel 281 to pneumatically connect the filtration device 293 with the vessel 281.

[0065] During dry bulk material unloading operations, as the gas source 290 may introduce pressurized gas into the vessels 202 of the container units 200 and the dry bulk material may be pushed out of the vessels 202 and transferred into the corresponding material handling unit 284 via the conduit 288. The dry bulk material 201 may flow into and collect at the bottom of one or more of the vessels 281 of the material handling unit 284. The dry bulk material 201 may be discharged via the material outlet 289 onto the conveyor belt 285 and directed into the mixer 286, as described above. A portion of the dry bulk material 201 injected into the vessel 281 may become airborne within the vessel 281. Instead of being discharged into the atmosphere via the opening 297, the gas carrying the airborne dry bulk material 203 may be directed to flow through the conduit 294 and the filtration device 293, which may filter out and retain the airborne dry bulk material 203 and permit the clean gas to be exhausted into the atmosphere, as indicated by the arrows 295.

[0066] In view of the entirety of the present application, including the figures and the claims, a person having ordinary skill in the art will readily recognize that the present disclosure introduces an apparatus comprising a dry bulk material transport system comprising: (A) a plurality of container units each operable to: (i) contain dry bulk material; and (ii) be transported between a dry bulk material storage facility and a wellsite via a truck trailer; and (B) an unloading system located at the wellsite and operable to: (i) pneumatically connect with one or more of the container units; (ii) pneumatically unload the dry bulk material out of the one or more of the container units; and (iii) move the dry bulk material into a mixer.

[0067] The dry bulk material may comprise one or more of cement, guar, fiber, silica, and/or sand.

[0068] The wellsite may be a hydraulic fracturing wellsite.

[0069] The unloading system may comprise a plurality of material handling units each operable to: pneumatically connect with the one or more of the container units; pneumatically receive the dry bulk material from the one or more of the container units; and move the dry bulk material into the mixer. In such implementations, among others within the scope of the present disclosure, the unloading system may further comprise a filtration system operable to:

pneumatically connect with one or more of the material handling units; and filter airborne dry bulk material discharged from the one or more of the material handling units.

[0070] The unloading system may further comprise a gas source operable to increase pressure within the one or more of the container units to force the dry bulk material out of the one or more of the container units. [0071] One or more of the container units containing the dry bulk material may be stored at the wellsite.

[0072] One of the container units may be stackable on top of another of the container units.

[0073] The transport system may further comprise a plurality of truck trailers operable to transport the container units between the dry bulk material storage facility and the wellsite. The container units may be operable to be disconnected from corresponding truck trailers.

[0074] Each of the container units may comprise: (A) a plurality of vessels each comprising a material inlet, a gas inlet, and a material outlet, wherein each vessel is operable to contain the dry bulk material; (B) a conduit system pneumatically connected with each of the vessels via a corresponding gas inlet and operable to: (i) pneumatically connect with a gas source; and (ii) communicate a gas from the gas source into each of the vessels; and (C) a frame maintaining the vessels and the conduit system in position.

[0075] Each of the container units may comprise a material inlet, and each of the container units may be operable to receive the dry bulk material via its material inlet at the dry bulk material storage facility. In such implementations, among others within the scope of the present disclosure, at least a portion of the dry bulk material storage facility may be an enclosed structure, and each of the container units may be operable to receive the dry bulk material while located within the enclosed structure of the dry bulk material storage facility.

[0076] The present disclosure also introduces an apparatus comprising a dry bulk material unloading system comprising: (A) a transportable container unit operable to contain dry bulk material; (B) a material handling unit located at a wellsite and operable to: (i) pneumatically connect with the container unit; (ii) pneumatically receive the dry bulk material from the container unit; and (iii) move the dry bulk material into a mixer; and (C) a gas source operable to: (i) pneumatically connect with the container unit; and (ii) introduce gas into the container unit to cause the dry bulk material to move from the container unit into the material handling unit.

[0077] The dry bulk material may comprise one or more of cement, guar, fiber, silica, and/or sand.

[0078] The wellsite may be a hydraulic fracturing wellsite.

[0079] The dry bulk material unloading system may further comprise a filtration system operable to: pneumatically connect with the material handling unit; and filter airborne dry bulk material from gas discharged from the material handling unit. In such implementations, among others within the scope of the present disclosure, the filtration system may be operable to pneumatically connect with a hatch opening of the material handling unit.

[0080] The container unit may comprise: (A) a plurality of vessels each comprising a material inlet, a gas inlet, and a material outlet, wherein each vessel is operable to contain the dry bulk material; (B) a conduit system pneumatically connected with each of the vessels via a corresponding gas inlet and operable to: (i) pneumatically connect with the gas source; and (ii) communicate the gas from the gas source into each of the vessels; and (C) a frame maintaining the vessels and the conduit system in position.

[0081] The present disclosure also introduces a method comprising: loading dry bulk material into a container unit at a dry bulk material storage facility; transporting the container unit to a wellsite via a truck trailer; pneumatically connecting the container unit with a material handling unit at the wellsite; pneumatically unloading the dry bulk material out of the container unit; and moving the dry bulk material into a mixer.

[0082] The dry bulk material may comprise one or more of cement, guar, fiber, silica, and/or sand.

[0083] The method may comprise directing air containing airborne dry bulk material discharged from the material handling unit through a filter to filter out the airborne dry bulk material from the air. In such implementations, among others within the scope of the present disclosure, the method may comprise pneumatically connecting the filter with an opening in the material handling unit.

[0084] The method may comprise: pneumatically connecting a gas source with the container unit; and operating the gas source to increase pressure within the container unit to force the dry bulk material out of the container unit.

[0085] The method may comprise mounting the container unit onto the truck trailer.

[0086] The method may comprise: dismounting the container unit from the truck trailer; and storing the container unit at the wellsite.

[0087] The container unit may be a first container unit, the truck trailer may be a first truck trailer, and the method may comprise: loading the dry bulk material into a second container unit at the dry bulk material storage facility; transporting the second container unit to the wellsite via a second truck trailer; dismounting the second container unit from the second truck trailer; and storing the second container unit at the wellsite. In such implementations, among others within the scope of the present disclosure, the method may comprise stacking the second container unit on top of the first container unit.

[0088] At least a portion of the dry bulk material storage facility may be an enclosed structure, and loading the dry bulk material into the container unit may comprise loading the dry bulk material into the container unit while the container unit is located within the enclosed structure.

[0089] The foregoing outlines features of several embodiments so that a person having ordinary skill in the art may better understand the aspects of the present disclosure. A person having ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same functions and/or achieving the same benefits of the embodiments introduced herein. A person having ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.

[0090] The Abstract at the end of this disclosure is provided to permit the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Claims

WHAT IS CLAIMED IS:

1. An apparatus comprising:

a dry bulk material transport system comprising:

a plurality of container units each operable to:

contain dry bulk material; and

be transported between a dry bulk material storage facility and a wellsite via a truck trailer; and

an unloading system located at the wellsite and operable to:

pneumatically connect with one or more of the container units;

pneumatically unload the dry bulk material out of the one or more of the container units; and

move the dry bulk material into a mixer.

2. The apparatus of claim 1 wherein the dry bulk material comprises one or more of cement, guar, fiber, silica, and/or sand.

3. The apparatus of claim 1 wherein the wellsite is a hydraulic fracturing wellsite.

4. The apparatus of claim 1 wherein the unloading system comprises a plurality of material

handling units each operable to:

pneumatically connect with the one or more of the container units;

pneumatically receive the dry bulk material from the one or more of the container units; and move the dry bulk material into the mixer.

5. The apparatus of claim 4 wherein the unloading system further comprises a filtration system operable to:

pneumatically connect with one or more of the material handling units; and

filter airborne dry bulk material discharged from the one or more of the material handling units.

6. The apparatus of claim 1 wherein the unloading system further comprises a gas source operable to increase pressure within the one or more of the container units to force the dry bulk material out of the one or more of the container units.

7. The apparatus of claim 1 wherein one or more of the container units containing the dry bulk material are stored at the wellsite.

8. The apparatus of claim 1 wherein one of the container units is stackable on top of another of the container units.

9. The apparatus of claim 1 wherein the transport system further comprises a plurality of truck trailers operable to transport the container units between the dry bulk material storage facility and the wellsite.

10. The apparatus of claim 9 wherein the container units are operable to be disconnected from corresponding truck trailers.

11. The apparatus of claim 1 wherein each of the container units comprises:

a plurality of vessels each comprising a material inlet, a gas inlet, and a material outlet, wherein each vessel is operable to contain the dry bulk material;

a conduit system pneumatically connected with each of the vessels via a corresponding gas inlet and operable to:

pneumatically connect with a gas source; and

communicate a gas from the gas source into each of the vessels; and

a frame maintaining the vessels and the conduit system in position.

12. The apparatus of claim 1 wherein each of the container units comprises a material inlet, and wherein each of the container units is operable to receive the dry bulk material via its material inlet at the dry bulk material storage facility.

13. The apparatus of claim 12 wherein at least a portion of the dry bulk material storage facility is an enclosed structure, and wherein each of the container units is operable to receive the dry bulk material while located within the enclosed structure of the dry bulk material storage facility.

14. An apparatus comprising:

a dry bulk material unloading system comprising:

a transportable container unit operable to contain dry bulk material;

a material handling unit located at a wellsite and operable to:

pneumatically connect with the container unit;

pneumatically receive the dry bulk material from the container unit; and move the dry bulk material into a mixer; and

a gas source operable to:

pneumatically connect with the container unit; and

introduce gas into the container unit to cause the dry bulk material to move from the container unit into the material handling unit.

15. The apparatus of claim 14 wherein the dry bulk material comprises one or more of cement, guar, fiber, silica, and/or sand.

16. The apparatus of claim 14 wherein the wellsite is a hydraulic fracturing wellsite.

17. The apparatus of claim 14 wherein the dry bulk material unloading system further comprises a filtration system operable to:

pneumatically connect with the material handling unit; and

filter airborne dry bulk material from gas discharged from the material handling unit.

18. The apparatus of claim 17 wherein the filtration system is operable to pneumatically connect with a hatch opening of the material handling unit.

19. The apparatus of claim 14 wherein the container unit comprises:

pneumatically connect with the gas source; and

communicate the gas from the gas source into each of the vessels; and

a frame maintaining the vessels and the conduit system in position.

20. A method comprising:

loading dry bulk material into a container unit at a dry bulk material storage facility;

transporting the container unit to a wellsite via a truck trailer;

pneumatically connecting the container unit with a material handling unit at the wellsite;

pneumatically unloading the dry bulk material out of the container unit; and

moving the dry bulk material into a mixer.

21. The method of claim 20 wherein the dry bulk material comprises one or more of cement, guar, fiber, silica, and/or sand.

22. The method of claim 20 further comprising directing air containing airborne dry bulk

material discharged from the material handling unit through a filter to filter out the airborne dry bulk material from the air.

23. The method of claim 22 further comprising pneumatically connecting the filter with an

opening in the material handling unit.

24. The method of claim 20 further comprising:

pneumatically connecting a gas source with the container unit; and

operating the gas source to increase pressure within the container unit to force the dry bulk

material out of the container unit.

25. The method of claim 20 further comprising mounting the container unit onto the truck trailer.

26. The method of claim 20 further comprising:

dismounting the container unit from the truck trailer; and

storing the container unit at the wellsite.

27. The method of claim 20 wherein the container unit is a first container unit, wherein the truck trailer is a first truck trailer, and wherein the method further comprises:

loading the dry bulk material into a second container unit at the dry bulk material storage facility; transporting the second container unit to the wellsite via a second truck trailer;

dismounting the second container unit from the second truck trailer; and

storing the second container unit at the wellsite.

28. The method of claim 27 further comprising stacking the second container unit on top of the first container unit.

29. The method of claim 20 wherein at least a portion of the dry bulk material storage facility is an enclosed structure, and wherein loading the dry bulk material into the container unit comprises loading the dry bulk material into the container unit while the container unit is located within the enclosed structure.